MCEN 4173/5173 Chapter 2

Building An FEA Model

Fall, 2006

FEA Software Packages

ALGOR ANSYS COSMOS/M STARDYNE NASTRAN SAP90 ADINA ABAQUS MARC DYTRAN .

FEA Software Packages Licenses: floating license, first-come-first-serve

For ANSYS in this class: Education version
Limited function. Total number of nodes < 32000

Two license server flexlm.colorado.edu For labs. For computers managed by ITS. 30 seats. magellan.colorado.edu For research. For individual computers. 25 seats.

Ingredients in an FEA model P

undeformed

P
deformed

X2

X2

X1

X1

Basic information that needs to be provided: 1. 2. 3. 4. Geometry. Material properties: Youngs modulus, Poissons ratio, bending stiffness Boundary conditions, prescribed forces or displacements. Type of analysis: static, transient, modal, buckling, .

Ingredients in an FEA model

Additional ingredients: Elements or mesh:
Strategy to create a good mesh Element types

Time functions:
A time function defines how the prescribed boundary conditions change with time, such as ramp, or sinusoidal. In FEA, Time means a physical time that you count by a clock (such as in dynamics), or it means that one thing happens before another thing (such as in statics). In some FEA packages, the default time function for static analysis is a ramp function.

Ingredients in an FEA model

Six basic ingredients of an FEA software package 1. 2. 3. 4. 5. 6. Type of analysis Geometry (defined through nodes) Elements Material properties Boundary conditions Time functions

As long as these six components are defined, an analysis can be conducted. It usually does not matter in what sequences these components are given.

Physical model vs FEA model

Developing a physical model is a process that simplifies a real-world problem into a problem that is suitable by FEA. Considerations in building a physical model
1. 2. The nature of real-world problem The cost of conducting FEA

In many cases, the cost of conducting FEA is a major barrier, which imposes a great challenge. Sometimes, we have to sacrifice accuracy in order to reduce the cost.

Physical model vs FEA model

Example: 3 2

If the loads applied are uniform along 1-direction, then 3 2

2D

Physical model vs FEA model

If the two layers of this laminate are glued together, do we need to consider the small layer of glue?
If the two layers are glued together perfectly, and will not separate under working conditions,

3 2

Ignore the interface

2D

If the strength of interface is a major concern in your design,

3 2

Consider the interface

2D

Physical model vs FEA model

If you want to consider the initiation and propagation of damages of interface (delamination)

3 2

Consider the interface

2D

3 2

2D

Physical model vs FEA model

After a physical model is decided, the next step is to build an FEA model

Considerations in building an FEA model 1. 2. The accuracy of the FEA model The cost of conducting FEA

FEA model
Factors that affect the cost: 1. Degree of Freedoms (DOF): p

2. Number of Nodes : N

3. How the nodes are numbered

4. Number of Integration Points in Each Elements 5. Nonlinear Analysis

FEA model
Factors that affect the cost:

In general, The type of analysis (static, dynamic,, linear or nonlinear ) is decided at physical model level. The number of nodes and number of integration points are decided at FEA model level. But a good physical model can reduce the number of nodes by one or two order of magnitude. Rule of Thumb

FEA model
Example: Abrasive Wear in Seals-Background

20 18 16 1st cycle 2nd cycle 4th cycle

-Ture Stress (MPa)

14 12 10 8 6 4 2 0 0 0.25 0.5 0.75 1

Seals in a joint

-True Strain

Stress-strain behavior of the material for the seal

Abrasive particle ~10-60m

FEA model
Example: Abrasive Wear in Seals-Physical Model

Scratching simplification

Elastomers Abrasive particle

100m~1mm

Cross-section of the 3D case

FEA model
Example: Abrasive Wear in Seals-Physical Model
6mm

Scratching

3mm A D Knife x

2D
AB~6mm Tip Radius ~6m

3mm

FEA model
Example: Abrasive Wear in Seals-FEA Model

1mm

100m

FEA model only has ~8000 nodes

Cost: on a Compaq (HP) alpha workstation, one week for one simulation