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ASHOKKUMAR.K
Senior Engineer -CAE
Page 1
Training Proposal - FEA Training Courses
▪ Day 1
How to solve Engineering Problems, Introduction – FEA , Equilibrium, Strain-Displacement Relationship, Stress,
Hooke's Law, Degrees of Freedom, Element Type, Element Shape Function, Element and Global Stiffness Matrices,
Loads and Boundary Conditions, Rigid body Motions, Solving the System of Equations, Sample Problem Using Bar
Elements, Characteristics of FE Analysis.
▪ Day 2
Structural stress analysis , static analysis Vs Dynamic analysis, Linear Vs Nonlinear, Table of Consistent Units ,
modeling decisions, Types of loads, Plane stress, Plane strain, Types of symmetry, Types of nonlinearity, Line element,
2D element,3d element, shell element, solid element, Meshing, How to choose elements for particular analysis? Stress
singularities, How to verify the results?
▪ Day 3
Dynamic analysis - modal analysis, Benefits of modal analysis, Free – Free run, How many natural Frequencies
can any object have? Why to evaluate natural Frequency? Theoretical foundations, Frequency, Resonance,
Dynamic Equilibrium, What are the Factors Affecting Natural Frequencies? Prestress analysis, Spin softening,
Stress Stiffening, Large deflection, Difference between Rigid element & weight factor.
ASHOKKUMAR.K
SENIOR ENGINEER -CAE
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How to solve Engineering Problems
Acoustic/NVH. -Vibration
CFD
FDM
Thermal & Fluid
ASHOKKUMAR.K
SENIOR ENGINEER -CAE
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FINITE ELEMENT ANALYSIS
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SENIOR ENGINEER -CAE
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Introduction FEA Training Courses
▪ Introduction to FEA
▪ FEA Best Practices
▪ Static
▪ Dynamics
▪ Structural Nonlinearities
ASHOKKUMAR.K
SENIOR ENGINEER -CAE
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Overview of the Finite Element Method
ASHOKKUMAR.K
SENIOR ENGINEER -CAE
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OVERVIEW OF THE FINITE ELEMENT METHOD
▪ Introduction - FEA
▪ Equilibrium
▪ Strain-Displacement Relationship
▪ Stress
▪ Hooke’s Law
▪ Degrees of Freedom
▪ Element Type
▪ Element Shape Function
▪ Element and Global Stiffness Matrices
▪ Loads and Boundary Conditions
▪ Solving the System of Equations
▪ Sample Problem Using Bar Elements
▪ Characteristics of FE Analysis.
ASHOKKUMAR.K
SENIOR ENGINEER -CAE
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Overview What is FEA?
▪ Historical Note
• The finite element method of structural analysis was created by academic and industrial
researchers during the 1950s and 1960s.
• The underlying theory is over 100 years old, and was the basis for pen-and-paper
calculations in the evaluation of suspension bridges and steam boilers.
ASHOKKUMAR.K
SENIOR ENGINEER -CAE
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Overview What is FEA?
▪ The finite element model, which has a finite number of unknowns, can only approximate the
response of the physical system, which has infinite unknowns.
— So the question arises: How good is the approximation?
— Unfortunately, there is no easy answer to this question.
It depends entirely on what you are simulating and the tools you use for the simulation.
We will, however, attempt to give you guidelines throughout this training course.
ASHOKKUMAR.K
SENIOR ENGINEER -CAE
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Overview What is FEA?
ASHOKKUMAR.K
SENIOR ENGINEER -CAE
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Overview Equilibrium
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SENIOR ENGINEER -CAE
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Overview Equilibrium
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SENIOR ENGINEER -CAE
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Overview Strain-Displacement Relationship
▪ In a structural finite element analysis, the displacements (U) throughout the model
are found directly from the governing equation.
▪ However, the analyst may also be interested in other quantities, such as strain and
stress.
▪ Strain can be defined as the change in the length divided by the original length.
▪ Thus, strain (ε) and displacement (U) are directly related, and once the displacement
field is known, the strain can be found, as in this 1D case:
ASHOKKUMAR.K
SENIOR ENGINEER -CAE
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Overview Stress
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SENIOR ENGINEER -CAE
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Overview Hooke’s Law
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SENIOR ENGINEER -CAE
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Overview Degrees of Freedom
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SENIOR ENGINEER -CAE
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Overview Element Type
▪ The DOFs at a node are a function of the element type connected to the node.
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SENIOR ENGINEER -CAE
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Overview Element Shape Function
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SENIOR ENGINEER -CAE
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Overview Effect of Element Shape Function
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SENIOR ENGINEER -CAE
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Overview Element Stiffness Matrices
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SENIOR ENGINEER -CAE
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Overview Global Stiffness Matrix
▪ Once defined, the element stiffness matrices are assembled into global stiffness matrix.
— The global stiffness matrix describes the stiffness of the entire structure.
— The global stiffness is represented in the governing equation by K.
— The size of the global stiffness matrix is equal to the total number of nodes
times the number of DOFs per node.
▪ The more elements in the model, the more DOFs, the more accurate the global
stiffness definition.
ASHOKKUMAR.K
SENIOR ENGINEER -CAE
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Overview Element and Global Stiffness Matrices
▪ The assembly of the global stiffness matrix is based on how the elements are connected.
— When two adjacent elements share nodes, the element stiffness
coefficients are added.
— Therefore, if two adjacent elements do not share nodes, their stiffness
are not linked, and there is no connectivity.
— A common modeling error occurs when adjacent elements do not share
nodes, which is analogous to modeling a crack between the elements.
ASHOKKUMAR.K
SENIOR ENGINEER -CAE
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Overview Loads and Boundary Conditions
▪ Once the global stiffness matrix is defined, the applied loads must be input.
— After all, the goal of the structural analysis is to determine the response of
the structure to applied loads.
▪ Loads are in many forms:
— Forces and moments at nodes.
— Pressures on surfaces of elements.
— Temperature distributions.
— Centrifugal loads due to angular velocity (spinning).
— Gravity.
ASHOKKUMAR.K
SENIOR ENGINEER -CAE
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Overview Loads and Boundary Conditions
▪ Once the global stiffness (K) and loading information (F) has been
determined, the governing equation can now be solved for the
nodal displacements (U).
— The governing equations are in the form of simultaneous equations.
— The solution for U can be obtained by inverting K.
ASHOKKUMAR.K
SENIOR ENGINEER -CAE
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Overview Loads and Boundary Conditions
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Overview Loads and Boundary Conditions
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Overview Solving the System of Equations
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Overview Sample Problem Using Bar Elements
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Overview Sample Problem Using Bar Elements
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Overview Sample Problem Using Bar Elements
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Overview Sample Problem Using Bar Elements
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Overview Sample Problem Using Bar Elements
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Overview Sample Problem Using Bar Elements
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Overview Sample Problem Using Bar Elements
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Overview Sample Problem Using Bar Elements
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Overview Characteristics of FE Analysis
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Stress Analysis Basics
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Stress Analysis Basics Overview
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SENIOR ENGINEER -CAE
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Stress Analysis Basics How Would a Structure Fail?
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SENIOR ENGINEER -CAE
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Stress Analysis Basics How would a structure fail?
▪ When a structure is loaded, if stress exceeds the yield strength or ultimate strength
of the material, failure will occur.
▪ If the stiffness of a structure is too low, the deflection of the structure when
loaded is large, which will affect the precision of motion of the mechanical
system, and problems in vibration and noise will occur.
▪ For structures, the ability to sustain tension and compression is much higher
than the ability to sustain bending, for example, breaking egg shells, dome
structures.
ASHOKKUMAR.K
SENIOR ENGINEER -CAE
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Stress Analysis Basics
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SENIOR ENGINEER -CAE
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Stress Analysis Basics General Analysis Steps
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SENIOR ENGINEER -CAE
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Stress Analysis Basics Geometry Summary
▪ Preprocessing
— Geometry
— Meshing
▪ Solution
— Loading
— Solve
▪ Post processing
— Review results
— Check validity of solution
ASHOKKUMAR.K
SENIOR ENGINEER -CAE
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Stress Analysis Basics Geometry
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SENIOR ENGINEER -CAE
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Stress Analysis Basics Geometry
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SENIOR ENGINEER -CAE
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Stress Analysis Basics Meshing
▪ Meshing is the process used to “fill” the solid model with nodes and
elements, i.e., to create the FEA model.
— Remember, you need nodes and elements for the finite element solution,
not just the solid model. The solid model does NOT participate in the
finite element solution.
ASHOKKUMAR.K
SENIOR ENGINEER -CAE
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Stress Analysis Basics Meshing
▪ Element attributes are characteristics of the finite element model that you must
establish prior to meshing.
They include:
— Element types
— Real constants
— Material properties
ASHOKKUMAR.K
SENIOR ENGINEER -CAE
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Stress Analysis Basics Meshing
▪ Element type:
The element type is an important choice that determines the following
element characteristics:
• Degree of freedom (DOF) set. A thermal element type, for example, has one
dof: TEMP, whereas a structural element type may have up to six dof: UX,
UY, UZ, ROTX, ROTY, ROTZ.
• Element shape -- brick, tetrahedron, quadrilateral, triangle, etc.
• Dimensionality -- 2D (X-Y plane only), or 3D.
• Assumed displacement shape -- linear vs. quadratic.
.
ASHOKKUMAR.K
SENIOR ENGINEER -CAE
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Stress Analysis Basics Meshing
▪ Real constants:
— Real constants are used for geometric properties that cannot be
completely defined by the element’s geometry. For example:
• A beam element is defined by a line joining two nodes. This defines only the
length of the beam. To specify the beam’s cross-sectional properties, such as
the area and moment of inertia, you need to use real constants.
• A shell element is defined by a quadrilateral or triangular area. This defines
only the surface area of the shell. To specify the shell thickness, you need to
use real constants.
• Most 3D solid elements do not require a real constant since the element
geometry is fully defined by its nodes.
ASHOKKUMAR.K
SENIOR ENGINEER -CAE
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Stress Analysis Basics Meshing
▪ A note on units:
— You do not need to tell to CAE SOFTWARE the system of units you are using.
Simply decide what units you will use, then make sure all of your input is
consistent.
• For example, if the model geometry is in inches, make sure that all other input
data — material properties, real constants, loads, etc. — are in terms of
inches.
— CAE SOFTWARE does NOT do units conversion! It simply accepts all numbers
you input without questioning their validity.
ASHOKKUMAR.K
SENIOR ENGINEER -CAE
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Stress Analysis Basics Table of Consistent Units
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SENIOR ENGINEER -CAE
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Stress Analysis Basics material properties
▪ Material properties:
— Every analysis requires some material property input: Young’s modulus
for structural elements, thermal conductivity for thermal elements, etc.
ASHOKKUMAR.K
SENIOR ENGINEER -CAE
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Types of Materials:
▪ Linear material
▪ Multi Linear material ( stress vs strain curve data)
▪ Bilinear material
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SENIOR ENGINEER -CAE
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Stress Analysis Basics Loading
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SENIOR ENGINEER -CAE
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Stress Analysis Basics Reviewing Results
▪ It is always a good idea to do a “sanity check” and make sure that the
solution is acceptable.
▪ What you need to check depends on the type of problem you are
solving, but here are some typical questions to ask:
— Do the reaction forces balance the applied loads?
— Where is the maximum stress located?
▪ If it is at a singularity, such as a point load or a re-entrant corner, the value is
generally meaningless.
— Are the stress values beyond the elastic limit?
▪ If so, the load magnitudes may be wrong, or you may need to do a nonlinear
analysis.
ASHOKKUMAR.K
SENIOR ENGINEER -CAE
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▪
Modeling Decisions
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SENIOR ENGINEER -CAE
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Modeling Decisions Overview
▪ Before starting an analysis in CAE software, you need to make a few decisions, such
as the analysis type needed and the type of model you want to build.
▪ In this chapter, we will discuss some of the decision making process.
▪ The purpose is to give you an idea of the amount of planning generally needed
before “jumping in” to do the analysis.
▪ Topics covered:
— Which analysis type?
— What to model?
— Which element type?
ASHOKKUMAR.K
SENIOR ENGINEER -CAE
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Modeling Decisions Which Analysis Type?
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Modeling Decisions Which Analysis Type?
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Modeling Decisions Which Analysis Type?
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SENIOR ENGINEER -CAE
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Modeling Decisions Which Analysis Type?
▪ Inertia and damping forces are usually significant if the applied loads vary rapidly with
time.
▪ Therefore you can use time-dependency of loads as a way to choose between static
and dynamic analysis.
— If the loading is constant over a relatively long period of time, choose a
static analysis.
— Otherwise, choose a dynamic analysis.
▪ In general, if the excitation frequency is less than 1/3 of the structure’s lowest natural
frequency, a static analysis may be acceptable.
ASHOKKUMAR.K
SENIOR ENGINEER -CAE
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Modeling Decisions Which Analysis Type?
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Nonlinear phenomena
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Modeling Decisions What To Model?
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Modeling Decisions What To Model?
▪ Details:
— Small details that are unimportant to the analysis should not be included in the
analysis model. You can suppress such features before sending a model to
any CAE tool from a CAD system.
— For some structures, however, "small" details such as fillets or holes can be
locations of maximum stress and might be quite important, depending on your
analysis objectives.
ASHOKKUMAR.K
SENIOR ENGINEER -CAE
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Modeling Decisions What To Model?
▪ Symmetry:
— Many structures are symmetric in some form and allow only a
representative portion or cross-section to be modeled.
— The main advantages of using a symmetric model are:
• It is generally easier to create the model.
• It allows you to make a finer, more detailed model and thereby obtain better
results than would have been possible with the full model.
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SENIOR ENGINEER -CAE
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Modeling Decisions What To Model?
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SENIOR ENGINEER -CAE
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Modeling Decisions What To Model?
▪ Axisymmetry:
— Symmetry about a central axis, such as in light bulbs, straight pipes,
cones, circular plates, and domes.
— Plane of symmetry is the cross-section anywhere around the structure.
Thus you are using a single 2D “slice” to represent 360° — a real savings
in model size!
— Loading is also assumed to be axisymmetric in most cases.
However, if it is not,
and if the analysis is linear,
the loads can be separated into harmonic
components for independent solutions
that can be superposed.
ASHOKKUMAR.K
SENIOR ENGINEER -CAE
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Modeling Decisions What To Model?
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Modeling Decisions What To Model?
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Modeling Decisions What To Model?
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Modeling Decisions What To Model?
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Modeling Decisions What To Model?
▪ Stress singularities:
— A stress singularity is a location in a finite element model where the stress
value is unbounded (infinite).
— Examples:
• A point load, such as an applied force or moment
• An isolated constraint point, where the reaction force behaves like a point load
• A sharp re-entrant corner (with zero fillet radius)
— As the mesh density is refined at a stress singularity, the stress value increases
and never converges.
ASHOKKUMAR.K
SENIOR ENGINEER -CAE
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Modeling Decisions What To Model?
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SENIOR ENGINEER -CAE
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Modeling Decisions What To Model?
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Modeling Decisions Which Element Type?
▪ Line elements:
— Beam elements are used to model bolts, tubular members, C-sections,
angle irons, or any long, slender members where only membrane and
bending stresses are needed.
— Spar elements are used to model springs, bolts, preloaded bolts, and
truss members.
— Spring elements are used to model springs, bolts, or long slender parts,
or to replace complex parts by equivalent stiffnesses.
ASHOKKUMAR.K
SENIOR ENGINEER -CAE
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Modeling Decisions Which Element Type?
▪ Shell elements:
— Used to model thin panels or curved surfaces.
— The definition of “thin” depends on the application, but as a general
guideline, the major dimensions of the shell structure (panel) should be at
least 10 times its thickness.
ASHOKKUMAR.K
SENIOR ENGINEER -CAE
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Modeling Decisions Which Element Type?
▪ 2D solid elements:
— Used to model a cross-section of solid objects.
— Must be modeled in the global Cartesian X-Y plane.
— All loads are in the X-Y plane, and the response (displacements) are also
in the X-Y plane.
— Element behavior may be one of the following:
• Plane stress
• Plane strain
• Axisymmetric
• Axisymmetric harmonic
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SENIOR ENGINEER -CAE
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Modeling Decisions Which Element Type?
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Modeling Decisions Which Element Type?
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Modeling Decisions Which Element Type?
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Modeling Decisions Which Element Type?
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Meshing
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Meshing Mapped Meshing
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Meshing - Element distortion
Element distortion
▪ Use of distorted elements in irregular and complex geometry is common but there are some
limits to the distortion.
▪ The distortions are measured against the basic shape of the element
▪ Square ⇒ Quadrilateral elements
▪ Isosceles triangle ⇒ Triangle elements
▪ Cube ⇒ Hexahedron elements
▪ Isosceles tetrahedron ⇒ Tetrahedron elements
ASHOKKUMAR.K
SENIOR ENGINEER -CAE
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Meshing - Element distortion
Rule of thumb:
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SENIOR ENGINEER -CAE
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Meshing - Element distortion
▪ Angular distortion
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Meshing - Element distortion
▪ Curvature distortion
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Meshing - Element distortion
Volumetric distortion
▪ Area outside distorted element maps into an internal area – negative volume
integration
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Meshing - Element distortion
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Meshing - Element distortion
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MESH COMPATIBILITY
▪ The displacement field is continuous along all the edges between elements
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MESH COMPATIBILITY
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MESH COMPATIBILITY
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MESH COMPATIBILITY
Straddling elements
▪ Avoid straddling of elements in mesh
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SENIOR ENGINEER -CAE
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Stress Analysis Basics How to validate & check accuracy of FEA results?
FEA ACCURACY
▪ Visual check – Discontinuous or abrupt change in stress pattern across the elements indicate
need for local mesh refinement in the region.
▪ 10 – 15% difference in FEA & Experimental results is considered as good correlation.
▪ Probable reasons for more than 15% deviation – wrong boundary conditions, Material properties,
presence of residual stress, localized effects like welding, bolt, torque, experimental errors etc.
ASHOKKUMAR.K
SENIOR ENGINEER -CAE
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Stress Analysis Basics Reviewing Results
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SENIOR ENGINEER -CAE
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Stress Analysis Basics Reviewing Results
▪ Stresses:
— The following stresses are typically available for a 3D solid model:
• Component stresses — σX, σY, σZ, σXY,σYZ, σXZ (global Cartesian
directions by default)
• Principal stresses — σ1, σ2, σ3, σEQV (von Mises), σINT (stress intensity)
— Best viewed as contour plots, which allow you to quickly locate
“hot spots” or trouble regions.
• Nodal solution: Stresses are averaged at the nodes, showing smooth,
continuous contours.
• Element solution: No averaging, resulting in discontinuous contours.
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Stress Analysis Basics Reviewing Results
• Plot the element solution (unaveraged stresses) and look for elements with
high stress gradients. These regions are candidates for mesh refinement.
• Re-mesh with twice as many elements, re-solve, and compare the results.
(But this may not always be practical).
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SENIOR ENGINEER -CAE
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DYNAMIC ANALYSIS
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Mechanical Vibration
▪ Any motion which repeats itself after an interval of time is called vibration.
▪ Machines with repetitive power sources, such as engine, motor, turbine,
compressor, often have vibration problems.
▪ Vibration will cause uncomfortable feeling or noise. Serious vibration
problems may cause malfunctions or failure.
▪ Three major components in a vibration system: mass, spring, and damper.
▪ Spring is to temporarily store energy during vibration, to provide restoring forces,
and also to measure force. The damper is to consume the energy.
ASHOKKUMAR.K
SENIOR ENGINEER -CAE
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Dynamic Analysis Basics - Dynamic Equilibrium
(t)
Dynamic Effects
▪ Inertia force
▪ Damping force
▪ Elastic Force
▪ External force
ASHOKKUMAR.K
SENIOR ENGINEER -CAE
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Dynamic Analysis Basics - Harmonic Response Analysis Equilibrium
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Dynamic Analysis Basics - Modal Analysis Equilibrium
Dynamic Effects
▪ In free vibration Damping & external force are ignored
▪ Nonlinearities are ignored (such as contacts, geometrical nonlinear & nonlinear material)
ASHOKKUMAR.K
SENIOR ENGINEER -CAE
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Dynamic Analysis Basics - Modal Analysis
Eigenvalue Analysis
▪ Methods of solving eigenvalue Equations
▪ Lanczos method
▪ Subspace iteration
▪ QR method
▪ Inverse iteration
▪ The bisection method (sturm sequences)
▪ Given’s method and house holder’s method
▪ Jagobi’s method
ASHOKKUMAR.K
SENIOR ENGINEER -CAE
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Dynamic Analysis Basics Overview
▪ Overview
— Modal Analysis ( Free vibration )
— Theoretical Foundations
— Prestress
— Rotating Parts
— Large Deflection
— Spin softening
— Main Steps for modal Analysis
— Material Properties
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Modal Analysis Overview
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Modal Analysis Overview
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Modal Analysis Overview
MODAL ANALYSIS
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Modal Analysis Overview
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Modal Analysis Theoretical Foundations
Period of vibration
Angular Frequency
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Modal Analysis Theoretical Foundations
Mass Frequency
Stiffness Frequency
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Modal Analysis Theoretical Foundations
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SENIOR ENGINEER -CAE
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Modal Analysis Theoretical Foundations
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SENIOR ENGINEER -CAE
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Modal Analysis Rotating Parts
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Modal Analysis Prestress
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Modal Analysis Large Deflection
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Modal Analysis Spin Softening
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Modal Analysis Spin Softening
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SENIOR ENGINEER -CAE
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Modal Analysis Main Steps
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Modal Analysis - Material
▪ Remember density!
▪ Linear elements and materials only. Nonlinearities are ignored.
▪ True linear behaviors – Multipoint's constraints are allowed ( RBE2 & RBE3)
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JANUARY 2011
Modal Analysis – Difference between RBE2 & RBE3 elements
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Modal Analysis – Difference between RBE2 & RBE3 elements
▪ Applicability: the usage of either of the commands has its own limitations,
more importantly, in terms of stiffening effects and constrained equations.
While, using RBE2 may lead to a more determinant set of equations, it may result in
directional model stiffening; something which can be avoided by using RBE3 (with a
possible compromise on the accuracy of resulting solution). The use of RBE2 is
generally avoided due to the stiffening effects.
▪ RBE2 – Rigid element
▪ RBE3 – Weight Factor element (interpolation Element)
▪ Depends on the applications choose the Rigid element or Weight Factor element.
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JANUARY 2011
Modal Analysis – Difference between RBE2 & RBE3 elements
Moment about
Global Z axis
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Modal Analysis – Difference between RBE2 & RBE3 elements
Mode 1
RBE2 RBE3
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JANUARY 2011
Modal Analysis – Difference between RBE2 & RBE3 elements
Mode 2
RBE2 RBE3
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Modal Analysis – Apply BC’s & solve
Symmetry BC Anti-Symmetry BC
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Modal Analysis – Apply BC’s & solve
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JANUARY 2011
Modal Analysis
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Page 130
JANUARY 2011
Modal Analysis – Natural Frequency constants of Beams
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JANUARY 2011
Thank You
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