Finite Element Methods and its

applications in Engineering
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Dr.V.Senthilkumar
Assistant Professor
Department of Production Engineering
National Institute of Technology, Tiruchirappalli

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Finite Element Methods for Engineers
Content
• Introduction to the Finite Element Method (FEM)
• Steps in Using the FEM: An Example from Solid
Mechanics
• One Dimensional Truss and Beam elements
• Two dimensional elements
• Plane stress/Plane Strain formulations
• Three dimensional elements
• Manufacturing problems: case studies
• Conclusion
• References

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• Many problems in engineering and applied science are
governed by differential or integral equations.

• The solutions to these equations would provide an exact,

closed-form solution to the particular problem being
studied.

• However, complexities in the geometry, properties and in

the boundary conditions that are seen in most real-world
problems usually means that an exact solution cannot be
obtained or obtained in a reasonable amount of time.

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• Current product design cycle times imply that engineers
must obtain design solutions in a ‘short’ amount of time.

• They are content to obtain approximate solutions that can

be readily obtained in a reasonable time frame, and with
reasonable effort. The FEM is one such approximate
solution technique.

• The FEM is a numerical procedure for obtaining

approximate solutions to many of the problems encountered
in engineering analysis.

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• In the FEM, a complex region defining a continuum is
discretized into simple geometric shapes called elements.

• The properties and the governing relationships are assumed

over these elements and expressed mathematically in terms of
unknown values at specific points in the elements called nodes.

• An assembly process is used to link the individual elements to

the given system. When the effects of loads and boundary
conditions are considered, a set of linear or nonlinear algebraic
equations is usually obtained.

• Solution of these equations gives the approximate behavior of

the continuum or system.

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• The continuum has an infinite number of degrees-of-freedom
(DOF), while the discretized model has a finite number of
DOF. This is the origin of the name, finite element method.

• The number of equations is usually rather large for most real-

world applications of the FEM, and requires the computational
power of the digital computer. The FEM has little practical
value if the digital computer were not available.

• Advances in and ready availability of computers and software

has brought the FEM within reach of engineers working in
small industries, and even students.

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Two features of the finite element method are worth noting.

• The piecewise approximation of the physical field

(continuum) on finite elements provides good precision even
with simple approximating functions. Simply increasing the
number of elements can achieve increasing precision.

• The locality of the approximation leads to sparse equation

systems for a discretized problem. This helps to ease the
solution of problems having very large numbers of nodal
unknowns. It is not uncommon today to solve systems
containing a million primary unknowns.

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• It is difficult to document the exact origin of the FEM, because the
basic concepts have evolved over a period of 150 or more years.

• The term finite element was first coined by Clough in 1960. In the
early 1960s, engineers used the method for approximate solution of
problems in stress analysis, fluid flow, heat transfer, and other
areas.

• The first book on the FEM by Zienkiewicz and Chung was

published in 1967.

• In the late 1960s and early 1970s, the FEM was applied to a wide
variety of engineering problems.

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• The 1970s marked advances in mathematical treatments, including
the development of new elements, and convergence studies.

• Most commercial FEM software packages originated in the 1970s

(ABAQUS, ADINA, ANSYS, MARK, PAFEC) and 1980s
(FENRIS, LARSTRAN ‘80, SESAM ‘80.)

• The FEM is one of the most important developments in

computational methods to occur in the 20th century. In just a few
decades, the method has evolved from one with applications in
structural engineering to a widely utilized and richly varied
computational approach for many scientific and technological areas.

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• The FEM offers many important advantages to the design engineer:

• Easily applied to complex, irregular-shaped objects composed

of several different materials and having complex boundary
conditions.

• Applicable to steady-state, time dependent and eigenvalue

problems.

• Applicable to linear and nonlinear problems.

• One method can solve a wide variety of problems, including

problems in solid mechanics, fluid mechanics, chemical reactions,
electromagnetics, biomechanics, heat transfer and acoustics, to
name a few.

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• General-purpose FEM software packages are available at
reasonable cost, and can be readily executed on
microcomputers, including workstations and PCs.

• The FEM can be coupled to CAD programs to facilitate solid

modeling and mesh generation.

• Many FEM software packages feature GUI interfaces, auto-

meshers, and sophisticated postprocessors and graphics to speed
the analysis and make pre and post-processing more user-
friendly.

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• Simulation using the FEM also offers important business advantages to
the design organization:

• Reduced testing and redesign costs thereby shortening the product

development time.

• Identify issues in designs before tooling is committed.

• Refine components before dependencies to other components

prohibit changes.

• Optimize performance before prototyping.

• Discover design problems before litigation.

• Allow more time for designers to use engineering judgement, and

less time “turning the crank.”

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• Several approaches can be used to transform the physical
formulation of a problem to its finite element discrete analogue.

• If the physical formulation of the problem is described as a

differential equation, then the most popular solution method is
the Method of Weighted Residuals.

• If the physical problem can be formulated as the minimization

of a functional, then the Variational Formulation is usually
used.

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• One family of methods used to numerically solve differential equations
are called the methods of weighted residuals (MWR).

• In the MWR, an approximate solution is substituted into the differential

equation. Since the approximate solution does not identically satisfy the
equation, a residual, or error term, results.

Consider a differential equation

Dy’’(x) + Q = 0 (1)

Suppose that y = h(x) is an approximate solution to (1). Substitution then

gives Dh’’(x) + Q = R, where R is a nonzero residual. The MWR then
requires that

Wi(x)R(x) = 0 (2)

where Wi(x) are the weighting functions. The number of weighting

functions equals the number of unknown coefficients in the approximate
solution.
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• There are several choices for the weighting functions, Wi.

• In the Galerkin’s method, the weighting functions are the same

functions that were used in the approximating equation.

• The Galerkin’s method yields the same results as the variational

method when applied to differential equations that are self-adjoint.

• The MWR is therefore an integral solution method.

• Many readers may find it unusual to see a numerical solution that

is based on an integral formulation.

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• The variational method involves the integral of a function that
produces a number. Each new function produces a new
number.

• The function that produces the lowest number has the

additional property of satisfying a specific differential equation.

• Consider the integral

D/2 y’’(x) - Qy]dx = 0. (1)

The numerical value of can be calculated given a specific

equation y = f(x). Variational calculus shows that the
particular equation y = g(x) which yields the lowest numerical
value for is the solution to the differential equation

Dy’’(x) + Q = 0. (2)
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• In solid mechanics, the so-called Rayeigh-Ritz technique
uses the Theorem of Minimum Potential Energy (with the
potential energy being the functional, ) to develop the
element equations.

• The trial solution that gives the minimum value of is the
approximate solution.

• In other specialty areas, a variational principle can usually be

found.

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 The three main sources of error in a typical FEM solution are
discretization errors, formulation errors and numerical
errors.

 Discretization error results from transforming the physical

system (continuum) into a finite element model, and can be
related to modeling the boundary shape, the boundary
conditions, etc.

Discretization error due to poor geometry Discretization error effectively eliminated.

representation.
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 Formulation error results from the use of elements that don't precisely
describe the behavior of the physical problem.
 Elements which are used to model physical problems for which they
are not suited are sometimes referred to as ill-conditioned or
mathematically unsuitable elements.
 For example a particular finite element might be formulated on the
assumption that displacements vary in a linear manner over the
domain. Such an element will produce no formulation error when it is
used to model a linearly varying physical problem (linear varying
displacement field in this example), but would create a significant
formulation error if it used to represent a quadratic or cubic varying
displacement field.

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 Numerical error occurs as a result of numerical calculation
procedures, and includes truncation errors and round off errors.

 Numerical error is therefore a problem mainly concerning the

FEM vendors and developers.

 The user can also contribute to the numerical accuracy, for

example, by specifying a physical quantity, say Young’s
modulus, E, to an inadequate number of decimal places.

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 Can readily handle complex geometry:
 The heart and power of the FEM.
 Can handle complex analysis types:
 Vibration
 Transients
 Nonlinear
 Heat transfer
 Fluids
 Can handle complex loading:
 Node-based loading (point loads).
 Element-based loading (pressure, thermal, inertial forces).
 Time or frequency dependent loading.
 Can handle complex restraints:
 Indeterminate structures can be analyzed.

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 Can handle bodies comprised of nonhomogeneous materials:
 Every element in the model could be assigned a different set of
material properties.
 Can handle bodies comprised of nonisotropic materials:
 Orthotropic
 Anisotropic
 Special material effects are handled:
 Temperature dependent properties.
 Plasticity
 Creep
 Swelling
 Special geometric effects can be modeled:
 Large displacements.
 Large rotations.
 Contact (gap) condition.

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 A specific numerical result is obtained for a specific problem.
A general closed-form solution, which would permit one to
examine system response to changes in various parameters,
is not produced.

 The FEM is applied to an approximation of the mathematical

model of a system (the source of so-called inherited errors.)

 Experience and judgment are needed in order to construct a

good finite element model.

 A powerful computer and reliable FEM software are essential.

 Input and output data may be large and tedious to prepare

and interpret.

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 Numerical problems:
 Computers only carry a finite number of significant
digits.
 Round off and error accumulation.
 Can help the situation by not attaching stiff (small)
elements to flexible (large) elements.
 Susceptible to user-introduced modeling errors:
 Poor choice of element types.
 Distorted elements.
 Geometry not adequately modeled.
 Certain effects not automatically included:
 Buckling
 Large deflections and rotations.
 Material nonlinearities .
 Other nonlinearities.

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Seven basic steps in Finite Element Method
These seven steps include
1.Modeling
2.Discretization
3.Stiffness Matrix
4.Assembly
5.Application of BC’s
6.Solution
7.Results
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 First step

A1= A1’ + A2’ / 2

Second step

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 Now

After applying these conditions and solving for constants we have

a0=x1+x2/2
a1= x2-x1/2

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U = Nq

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Third step

But

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Fourth step

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Fifth step

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Sixth step

Elimination method
Penalty approach method

Last step

The presentation of results, finding the parameters

like displacements, stresses and other required parameters.

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Body force distribution for 2 noded bar element

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Surface force distribution for 2 node bar element

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After applying elimination method we have Q2 = 0.26mm

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Temperature effect on 1D bar element

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Thermal load vector

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Stress component because of thermal load

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Global stiffness matrix:

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Thermal load vector:
We have the expression of thermal load vector given by

similarly

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Global load vector:

Q2= 0.22mm

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Stress in each element:

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Quadratic 1D bar element

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Element strain displacement matrix

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Stiffness matrix:

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 Body force:

Surface force term:

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 ANALYSIS OF TRUSSES

Assumptions are:
•Truss element is only a prismatic member ie cross sectional area is uniform along its length
•It should be a isotropic material
•Constant load ie load is independent of time
•Homogenous material
•A load on a truss can only be applied at the joints (nodes)
•Due to the load applied each bar of a truss is either induced with tensile/compressive forces
•The joints in a truss are assumed to be frictionless pin joints
•Self weight of the bars are neglected

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Strain energy for a bar element we have
U = ½ qTKq
For a truss element we can write
U = ½ qlT K ql
Where ql = L q and q1T = LT qT

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Therefore
U = ½ qlT K ql

Where KT is the stiffness matrix

of truss element

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Stress component for truss element
The stress  in a truss element is given by
= E
But strain = B ql and ql = L q

Therefore

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= 901.3 mm
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By elimination method the matrix reduces to 2 X 2
and solving we get

Q3= 0.28mm and Q4 = -1.03mm.

With these displacements we calculate stresses in each element

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Beam element

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Potential energy approach

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Hermite shape functions:

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 Therefore

Similarly we can derive

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Stiffness matrix:

Strain energy in the beam element

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Beam element forces with its equivalent loads
Uniformly distributed load

Bending moment and shear force

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Load vector because of UDL

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 From KQ=F we write

At node 1 since its fixed both q1=q2=0

node 2 because of roller q3=0
node 3 again roller ie q5= 0
By elimination method the matrix reduces to 2 X 2 solving this
we have Q4= -2.679 X 10-4mm and Q6 = 4.464 X10-4mm

To determine the deflection at the middle of element 2

we can write the displacement function as

= -0.089mm
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