Lecture 1

Structural Mechanics:
Design and Analysis with FEM Application
 Contents:

• Example and Applications

• Overview about FEM Design and Analysis with ANSYS

• Basic Concepts

• Finite Element Analysis

• Steps for Problem Formulation

• Demonstrations (CAE Design and Analysis)

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Example and Applications

Design of Pneumatic Design of Mechatronics

Design of
Cylinder System
Loadcell

Design of Robotics System Design of wind turbine Bridge design

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Example and Applications

Design of
Loadcell

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Example: 3D Cantilever Beam

Steel, structural ASTM A36 steel, elastic limit = 250 MPa

Normal Working condition ?? 6

Demonstration: Cantilever Beam:
Analytical Solution
• Given: L = 20 in, b = 4 in; h=2 in; F = 10 lbf; E = 3x106 psi (lbf/in2)
Determine the maximum Stress
• Max moment: 𝑀𝑀𝑚𝑚𝑚𝑚𝑚𝑚 = 𝐹𝐹𝐹𝐹 = 10 ibf x 20 in = 200 ibf.in

𝑀𝑀𝑚𝑚𝑚𝑚𝑚𝑚 200 𝑖𝑖𝑖𝑖𝑖𝑖.𝑖𝑖𝑖𝑖

• Max Stress: 𝜎𝜎𝑚𝑚𝑚𝑚𝑚𝑚 = 𝑦𝑦𝑚𝑚𝑚𝑚𝑚𝑚 = 32 𝑖𝑖𝑖𝑖4
× 1 𝑖𝑖𝑖𝑖 = 𝟕𝟕𝟕𝟕 𝑖𝑖𝑖𝑖𝑖𝑖/𝑖𝑖𝑖𝑖2
𝐼𝐼
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Determine the maximum deflection

𝐹𝐹𝐿𝐿3
• Max Deflection: 𝛿𝛿𝑚𝑚𝑚𝑚𝑚𝑚 = 𝑎𝑎𝑎𝑎 𝑥𝑥 = 𝐿𝐿
3𝐸𝐸𝐸𝐸

𝑏𝑏ℎ3 4 𝑖𝑖𝑖𝑖 ×(2 𝑖𝑖𝑖𝑖)3 32 𝑖𝑖𝑖𝑖4

Where Inertia moment: 𝐼𝐼 = = = 12
12 12

10 𝑖𝑖𝑖𝑖𝑖𝑖 × (20 𝑖𝑖𝑖𝑖)3

Thus, Max Deflection: 𝛿𝛿𝑚𝑚𝑚𝑚𝑚𝑚 = 32 𝑖𝑖𝑖𝑖4
= 0.00033 𝑖𝑖𝑖𝑖 = 0.33 × 10−3 𝑖𝑖𝑖𝑖
3×30.106 𝑝𝑝𝑝𝑝𝑝𝑝 × 12

1 MPa = 106 Pa (N/m2) = 0.145x103 psi (lbf/in2) 7

/title Simple Cali-lever Beam ! MESHING
finish ! Define size of elements
/clear ESIZE,2

/PREP7 ! preprocessor phase ! ! Create a mesh for model

LMESH,ALL
! Define Element type
ET,1,BEAM3 ! SOLUTION
/SOLU
! define parameters (mm) - Real Constants ANTYPE,0 ! Static analysis
R,1,8,(32/12),2,(6/5) !AREA=8; IZZ=(32/12); HEIGHT=2; ! apply some constraints
SHEARZ=(6/5). NSEL,S,LOC,X,0
D,ALL,ALL,0
! Define material properties ! APPLY LOAD
MP,EX,1,30E6 NSEL,S,LOC,X,20
F,ALL,FY,10
! MODELLING ALLSEL,ALL
! Design model solve
! Define key points finish
K,1,0,0,0
K,2,20,0,0
L,1,2 Code: VGU Example 1a&1b
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!POST-PROCESSING
/POST1
PLDISP,1 ! Plot deformation with undeformation, 1
ANCNTR ! Plot animation
PRRF ! Reaction forces
PRDI ! List nodal displacements
ETABLE,SMAXI,NMISC, 1 ! make table ‘smaxi’ using maximum stress
ETABLE,SMAXJ,NMISC, 3 ! make table ‘sminj’ using maximum stress
PLLS,SMAXI,SMAXJ,1,0 ! Plot ETABLE data

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9. Plot deformed shape.
PLDISP,1 ! Plot deformation with undeformation, 1

Maximum Deflection
0.00336 (in)

ANCNTR
! Animate stress contour

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PLNSOL,U,SUM,0,1 ! Contour Plot of deflection

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10. List reactions.
PRDI ! List nodal displacements

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11. List the deflections at each node.
PRDI ! List nodal displacements

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12. Define element table items for plotting and listing of various stress components.
13. List element table items.
14. Plot element table items.

ETABLE,SMAXI,NMISC,1 ! make table ‘smaxi’ using maximum stress

ETABLE,SMAXJ,NMISC,3 ! make table ‘sminj’ using maximum stress
PLLS,SMAXI,SMAXJ,1,0 ! Plot ETABLE data

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/ESHAPE,1 ! Display element shapes using section data
/DSCALE,ALL,1 ! Plot using true scale
/VIEW,1,1,1,1 ! Change to isometric view
LNSOL,U,Y,0,1 ! Plot displacement in y

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What about complex structure?

No analytical solution ! -- > Numerical Solution --- > FEM

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 Contents:

• Example and Applications

• Overview about FEM Design and Analysis with ANSYS

• Basic Concepts

• Finite Element Analysis

• Steps for Problem Formulation

• Demonstration

17
Overview about FEM Design and Analysis
We need to know concepts:
1. Design a model
2. External (or applied) forces
3. Constraints and Reaction Forces
4. Stress (strength of materials/structure or failure test)
5. Strain (show deformation of structure)
6. Displacement (Rotation)
7. Stress-strain relationship
8. Failure Theory (Normal operation)
9. Stiffness (ability to resist deformation)
10. Stability (ability to avoid rapidly growing deformations caused by an initial
disturbance; e.g., buckling)
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 Contents:

• Example and Applications

• Overview about FEM Analysis

• Basic Concepts

• Finite Element Analysis

• Steps for Problem Formulation

• Some Demonstrations

19
 Basic Concepts of FEM
• External (or applied) forces
• Constraints
• Reaction Forces

A, B, C: Applied forces
Pin joint, roller joint: Constraints
𝑅𝑅𝐿𝐿𝐿𝐿 , 𝑅𝑅𝐿𝐿𝐿𝐿 , 𝑅𝑅𝑅𝑅 : Reaction forces

Fixed joint

Bridge Structure

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Basic Concepts of FEM

• Stress (strength of materials/structure or failure test)

• Strain (show deformation of structure)

• Stress-strain relationship

• Failure Theory

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 Basic Concepts of FEM : Stress
Stress (1-D)
• Force of resistance per unit area offered by a body against deformation
σ = P/A
P = External force or load
A = Cross-sectional area

-Small element
-(internal force at one point)
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Basic Concepts of FEM : Stress
 Stress (2-D, 3-D): (𝜎𝜎𝑥𝑥 , 𝜎𝜎𝑦𝑦 , 𝜎𝜎𝑧𝑧 , 𝜏𝜏𝑥𝑥𝑥𝑥 , 𝜏𝜏𝑥𝑥𝑥𝑥 , 𝜏𝜏𝑦𝑦𝑦𝑦 )

 Principal Stress (2-D, 3-D)

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Basic Concepts of FEM : Stress

Von Mises yield criterion https://en.wikipedia.org/wiki/Material_failure_theory

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Basic Concepts of FEM : Stress
Stress at failure
Von Mises yield criterion:
A material is said to start yielding when the von Mises stress
(𝜎𝜎𝑒𝑒 ) reaches a value known as yield strength ([σ]), or elastic limit

When Von Misses equivalent stress exceeds the uniaxial Uniaxial material yield strength
material yield strength, general yielding will occur. - Do experiments
- Tabulate for each type of
materials

Max(𝜎𝜎𝑒𝑒 ) ≤ 𝜎𝜎 ∓ 5%
Need to determine
NX10
Given on datasheet 25
Basic Concepts of FEM : Stress

After finishing simulation

Max(𝜎𝜎𝑒𝑒 )

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1. Failure checking due stress

Given yield strength ([σ]), or elastic limit:

𝑖𝑖𝑖𝑖𝑖𝑖
𝜎𝜎 = elastic limit =250 MPa = 36259.4 ( 2 )
𝑖𝑖𝑖𝑖

Q: Failure/Durability check

𝑖𝑖𝑖𝑖𝑖𝑖
Max(𝜎𝜎𝑒𝑒 ) = 75 ( 2 )
𝑖𝑖𝑖𝑖

Max(𝜎𝜎𝑒𝑒 ) ≤ 𝜎𝜎 ∓ 5%

=== > Conclusion: The structure is enough durability or no failure

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Basic Concepts: Strain and Deformation
- Strain in1-D: Change in dimension of an object under application of external
force) Strain:
ε = ∆L/Lo
∆L = Change in length
L = Length
- Strain in 2, 3-D: (𝜖𝜖𝑥𝑥𝑥𝑥 , 𝜖𝜖𝑦𝑦𝑦𝑦 , 𝜖𝜖𝑧𝑧𝑧𝑧 , 𝜖𝜖𝑥𝑥𝑥𝑥 , 𝜖𝜖𝑥𝑥𝑥𝑥 , 𝜖𝜖𝑦𝑦𝑦𝑦 )

- Deformation (Displacement):
- the change is shape of the body by
some pressure or force
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Basic Concepts of FEM : Stress-strain relationship

Stress-strain (1-D) Stress-strain (3-D)

• Hooke’s Law:
σ ( x) = Eε ( x)

where
du
ε ( x) =
dx

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Basic Concepts of FEM : Displacement
- Displacement (u, v, w: 3-D): the distance from which one node or element (beam,
column, frame, etc) moved from its original location
- Displacement-Strain
external or applied forces

Structure

(𝜎𝜎𝑥𝑥 , 𝜎𝜎𝑦𝑦 , 𝜎𝜎𝑧𝑧 , 𝜏𝜏𝑥𝑥𝑥𝑥 , 𝜏𝜏𝑥𝑥𝑥𝑥 , 𝜏𝜏𝑦𝑦𝑦𝑦 ) : (Stress)

(𝜖𝜖𝑥𝑥𝑥𝑥 , 𝜖𝜖𝑦𝑦𝑦𝑦 , 𝜖𝜖𝑧𝑧𝑧𝑧 , 𝜖𝜖𝑥𝑥𝑥𝑥 , 𝜖𝜖𝑥𝑥𝑥𝑥 , 𝜖𝜖𝑦𝑦𝑦𝑦 ): (strain)

(𝑢𝑢, 𝑣𝑣, 𝑤𝑤): (Displacements)

(Deformation)
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Basic Concepts of FEM : Displacement
Elastic Deformation of an Axially Loaded Member

PL
Deformation can be calculated using δ =
AE
SIGN CONVENTION

δ = + ve When the member is tension

δ = −ve When the member is

compression
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Basic Concepts of FEM : Displacement
Elastic Deformation of an Axially Loaded Member (1-D)

PL
Total deformation: δ tot = ∑
AE
The Above Figure: δ tot = δ AB + δ BC + δ CD
PAB LAB PBC LBC PCD LCD
δ tot = + +
AE AE AE

Stiffness condition
======= > 𝛿𝛿𝑀𝑀𝑀𝑀𝑀𝑀 ≤ [𝛿𝛿] ======= > - maximum allowable total deflections
- good for design requirements 32
Basic Concepts of FEM : Displacement
Stiffness Condition for bending beam
Deflection

𝛿𝛿𝑀𝑀𝑀𝑀𝑀𝑀

Beam deflection must be checked

Stiffness condition
======= > 𝛿𝛿𝑀𝑀𝑀𝑀𝑀𝑀 ≤ [𝛿𝛿]

Material dependent Elastic modulus

Property
Geometry dependent Stiffness
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Basic Concepts of FEM : Displacement
Stiffness Condition for bending beam
Deflection

𝛿𝛿𝑀𝑀𝑀𝑀𝑀𝑀

Span
Allowable deflections [𝛿𝛿]
- Civil Engineering: ACI318–2011 (Example)
+ reinforced concrete members
 maximum allowable deflection is span/360 under live loads and span/240 under live load and long term
deflections.
 Try not to exceed 40mm long term, or 20mm short term.

+ steel structures
 maximum allowable deflection is span/180 and otherwise it is span/150
Other applications depend on what structure/ Machine element design, and so on
== > should be defined with goal designs
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Defined with goal designs

20m, 2 tons [𝛿𝛿] Allowable deflections

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Basic Concepts of FEM : Displacement
Stiffness Condition for bending beam
Stiffness condition
𝛿𝛿𝑀𝑀𝑀𝑀𝑀𝑀 ≤ [𝛿𝛿]

𝛿𝛿𝑀𝑀𝑀𝑀𝑀𝑀 = 7.40925 𝑚𝑚𝑚𝑚

10800
𝛿𝛿 = = 720 𝑚𝑚𝑚𝑚
150
Conclusion:
The structure is enough Stiffness
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 Basic Concepts of FEM : Normal Working condition

How to know the structure is working

normally (or ) under external forces?
- Failure/Durability check
- Stiffness check
- Stability (buckling) check

==== > FEM Analysis

Failure
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Basic Concepts of FEM : Normal Working condition

 Endurance (Failure criterion): The elastic properties of the material is the main one

to be considered. However, stiffness and stability (buckling)

 It is the stiffness, which comes into focus as a design parameter.

 Stiffness (as we have noted) of a ‘structure’ is its ability to resist elastic deformation

(deflection) on loading → depends on the geometry of the component.

 Stability (ability to avoid rapidly growing deformations caused by an initial

disturbance; e.g., buckling)

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 Contents:

• Example

• Overview about FEM Analysis

• Basic Concepts

• Finite Element Analysis

• Steps for Problem Formulation

• Some Demonstrations

39
What is the FEM?

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Source: MIT Lecture
What is the FEM?

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Source: MIT Lecture
Cantilever Beam

𝑦𝑦(𝑥𝑥)|(x=0) =0
̇ |(x=0) =0
𝑦𝑦(𝑥𝑥)
In this sample case, you know analytical
solution, --- > No need numerical solution 42
What is the FEM?

43
Source: MIT Lecture
What is the FEM?

44
Source: MIT Lecture
What is the FEM?

45
Source: MIT Lecture
What is the FEM?

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Source: MIT Lecture
What is the FEM?

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Source: MIT Lecture
What is the FEM? Advantages vs. Disadvantages

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Source: MIT Lecture
Finite Element Analysis

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Finite Element Analysis

Elements are defined by the following properties:

1. Dimensionality

2. Nodal Points

3. Geometry

4. Degrees of Freedom

5. Nodal Forces

(Non homogeneous RHS of the DE)

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Finite Element Analysis
Element Types Element Types

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Finite Element Analysis
Nodal versus Elemental Stresses
• Nodal Values are the averaged values of
stresses at each node
• What stresses should one examine when
taking a look at the stress plot?

• Comparing nodal stresses and elemental

stresses is a way of understanding if the mesh
is fine enough, and if the results have
converged at the highest stress location in the
geometry.

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 Contents:

• Example

• Overview about FEM Design and Analysis

• Basic Concepts of FEM

• Finite Element Analysis

• Steps for Problem Formulation

• Some Demonstrations

53
Steps for Problem Formulation
1. Model design
2. Assign materials (Properties)
3. Mesh (Tetrahedral)
4. Constraints
5. Load (or Applied forces)
6. Solutions
7. Post-processing

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Steps for Problem Formulation
Preprocessing:
1. Define parameters.
2. Define element type.
3. Define real constants.
4. Define material properties. (Young’s
Modulus, EX, poison ratio, nuyxy)
5. Create models (element and meshing)
Solution:
6. Apply constraints and loads to the
model.
7. Solve.
Postprocessing:
8. Plot deformed shape.
9. Plot stresses
10. Plot and List reactions.
11. List the deflections at each node.
12. Define element table items for
plotting and listing of various stress
components.
13. List element table items.
14. Plot element table items.
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 Contents:

• Example

• Overview about FEM Analysis

• Basic Concepts of FEM

• Finite Element Analysis

• Steps for Problem Formulation

• Demonstrations (CAE Design and Analysis)

56
Overview about FEM Design and Analysis Code: VGU Example 2b

Two-Dimensional Truss L,1,2 ! line

L,1,3
title, Bridge Truss Tutorial L,2,3
finish L,2,4
/clear
L,3,4
/PREP7 ! preprocessor phase !
L,3,5
! define parameters (mm)
height = 3118
L,4,5
width = 3600 L,4,6
! L,5,6
! define keypoints L,5,7
! L,6,7
K,1, 0, 0 ! keypoint, #, x, y !
K,2, width/2,height ! element definition
K,3, width, 0 !
K,4, 3*width/2, height ET,1,LINK1
K,5, 2*width, 0 R,1,3200
K,6, 5*width/2, height MP,EX,1,200e3
K,7, 3*width, 0 LESIZE,ALL, , ,1,1,1
! LMESH, all
! define lines
FINISH ! finish pre-processor
/SOLU ! enter solution phase

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! apply some constraints
DK,1,ALL,0 ! define a DOF constraint at a key point
DK,7,UY,0
!
! apply loads Code: VGU Example 1b
!
FK,1,FY,-280e3 ! define a force load to a key point
FK,3,FY,-210e3
FK,5,FY,-280e3
FK,7,FY,-360e3
!
SOLVE ! solve the resulting system of equations
FINISH ! finish solution
/POST1
PRRSOL,F ! List Reaction Forces
PLDISP,2 ! Plot Deformed shape
PLNSOL,U,SUM,0,1 ! Contour Plot of deflection
ETABLE,SAXL,LS, 1 ! Axial Stress
PRETAB,SAXL ! List Element Table
PLETAB,SAXL,NOAV ! Plot Axial Stress

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Overview about FEM Design and Analysis

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