2d I 3d Naponsko Deformaciona Analiza U Solidworks-U

Introduction to Finite Element
Ghapter 10
Two-Dimensional Surface Analysis
@@ffi
Understand the basic assumptions for
2D elements.
Understand the Basic differences
between H-Element and P-Element.
t Create and Refine 2D Surface elements.
a Understand the Stress concentration
effects on Shapes.
Perform Basic Plane Stress Analysis
using SolidWorks Simulation.
lntroduction
The recent developments in computer technology have triggered tremendous
advancements in the development and use of2D surface, iD surface
and 3D solid
elements in FFA. Many problems that once required sophisticated
analyticar procedures
and the use of empirical equations can now be analyzed through the
use offga.
At the same time, users of FEA software must be cautioned that it is very easy to
fali into
the trap of blind acceptance ofthe answers produced by the FEA
software. unlike the
line elements (Truss and Beam elements), where the analytical solutions
and the FEA
solutions usually matched perfectly, more care must be taken w ith 2D/3D
surface and 3D
solid elements since only very few analytical solutions can be eas y
obtained. on the
other hand, the steps required to perfom finite element analysis
using 2Dl3D surface and
3D solid elements are in general less complicated than that of line elements.
In this chapter, we will examine the use of two-dimensional sorid finite

erements. Three-
dimensional problems can be reduced to two dimensions if they satisfy
the assumptions
associated with two-dimensional surface elements. There are
four basic types of surface
solid elements, listed in historical development order:
1. Plane stress Elements: plane stress is defined to be a state ofstress

that the normar
slress and the s/z ear stresses directed perpendicular to the plane
are assumed to be
zefo.
2. Plane Strain Elements: plane strain is defined to be a state of strain

thar the normar
strain and, the shear strains directed perpendicular to the plane are
assumed to be
zero.
3' Axisymmetric Elements: Axisymmetric structues, such as storage

tanks, nozzles
and nuclear containment vessels, subjected to uniform internal
pressures, can be
analyzed as two-dimensional systems using lx isymmetric Elements.
4. shell Elements: Sherl elements are surface elements with a thickness

that is generaliy
small compared to their other dimensions. The shell element is
the most vers;ile ,;;
of surface elements. Unlike the plane stress elements, shell elements
can have loais'
that are not parallel to the object surfaces.
ln solidworks simulation, the plane stress and prane strain analyses

can be performed by
using the 2D surface elements. To perform a piane stress/prani
strain *uty.rr, u ,u.ruJ"
model or a solid model is required. This chapter demonstrates
the use ofthe 2D surface
element to solve the classical stress concentiation problem a plate
project is simple enough to demonsfate the necessary steps-
with a hole in it. This
foi the finite element
process, and the FEA results can be compared to the anarytical
solutions to assure the
acguracy of the FEA procedure. Generally, members that are
thin and whose loads act
only in the plane can be considere d, tobe tnder prane stress; on the
other hand, members
that are thick with loads act only in the plane can be considered
to be und,er prane straini..
Problem Statement
Determine the maximum normal stress that loading produces in the 6061-T6 aluminum
plate.
0.25 in.
T 300 lb.
2.0
->
I
A .75 in.
Preliminary Analysis
o Maximum Normal Stress
The nominal normal stress developed at the smallest cross section (through the center of
the hole) in the plate is
Onominal : P
A
: Tifr-" = e6oPsi'
3.0
2.75
F I' + { -t- {- -t-
Stress Concentration
factor K J. -
75
L
\ + -,t
L ! I \ J- {- -t-
2.25
2.0
0.1 0.2 0.3 0.4 0.s 0.6 0.7 0.8
Geometric 1ug161 Hole Diameter

Plate width
Geometric factor: .7512 = 0.375

Stress concentration factor K is obtained from the graph, K:2.27
ouex : K onominar : 2.27 x 960 - 2180 psi.

l0-4 Introduction to Finite Element Analvsis
Maximum Displacement
We will also estimate the displacement under the loading condition. For a statically
determinant system the stress results depend mainly on the geometry. The material
properties can be in eruor and still the FEA analysis comes up with the same stresses.
However, the displacements always depend on the material properlies. Thus, it is
necessary to always estimate both the stress and displacement prior to a computer
FEA analysis.
The classic one-dimensional displacement can be used to estimate the displacement

of the problem:
cPL
EA
Where P:force, L:length, A-area, E: elastic modulus, and 3 : deflection.
0.25 in.
300 lb.
<-- I 300 lb.
2. 0 in.
-}
I
A .75 in.
A lower bound of the displacement ofthe right-edge, measured from the center of the
plate, is obtained by using the full area:
pL _ 300x3
61o*", :
E'A - tonO x 1z x o:s) : 1'8E-4 in'
and an upper bound ofthe displacement would come from the reduced section:
: PL 300x3
6upp",
EA l0E6x(1.25x0.25) = 2.88E-4 in.
but the best estimate is a sum from the two regions:
6ur.rur"
_ PL _ 300 x 0.375 300 x2.625
EA l0E6 x (1.25 x 0.2s) 10E6x(2.0x0.2s)
: 3.6E-5 + 1.58E-4 :1.948-4 in.
Two-DimensionalSurlaceAnalvsis 10-5
Geometric Gonsiderations of Finite Elements

For Linear Statics analysis, designs with symmetrical features can often be reduced to
expedite the analysis.
For our plate problem, there are two planes of symmetry. Thus, we only need to create an
FE model that is one-fourth of the actual system. By taking advantage of symmetry, we
can use a finer subdivision of elements that can provide more accurate and faster results.
In performing a plane stress analysis, although only the selected surface is analyzed, it is
necessary to consider the constraints in all directions. For our plate model, deformations
will occur along the axes of symmetry; we will therefore place rol1er constraints along
the two center lines as shown in the figure below.
.:. One should also be cautious of using symmetrical characteristics in FEA. The
symmetry characteristics of boundary conditions and loads should be considered.
Also note the symmetry characteristic that is used in the Zrnear Statics Analysis does
not imply similar symmetrical results in vibration or buckling modes.
Starting SolidWorks
t ----------r .
I Rtfi $ t. SolidWorks
Setect the SolidWorks option on the ,S/a// menu or select the
I -qfli
: I Solidworks main icon on rhe desktop to start Solidltor*s. The
f window will appear on the screen.
I Edition h
L.'w-.*@wg{
2. Click on the New icon, located in the Standard

toolbar as shown.
NEw {Etrl+NJ
Creates d neq,, d,lcument,
Select Part by clicking on the fimt icon in the _ty'ew

Solidll'orks Document dialogbox as shown.
f;- -r
I
L*_ry P
+. Click on the OK button to accept the settings.
--ffiae*ffit
5. Select the options icon from the Menu toolbar to open the options dialogbox.
6. Click Units as shown in the figure.

Dr#ting standard
ti Annotation5 7. On your own, set tlte Unit systen to IPS (inch,
( Dimensions pound, second) as shown.
: Virtunl 5harp5
Unit Eystem
,+: Table5
i.'r MKS {meEr. kilogram" second}
Detailing
t-.], CGS {centiffeEr, gram, second)
Gridlsn.p
iffi ,:-'l l,lMGS
tmillimebprJ qrarn, second)
u.t{H
Md-dl 0rsplay +{PS [ndr, pound, second)
'ldustom
MatErial PrBpertiee
ImagE quatity
Creating the CAD Model
.t To perform the surface FEA analysis, we will first create a solid model and use the
front face of the since solid model in SolidWorks Simulation.In the next chapter, the
procedure to create a surface model from a sketch is illustrated.
1. Click the Extruded Boss/Base icon, in

the Features toolbar, to create a new
extruded feature.
2. Click the Front Plane, in the

graphics area, to set the sketching
plane ofour sketch as shown.
3. Click the Rectangle icon in the

Sketch toolbar as shown.
4. Start the first comer ofthe rectangle at

the origin and create the rectangle as
shown.
l0-8 lntroduction to Finite Element Analysrs
5. On your own, use the Smart Dimension

command to adjust the sketch as shown.
6. Click the Circle icon in the

7. Click the origin to align the center

of the circle.
8. Create a circle ofarbitrary size as

shown.
Two-DimensionalSurfaceAralvsis 10-9
9. On your own, create and adjust the diameter of the

circle to 0.75.
10. Using the Trim Entities command, modily the

sketch as shown in the figure below.
1 1. Click the Exit Sketch icon in the Sketch

toolbar as shown.
12. On your own, using the extrusion distance of

0.25 in, create the solid feature as shown.
10-10 Introduction to Finite Element Analvsis
Activate the SolidWorks Simulation Module

Solidll/orks Simtrlation is a multi-discipline Computer Aided Engineering (CAE) tool that
enables users to simulate the physical behavior ofa model, and therefore enable users to
improve the design. SolidWorks Simulation can be used to predict how a design will
behave in thc real world by calculating stresses, deflections, frequencies, heat transfer
paths, etc.
The SolidWork Simulation product line leatures two areas of Finite Element Anaiysis:
Structure and Thermal. Stnrcture focuses on the structural integrity of the design, and
thermal ey aluates heat-transfer characteristics.
$ Lofted eos:€ase
trffi
Extruded HEle 1. Stafi SolidWorks Simulation by selecting
Cut ',{i?ard the Office Products tab in the
B Eoundary BossjBase
CommandManager area as shown.
i_
i,EE ft
Solididnrks i SolidilErkt
ir 2. In the SolidWorks Office list, choose SolidWorks
-.
|.(ouEfig :lntutd , t!- Simulation as shown.
I,n To0lbo
I "'J
OfficP Produrts r,-
' :1 ti, jl
3. In the CommandMonoger area, choose

F.E!-.li
Simulation as shown.
.f. Note that lhe SolidWorks Simulation module is integrated as part of SolidWortrs. All
of the SolidWorks Simulation commands are accessible through the icon panel in the
CommandManager area.
4. To starl a new study, click the New Study item listed

under the Studv Advisor as shown.
5. Select Static as the type ofanalysis to be
performed with So lidWorks Simulation.
.1. Note the different types of analyses are

available, which include both structural static
and dy,namic analyses, as well as the thermal
analysis.
6. Click OK to start the definition of a structural static

analysis.
4 In the FeatureManager area, note that a new

panel, the FEA Stub, window, is displayed with
all the key items listed.
Also note the Study 1 tab is activated,

which indicates the use of the FEA model.
On your own, save a copy of the culaent

model.
10-12 Introduction to Finite Element Analysis
Defining a Surface Model
1 . Right-mouse-click once on the model

name to bring up the option list and
select Define Shell by Selected
Faces as shown.
2. In the graphics area, select the

front face of the solid model.
* For the surface model, the thickness ofthe surface

needs to be defined separately from the solid
model.
J. Confirm the Type option is set to Thin as shown.

Note the Thin option is for plane stress analysis.
4. Enter 0.25 as the Shell thickness as shown.
5. Click on the OK button to accept the Shell

Definition settings.
.!. Note the defined surface model is a 3D FEA model, but only the front face
geometry of the CAD is referenced.
Assign the Element Material Property
} Next we will set tp the Material Property for the elements. The Material property
contains the general material information, stch as Modulus of Elasticity, poisson's
Ratio, etc. that is necessary for the FEA analysis.
1. Choose the Apply Materials option

from the pull-down menu as shown.
'f' Note the default list of materials, which are available in the pre-define d sotidl{orks
Simulation material library, is displayed.
2. Select 6061 -T6 Aluminum in the Material list as shown.

3. Set the Units option to display English (lPS) to make the selected material
available for use in the current FEA model.
ilaterlals in he detault library 6 rct be edtted,

.you
must fiist epy ihe mbrid io
i.*aruryS4-.__-:l
E€tr""-.--__:
:: -. 1rf,.,1;c1,. - :
l5al
rri: ,a
:
i'r..,'ltt""'' .,i.";h";5.;' .
tsil @l '':.',rr.. i-ll+l
4. Click Apply to assign the material property then click Close to exit
the material assignment command.
Applying Boundary Conditions - Constraints
1. Choose Advanced Fixtures by clicking

the icon in the toolbar as shown.
2. Select the bottom

horizontal edge of the
front surface as the
entity to apply
c onstraints.
Activate the Direction Reference list option box by

clicking on the inside of the Reference list box as
shown.
4. Select the front face of the

CAD model as the direction
reference.
Set the distance measurement to inches, to match
with the systems units we are using.
lnthe Translation constraints list, click on the

Normal to Plane and Along Plane Dir 2 icons
to activate the constraint.
Set the Normal to Plane and, Along Plane Dir 2

distances to 0 as shown.
Click on the Along Plane Dir 1 and Along

Plane Dir 2 icons to activate the constraint.
Set the Along Plane Dir I and, Along Plane Dir 2

angles to 0 as shown.
10. Click on the OK button to accept the first Fixture

constraint settings.
.1. The small arrows indicate constraints have been applied to the
associated edge.
l0-16 Introduction to Finite Element Analysis
* For the vertical edge on the left, we will apply a separate constraint set.
I 1. Choose Advanced Fixtures by clicking

the icon in the toolbar as shown.
12. Select the left vertical edge of

the front surface as the entity to
apply constraints.
13. Activate the Direction Reference list option box by

clicking on the inside of the Reference list box as
shown-
14. Select the front face ofthe

CAD model as the direction
reference.
I 5. Set the distance measuement to inches, to match
16. In the Translation constraints 1ist, click on the

Along Plane Dir 1 and Normal to Plane icons
to activate the constraint.
17. Set the Normal to Plane and Along Plane Dir I

distances to 0 as shown.
18. Click on the Along Plane Dir 1 and Along

Plane Dir 2 icons to activate the constmint.
19. Set the Along Plane Dir I and Along Plctne Dir 2
angles lo 0 as shown.
20. Click on the OK button to accept the first Fixture

t Note the applied constraints, to the two associated edges, account for the
symmetry of the system.
Applying the External Load
1. Choose External Loads ) Force by

clicking the icon in the toolbar as shown.
2. Select the right edge ofthe front

surface as shown.
Activate the Direction Reference list option box

by clicking on the inside of the Reference list
box as shown.
4. Click the top edge ofthe

front surface to set the
force direction as shown.
Set the Units to English (lPS), to match with the
systems units we are using.
Enter /50 lbf as the applied force.
Activate the Reverse Direction option by

clicking on the box in front of the option as shown.
8. Click on the OK button to accept the F'o rce/Torque

settings.
10-20 Infoduction to Finite Element Analysis
H-Element versus P-EIement

There are two different approaches to FEA: H-element method and P-element method.
Finite elements used by commercial programs in the 1970s and 80s, were all H-elements.
The stress analysis of the H-element concentrates primary at the nodes. The H-element
uses a low order interpolating polynomial, which usually is linear or quadratic. Strain is
obtained by taking the derivatives of the displacement and the stress is computed from
the strain. The relative simplicity ofthis approach allows efficient and direct solution of
the analysis. In order to gain accuracy for complex geometries or to represent a highly
varying stress distribution, finer elements must be used. The increase in the number of
elements will also increase the solution time and computer disk space. This is why the H-
element method requires the refinement of mesh around the high stress areas. The
process of mesh refinement is called convergence analysis, or H-convergence. Note that
Solidlfiorks Simulation uses the H-element approach.
A new type of element. P-element, was developed in late 1980s. The p-element is unique
because convergence is obtained by increasing the order of the interpolating polynomials
in each individual element. Generally speaking, the P-method uses a constant mesh,
which is usually coarser than an H-element mesh. The FEI Solver will detect the areas
where high gradients occur and those elements have their order ofthe interyolating
polynomials automatically increased. This allows for the monitoring of expected error in
the solution and then automatically increases polynomial order as needed. This is the
main benefit of using P-elements. We can use a mesh that is relatively coarse, thus
computational time will be low, and still get reasonable results. One should realize that
despite the automatic process ofthe P-elements analysis, areas of the model that are of
particular interest or with more complex geometry or loading could still benefit from the
user specifliing an increase in mesh density.
Create the first FEA Mesh - Coarse Mesh
F As a rule in creating the first FEA mesh in using the H-element approach is to start
with a relatively small number of elements and progressively move to more refined
models. The main objective of the first coarse mesh analysis is to obtain a rough idea
of the overall stress distribution. In most cases, use ofa complex and/or a very
refined FEA model is notjustifiable since it most likely provides computational
accuracy at the expense ofunnecessarily increased processing time.
E
ltt
r*-
ll,il 1. Choose Create Mesh by clicking the icon in the
Run, RerultE ,. !E
Ad!,i!Er :r:i:,]-r-t*n f,ompare toolbar as shown.
1aSujr Results
riol
Switch on the Mesh Parameters options to

show the additional control options.
Set the Un l/s to inches as shown.
4. Enter 0.15 inch as the Global Element size.
5. Enter 0.015 inch as the Size tolerance.
.! A rule of thumb to use as the first mesh is to have

at least 4 to 5 elements on the edges ofthe model.
The shortest edge in our model is about 0.6
inches, so we will use 0. 15 as the element size.
Click on the OK button to accept the Mesh

settings.
10-22 Intoduction to Finite Element Analvsis
* The Aomatic mesh fvnction tn Solidl(orks Simulation has generated a fairly

uniform and consistent mesh of elements.
'7
. In the FEA Slr;d-r window, click once with
the rightmouse-button on the Mesh item
to display the option list and select
Details as shown.
* The current coarse mesh consists of595

nodes and 270 surface elements.
8. Click on the [X] icon to close the Mesh Details dialog box.
Two-DimensionalSurfaceAnalysis 10-23
Run the Solver
1. Click on the Run button to starts

the FEA Solver to calculate the
results.
2. ln the FEA Study wifldow, click once with

the right-mouse-button on the Srressl item
to display the option list and select Edit
Definition as shown.
Set the,gtress Component to P1: 1st Principal

Stress as shown.
Set the Display Units to psi.
Set the Deformed Shape optiorr to Automatic.
The Automatic Deformed Shape option will enable

the display ofa scaled up deformation. Note that the
true deformation is relatively small, and the
deformation will not be visible if the display option is
set to True scale.
6. Click OK to display the results.
Plor rypa slalic nodd slr66 (Top) sf6sl
t
-Rae$!.!*s&f"jas,Qq"ry!qry
{' Note the FEr4 sorver carcurated Max. Stress is a bit lower
than the result from the
preliminary analysis on page 10-4.
7 . In the FEA Study window , click once

with the right-mouse-bunon on the
Displacementl item to display the option
list and select Show to view the
displacement.
Two-DimensionalSurfaceAnalysis 10-25
Refinement of the FEA Mesh - Global Element Size 0.10

.1. One way of refinement is simply to adjust the Global Element sLe to a smaller value.
We will reduce the Global Element size to 0.1O.
1. Choose Create Mesh by clicking the icon in the

toolbar as shown.
2. Click on the OK button to

proceed with deleting the old |. Reme5hing will deletethe rEsult! fsr studl study1,
mesh and create a new mesh of
the FEA model.
: - - __----:---*
r UK" ! I Lancel l
E Standa.d mesh
- Cur,/ifurE bnsed mE h
3. Enter 0.10inchasthe Global Element size.
!n
i3 AutomEtic bEnEition
4. Click on the OK button to accept the

Mesh settings and create a new mesh.
Intoduction to Finite Element
5. On your own, examine the details of the

refinement.
.!. The current coarse mesh consists of1241

nodes and 580 surface elements, which is
abottt ll5c'/o increase of elements
compared lo the first mesh.
Click on the Run bufion to start

results.
l. The FEA Solver calculated the Max. Stress with the refinement to be 2022.7 psi.
URES (in)
* The Max. Displacement is 2.054e4, which is very similar to the
2.054e-004
result from the first mesh.
Lgl0e-004
1 .766e-004
1.622e-004
Two-DimensionalSurlbceAnalysis I0-27

* We will next adjust the Global Element size to 0.05 inch and observe the changes in
the results.
1. Choose Greate Mesh by clicking the icon in the

toolbar as shown.

proceed with deleting the old
mesh and create a new mesh of
the FEA model.
3. Enter 0.05 inch as the Global Element size.
4. Click on the OK button to accept the Mesh

settings and create a new mesh.

refinement.
.1. The current coarse mesh consists of4787

nodes and 2314 surface elements" which is
abolt 760%o increase ol elements.
t?t n- :
lri -H
RunLResults iDEt
H i qa.ooi :l- . . Conpare . ir Dc'-
'---- [{I o-^-,
6. Click on the Run button to start the
FEA Solver to calculate the results.
Run
SliriE the salver lor the nciive ltudy,
7. The FEA Solver calctiated the Max. Stress with the refinement to be 2175.7 psi.
Prd iyp.: sa. nodarnG* (op) sl'es.l
r::::1
ffi -'-
s..
a
l** r,,,.
URES (in)
2.050e-004 8. The Max. Displacement is 2.050e-4, which is very similar to

'l .S07E-004 the result from the first mesh.
1 .764e-004
'i' we will next adjust the Global Element size to 0.03 inch and observe the chanses in
the results-

toolbar as shown.
Remeshing will delete the rerult5 for study: study1.

...Jt.,|
mesh and create a new mesh
of the FEA model-
3. On your own , adjust the Global

Element size to 0.03 inch and perform
the analysis.
Jacobian check for shell
4. The FEA So/ver calculated the

Maximum Stress with the refinement
to be 2231.5 psi. and the Maximum
Displacement of 2.048e.4 inch.
TihB tn rnmhlFrE ftFrhlhh.6ft.+.1
Prdlype sai. nodarnress (Top) eressl
t
Introduclion to Finite Elenent

.1. We will next adj ust the Global Element size to 0.02 inch and obserwe the changes in
the results.
lg4 Fr-
{,8 t:l
Run Resuli.s
Adri16r Cofitpare 1. Choose Create Mesh by clicking the icon in the
Res!lt5
toolbar as shown.
ffi r.un
!f Run Deliqn Srenario:
areateJ

of the FEA model.
f"r''*l T G".d I
3. On your own, adjlst the Global

Element size to 0.02 inch and
perform the analysis.
4. The FEA Solver calculated the Max.

Stress with the refinement to be
2249.2 psi and the Maximum
Displacement of 2.047 e-4 inches.
Potl./p3 srat.nodal3lEss(dpJSrrE:sl
Comparison of Results
The accuracy of the sotidworks simuration resurts for this problem
can be checked by
comparing them to the anallicar results presented earlier. In the preriminary
Anarysis
section, the maximum stress was calculated using a stress concentration
factor and ihe
value obtained was 2180 psi. one should realizelhe analytical result
is obtained through
the use ofcharts from empirical data and therefore involves some
degrees of error. The
stress obtained by finite element analysis using so/l dworis simutation
lraximum ranging
from 1938 to 2249 psi. rt the preriminary Anaiysis sectiln, the maximum
dispracemlni"
was also estimated to be around r.94E-4 inches, measured
from the center of ihe hole to
one end of the plate. The maximum displacement obtained
by finite element analysis
using solidworks simulation was around 2.050E-4 inches. The
agreement between the
analytical results and those ftom sotidllortu simulation demonstrates
the potential of
SolidWorks Simulation as a very powerful design tool.
In FEA, the process of mesh refinement is called convergence analysis,

or H_
convergence. For our analysis, the refinement ofthe mesh
does show the FEA results
converging near the analytical results. The refinement to the
size of 0.03^o,05 inches is
quite. adequate for our analysis. Any further refinement
does not provide any additional
insight and is therefore not necessar:y.
Global Number of o.* (Psi) D*",.(in)

Element size Elements
0.1 s 270 1938 2.057e-4
0.10 580 2023 2.054e-4
0.05 2314 2t76 2.050e-4
0.03 6363 2232 2.048e-4
0.02 14448 2249 2.047e-4
N
o)
OF
,-i oi
(.)
o,
&H€XSpHBEEH
<")sro(or--oootdc.i("i+
Questions:
1. What are the four basic types of two-dimensional solid elements?
2. what type of situation is more suitable to perform a plane stress analysis than a
Plane Strain analysis?
3. For plane stress analysis using two-dimensional surface elements. how was the
surface created?
4. which type of two-dimensional solid elements is most suitable for members that are
thin and whose loads act only in the plane?
5. why is it important to recognize the symmetrical nature of design in performing FEA

analysis?
6. why is it important to notjust concentrate on the stress results but also examine the
displacements of FEA results?
'7. In the tutorial, did the changes in the refinement of the elements help the stress
results? By how much?
Exercises:
Determine the maximum stress produced by the loads.
1.
Material: Steel Plate

Thickness: 25 mm
A 750 nrn
T 0.15 m
.3m
I
5KN
->
0.25 m 0.15m 0.15 m
2. An upward force of 1000 N is applied to the handle of the wrench.
Material: Steel
Thickness: 8 mm
Introduction to Finite Element Analysrs 1 1-l
Chapter 11
Three-Dimensional Solid Elements
P d &E sralt Brd shess s6sl
,::::::
g'''
l:;.'
t Perform 3-D Finite Element Analysis.

r Understand the concepts and theory of
Failure Criteria.
r Greate 3-D Solid models and FE models.
t Use the SolidWorks Simulation Mesh
Control.
t Use the different Refinement options to
examine Stress Results.
t
11-2 Intoduction to Finite Element Analysis
lntroduction
In this chapter, the general FEA procedure for using three-dimensional solid elements is
illustrated. A finite element model using three-dimensional solid elements may look the
most realistic as compared to the other types of FE eiements. However, this type of
analysis also requires more elements, which implies more mathematical equations and
therefore more computational resources and time.
The main objective of finite element analysis is to calculate the stresses and
displacements for specified loading conditions. Another important objective is to
determine if failure will occur under the effect ofthe applied loading. It should be
pointed out that the wordfailure as used for failure criteria is somewhat misleading. In
the elastic region of the material, the system's deformation is recoverable. Once the
system is stressed beyond the elastic limit, even in a small region of the system,
deformation is no longer recoverable. This does not necessarily imply that the system has
failed and cannot carry any further load.
STRAIN
Elastic Plastic
Stress-Strain diagram of typical ductile material
Several theories propose different failure criteria. In general, all these theories provide
fairly similar results. The most widely used failure criteria are the Von Mises yield
criterion and the Tresca yield criterion. Both the Von Mises and. Tresca stresses are
scalar quantities, and when compared with the yield stress ofthe material they indicate
whether a portion of the system has exceeded the elastic state.
Von Mises Criterion: (Note that o1, 02, 03 are the three principal stresses.)
.)
2 6rr' - (ot oz)' + (o2 - o3)' + (o.] - ot)',2
Tresca Yield Criterion:
1
2"
.r,": I2 (or - or)
Three-Dimensional Solid Elements I 1-3
This chapter illustrates the general FEA procedure ofusing three-dimensional solid
elements. The creation ofa solid model is first illustrated and solid elements are
generated using the Solidllorks Simulation mesh commands. In theory, all designs could
be modeled with three-dimensional solid elements. The three-dimensional solid element
is the most versatile type of element compared to the more restrictive one-dimensional or
two-dimensional elements. The procedure involved in performing a three-dimensional
solid FEA analysis is very similar to that of a two-dimensional solid FEA analysis, as
was demonsffated in Chapter 10. As one might expect, the number ofnode-points
involved in a typical three-dimensional solid FEA analysis is usually much greater than
that ofa two-dimensional solid FEA analysis.
Problem Statement
Determine the maximum normal stress in the AL6061 member shown; the c-link design
is assembled to the frame at the upper hole (A 0.25) and a vertical load of200 lbs. is
applied at the top ofthe notch on the lower arm as shown.
I l-4 Introduction to Finite Element Analysis
The analysis ofstresses due to bending moment has been restricted to straight members
as illustrated in Chapter 7 through Chapter 9. Note that a good approximation may be
obtained if the curvature of the member is relatively small in comparison to the cross
section ofthe member. However, when the curvature is large, the stress distribution is no
longer linear, it becomes hyperbolic. This is due to the fact that, in a curved member, the
neukal axis ofa transverse section does not pass through the centroid of that section.
The distance R from the center of curvature C to the neutral axis is then defined by the
equation:
A
P= (A is the cross sectional area.)
ldA
Jr.
For some of the more commonly used shapes, the R values are as shown:
no.dius
L'ilcle Rectangle Tlapezoicl
-h .5 h2(bi+bo)
t: s 1ryf; 1",6u"+ 1
lr, 'il't
R:
(bir; -bor'1) hf - h tlrt - b")
Three-Dimensional Solid Elements 1 1-5
The bending stress in a curved beam, at location r measued from the center of curvature
C, can be expressed as:
M(R-r)
'
6P:
Aer
-
For our analysis, we can establish an

equivalent load system in the upper portion of
the member, through the centroid of the cross
section, as shown.
P:200 lbs.
M:350 in-lb.
The normal stress at the cross section is a combination ofthe stresses from the normal
force P and the bendiflg moment M. The stress distributions axe as shown in the figure
be1ow.
The maximum normal stress occurs on the inside edge, the edge that is closer to the
center of the curvature C.
The normal stress from tle normal force P:
Onormal force
P : -ltT
200 rb
: 800 psi
A
The bending skess component:

M(R-r)
0 :
bending moment Aef
To calculate the bending stress, we will first calculate the R and e values:
ll
R= l."
=.5/ (tn(1.25t.7s))=0.9788
,NT
,
e:1-0.9788= 0.0212
The maximum bending stress, which is at the inside edge (r: 0.75), can now be
calculated:
O bending moment = 350 (0.9788 - .75) I (0.25 x .0212 x.75) = 20146 psi
Therefore
O maximum: O normal force + 6 bendingmoment: 800 + 20146 = 20946 psi
l{o.xim um Stness
The normal stress at the outer edge can also be calculated:
obending@ r.us = 350 (0.9788- 1.25) I (0.25x.0212x1.25): -14327 ps'
Therefore
o qtzs : o normal force * o bending moment : 800 - 14327 = -13527 psi

Three-Dimensional Solid Elements I t-7
Starting SolidWorks
sorid+rark!
Sotidworks main window will appear on the screen.
I |
1 ., 'oI'* I
2. Click on the New icon, located in the Standard

toolbar as shown.
I'iEw {ftrl+N)
CreEles E neur doaument.
3. Select Part by clicking on the first icon in the New

SolidWorks Document dialog box as shown.
T:. r--l
ll -:=--
l--
oor,[ 4.
rf I
Click on the OK button to accept the settings.
5. Select the Options icon from the Menu toolbar to open the Options dialogbox.
6. Click Units as shown in the figure.
7. On your own, set the Unit system to IPS (inch,

pound, second) as shown.
Lhit systEm
. IrlKs {meter, kilogram, second}
CGE {'-enfimetEr, Eram, second}
. l,{t{GS {0rillimeter, gram, serond}
g.lCS [inch. pound, secon{
hEustom
Creating a CAD Model in SolidWorks
.1. To perform the surface FEA analysis, we will first create a solid model using the
Sweep command. The Sweep operation is defined as moving a planar section through
a planar (2D) or 3D path in space to form a three-dimensional solid object. In
SolidWorks, we create a swept feature by defining a 2D sketch of a cross section and
a path. To create the path, we can use a sketch, existing model edges, or curves. The
sketched profile is then swept along the planar path. The Sweep operation is used for
objects that have uniform shapes along a trajectory.
F Define the Sweep Path
1. Click the Sketch tab, in the CommondMandger, to

display the sketch toolbar.
2. Click the Sketch icon, in the Sketch toolbar, to start a

new 2D sketch.
3. Click the Front Plane, in

the graphics area, to align the
sketching plane of our sketch
as shown.
Three-Dimensional Solid Elements 1t-9
4. Click the Line icon in the Sketch toolbar as

shown.
5. Start the first endpoint ofthe line series

at the origin and create the three line
segments as shown.
\-@-r'J- e+
trI-.S.4-A *'fl,
o'o iTl-l* : 6. Click the Fillet icon in the Sketch toolbar
shown.
as
Ery
Sketch Fitlet
7 . Create the two rounded corners as shown.
Click the Smart Dimension icon in the

t_
9. On your own, use the Smart

Dimension command to create the
dimensions and adjust the sketch as
shown.
10. Click the Exit sketch icon in the Sketch

toolbar to exit lhe 2D Sketch mode.
) Define the Sweep Section
In the Model History Tree matager window, click

the Partl item to deselect the Sketchl item.
Click the Sketch icon, irtthe Sketch toolba\ to create

a new 2D sketch.
Three-Dimensional Solid Elements 11-11
3. Inside the graphics area, expand the model

history tree by clicking on the [+] icon in front
of the Parl1 item.
4. Click the Right Plane, tn the Modet Histoty

Tree, to ahgn the sketching plane ofour sketch
as shown.
5. Click the Normal To icon to adjust the display to be

perpendicular to the sketching plane.
6. Click the Rectangle icon in the Sketch

toolbar as shown.
7 . Create a rectangle, roughly centered at the

origin, as shown.
8. On your own, create and adjust the

dimensions of the sketch as shown.
9. Click the Exit Sketch icon tn the Sketch

toolbar to exit the 2D Sketch mode.
1l-12 Introduction to Finite Element Analysis
F Create the Swept Feature
l. Select the Features tab in the CommandManager as

shown.
Click the Swept Boss/Base icon

to execute the Sweep command.
Note the last sketch, the profile sketch, was pre-

selected and therefore it is automatically placed as
the profile ofthe swept feature.
Click the Path selection box as shown.
Paft1 (Defnult< {Default>-..,

Se rr, o rt
AnnotBtioni Select the first sketch, Sketchl, from the Design

I Materral <not 5pe':ified > History Tree as the path for the swept feature.
Click OK to accept the settings and proceed to

create the swept feature.
Three-Dimensional Solid Elements ll-r3
) Greate a Cut Feature
1. Click the Extruded Cut icon to execute the Cxtnrslon

command.
2. Click the front surface of the model, in the

graphics area, to align the sketching plane
of our sketch as shown.
3. On your own, create and modify the 2D

sketch as shown.
4. Click the Exit Sketch icon in the Sketch

5. Click the down arrow nextto the Selecte(l

Conto r option to view the available options.
6. Click the sketched circle to select the contour

as the l't contour to be extruded.
7. Click inside the sketched rectangle to select

the region as the 2nd entity to be extruded.
Set the extrusion Direction I option to

Through All as shown.
Click OK to proceed with the settings and create

the extruded cut feature.
10. On your own, save the completed CAD

model with the file name:
Solid3D.sldprt.
Three-Dimensional Solid Elements I1-15
Activate the SolidWorks Simulation Module

solidworks simulation is a multi-discipline computer Aided Engineering (cAE) tool that
enables users to simulate the physical behavior ofa model, and therefore enable users to
improve the design. SolidWorl<s Simulation can be used to predict how a design will
behave in thc real world by calculating stresses, deflections, frequencies, heat transfer
paths, etc.
The solidworks simtlation product line features two areas of Finite Element Analysis:
Structure and Thermal. Stntcture focuses on the structural integrity of the design, and
I he r ma I ev aluates heat-transfer characteristics-
l. Start SolidWorks Simulationby selecting

the Office Products tab in the
2. In the SolidWorks Ofice list, choose SolidWorks

3. In the CommandManager area, choose

* Note that the solidworks Simulation module is integrated as part of solidwort<s. A1l
of the Solidworks simulation commands are accessible tkough the icon panel in the
( -u n t t tnncl Ma nogcr area.
4. To start a new study, click the New Study item listed

under the Studv Advr'sor as shown.
5. Select Static ofanalysis to be

as the type
perlolmed with So I idWorks S imu I at ion.
* Note the different types ofanalyses are

ffi nucktinq and dynamic analyses, as well as the thermal
analysis.
lqfl--l rn",*"t
r--ii,
lQl Drop TEst
rll{r
It- | -..
iauque
:'
lQl] FressureVesselDesign
6. Click OK to start the defrnition of a stuctural static

analysis.
* ln the FeatureManager area, note that a new

panel, the FEA Slady window, is displayed with
.i. Also note that Study 1 tab is activated,

. On your own, save a copy of the current

model.
Fite name. Solid3D,SLDPRTl
Save as type iPart i-,p(:',sldprt)

[t{rriFiirii. ldd a de;cii1:licn
Three-DimensionalSolidElements ll-17

F Next we will set up the Material Property for the elements. The Material Property
contains the general material information, such as Modulus of Elasticity, Poisson's
1. Choose the Apply Material option

* Note the default list of materials, which are available in the pre-defined SolidWorks
2. Select 6061-T6 Aluminum in the Material list as shom.

3. Set the Units option to display English (lPS) to make the selected material
available for use in the cunent FEA model.
{ f.*.] il ..1 .i11i,,1 [.*cre.]
4. Click Apply to assign the material propefty ihen click Close to exit
the material assignment command.
11-18 Infioduction to Finite Element
Applying Boundary Gonditions - Constraints
1. Choose Fixed Geometry by clicking the

fixture icon in the toolbar as shown.
2. Select the cylindrical surface of the

top portion of the model as the entity to
apply tbe Fixed constraint.
Click on the OK button to accept the Fixture

conshaint settings.
Three-DimensionalSolidElements 11-19
Applying the External Load to the system
1. Choose External Loads ) Force by

2. Select the horizontal surface ofthe

notch of the lower section of the
model as shown.
Set the Units to English (lPS), to match with the

Enter 200 lbfas the applied force.
Click on the OK button to accept the

Force/Torque settings and create the load.
Introduction to Finite Elenrent

with a relatively small number of elements and progressively
-oui to more refined
models. The main objective ofthe first coarse mesh analysis is to obtain a rough idea
ofthe overall stress distribution. In most cases, use ofa complex and/or a very-
refined FEA model is notjustifiable since it most rikely provides computational
accuracy at the expense ofunnecessarily increased processing time.
&
GERec0lir
HUl]
.r.
Aduts,:r l:-, (omFnrE 1. Choose Create Mesh by clicking the icon in the
:r , i F.esuits
toolbar as shown.
: t&
ft,q Run
Run Design Srenarior
2. Switch on the Mesh Parameters options, to

show the additional control options.
3. Set the Uzlts to inches as shown.
4. Enter 0.75 inch as the Global element size.
5. Enter 0.015 inch as the Size tolerance.
* In general, a good rule of thumb to follow in

creating the first mesh is to have 3 to 4 elements
on the edges of the model. The shortest edge in
our model is about 0.5 inches, so we will use 0. 15
as the element size.

settings.
Three-DimensionalSolidElements 1l-21
* The Automatic mesh lunctron tn

SolidWorks Simulation has generated a
fairly uniform and consistent mesh of
elements.
7 . ln the FEA Stady window, click once

with the right-mouse-button on the Mesh
item to display the option list and select
Details as shown.
Studj 1 [-DefEult-] ,
.
Automalic lrBnsition. loff
Loops
lnclude MeshAr.:to off
JaEobiaa Foints d porlr * The current coarse mesh consists of
Element size i 0.1174!l in I 1 747 nodes and,7215 solid elements.
!'{ilh Aspect Batio > 10
8. Click on the [X] icon to close the Mesh Details dialog box.
Inftoduction to Finite Element
Run the Solver
Click on the Run button to start

results.
Once the Solver has comPleted

the calculations, the displaY will
switch to the stress distribution.
2. In the FEA Study window, click once with

the right-mouse-button on the S/ress1 item
to display the option list and select Edit
J. Confirm the Stress Componerr is set to VON: Von

Mises Stress as shown.
Set the display units to PSi.
Set the DeJormed Shape option to Automatic.
The Automatic Deformed Shape option will

enable the display of a scaied up deformation. Note
that the true deformation is relatively small, and
the deformation will not be visible if the display
option is set to True scale.
Tbree-Dimensional Solid Elements I l-23
6. Click OK to display the results.
Plcivpe Sleilc .odalstess SlESsl

Defomau.. s.ale 6 !,87s
* Note the FEA calculated Max. Stress is very similar to the result from the
preliminary analysis on page 1 1-6.
7 . In the FEA Srady window, click once

with the right-mouse-button on the
Displacementl item to display the
option list and select Show to view
the displacement.
.1. The max. displacement

occured at the Iower
lji pofiion of the model,

which rnatches with the
applied constraint and
loading situation.
Refinement of the FEA Mesh - GIobal Element Size 0.10

* one way of refinement is simply to adjust the Global Element sze to a smaller value.
We will need to delete the old mesh and create a new mesh.

toolbar as shown.
Rtrn Desiqn Scenarios
2. Click on the OK button to REmeEhinq will deletethe resultsfor studyr Study1.

proceed with deleting the
..L
old mesh and create a new
mesh of the FEA model.
- oKN I i--il;-l
3. Enter 0.10 inch as the Global element size.
4. Click on the OK button to accept the Meslz settings

and create a new mesh.
1...j Automatir transition

Three-Dimensional Solid Elements tt-25

refinement.
* The current coarse mesh consists of

18443 nodes and 11637 solid elements,
which is about 38% increase of elements
compared lo the first mesh.
6. Click on the Run button to starts

results.
* The FEA Sa/uer calculated the Max. Von Mises Stress with the refinement to be
21140 psi.
lype: Slnl c n.dal stress 9re.s1

Refinement of the FEA Mesh - Mesh Control Option

.!. Another method ofrefining the mesh is to only refine the high stress areas. Since the
Max. Stress occurs on the inside surfaces, we will refine the mesh in those areas by
using the Mesh Control option.
7. In the FEA Slady window, click once

with the right-mouse-button on the Mesh
item to display the option list and select
Apply Mesh Control as shown.
2. Select the lower inside curwed

surface as shown.
Select the adjacent vertical surface as

shown.
Set the Element size on the selected surfaces

to be 0.05 inches, which is halfofthe
Global Element size.
Click on the OK button to accept the Mesh

Control settings.
Three-Dimensional Solid Elements l1-27
i
Gi&
Run , Resu,tE ltE
',qddi5or irefar|*E,, ConFEre
qE5'-i;: aesults
1R,n
@ toolbar as shown.
Run Design Scenarios
C reate
r Run All{tudier

of the FEA model.
8. Confirm the Global element size is set to 0.70

inches as shown.

The Mesh Control option allows us

to refine the mesh in the high stress
areas; this approach can be more
effective than rehning the Global
Element size.
lntroduction to Finite Element

refinement.
.1. The curent coarse mesh consists of 25894

nodes and 16462 solid elements, which is
about 440/o increase of elements, compared
to the last mesh.
PErcentnqe ol elEmenti
wilhAspect Bati! { l
Percenlaqe ol elemenh
11. Click on the Run burton to staft the

FEA Solver to calculate the results.
* The FEA so/ver calculated the Max. von Mises Stress with the refinement to be
21 150.8 psi. The refinement only changes the stress value by 1 .6%,which implies
the FEA mesh is quite adequate.
type Staiic nodetstres. Siressl

Plol
Deloihiilon scala 6 9:31i
H.?1'1508
Sg rs.3sE E
'.
- 1t F26.A
. 15,864.11
,14,102I
.I2,340!
. 10,578.9
. . 5,292 S
::.lr-:,531.0
*tit
r,,,-'
Three- Dimensional Solid Elements I t-29
Refinement of the FEA Mesh - Automatic Transition

.i. To confirm the FEA result has converged adequately, we will next adjust the mesh by
using the Automatic Transition option.
L Choose Create Mesh by clicking the icon in the

toolbar as shown.
Remeshing will deletethe relult5for study: Study 1,

.l.
mesh and create a new mesh j oK H I Can.el I
of the FEA model.
Switch on the Automatic transition option as

shown.
The Automatic Transition option will add additional

elements to make the transition of different element
sizes more gradual.

refinement.
.1. The current mesh consists of50547 nodes

and 33579 solid elements, which is about
a 200% increase of elements, compared to
the last mesh.
6. Click on the Run button to start

results.
* The FEA solver calcrlated the Max. von Mises stress with the refinement to be
2'1118.7 psi. The refinement only changes the stress value by 1.0%, which implies
the previous FEA mesh is quite adequate.
Follype Slat c nodr slress Stressj

Delomotion s.Ete 6 !27a,
H
4g rs,r59.2
:{'.
1 _ 17,59!.7
15,640 2
_ i4,0807
10,561.7
..
. a,an22
JlItt - I842.7
Hiit
I.,
--+ Y eld strenqihr 3S,885.4
Three-Dimensional Solid Elernents I 1-31
Comparison of Results
In FEA, the process of mesh refinement is called convergence analysis. The
convergence
study is necessary for both surface and solid elements. Fir our analysis,
the refinem-ent of
the mesh does show the FEA results converging near the analytical
result. The refinement
to the size of0.10 inches is quite adequate for our anarysis. Note the use
of the Mesh
control and the Automstic Transition options allow the more efficient and effective
refinements of the mesh in the high stress areas.
The accuracy of the solidlrorks simurarion results for this problem

can be checked by
comparing them to the analytical results presented earlier. In the pretiminary
Anarysis
section, the maximum stess was calculated using the curved beam
theory and the value
obtained was 20946 psi. The maximum Von Mises stress obtained
by finite element
analysis using so lidllorks simuration ranged from 21075 to 21r5r psi.
The agreement
between the analytical result and those from soricrworr<s simuratioi
isr.ry go"od.
Global Mesh Number of o'"",, (psi)

Element size Control Elements
0. 1s 7215 2107 5
0. l0 1t637 21140
0. 10 0.05 16462 21151
0. 10 0.05 -Auto 33s79 21119
Transition
(o
o)-
You are also encouraged to create and compare FEA analyses

of the same problem
using one-dimensional beam elements and 2D surface eleir.rents.
what are the
advantages/limitations of perrorming multiple analyses using
different types ofFEA
elements?
Notes on FEA Linear Static Analyses
In examining the FEA results, one should first examine the deformed shape to check for
proper placement ofboundary conditions and to determine if the caiculated deformation
of the model is reasonable. It is always important to perform a convergence study to
obtain more accurate results. Besides using hand caiculations to check the results ofthe
FEA analyses, it is also quite feasible to check the results by using other element types.
For example, the curved-beam problem, illustrated in this chapter, can also be analyzed
using the lD beam elements andlor 2D surface eiements. We do need to r ealize that
different elements have different limitations; for example, the stress concentration effects
are not present with the beam elements. But the purpose ofperforming a second and/or a
third analysis is to assure the results of the first analysis; so it is not necessary to expect
all element types to produce exactly the same results. This concept is fuither illustrited in
the next chapter.
It should be emphasized that, when performing FEA analysis, besides confirming that the
systems remain in the elastic regions for the applied loading, other considerations are also
impoftant; for example, large displacements and buckling of beams, which can also
invalidate the linear statics analysis results. In performing finite element analysis, it is
also necessary to acquire some knowledge of the theory behind the method and
understand the restrictions and limitations ofthe software. There is no substitution for
experience.
Finite element analysis has rapidly become a vital tool for design engineers. However,
use of this tool does not guarantee correct results. The design engineer is still responsible
for doing approximate calculations, using good design practice, and applying good
engineering judgment to the problem. It is hoped that FEA will supplement these skills to
ensure that the best design is obtained.
t
Three-Dimensional Solid Etements I l-33
Questions:
l. What are the most widely used failure criteria?
2. What are the main objectives of finite element analysis?
3. What will happen to the system if it is stressed beyond the elastic limit?
4. What are the necessary items to create a swept featue in SolidWorl<s?
5. What is the purpose of doing a convergence study?
6. Under what condition is the bending stress developed in a curved beam no longer
linear?
7. Can a curved beam problem be analyzed with the 1D beam element? What is the
main limitation of performing such an analysis?
8. What are the advantages ofusing 3D elements over using the lD or 2D elements?
11-34 Introduction io Finite Element
Exercises:
1. For the steel U-shape design (diameter: Ve"), determine the maximum stress
developed under a loading ofP:200 lb.
///+
'ffi--
,*r# ]_]
T,
For the above problem, perform additional FEA analyses using the two cross-sections
shown below and compare the results.
--r_
I
E-
,JJ
Chapter 12
3D Thin Shell Analysis
Pdiypa sac nda 3€$ (rop)sreer
w.5,.6.060
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,YEdjleiqlh6,D42zo00o
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Ewmu@@Weffiree
Understand the procedures to create
Solid and Shell FEA models.
Create a surface Model and perform an
FEA Analysis, using Shell elements.
Apply proper constraints to the different
types of elements.
Understand the Basic differences of the
different 3D FEA elements.
12-2 Intoduction to Finite Element Analvsis
lntroduction
In the previous chapter, we have examined the use ofthe three-dimensional solid element
to perform FEA analyses. Although, the three-dimensional (3-D) solid element is perhaps
the most versatile rype of element compared to the other types of elements; certain
situations do exist where the 3-D solid elements might not be the most effective option in
performing FEA analyses. For example, designs that are made of thin materials, such as
pressure containers, tanks and drums. Also, designs with long and narrow features, such
as pipes and frames. For these types ofdesigns, if analyzed with the 3-D solid elements,
wili typically result in a very large number of elements and therefore require much more
computing power and time to perform the FEA analyses.
The three-dimensional thin shell element is another type of 3-D element that is
particularly designed to aid the FEA analyses ofthin shell designs. In theory, all designs
could be modeled with three-dimensional solid elements. A thin shell design can also be
analyzed, using 3D solid elements. Two of the main considerations in selecting the
element type to use are (1) the amount of time it takes to perform the analysis, and (2) the
accuracy of the results.
With the advancements in computer technology in the last few decades, it is now quite
feasible to perform multiple FEA analyses using different types of elements. In many
instances, performing FEA analyses may be faster than hand calculations; and one should
also realizing that hand calculations might not be possible in many situations. In this
chapter, the procedures to perform FEA analyses using the above two types of elements
are illustrated. To assure the accuracy ofFEA results, performing a second and/or a third
analysis can be very practical and effective.
3D Thin Shell
In FEA analysis, the 3D solid element is the most versatile type of element, as all designs
are three dimensional objects.
3D Solid
analysis
In FEA analysis, if a part is relatively thin compared to its length and width, using shell
elements would be more efficient than using 3D solid elements. ln SotidWorks
simulation, we can also create a surface model, which is an idealization ofthe design.
Thin Shell
analysis
Resides selecting the proper type of elements to be used in the FEA analyses, options to
simplifz the FEA analyses, such as symmetry, should also be considered. Symmetry is an
important characteristic that is often seen in designs. Symmetrical designs ire generally
more pleasing to the eye and also provide the desirable functionalities in designs. As ii
was illustrated in chapter 11, symmetry can greatly reduce the computing time in FEA
analyses.
l2-4 lntroduction to Finite Element Analysis
Problem Statement
Determine the tangential and longitudinal stresses of the thin-wall cylindrical pressure
vessel shown in the figure below. The pressure vessel is made ofsteel and is subject to an
internal pressure of 15MPa. The dimensions of the vessel are: End radius 300mm,
cylindrical length 500mm and wall thickness 25mm.
On the cylindrical section of the pressure vessel, the two principle stresses are (1) the
tangential and (2) longitudinal stresses. The principle stresses on the hemispherical
ends are tangential stress. These primary stresses are identified as shown in the hgure
below.
From strength of Materials, the principle stresses on the cylindrical section ofthe
pressure vessel walls, which are the tangential and longitudinal stresses, can be
determined by
6tur€ential
Pdi
otangentiar : n :15.0 x 106 x (2 x0.275)l(2x0.025)
= 165 MPa
olongitudinal : iPd = 15.0x 106x (2 xO.27Sl@x0.025)

: 82.5 MPa
The principle stresses on the hemispherical section are tangential sffesses, which can be
determined by
O€t*g"ntiur: ru = 15.0x 106x (2 xO.2Z5)l$xO.O2S)

4t
: 82.5 MPa
In the following sections, we will perform three FEA analyses, using two different types
of FEA elements: Shell and 3D Solid elements.
lntroduction to Finite Element
Starting SolidWorks
I. Select the SolidWorks option on the Start menu or select the
SolidWorks icon on the desktop to start SolidWorks.The
SolidWorks main window will appear on the screen.
2. Click on the New icon, Iocated tn the Standard

toolbar as shown.
New (Ctrl+Iil
Crentes B ne14 dorumeFt,
Select Part by clicking on the first icon in the New

Solidlltorks Document dialogbox as shown.
|-:ilI 4. Ctick on rhe OK burron ro accept rhe serrinss.

Ita(t
.-:"a--.:--r:::-::11
5. select the options icon from the Menu toolbar to open the options diarogbox.
6. Click Units as shown in the fisure.
7. On your own, set the (Jnit

q\tten to MKS
(meter, kilogram, second) as shown.
Lhit sy5tenl
s l'1K5 kjlEgiam, se,:ond}
',aGS {meter,
{centimetEr, gram, ser:Dnd)
tl cs {m limEter, grarrt, secondi
, IPS {nch, plund, se,:ondJ
Custonl
Creating a 3D Solid Model in SotidWorks
'l' To perform the 3D solids FEA analysis, we will first create a solid model using the
Revolve command. The Revolve operation is defined as creating a solid by iaking
a planar section rotating about an axis ofrotation.
1. Click the Revolved Boss/Base icon, in the Features

toolbar, to create a new revolved feature.
2. Click the Front Plane,

in the graphics area, to
align the sketching plane
ofour sketch as shown.
3. On your own, create the 2D

sketch as shown. Note the
top vertical edge, the bottom
horizontal edge and the
centers of the arcs are
aligned to the origin ofthe
coordinate system.
4. Click the Exit sketch icon in the Sketch

Select the vertical edge, aligned to the origin of the

coordinate system, as the axis olrotation.
Click on the Reverse Direction icon to set the

revolve direction into the screen.
Set the Revolve Angle to 90.00 deg as shown.
Click OK to proceed with the settings and create

the revolved feature.
* Note that the symmetrical nature of the

design makes it more effective to
perform the FEA analysis with respect
to the symmefy planes.
Activate the SolidWorks Simutation Module
solidworks simulation is a multi-discipline computer Aided Engineering (cAE) tool that
enables users to simulate the physical behavior ofa niodel, and therefore enables users to
improve the design. solidworks Simulation can be used to predict how a design will
behave in the real world by calculating stresses, deflections, frequencies, heaitransfer
paths, etc.
The solidworks simttlation product line features two areas of Finite Element Analysis:
Structure and rhermal. structure foctses on the structural integrity ofthe design, and
therm al evaluates heat-transfer characteristics.
1. Stan Solidllorks Simulation by selecting

the Office Products tab in the
;G rs
L':. 2. In the Solidllrorks Office list, choose SolidWorks
Salidftor|..5 Solidit'jsrks
E'ruting Simulation as shown.
LJ.
3. In the CommandManager area, choose

'i' Note that the solidworks simulation module is integrated as pafi of solidworks . All
of the solidllrorks simukttion commands are accessible through the icon panel in the
CommandManager area.
4. To start a new study, click the New Study item listed

under the Study Advisor as shown.
5. Select Static
as the rype ofanalysis to be
performed with Solidlho rks Simulation.
* Note the different types ofanalyses are

and dynamic analyses, as well as the thermal
analysis.
6. Click OK to start the definition of a structural static

analysis.
Pa*1 * In lhe FeatureManager area, note that a new

panel, the FEA Study window, is displayed with
{. Also note the Study 1 tab is activated,

On your own, save a copy ofthe curent

model-
) Next we will set tp the Material Property for the elements. The Material property
contains the general material information, stch as Modulus of Elasticity, poisson's
1. Choose Apply Material option

'l' Note the default list of materials, which are available in the pre-define d solidworlc
2. Select Alloy Steel in the Material list as shown.

3. Confirm the Units option to display Sl - N/m^2 (pa).
4. Click Apply to assign the material property then click Close to exit
the Material Assignment command.
Applying Boundary Gonditions - Constraints
'!' For our solid analysis, the model we created is a % solid model of the pressure
container which is symmetrical about the horizontal mid-plane and two vertical
planes. we will need to apply roller constraints to the three symmetry pranes,
'
not allowed in the perpendicular directions of the syrnmetry planes. ^
motions
Choose Roller/Slider by clicking the fixture icon

in the toolbar as shown_
2. Select the front surface ofthe model

as the entity to apply the constraint.
3. On your own, rotate the 3D model to view the back plane as shown.
4. Select the track surface ofthe

model as the entity to apply the
constraint-
5. On your own, rotate and select the

bottom surface as shown.
Click on the OK button to accept the Fixture

Applying the Pressure to the System
1. Choose External Loads ) Pressure by

2. Select the inside surfaces of

the model as shown.
Set the [/zils to N/m^2, to match with the

4. Enter 15e6 N/m^2 as the applied force.
Click on the OK button to accept the Pressure

settings and create the load.
3D Thin Shell Analysis 12-15

with a relatively small number of elements and progressively move to more refined
of the overalI stress distribution.
EA
tlEt
Run '-_: -- - aafipare 1 . Choose Create Mesh by clicking the icon in the
Reirits
toolbar as shown.
2. Switch on the Mesh Parameters options, to show the

additional control options.
J. Set the mesh option to Standard mesh.
4. Sel lhe Units to meters as shown.
5. Enter 0.025m as the Global Element size.
9 Stdndard mesh
Curlatlre bdsed
:'. In general, a good rule of thumb to follow in creating
mesh
the first mesh is to have about 3 to 4 elements on the
m edges of the model. Since our model has fairly small
cross section, we will use the wall thickness as the
element size.
6. Click on the OK button to accept

the Mesh settings.
Introduction to Finite Element Ana
Run the Solver and view the results
Click on the Run button to staft the FEA

Solver to calculate the results.
Once the solver has completed the

calculations, the display will switch to
the stress distribution.
* Note the FEI solver calculated Max. Stress is very similar to the result from the
preliminary analysis on page 12-5.
2. On your own, examine the mesh details.

Current mesh consists of5961 nodes
and 3136 elements.
313E
.i. To confirm the FEA results are valid, we will adjust the mesh by tsing a Global
Element size of 0.0125.
1 . On your own, adjust the mesh size to 0'0725 as shown.
2. Click on the Run button to start the FEA Solver

to calculate the results.
PLot iyFe Si.nL. nodalstress slressl

oelErhat on sce e: 26634
* The FEA So/ver calculated the Max. Von Mises Stress with the refinement to be
164.6MPa, which varied just a bit from the previous mesh. This confirms the
FEA is adequate.
Inhoduction to Finite Element
Starting a New 3D Surface Model

.1. To perform the 3D FEA thin shell analysis, we will first create a new surface model.
1. Click on the New icon, Iocated in the Standard

toolbar as shown.
SelectPart by clicking on the first icon in the Ner.u

SolidWorks Document dialog box as shown.
T,-:1.
L g h,--, 1 :. Cti.f on the OK burlon ro accept Lhe serrings.
I--:-E-{:.
-!'T:+'
4. Select the Options icon frorr the Menu toolbar to open the Options dialogbox.
5. On your own, set the Urlts to MKS (meter,

kilogram, second) as shown in the figures.
Lhit syEtem
Q. l4l$ {meter. kilogram, second)
.
,.CGS
. {Eefitimeter, gram, second)
kIMGS {millimeter, gram, second}
IPS dnch, pound, semnd)
' austom
6. In the pull-down menu, select:
lnset) Surface ) Revolve
Click the Front Plane, in the

graphics area, to align the
sketching plane ofour sketch as
shown.
8. On your own, create the 2D sketch as

shown. Note the sketch consists of an
arc connected to a vertical line and one
vertical center line. A1so, note the
alignment between the top endpoint, the
center point, and the bottom endpoint to
the origin.
9. Click the Exit Sketch iconinthe Sketch

10. Confirm the center line is selected as the axis of

rotation.
1 1. Ifnecessary, set the rotation direction by clicking

on the Reverse icon.
12. Set the Revolve Angle to 90.00 deg as shown.
13. Click OK to proceed with the settings and create

the revolved feature.
14. On your own, save a copy of the

current model-
3D Thin Shell Analysis 12-21
Starting a New FEA Study
To start a new study, click the New Study item

listed under the,Stady Advisor as shown.
2. Select Static as the type

ofanalysis to be
performed with So lidWorks Simulation.
J. Click OK to start the definition of a structural static

analysis.
In the FeatureManager area, note that a new

panel, the FEA Study window, is displayed with
Right-mouse-click once on the Study 1 tab to

display the option list and select Rename as
shown.
5. On your own, rename the FEA study to Shell.

Completing the Definition of the Surface Model
1 . Click on the model name in the study window

and notice the thickness of the model has not
been defined.
2. Right-mouse-click once on the

model name to bring up the
option list and select Edit
J. Confirm the Type option is set to Thin as

shown.
4. Enter 0.025 m as the surface thickness as

shown.
Click on the OK button to accept the Shell

Definition settings.
f she {-oef!utt-) 6. Notice the waming icon is removed in the study

ShelllD window, indicating the surface model is fully
Conne,:tiDr,5 defined.
FixtureJ
External Londi
tvtElh
> Next we will set up the Material Property for the elements. The Material property
contains the general material information, stch as Modulus of Elasticity, poisson;s
1. Choose the Apply Material option from the

pull-down menu as sbown.
* Note the default list of materials, which are available in the pre-define d, solidll'orks
2. Select Alloy Steel in the Malertal list as shown.

3. Confirm the Units option to display Sl - N/m^2 (pa).
y"J#ir5t::i:y".y*rcibe edted. y@hlsr6r,r@py $eroiBi.r io
fi;Ed;:;t;:--'I;
i!.y,e:e!i.:--
-],j
,'...o.,r=r:.., ,l
.. .1:. .. ...ttt. :t. . tu....
4. Click Apply to assign the material propefty then click Close to exit
the Material Assignment command.
Applying Boundary Conditions - Constraints

'i' For our solid analysis, the model we created is a % solid model ofthe pressure
container which is symmetrical about the horizontal mid-plane and two vertical
planes. The most impoftant differences between 3D shell analysis and 3D solid
analysis is in applying the constraints; shell elements have rotational degrees of
freedom and the constraints for shell model must be applied to edges or
"o.ves.
1. Choose Advanced Fixtures by clicking the

2. Select the two edges aligned to

the Front Plane of the model as
the entities to apply the
constraint.
3. Click in the Direction reference box to

activate the selection of the direction
reference.
Shelll0 {Defiult{ {DefiLrlt,,,
!l Annotationr 4. In the model history tree, select the Fro nt plane of

Sr#a,:e Bodies{1) the CAD model as the direction reference.
: f,lntErial {nnt -;pe':rfred >
Set the distance measurement to meters, to match
with the sysrems units we are using.
In the Translation constraints list, click on the

Normal to Plane icon to activate the constraint.
Set the Normal to Plane distance to 0 as shown.
Click on the Along Plane Dir 1 and Along plane

Dir 2 icons to aclivate the consrraint.
Set the Along Plane Dir I and Along plane Dir 2

10. Click on the OK button to accept the Fixture

Introduction to Finite Elemenr
I 1. Choose Advanced Fixtures by clicking the

I2. Select the two edges on the

left side of the model as the
entities to apply the
constraint.
ShellSD (Default< <Default,,,

Senrorr
Annotntions
Surface Eodier{1) I 3. Click in theDirection reference box to activate
[,'literiil {not 5pe':ified } the selection of the direction reference.
Front
ToF 14. In the model history tree, select the Right Plane of
\ the CAD model as the direction reference.
Lr q1\)
15. Set the distance measurement to meters, to match

with the sysrems units r,r e are using.
16. In the Translations constraints list,

click on the
17. Set the Normal to Plane distance to 0 as shown.
18. Click on the Along Plane Dir 1 and Along plane

Dir 2 icons to activate the constraint.
19. Set the Along Plane Dir I and Atong plane Dir 2
3D Thin Shell Analysis 12-2'7
20. Click on the OK button to accept the Fixture

21. Choose Advanced Fixtures by clicking the

22. Select the inside edge oL the bottom

surfoce of the model as the entity to
apply the constraint.
23. On your own, set the Top Ptane ofthe

CAD model as the direction reference.
24. Set the distance measurement to meters, to match

25. In the Translations constraints list, click on the

26. Set the Normal to Plane distance to 0 as shown.
27. Click on the Along Plane Dir 1 and Along

Plane Dir 2 icons to activate the constraint.
28. Set the Along Plane Dir I and Along Plane Dir 2
29. Click on the OK button to accept thb Fixture

Applying the Pressure to the system
1. Choose External Loads ) Pressure by

2. Select the inside faces ofthe

model as shown.
Set the Unirs to N/m^2, to match with the

Enter f5e6 N/m^2 as the applied force.
Click on the OK button to accept the Pressure

settings and cieate the load.
Create the first FEA Mesh - Goarse Mesh
) As a rule in creating the first FEA mesh in using the H-element approach is to start
with a relatively small number of elements and progressively
-ou. to more refined
of the overall stress disrriburion.
l. Choose Create Mesh by clicking the icon in the

toolbar as shown.
Switch on the Mesh Parameters option, to show

the additional control options.
Set the mesh to Standard mesh and Un lls to

meters as shown.
4. Enter 0.025 rneters as the Global eleuent size.
, We are using the same element size as the previous

3D solid analysis; this will allow us to compare the
two analyses.
5. Click on the OK button to accept the

Mesh settilgs.
Inffoductiol to Finite Element
Run the Solver and view the results
Click on the Run button to stafi the FEA

Solver to calculate the results.
* Once the solver has completed the calculations,

the display will s$,itch to the stress distribution.
Floiiype: Stali. n.dEl slr€ss lToFt slres.l

Deiornrli.n scal. :4r.426
* Note the FEA calculated Max. Stress is about 4Yo lower than the result from the
preliminary analysis on page I2-5.
2. On your own, examine the mesh

details. Current mesh consists of
1672 nodes and 797 elements,
which are only about one quarter
of the elements in the solid mesh
performed in the previous section.
This also indicates the solution
time is much less than the solid
analysis.
3D Thin Shell

* The shell model, without the small cross section, arlows us to create
a more uniform
mesh, we will adjust the mesh to a global element size of 0.010.
!j Heh Taranreters. . A l
I. On your own, adjust the mesh size to 0.010 as

' Curuahlre based mesh shown.
FI m
A o.o toom
u4riJ-u;.il4rd4{E
. 0.000sn - :
l44jJ*tti",iJ,itdd{iti,
Lj AubmatiE bEnsition
Click on the Run button to start the

FEA Solver to calculate thc results.
* The FEA,solver calculated the Max. von Mises Stress with the refinement
to be
160.3MPa, which is about 3% ditTerEnce to the preliminary results. Note the
refinement generated 5280 elements, which is about 6.6 times nrore elements
than
the previous mesh.
Questions:
1. For designs that are thin and symmetrical about an axis, what are the different FEA
analyses available in SolidWorkg Simulation?
2. What are the advantages and disadvantages ofperforming a shell analysis over a 3D
solid analysis?
3. In SolidWorks Simulation, how do you sefup the FEA model to be a surface model?
4. What are the requirements to apply constmints on thin shell models?
5. How do you specify the thickness ofa thin shell model?
6. What are the differences in applying constraints on thin shell models vs. solid
models?
Exercises:
1. Determine the maximum Von Mises stress of the thin-wall round-bottom cylindrical
pressure vessel shown in the figure below; dimensions are in mm. The pressure vessel
is made of steel and is subject to an internal pressure of 10MPa. For the FEA
analyses, set all degrees of freedom to fixed at the top edge of the opening. (The
Radius 225 and Radius 200 arcs share the center point, which is measured 200 mm
along the vertical axis. The Radius 265 and Radius 235 arcs also share the same
center point at the origin.)
2. Determine the maximum von Mises stress of the thin-wall flat-bottom cylindrical
pressure vessel shown in the figure below; dimensions are in inches. The pressure
vessel is made ofsteel and is subject to an internal pressure of45psi. For the FEA
analyses, set all degrees of freedom to f ixed at the top edge ofthe opening.
Shell thickness:
0.3

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Introduction to Finite Element

In this chapter, we will examine the use of two-dimensional sorid finite

1. Plane stress Elements: plane stress is defined to be a state ofstress

2. Plane Strain Elements: plane strain is defined to be a state of strain

3' Axisymmetric Elements: Axisymmetric structues, such as storage

4. shell Elements: Sherl elements are surface elements with a thickness

ln solidworks simulation, the plane stress and prane strain analyses

Geometric 1ug161 Hole Diameter

Geometric factor: .7512 = 0.375

ouex : K onominar : 2.27 x 960 - 2180 psi.

The classic one-dimensional displacement can be used to estimate the displacement

but the best estimate is a sum from the two regions:

Geometric Gonsiderations of Finite Elements

2. Click on the New icon, located in the Standard

Select Part by clicking on the fimt icon in the _ty'ew

6. Click Units as shown in the figure.

1. Click the Extruded Boss/Base icon, in

2. Click the Front Plane, in the

3. Click the Rectangle icon in the

4. Start the first comer ofthe rectangle at

5. On your own, use the Smart Dimension

6. Click the Circle icon in the

7. Click the origin to align the center

8. Create a circle ofarbitrary size as

9. On your own, create and adjust the diameter of the

10. Using the Trim Entities command, modily the

1 1. Click the Exit Sketch icon in the Sketch

12. On your own, using the extrusion distance of

Activate the SolidWorks Simulation Module

OfficP Produrts r,-

3. In the CommandMonoger area, choose

4. To starl a new study, click the New Study item listed

.1. Note the different types of analyses are

6. Click OK to start the definition of a structural static

4 In the FeatureManager area, note that a new

Also note the Study 1 tab is activated,

On your own, save a copy of the culaent

Defining a Surface Model

1 . Right-mouse-click once on the model

2. In the graphics area, select the

* For the surface model, the thickness ofthe surface

J. Confirm the Type option is set to Thin as shown.

4. Enter 0.25 as the Shell thickness as shown.

5. Click on the OK button to accept the Shell

1. Choose the Apply Materials option

2. Select 6061 -T6 Aluminum in the Material list as shown.

ilaterlals in he detault library 6 rct be edtted,

tsil @l '':.',rr.. i-ll+l

Applying Boundary Conditions - Constraints

1. Choose Advanced Fixtures by clicking

2. Select the bottom

Activate the Direction Reference list option box by

4. Select the front face of the

lnthe Translation constraints list, click on the

Set the Normal to Plane and, Along Plane Dir 2

Click on the Along Plane Dir 1 and Along

Set the Along Plane Dir I and, Along Plane Dir 2

10. Click on the OK button to accept the first Fixture

I 1. Choose Advanced Fixtures by clicking

12. Select the left vertical edge of

13. Activate the Direction Reference list option box by

14. Select the front face ofthe

16. In the Translation constraints 1ist, click on the