Finite Element Analysis

Randall Bock, Professor of Continuing Education

The Pennsylvania State University

Who am I ?

rgb@psu.edu

Research Engineer
Professor of Continuing Education
Happy Valley SWUG, Leader
CSWP, CSSP

Week 1

EDSGN 496A: SolidWorks

Fundamentals

SKETCH: The Design Environment

Introduction, Objectives, and Goals
User Interface
Associative Design
Design Intent & Constraints
CommandManager: Sketch & Features
Extruded Base
Basic Strategy

Image courtesy of Innovation Engineering Inc.

www.hvswug.org

The Plan

SolidWorks Simulation

Traditional Design
What is the Finite Element Method
SolidWorks Simulation
FEA Fundamentals
Linear Study
Mesh: Controlling, Converging & Analyzing
Symmetry, Singularities, Simplification
Nonlinear Study
Examples, Tips, and Tricks Throughout

A Traditional Design Cycle

Build a 3D model.

Manufacture prototype.

Test the prototype.

Analyze results

modify the model

build a new prototype

test it again

repeat

SolidWorks

$ Prototype

Test

Satisfied?
Yes
Mass Production

No

FEA Integrated Design Cycle

SolidWorks

FEA

Satisfied?
Yes

$ Prototype
No

Test

Mass Production

No

What is
the FEM ?

SolidWorks
Simulation

Tools > SimulationXpress

SimulationXpress

Sidebar

Limitations
1. PARTs (one solid body)
2. Static analysis only (stress)
3. Optimize one variable
4. Isotropic materials
5. Uniform loads
6. Fixed restraints

SolidWorks Simulation 2010

Simulation Premium

Nonlinear

Flow
Simulation

Simulation Professional
Static*

Frequency

Buckling

Thermal

Drop Test
Linear
Dynamics

Motion*

Fatigue

Optimization

Pressure
Vessel

Sustainability

EventEvent-based
Motion
Composites

*Included with SolidWorks Premium

SolidWorks Simulation

Tools > Add-Ins

Advantages

Parts & Assemblies

Non-linear, thermal, buckling, frequency, drop test,
optimization, fatigue
Isotropic & orthotropic materials
Uniform & non-uniform loads
Multiple restraints
More

FEA
Fundamentals

FEA Fundamentals

Define and discretize the domain

Specify approximating function and B.C.
Create and converge system of equations
Resolve for quantities of interest

FEA Fundamentals

Define the domain

FEA Fundamentals

Discretize the domain

MESH

FEA Fundamentals

Discretize using tetrahedrons: 1st order (linear)

1 element
4 nodes

First Order Structural Tetrahedron Element:

4 nodes
12 dof
12 x 12 matrix

FEA Fundamentals

Discretize using tetrahedrons: 2nd order (quadratic)

1 element
10 nodes

Second Order Structural Tetrahedron Element:

10 nodes
30 dof
30 x 30 matrix

FEA Fundamentals

Discretize using tetrahedrons: 2nd order

1 element
10 nodes

Second Order Structural Tetrahedron Element:

10 nodes
30 dof
30 x 30 matrix

Curved

FEA Fundamentals

Neighboring elements share nodes

4 element
7 nodes
DOF ?

FEA Fundamentals

Cube

12 element
9 nodes
DOF ?

FEA Fundamentals

Specify approximating function

And also an

FEA Fundamentals

Specify approximating function

FEA Fundamentals

Specify approximating function (2D Triangle, linear)

u ( e ) ( x, y ) = o + 1 x + 2 y

EACH ELEMENT

FEA Fundamentals

Specify approximating function (new node values)

u ( e ) ( x, y ) = o + 1 x + 2 y

FEA Fundamentals

Specify approximating function (unknown coefficients)

u ( e ) ( x, y ) = o + 1 x + 2 y

FEA Fundamentals

Specify approximating function (current node values)

u ( e ) ( x, y ) = o + 1 x + 2 y

FEA Fundamentals

Sidebar

Specify approximating function (2D Triangle, quadratic)

u ( e ) ( x, y ) = o + 1 x + 2 y + 3 x 2 + 4 xy + 5 y 2

Sidebar

FEA Fundamentals

FEA Fundamentals

Specify approximating function

u ( e ) ( x, y ) = o + 1 x + 2 y

FEA Fundamentals

Specify approximating function

u ( e ) ( x, y ) = o + 1 x + 2 y

Equilibrium equations

(Hooks Law 2D)

E u v
u v

+
+ + G + = 0
2

y y x
1 x x y
E u v
u v

+ G + +
+ = 0
2
x y x 1 x y

FEA Fundamentals

Specify approximating function

u ( e ) ( x, y ) = o + 1 x + 2 y

Equilibrium equations

(Hooks Law 2D)

E u v
u v

+
+ + G + = 0
2

y y x
1 x x y
E u v
u v

+ G + +
+ = 0
2
x y x 1 x y

FEA Fundamentals

Specify approximating function

u ( e ) ( x, y ) = o + 1 x + 2 y

Equilibrium equations

(Hooks Law 2D)

E u v
u v

+
+ + G + = 0
2

y y x
1 x x y
E u v
u v

+ G + +
+ = 0
2
x y x 1 x y

Sidebar

Moduli conversion

Approximate Solution
Hooks Law
+

E u v
u v
+ + G + = 0
2
y y x
1 x x y

+G

E u v
u v
+ +

+ =0
x y x 1 2 x y

u ( e ) ( x, y ) = o + 1 x + 2 y

FEA Fundamentals

Specify approximating function

u ( e ) ( x, y ) = o + 1 x + 2 y

Equilibrium equations

(Hooks Law 2D)

E u v
u v

+
+ + G + = 0
2

y y x
1 x x y
E u v
u v

+ G + +
+ = 0
2
x y x 1 x y

FEA Fundamentals

Specify approximating function

u ( e ) ( x, y ) = o + 1 x + 2 y

Equilibrium equations

(Hooks Law 2D)

E u v
u v

+
+ + G + = 0
2

y y x
1 x x y
E u v
u v

+ G + +
+ = 0
2
x y x 1 x y

v
Slope Field:
=vx
x
v
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x
v
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v
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v
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v
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x

Solutions:

v
=vx
x
v

Solutions:

v
=vx
x
v

FEA Fundamentals

Specify the boundary conditions

Load

Restraint

FEA Fundamentals (basic strategy)

Create and converge system of equations

1) Plug initial mesh geometry into

u ( e ) ( x, y ) = o + 1 x + 2 y

2) Plug new node values from 1) into

+

E u v
u v
+ + G + = 0
2
y y x
1 x x y

+G

E u v
u v
+ +

+ =0
x y x 1 2 x y

3) Subtract 1) from 2)

4) Difference 3) drives next iteration

FEA Fundamentals

Resolve for other quantities of interest, e.g.

Strain ()
Stress ()
von Mises Stress: eq = 0.5[( 1 2 )2 + ( 2 3 )2 + ( 3 1 )2 ]

Linear

Linear elastic stress analysis

Small displacements with constant b.c.

Material properties constant (ductile)
Load applied slowly
Ultimate or Tensile
Yield

Defining a Study
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

(fea fundamentals)

Define the type of analysis. (specify approx. function)

Create a study.
Define material for each component.
Define Connections. (b.c.: component-component)
Define Fixtures. (b.c.: reduce model DOF)
Define External Loads. (b.c.: force, pressure, torque)
Define the Mesh. (discretize the domain)
Run the analysis. (solve linear system)
View Results.
Interpret results.

Analytical vs. FEA (node)

FEA Solution

max = Kn n
Stress concentration factor, (flat plate, circular hole, D/W>0.65):

D
K n = 2 + 1
W

Normal stress, at hole cross section:

n =

P
(W D) T

Plate geometry:

D = hole diameter = 70 mm
W = plate width = 100 mm
T = plate thickness = 10 mm
Load:

P = tensile load = 50,000 N

max = 338 MPa

National Agency for Finite Element

Methods and Standards

NAFEMS Benchmarks...
Help > SolidWorks
Simulation > Validation >
NAFEMS Benchmarks.

Flat Plate: vonMises (MPa) vs DOF

Mesh

vonMises*

Coarse
Default
Fine
Default w/ mesh ctrl.

* eq =

DOF

327
341
349
348

7,944
46,728
281,142
52,368

0.5 ( 1 2 ) + ( 2 3 ) + ( 3 1 )
2

Mesh

st
o
m
l
a
Its ^all about

the Mesh

Sidebar

Sidebar

Delaunay & Voronoi

vonMises (MPa): Default Nodes

vonMises (MPa): Default Elements

vonMises (MPa): Fine Nodes

vonMises (MPa): Fine Elements

Mesh > Details : Aspect Ratio

perfect tetrahedral element is 1.0

Adaptive Mesh: error reduction

p-adaptive: more efficient elements

up to 5th order approximation function

u( x, y ) = o + 1 x + 2 y + 3 x 2 + 4 y 2 + 5 x 3 + 6 y 3

( x, y ) = o + 1 x + 2 y + 3 x 2 + 4 y 2 + 5 x 3 + 6 y 3

h-adaptive: smaller elements where needed

Symmetry ?

SYMMETRY
IS A BIG DEAL

Sidebar

Kindergarten Entrance Exam

Consider Symmetry

Simplification: Symmetry

Simplification: Symmetry & 3D

Simplification: Symmetry & 2D

vonMises vs. Degree of Freedom

Fine
Mesh
Control
Default
Coarse

Shell

Flat Plate: vonMises (MPa) vs DOF

Mesh

Coarse
Default
Fine
Default w/ mesh ctrl.
Symmetry Shell

vonMises
326
340
349
352
347

DOF
7,902
46,581
280,218
52,197
1,531

Singularity

Reentrant Corner
Force

Force

h!
c
u
O

Consider Singularity: L-Bracket (MPa)

Study

Mesh Control 1
Mesh Control 2
Mesh Control 3
Adaptive Mesh

Sharp Corner
76
92
194
-

Radius Corner
101
101
101
115

Simplify & Split

McMaster-Carr

Work Load Limit Given

Simplify Geometry

Suppress nut & thread

Insert > Curve > Split Line

Split Line

Assembly Analysis

Assembly Analysis

Beam Elements

Beam Analysis

Shear Plot

LARGE
DISPLACEMENT

Time to consider nonlinear solutions

Nonlinear

Nonlinear stress analysis

Why?
Material Properties: f (, ) elastic, viscoelastic, plastic
Boundary Conditions
Geometry

Yield

Nonlinear stress analysis

Why?

Material Properties
Geometric: large spatial u, small local u

Small Displacement

Large Displacement

Nonlinear stress analysis

Why?

Material Properties
Geometric: large spatial u, small local u

Small Displacement

Large Displacement

Nonlinear stress analysis

Why?

Material Properties
Geometric
Boundary Conditions: contact problems

Contact during loading changes stiffness

Nonlinear stress analysis

Why?

Material Properties
Geometric
Boundary Conditions: contact problems

Contact during loading

changes stiffness
Large strain

Defining a Nonlinear Study

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Define the type of analysis.

Create a study.
Define materials
Define Connections.
Define Fixtures.
Define External Loads.
Define the Mesh.
Run the analysis.
View Results.
Interpret results.

Defining a Study
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Define the type of analysis.

Create a study.
Define materials Material > Prop. > Model Type
Define Connections.
Define Fixtures.
Define External Loads. LOAD STEP: force or disp.
Define the Mesh.
Run the analysis.
View Results.
Interpret results.

Apply Material

Model Type

Simulation > Research

Define Load Steps (force or disp.)

Resources

Joe Galliera, TTM Simulation, SolidWorks

SolidWorks Tutorials

SolidWorks Web Help

Make Math Fun w/ Direction Field Plotter

http://www.math.psu.edu/cao/DFD/Dir.html

Formula Plotter with Integral Curves

Voronoi / Delaunay Applet

http://www.cs.cornell.edu/home/chew/chew.html

Questions