Industrial FEA Modeling Course 2010

1
Industrial Finite Element Analysis

with
F
Femap V10 1.
V10. 1 1 and
d NX Nastran
N t V7 0
V7.
An introduction to Femap and NX Nastran using a blend of

theory and practice that will allow the student to quickly grasp
the nuances of building accurate FE models.
Four Day Introductory Class with sufficient material for six days of lectures.
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Course Outline:
I. Introduction to Finite Element Analysis
a.) The concept of finite element analysis - nodes, DOF, elements
b.) Basic element types - a quick overview
c.) Linear, elastic FEA
d.) F = K*U
e.)) Workshop
W kh using
i Femap
F and
d NX N
Nastran
t
Introduction to Femap / Panes / Toolbars / Preferences / Etc
Simple Solid Model Stress Analysis
II Theory and Usage of Finite Elements
II.
a.) Beam Elements:
i) Theory
ii)) Workshop
p
b.) Isoparametric Elements (plate and solid):
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i) Theory
ii) Workshops
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Course Outline (continued):

III. Foundations of FE Analysis and Modeling
a.) Units
b.) Surface modeling (plate elements)
i) Techniques of working with geometric surfaces and plate models
ii) Workshop basic surface modeling concepts / linear elastic analysis
iii) Techniques
T h i off simplifying
i lif i structures
t t into
i t FE models
d l ((use off mass
elements and rigid links)
iii) Workshop mid-surfacing geometry / vibration analysis
c.) Application of loads to FEA models
i) Utilization of pressure loads for pressure vessels and bearing loads
ii) Workshop surface modeling of thin walled structures / pressure load
iii) Workshop working with solid models to create bearing loads (simple
versus data surfaces)
d.) Constraints
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i) Theory on the application of symmetry: geometry and loads

ii) Workshop
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IV. Assembly Modeling
a.) Standard, linear connection technologies (rigid links)
i) Technology review and commentary
ii) Workshop
b.) Advanced NX Nastran connection technologies
i) Technology of surface-to-surface glued versus surface
contact.
ii) Workshops glued connection and surface-to-surface
V. Results Validation
a.) Definition of von Mises stress scalar and max/min principal stresses
b.) Interpretation of stress results w.r.t. to von Mises and principal stresses
c.) Fatigue in FEA
d.) Using Free-Body-Diagrams (FBD) to check loading and load path
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VI. Advanced Femap Modeling Topics
a.) Mesh Repair
i) Technology and Commentary
ii) Workshop mesh repair and introduction to Data Table
b.) Hexing Solids
i) Theory and Background
ii) Workshop hex meshing with introduction to master/slave pairing
c.) Advanced surfacing techniques
i) Theory behind surfacing within Femap
ii) Workshop using Solid Geometry menus for surfacing operations.
d.) Femap Program Files
i)) Theory
y and limitations of Femap
p macro creation
ii) Workshop create simple macro and user-defined toolbar.
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e.) Application Programming Interface (API)

i) Introduction to Femaps API for customization and automation of repetitive
modeling tasks.
tasks Discussion of Custom
Custom Tools
Tools.
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ii) Workshop Create simple API and place in user-defined toolbar.

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VII. Advanced Analysis Topics
a.) Geometric and Material Nonlinearities
b.) Dynamics: Modal and Transient
i) Introduction to Eigenvalue/Normal Modes Analysis
ii) Workshop Basis Normal Modes with Optimization
VIII. Troubleshooting and Modeling Guidelines
a.) Understanding online Help Documentation.
b.) Femap and NX Nastran Error Messages
i) Theory/Background on error messages
ii) Workshop Debug FEA model using error messages with online help
c.) Modeling guidelines and best practices
i)) Discussion of element q
quality
y indicators
ii) Workshop contouring element Jacobian over mesh
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d.) Open discussion / Comments

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Finite Element Analysis:

A numerical analysis technique for obtaining approximate solutions to many types of
engineering problems. The need for numerical methods arises from the fact that for
most practical engineering problems analytical solutions do not exist. While the
governing
g g equations
q and boundary y conditions can usually y be written for these
problems, difficulties introduced by either irregular geometry or other discontinuities
render the problems intractable analytically. To obtain a solution, the engineer must
make simplifying assumptions, reducing the problem to one that can be solved, or a
numerical procedure must be used. In an analytic solution, the unknown quantity is
given by a mathematical function valid at an infinite number of locations in the region
under study, while numerical methods provide approximate values of the unknown
quantity only at discrete points in the region.
region In the finite element method,
method the region of
interest is divided up into numerous connected subregions or elements within which
approximate functions (usually polynomials) are used to represent the unknown
quantity.
The physical concept on which the finite element method is based has its origins in the
theory of structures. The idea of building up a structure by fitting together a number of
structural
t t l elements
l t (see
( illustration)
ill t ti ) was usedd in
i the
th earlyl ttruss and
d framework
f k analysis
l i
approaches employed in the design of bridges and buildings in the early 1900s. By
knowing the characteristics of individual structural elements and combining them, the
governing equations for the entire structure could be obtained. This process produces
a set of simultaneous algebraic equations. The limitation on the number of equations
that could be solved posed a severe restriction on the analysis. The introduction of the
digital computer has made possible the solution of the large
large-order
order systems of Structures
St t modeled
d l d by
b fitting
fitti together
t th
equations. structural elements: (a) truss structure;
The finite element method is one of the most powerful approaches for approximate (b) two-dimensional planar structure.
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solutions to a wide range of problems in mathematical physics. The method has

achieved acceptance in nearly every branch of engineering and is the preferred
approach in structural mechanics and heat transfer. Its application has extended to
soil mechanics
mechanics, heat transfer
transfer, fluid flow
flow, magnetic field calculations
calculations, and other areas
areas.
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From McGraw-Hill Science and Technology Encyclopedia, 5th Ed.

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Four things to know about FEA:

Idealization of Geometry into a numerical Model
Engineering assessment of Loads.
Loads
Visualization of structural constraints into modeling Constraints.
Discretization of continua into a finite element analysis Mesh (meshing).
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Finite Element Analysis Concepts:

Nodes are used to define the geometry of the finite element (that is to say its spatial
characteristics). Nodes have degrees-of-freedom and can translate (3 DOF (TX, TY, & TZ)) and
rotate ((3 DOF ((RX, RY, & RZ))
)) in space.
p
Finite elements can be classed as point, line, surface and solid elements. Another way to think of
these elements is as having 0-D, 1-D, 2-D and 3-D characteristics (D=dimensional).
0-D elements are created on one node and can be meshed on geometric points.
1-D elements are created on two nodes and can be meshed on geometric lines.
2-D elements are created on three or four nodes (triangular or quad) and can be meshed
on geometric surfaces.
3-D elements are created on a minimum of four nodes (tetrahedral) or eight nodes (brick or
hexahedral) and can be meshed on geometric solids.
Examples of various element types are:
0-D elements are mass elements used to simulate concentrated weight without stiffness.
1-D elements are beam elements used to model space-frame structures (e.g., bus frames).
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2-D elements are plate elements used to model thin walled structures (e.g., pressure vessels,
airplane skins, sheet metal, ships or structural steel framing).
3-D
3 D elements
l t are solid
lid elements
l t used
d tto model
d l thick,
thi k contoured
t d objects
bj t (e.g.,
( castings).
ti )
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Linear, Elastic, Static Analysis (99% of the world)
Stresses can be scaled as a linear

function of the loads.
Stress
The structure is elastic.
Scale displacements as a ratio of
elastic moduli.
Strain
Force
F Stress is independent of your material
= choice.
Area
Static means no acceleration - no
F = 0 spinning off into space.
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F = 0
FEA is
i based on the displacement
i method, which
i boils
i down to:
{F} = [K ]{u}
With a little work

work, structures and materials can be described as springs.
springs
We typically know something about forces and / or displacements.
The
Th equations
ti are solved
l d for
f displacements........................
di l t
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Step 1: Satisfy static equilibrium
Fx = F1 + F2 = 0
F1 = F2
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Step 2: Relate strain to displacements
L u 2 u1
x = =
L L
St
Step 3
3: Relate
R l t stress
t tto strain
t i
x = E x
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Step 4: Relate force to stress
F1 F2
x1 = and x2 =
A A
The minus sign is required since a positive tensile stress

at End 1 is in the negative x direction.
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Step 5: Relate force to displacement
Using the prior equations and performing a little substitution yields:
EA
F1 = x A = E x A = ( u 2 u1 )
L
EA EA
F1 = u2 u1
L L
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Step 6: Assemble matrix
F1 EA 1 1 u1
=
F2 L 1 1 u 2
which g
give us: {F} = [K ]{u}
* If u1 and u2 are non

non-zero
zero then an infinite number of solutions
are possible or in mathematical terms, the determinant of the
stiffness matrix K is singular.
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Ea A a 1 2 Eb A b 1 1
ka = = =2 kb = = =1
La 1 Lb 1
F1 2 2 0 u1
u
*Where nodes share
=
2 +
2
elements, they share
F 2 2 1 1
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stiffness terms. Off

F 0 1 1 u 3 g
diagonal terms are zero.
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F1 2 2 0 u1 In this form, K is singular! One

of the displacements must be zero
F2 = 2 2 + 1 1 u 2 to obtain a unique solution. Lets
make u1 = 0 and then try y to find a
F 0 u
3 1 1 3 solution.
F1 is solved as a reaction force at

F1 2 2 0 0 the end of the solution based on the
known displacements u2 and u3. This
F2 = 2 2 + 1 1 u 2 allows us to rewrite the matrix as:
F 0 u
3 1 1 3
The determinant of the stiffness matrix
F2 3 1 u 2 is no longer zero (i.e., 2) and a solution
= can be found using any number of matrix
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F3 1 1 u 3 technologies.
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F2 3 1 u 2
= Let F2 = 0 and F3 = 1, find u2 and u3:
F3 1 1 u 3
1
u 2 0 1 1 1
=[K ] [K ] = 2 1 3
and 1
u 3 1
1
u2 = F1 = 2 u 2
2
3
u3 =
2
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Part I: Workshop using Femap and NX Nastran
Pre-Processing Workflow:
Walk through Interface. Introduce concept of
Panes / Tool Bars / Menu / Selector Orientation
Talk about Preferences and setting up one
directory (Scratch) to store all of the modeling
files.
Femap is 100% Windows - Undo / Redo
Import Geometry / Clean up Geometry using
Geometry / Solid / Remove Face.
Face
Apply 1e5 load in Z direction.
Apply Constraints Radial and Fixed.
Analyze
Analysis Script: Geo,

Mat, Prop, Mesh Sizing,
Mesh, Load, Constraint &
Analyze
y
Note: All analysis examples
in this class follows this
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general analysis outline.

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Import Geometry File: Introduction to Femap / Part I / LANDING GEAR LINK.X_T

Movie File: Introduction to Femap / Part I / Introduction to Femap and NX Nastran.avi
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Part II: Workshop using Femap and NX Nastran
Creation of model using the Tree all the way
day Same script except a bit slower.
day. slower
Delete unneeded geometry and mesh with
default mesh scaling. Talk about meshing
messages.
Apply constraints via the Selector and introduce
the selector logic a bit (i.e., what happens when
you are in selector mode with the mouse buttons
for model viewing).
Discuss Pick modes (Normal versus Front).
Create Rigid Link (create node and then
element).
Apply 1000 lbf load in X-direction
X direction
Create Analysis Set using Elem. Iterative Solver
Run and Post Process.
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Import Geometry File: Introduction to Femap / Part II / Avionics Instrumentation Turret.X_T

Movie File: Introduction to Femap / Part II / Avionics Instrumentation Turret.avi
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Using the dialog boxes with tricks
F
Femap Productivity
P d ti it (RTM):
(RTM)
Reading the User manual can provide insight
into how Femap functions.
Explore online help under User Manual.
Short cut key and Dialog boxes
Look at Using the Mouse
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Beam Elements: Nastrans Most Challenging Element
2D Beam model: The big difference is rotation. In

3D - each node has six degrees of
freedom (DOF).
The equations for this 2D beam can be developed

from straight mechanics (e.g., see Timoshenko):
Fy1 6 3L 6 3L v1
3L 2L 2 3L L2
z1 2EI
M
1
= 3
y2 L
F 6 3L 6 3L v 2
* If we had more than
one beam element how would
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M 3L L2 3L 2L2 the matrix look?

z1
z1 2 * How manyy DOF does this
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beam element have?

* What DOF would have to
be fixed to solve this problem?
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Beam orientation is often

difficult
ff to first
f grasp
g p but
then seems obvious...
Beams can be offset from

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their neutral axis and/or

from their shear center.
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The beam orientation vector is

the beam Cross Section Definition Y vector..
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Geometry preparation is done
Create Material (Steel)
Create Beam Property: Rect.
Rect tube
1.5x1.5x0.083
Assign Mesh sizing and mesh curves (the beam
orientation vector is the..)
Create Loads: We are simulating 500 lb of gear
on one side of the frame distributed front and
back (see graphic)
Mesh at 4 sizing / Discuss beam orientation.
Weld the parts together.
Set up Analysis Manager
Run
Post-Processing Workflow:
View Select (F5)
View Options (F6)
Beam models have some unique things..
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Open Model File: Beam Modeling / Part I / Pickup Cargo Rack Start.mod
Movie File: Beam Modeling/ Part I/ Cargo Rack Simulation Pre.avi
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P P
Pre-Processing
i Workflow:
W kfl
Create Material and Multiple Properties (Beams)
Beams are tube 1.5x1.5x0.083, rect. Tube
2x1x0.125 and plate 3x0.73
2x1x0.125 3x0.73
Assign Mesh sizing and Attributes on Curves
Mesh Geometry (curves)
Create Loads (500 lbf thrust per motor at top
and bottom of frame) and Constraints (welded
onto frame).
Set up Analysis Manager
Run
View Select (F5)
View Options (F6)
Validating the Beam Model
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Open Model File: Beam Modeling / Part II / Beam-Thruster Structure - Start.MOD

Movie File: Beam Modeling / Part II / Beam-Thruster Structure-Pre.avi
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Post-Processing: Beam Stresses

Beam stresses are calculated at the
stress recovery (SR) points (think beam
th
theory: stress
t = mc/I).
/I)
Beams have End A and End Bs this
is a beam world convention. Not a big
deal since the program will contour
selected items at both ends of the
beam.
Stresses are reported as Max
combined or Min combined or at SR
points you chose
chose. The Max is the
maximum value of the SR points.
Combined is just the combined axial
and bending stresses. Torsion is not
included.
Be careful about your torsion
assumptions.
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Beam Elements: Common pitfall when
creating beam models
Meshing curves separately you are then laying
d
down th
the beam
b elements
l t as separatet
independent entities. In this case, the program
does not know what to connect since they are
created independently. That is, each time you Just the
mesh a curve it creates its own set of nodes and tubes.sequential
elements When you run the model and you
elements. meshing g of the
have elements that are not connected then structure..
you may see the Error Message below.
If you are meshing curves one at a time (so to
speak) then you will need to merge up the
coincident nodes or weld the structure. This is
done under Tools / Check / Coincident Nodes.
Note: go slow on this one since you need to
check the Merge Coincident Node box.
Error Message:
g
^^^ USER FATAL MESSAGE 9137 (SEKRRS)
^^^ RUN TERMINATED DUE TO EXCESSIVE PIVOT RATIOS IN
MATRIX KLL.
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^^^ USER ACTION: CONSTRAIN MECHANISMS WITH SPCI OR

SUPORTI ENTRIES OR SPECIFY PARAM,BAILOUT,-1 TO
CONTINUE THE RUN WITH MECHANISMS. Note: When merging coincident nodes
*** USER INFORMATION MESSAGE 4110 (OUTPX2) make
k sure you actually
t ll Mergeem
M this
thi
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box needs to be checked.

Beam-Thruster / Beam-Thruster Structure - Finish.MOD
Beam-Thruster Structure-Extra Credit.avi
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General All Purpose Elements: Isoparametric Elements
Isoparametric elements can

model anything - since they
approximate the behavior of
the structure through the use
of many, simple polynomial
f ti
functions. However,
H since
i
they are approximate, the
user must apply good
engineering judgment
throughout the modeling
process.
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In order to develop stiffness equations, we must be able to map

displacements within the solid element from its nodal locations.
4
u xp = N i ( , ) u xi
i =1
4
x xp = N i ( , ) x xi
i =1
Ni is known as the shape function,

which does double duty as the
interpolation function for both
displacements and coordinates.
coordinates
= eta
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An example of a 1
linear shape function:
N1 = (1 )(1 )
= xi 4
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The development of an element stiffness matrix

is somewhat analogous to that for a simple rod.
Step 1: Satisfy static equilibrium F = 0
Step 2: Relate strain to displacements - simple 2D example

x x 0
u
y = 0 y v or = u

xy y
x
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Displacements within the quadrilateral are interpolated from
nodal displacements ui and vi using the shape functions Ni
u1
v
u N1 0 N 2 0 ... 1
= u 2 or u = Nd
v 0 N1 0 N2 ...
v2

.
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= Nd or = Bd where B = N
Matrix B is called the
strain-displacement
strain displacement matrix.
Step 3: Relate stress to strain
= E or = EBd
Step 4 and 5: Relate force to stress and then force to displacement

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F = EA or F = EBdA
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F = EBAd
Although this may look pretty simple, we need a more robust expression that
will provide an element stiffness at each nodal location. Without going into
the math in great detail, the element stiffness matrix looks like this:
{k} = [B ] [E][B ]dxdy

T
To determine k, one must
numerically integrate over the
whole
h l area or volume
l off the
h
element. Moreover, since we are
{k} = 11 11[B ]T [E][B ][ J ]dd using the general coordinate system, we
need to make one last changeg (Jacobian
(
transformation matrix).
{F} = {k}{d}
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Gaussian integration points - if we didnt use them - we would

be hurting in a big way. This technique is also known as Gauss Quadrature.
{ } 1 1[B ] [E][B ][ J ]dd

k = 1 1 T Numerical integration will use
thousands of CPU cycles solving for k
Gaussian Integration:
n m
I = Wi Wj ( i , j )
i =1j=1
*We have skipped

pp a bunch off math,,
but the theme is that a lot of the
action happens at the Gauss points.
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Stresses are computed at

the Gaussian integration
points. Nodal stress values
used in stress contouring are
then extrapolated (using the
shape functions) out to the
nodal points.
If the element is badly

distorted, these Gaussian
integration points will do a
poor job in capturing the
correct area or volume and
an even poorer job in
delivering accurate stress
values.
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FEA Isoparametric Stresses

In Isoparametric elements, stress are
first calculated at the Gauss points and
then extrapolated out to the nodal points
and interpolated to the centroid of the
element.
Each element is an island
island and the
computation of stress within that element
is unique to that element.
For a basic quad element with four
nodes, each stress component will be
reported at the nodes and the centroid.
FEA post-processors present plots of
averaged nodal stresses between
elements.
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An element stress convergence check

can be made by comparing the
elements
l t centroid
t id to
t nodal
d l stress
t values.
l
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Many types of structures are modeled best using plates

Thin walled structures, e.g., sheet metal, tanks, tubes, and composites
Detailed analysis of structural steel shapes
Slabs where a shear loading is not dominant, e.g., a Length/Thickness > 10
or the thickness of the structure does not change due to loading
Classically, plates carry only

transverse loads and are flat. Whereas,
shells can be curved and carry
membrane loads. In practice, we just use
FEA plates that combine both
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behaviors.
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Plate theory: 6 DOF at every node
Plate loading is dominantly defined by transverse loads. This type of loading

causes the plate to have lateral displacement w=w(x,y) in the z direction. The
strain-displacement
t i di l t ffunctions
ti are then
th formulated
f l t d as:
2w 2w 2w
x = z 2 y = z 2 xy = 2 z
x y x y
From this point forward, approximately the same approach is used for isoparametric
elements is followed, i.e., shape functions are used to interpolate the coordinates
and displacements. Consequently, your mileage may vary depending upon the shape
of your elements.
elements
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Plate Elements: Nastrans Most Commonly Used Element
T i Covered:
Topics C d
Introduction of curves/surfaces/plates.
Using the Selector logic for modeling versus
other methods within the interface.
Femap is a database that allows you to tag
tag
things like plate properties to surfaces.
Plates have top and bottom and so do
surfaces. Start to think about idealization.
Post processing is more than just contouring..
Workflow:
Build your own geometry starting with curves
and then extruding the curves. The I beam is a
6x8 by 64 long with 5 diameter web holes at 8
centers.
t
Flange is 3/8 with a web. Create two plate
properties and assign using the Selector.
Mesh size (1) and Mesh using the Selector.
Assign Load (pressure load of 50 psi) and simply
constrain on ends with pinned constraint.
constraint
Run and post process looking at element
stresses top and bottom.
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Cover von Mises, Major and Minor Prin stress

components.
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Start: Plate Modeling / No Geometry you get to build your own

Movie File: Plate Modeling and a Bit More Part I.avi / ..Part II.avi
42
Why do we care about this stuff?

Shape functions are simple polynomials.
The area or volume of the element is approximated.
pp
Stresses are computed at Gauss points not at nodal points.
Highly distorted elements - lead to poor Gaussian integration. Rocks in your Jello
The whole process uses quite a few approximations.
Displacement
p results will always
y be more accurate than stresses.
That is, stresses, reaction forces, etc. are derived.
A knowledgeable user makes better assumptions.

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Isoparametric Elements: Convergence
12
48
FL3
v2 =
3EI
bh 3
I= = 1 12 2 = 144
12
FL3 1 483
v2 = = = 2 .56
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3EI 3 100 144

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2.5 Quad Exact

4 elements
2 2 elements
Tip Displacementt
1 element
1.5
0.5
0
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0 5 10 15 20 25 30 35 40 45 50
Beam Length, x
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Quadrilaterals dont like to be skewed. 1.
General rules:
2
123
4 6 8 10
Aspect < 10 to 1
Skew < 30o
Taper < 30o
1 2 3 4
123
3 5 7 9
Avoid Diamonds
Y
3
Z X
2.5
Tip Displacement
Skewed elements are stiff and 1.5
give dangerous results. That is,

you can under predict the stresses 1
by large margins. This is the 0.5

downside to Isoparametric elements.
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0
0 5 10 15 20 25 30 35 40 45 50
Beam Length
Length, x
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Topics Covered:
Femap provides mesh quality diagnostics within
the Tools menu under Tools / Check / Distortion.
One can also use the Custom Tools menu to
create a contour map of these items (see Custom
Tools / Model Query / Distortion to Output
Vector). The plot on the upper left was created
with this custom tool.
Even though we may have quad elements with
a high Jacobian, they still outperform three-node
triangular elements.
See Bonus.mod for the six-node triangular mesh
example.
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Jacobian / Open model files and investigate.

No AVI file
47
The P-element or polynomial escalation
*The whole trick is

that the shape
p ffunction is
now parabolic - it can
handle a parabolic
distribution of displacement
ffrom one node to the next.
1 1 1
N 2 = (1 + )(1 ) (1 2 )(1 ) (1 + )(1 2 )
4 4 4
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1
N 6 = (1 + )(1 2 )
2
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The P-element or polynomial escalation
12
48
3
2.5
2
Q d8
Quad8
Tip Displacement
1.5
0.5
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0
0 5 10 15 20 25 30 35 40 45 50
Beam Length, x
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Why we dont like triangular elements....
12
48
3
2.5 Tri
2
Tip Displacement
1.5
parabolic
1
0.5
linear
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0
0 5 10 15 20 25 30 35 40 45 50
Beam Length, x
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Pre Processing Workflow:

Pre-Processing

Create Material and Property
Set Mesh sizing
g and then Mesh Geometry
y
Apply Loads and Constraints
Define Analysis Manager
Run
P tP
Post-Processing
i Workflow:
W kfl
View Select (F5) - Contour

View Options (F6)
Interrogation of model with Selector Tool.
Refine Mesh / Rerun
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Plate-Hole / Plate-Hole-Start.mod
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Mesh Convergence - Only one part of obtaining an accurate FE solution
h-refinement versus p-refinement.

Simple tests can verify mesh convergence (comparing Mistakes in loads, support
conditions, and so on will
th stress
the t att the
th centroid
t id versus the
th nodal
d l locations).
l ti ) propagate through
Mesh convergence is just minimizing the JUMPS from adaptive cycles and
element-to-element; nothing more - nothing less. produce an improved
solution to the wrong
problem. Also, poor
choices of element types or
an initial mesh that is too
coarse may not disclose
enough detail to permit the
revised mesh to be an
improvement Automatic
improvement.
adaptivity seems to
guarantee that final results
will be adequate, but of
course there can be no
such guarantee.
guarantee.
From R.D. Cook - FEM for
Stress Analysts, p.143 (1995).
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Re
Knowing when to say when?

52
Geometry preparation: slice off extra geometry

and refining
g the load patch.
p
Create Material and Property
Define Load (40 lbf) and Constraint (Fixed)
Set up Analysis Manager (Iterative Solver)
View Select (F5)

View Options (F6)
Using View Options and saving View Options
within the Window environment
Post-Processing tricks
Using the selector to interrogate the model
between nodal and elemental stresses (extra)
Remesh of Model for tighter convergence
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Re
Import Geometry File: Solid-Anvil / Solid-Anvil.x_t

There are a few avi files.start with Pre file
53
Beams are line elements that represent geometry (mechanical

structure)
t t ) that
th t has
h a uniform
if cross-section
ti andd iis llong ((e.g., it
its
Hardest are Beams length is 10 times longer than its height or width).
Beams are exact - no approximations are used.
Lateral contraction or expansion (Poissons effect) is not
accounted for - but for linear,
linear elastic,
elastic static analysis work it is an
extremely minor effect in beam structures.
Beams offer you the maximum design optimization opportunity!
Somewhat easier are If an engineering structure looks like a collection of surfaces

from a distance - say a car body or a vessel (tank) or
Plates submarine or airplane skin - then it is a good candidate to be
modeled with plate elements.
Plate thickness is an easily changed variable. Sizing
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optimization can be performed extremely quickly.

Good results for plate like structures but assumptions are still
used.
used
Re
Poissons effect is accounted for.

54
Solids make the fewest geometric approximations but make the

most numerical approximations. It takes a lot of solid elements
Easiest are Solids to give good results. This means that solids analysis work can
be time consuming and slow. This leaves you with fewer
chances to pursue design optimization strategies.
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Re
55
Units in FEA
Lbf = (in3)*(lbf*s2/in4)*(in/s2)
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For a dynamic analysis, how would we

check the structure?
Re
(Hint: if in English units the mass of the

structure x 386 should be the weight
(Tools / Mass Properties)).
56
Units in FEA
Conversions for exotic units based on generic steel

lb f/in lb f/mm N/mm N/in
Geometry in mm mm in
Elastic Modulus 30 10 6 lb f/in 2 4.65 10 4 lb f/mm 2 206.8 10 3 N/mm 2 1.334 10 8 N/in 2
gravity 386 in/sec 2 9810 mm/sec 2 9810 mm/sec 2 386 in/sec 2
Mass Density 7.324 10 -4 1.76 10 -9 7.827 10 -9 3.258 10 -3
lb sec 2 /in 4 lb f sec 2 /mm 4 N sec 2 /mm 4 N sec 2 /in 4
Output
Displacements in mm mm in
Stresses lb f/in 2 lb f/mm 2 N/mm 2 (MPa) N/in 2
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Re
57
Loads and Constraints

Loads:
Loads within an analysis deck get boiled down
to the node and element level there is no
geometry in an analysis deck.
In the pre
pre-processor
processor (a.k.a., Femap), you can
apply loads to geometry or directly to nodes and
elements. However, at the end of the day
everything goes to the nodes and elements in the
analysis deck.
Constraints:
Application of constraints follows the same
pattern you can apply them to geometry or
directly to the underlying nodes. (Note:
constraints always go to nodes see prior
discussion on FEA Theory).
Whether you go the Geometric route or via
Direct nodes it is y
your decision and whatever
you feel most comfortable with.
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The most important concept is that you

p
understand completelyy what y
you are
Re
doing
58
Surface Modeling
Geometry preparation: mid-surface solid

(thickness is 0.118).
Create Material (steel) and Property (plate
element)
Mesh sizing and meshing of surfaces.
Create Motor Mass (10 lbf) and attach to motor
mount with rigid links
Create constraints around base.
Set up Eigenvalue analysis (natural frequency).
View Select (F5)

View Options (F6)
Delete Results and Resize plate model to
0.1875 (not covered in AVI but I think you guys
know what to do).
do)
Rerun analysis and compare results.
Perform Static Stress Analysis using Body
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Acceleration Load of 10 g.
Interrogate plate element stress results (top and
bottom).
I
Import
tGGeo: S
Surface
f M
Modeling
d li / Part
P t I / Motor
M t Mount
M t w Motor.STP
M t STP
Re
Movie File: Surface Modeling / Part I / Surface Modeling-Pre Classic.avi

Movie File: Surface Modeling / Part I / Surface Modeling-Pre Selector.avi
Movie File: Surface Modeling / Part I / Surface Modeling-Post.avi
59
Surface Modeling
Pre-Processing
Pre Processing Workflow:
Geometry preparation from 3-D solid into

Surface Model for Plate Meshing: using hidden
Femap tools to measure distances (CTRL-D) while
within another dialog box,
box Midsurface tools
(Extend), Geometry / Solid / Stitch, Intersect,
Curve from Surface (slice). Another command
discussed is changing the pick mode from Normal
to Front while picking:
Create Material and Property ((two plate sizes))
Apply Mesh sizing and Mesh Geometry
Apply Loads and Constraints
Set up Analysis Manager and Run
P t P
Post-Processing
i Workflow:
W kfl
View Select (F5)

View Options (F6)
Post-Processing tricks
Optimization of plate models by changing the
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gusset thickness
Re
Import Geo: Surface Modeling / Part II / Surface-Midplane Modeling.X_T

Movie File: Surface Modeling / Part II / Surface-Midplane Modeling-Pre.avi
60
Surface Modeling
Workshop flow:
Import model, find symmetry and slice down

center.
The model has three components with
thicknesses of 0.125, 0.185 and 0.250.
Create mid-surface geometry using the target
thickness of the thickest component. Stitch
geometry together into three infitisimally thin
solids.
Prepare geometry for clean meshing. Offset
curves around dimples by 0.25, imprint several
curves and then create washes around the holes
with a distance of 0.10.
Work through trial meshes. Final mesh size will
be 0.25. Use Meshing Toolbox to tweak mesh
into something nice. Use Mesh Add and Mesh
Set.
Glued connections via Automatic
Create load: 1,000, 1,000 and 1,000.
Apply constraint and run.
run
Postprocessing with plate stresses on top and
bottom.
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Import Geometry: Surface Modeling / Part III / SUPPORT STRUCTURE FRAME.X_T

Movie File: Surface Modeling / Part III / Support Structure Frame Workshop.avi
61
Surface Modeling
Import model and create group of the yellow

geometry part. Work with groups and Automatic
Add
Add.
Explore Custom Tools / GeometryProcessing /
Find Tangent Surfaces. Use CTRL-D to measure
offset (-0.09/2).
Understand Geometry / Solid / Stitch (Femap
surfaces are infinitesimally thin solids.
Mesh Surfaces using the selector. Play with
surface meshing options to obtain improved
mesh.
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Re
Import Model: Surface Modeling / Part IV / Bus Seat Start.mod

Movie File: Surface Modeling / Part IV / Industrial Mid-Planning.avi
62
Engineering Assessment of Loads
First Law: A body will remain at

rest or will continue its straight line
motion if left alone.
Second Law: F=ma
Third Law: Action and Re-action
(or conservation of forces) - this is
the critical law for piece-parting
assemblies.
Simple stuff is quite useful: You

can check your actual FEA
applied loads via the f06 file
within the analysis manager
after the analysis has been
completed. The OLOAD is the
applied load and the
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SPCFORCE is the reaction load

after the analysis. These should
tie.Third Law.
Re
63
The giant slab of steel.

Gravity?
Straight forces?
Pressures?
Interaction loads which might be
a combination of forces and
moments?
0.998
Dynamic / Impact?
0.893
0.788
0.683
0.578
0.473
Nonlinear -- e.g., Follower Forces

0.368
0.263
0.158
0.0525
/ Stress Stiffening
-0.0525
-0.158
-0.263
-0.368
-0.473
Frictional forces?
-0.578
-0.683
-0.788
-0.893
-0.998
0. 6.25 12.5 18.75 25. 31.25 37.5 43.75 50. 56.25 62.5 68.75 75.
Sin
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Re
Think worst case..

64
Pressurized
structures are
pretty common.
The trick to their
loading is not the
structure must be
balanced. It cant
move off into Counter forces were applied
space
space. at the flanges to balance the
system.
Sum of Forces is
important to
check your
loading
loading.
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Re
65
V1
L1
C1
380.24
286.38 28.419
34.458
356.12
589.09
512.8
Free body diagrams

are still useful after all
198.
288.
these years.
years
Yes - we could do it
140.74
Z 34.458
all as an assembly.
Y
However, this part went

through five revisions.
revisions
The FBD was
invaluable.
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Re
66
Constraints
Symmetry - you gotta love it to be a good modeler.

Geometric Symmetry - mirror planes in model.
Loading Symmetry - loading is identical across or between mirror planes.
ux= 0
Y
X
uy= 0
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Re
67
Constraints
Beams and Plates nodes have six

degrees-of-freedom. Consequently, six
constraint DOF can be applied (e.g.,
TX, TY, TZ, RX, RY, and RZ).
Solid elements nodes have three

V1
L1 degrees-of-freedom. Consequently,
C1
1.7321
three constraint DOF can be applied
123 (e.g., TX, TY, and TZ).
123
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Z
Y
Output X
Set: MSC/NASTRAN Case 1
123 What do you think happens when you
Contour: Solid Von Mises Stress pp y a RX or RY or RZ constraint to a solid
apply
Re
element node?
What do all FEA models have in common
in regard to rigid body motion?
68
Constraints
Simple rules of symmetry

Visualize motion
Sketch it out on paper
45
Cyclic symmetry will occur in

many rotating structures. This
type of symmetry is also
known as sectorial symmetry
or rotational periodicity.
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Re
69
Constraints
Dont be reluctant to exploit

symmetry Fast models allows you
symmetry.
to check, check, and check your
results.
The key questions: - Is the
structure symmetric? - Are the loads
symmetric?
Avoid over constraining your
models. This can actually hide your
hot spots.
spots If in doubt - bound your
solutions with different boundary
conditions. This is no big deal if you
model runs fast.
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Re
70
Constraints
Geometry preparation: Symmetry and Surface

Preparation: Hidden Ctrl-Z command to bring up
the Locate dialog box to assist in locating the
Geometry / Solid / Slice plane
Auto meshing with control of mesh sizing from
Solid to Surface to Curve
Application of pressure load as a pin force. Use
of pressure load and then to the use of Modify /
Update Other / Scale Load to get the final 5,000
lbf load.
Constraints to enforce symmetry with respect to
the 6 DOF for every structure. Use of Geometry
Based versed Nodal Based same but different.
Analysis Manager / Run.
View
Vi Select
S l t (F5)
View Options (F6)
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Modeling Bearing/Pin Forces - Does it look right.
Discussion of modeling results.
results
Re
Import Geo: Constraints / MESSIER-DOWTY-LINK-CONSTRAINTS.X_T

Movie File: Constraints / M-D-Link-Constraints - Pre.avi and then Post.avi
71
Constraints
Import geometry file and inspect. Model is
symmetric.
Prepare geometry (Geo / Curve from Surface with
U d t Surface
Update S f On)
O ) for
f the
th line
li contact
t t constraint.
t i t
Elegant constraint modeling is done by defining
user coordinate systems see Model / Coord Sys /
Define Coordinate System.
Apply pin bearing constraint via user defined
cylindrical coord system at the center of the hooks
pin bearing.
Apply line contact constraint where the hook
contacts the bushing.
Apply 13,000 hook load.
Set up Analysis Manager enable Iterative Solver.
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Contour the Max. Prin Stress to verify behavior of the

hook model.
Re
Import Geo: Constraints / Raw Constraints / HOOK MODEL - SYMMETRIC.X_T

Movie File: Constraints / Raw Constraints / Raw Constraints Tutorial.avi
72
Assembly Modeling
Sway bar modeled with

10-node tetrahedrals.
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Re
This model required the attachment of a solid tetrahedral model (the sway bar)
with bolts to a suspension frame made out of plate elements.
73
Assembly Modeling
A spiders web of RBE3s
SDOF elements
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Re
The bolts (beam elements) were attached to the frame (plate elements) with MPC
elements (RBE3s). The same strategy was used to attach the solid elements onto the
bolts. Single degree-of-freedom springs (CBUSH elements) were used to simulate a flexible
rubber bushing between the suspension components.
74
Assembly Modeling
Comments:
Tying structures together can be quite
Tying
easy with a little idealization.
This exercise covers the use of RBE2
(super-stiff links that transmit rigidity and
spatial relationships) and RBE3 (links that
transmit force (no rigidity) and spatial
relationships).
Tasks:
Use template model to apply the various
connection technologies and evaluate the
results.
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Re
Open Model File: Assembly Modeling / Connections / Connection-Start.mod

Assembly Modeling 75
Surface-to-Surface Contact
NX Nastran Linear Contact for Sol 101:
It is almost necessary to read the manual. (NX Nastran

Userss Guide / Chapter 19)
User 19).
The NX Nastran linear contact has a legacy directly from
SDRC-Ideas. It is a well-proven technology and they are still
improving it.
Be careful of the defaults for Min and Max Contact
Search Dist. Actual contact elements are created within
the solver based on the regions that you create in Femap
and then the distances specified in these entries. One can
create virtual contact elements where one least suspects
it.
Num Allow Contact Changes default of 0.0 is often too
rigorous One suggestion from an experienced user is that it
rigorous.
should be 1% of the number of contact elements formed
within the solver (see your F06 file itll be listed in the first
contact iteration dialog)
Setting up contact regions can be done automatically
but it may be more effective in the long run to carefully
select your contact regions via the Connection Region
dialog boxes.
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The last dialog box to make contact. Think of the total

process as 1.) Connection Property; 2.) Region and 3.)
Connector.
Re
We are ready to create our contact behavior

between the four parts. Create contact and
glued property cards within the tree. Be careful.
Default Contact Search is 0.1 and for Glued
Contact it is 0.0001.
Follow avi and create connection regions using
surfaces and then create the connectors.
Run Analysis and view F06 file while running.
Analysis Workflow:
View Select (F5) and Review Results

Interrogate the results and see if the
contact behavior is reasonable. Contour
contact pressure.
Use the defaults for the Contact Property
Card. Review the results.
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Reset Max Contact Search Dist to 0.1

and set Glued Contact to defaults. Rerun
and review the results.
Re
Open Model File: Assembly Modeling / Intro to Contact / Cutting the Mustard Start.MOD
Movie File: Assembly Modeling / Intro to Contact / Intro to Contact.avi
Model has been created with bolts

created (beam elements and rigid links)
Create rigid link spider at the end of the
cylinder using the Femap API (see Custom
Tools). Apply FX=-2500 and MY=2500 to
the center node of the rigid link spider.
Create constraint on base of model at
the inside of the four holes (use Selector /
Surface / multiple).
Run Analysis
Analysis and Optimization Workflow:

Create contact surface between cylinder and
base (Geometry / Automatic / Contact)
Rerun Analysis
Create Bolt Preload (10,000 - elements)
Rerun Analysis
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Note: The model Advanced Assembly Modeling

y runs completed.
Final.mod has all the analysis p Assembly Modeling / Adv Assembly / Advanced Assembly Modeling Start.MOD
Re
Assembly Modeling / Adv Assembly / Advanced Assembly Modeling Pre.avi

Assembly Modeling / Adv Assembly / Advanced Assembly Modeling Surface Contact.avi
Assembly Modeling / Adv Assembly / Advanced Assembly Modeling Bolt Preload.avi
Glued Contact Between Solid Elements
Geometry has been prepared for meshing.

Tet mesh the top with a mesh sizing = 0.2 for the
Hex mesh on the bottom pick min. number of
elements = 4.
Create glued contact (Geometry / Automatic)
Apply loads via Selector (FY = 1000 lbf per
surface)
Create constrains around base
Run Analysis
Analysis and Optimization Workflow:

Interrogate the results and see if the stress
transfer across the glue connection appears
reasonable
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Re
Open Model File: Assembly Modeling / Hex to Tet Glued Contact / Hex to Tet Glued Contact Fitting Start.MOD
Movie File: Assembly Modeling / Hex to Tet Glued Contact / Glued Contact Example.avi
Glued Contact between Plate Elements
A detailed description is given on how Glued Contact
works.
Individual regions are created for each plate element
property.
An Eigenvalue analysis is done to show how the Glued
Contact Works.
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Re
Open Model File: Assembly Modeling / Plate Element Glued Contact / Plate Element GC Start.MOD
Movie File: Assembly Modeling / Plate Element Glued Contact / Plate to Plate Glued Contact.avi
Surface-to-Surface Contact Plate Elements
Comments:
This model is already to go - with only the contact
definition remaining to be defined.
The theme of this exercise is that plate elements
have normals -- that they have directions (outward
or inward). These normals can be viewed within
the Model Info tree via the Highlight Button.
We also explore debugging the model.
Workflow:
Define Contact behavior between the tubes
using the tree structure.
Run the analysis after defining the
C
Connection.
ti
Analysis fails - check plate element normals
and correct via Modify / Update Elements /
Reverse.
Rerun
Rerun analysis and post process results.
results
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Re
Open Model File: Assembly Modeling / Square Tube Contact / Square Tube Contact.MOD
Assembly Modeling / Square Tube Contact / Linear Contact - Rectangular Tube.avi
Mastering Femap 81
Grand Slam of WorkShops:
Comments:
This is the grand daddy of models. We will use
most everything taught in this course and a few
new things.
Using Beam Elements for Bolts
Rigid Links
Bolt Preload
Sinusoidal Bearing Load
Scaling loads.
Workflow:
Create curves for bolts ((beam elements).
)
Create beam elements (1.5 diameter) and
mesh curves.
Mesh Solids sizing on solids is at 1.25.
Create group with just geometry and beam
elements to apply rigid links.
Create Bolt Preload 100,000 lbf.
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Create Surface-to-Surface contact and then

run the analysis.
Re
So much more.
Master Exercise / WINCH DRUM SUPPORT.X_T

Mastering Femap Part I.avi / Part II .ave/ .Part III.avi / Part IV.avi
82
Two types of stress results are commonly used to provide

insight into the behavior of the structure:
von Mises stress
maximum principal stress
von Mises criterion - states that yielding of an The maximum principal stress criterion states
isotropic
p material will begin g when the von that fracture will occur when the maximum
Mises stress reaches a limiting value principal stress reaches a limiting value in
regardless of whether it is compressive or tension.
tensile (e.g., yield stress or ultimate stress of
the material).
1
( ) + ( ) + ( )2
2 2 2
1 x y y z z x

vonMises =
(
2 + 6 2 + 2 + 2
)

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xy yz zx
Re
83
Under pure uniaxial tension;
[ ]
1
1
vonMises = ( x ) + ( x )
2 2 2
2
vonMises = x
*The biggest
*Th bi st thing
thin to
t note
n t about
b ut the
th vonn
Mises stress is that it is neither positive
=
or negative!
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Re
84
Principal stresses: why is the maximum principal stress mostly positive?
x y x y
max,min = + xy
2
x 2 2
xy 1 2xy
max min principal= Tan1
y 2 x y
x xy zx In 3D the math gets a little

bit hairier and requires the
DET xy y yz = 0
use of determinants.
determinants The
zx yz z roots of the final equation are
evised 2010
the three principal stresses.

Re
85
Predicting failure
is highly
individualistic
SEndurance
a m 1
+ =
S Endurance S Ultimate Factor of Safety
a m 1
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+ =
S Endurance S Yield Factor of Safety
Re
Your load cycle was a half-sine wave?

86
Comments:
Stress results exist for the model which contains
solid, plate and beam elements.
The goal of this exercise is to contour stress results
over the solid
solid, plate and beam elements
elements.
Explore definitions of von Mises, max prin stress,
majorprn, etc.
Things to do:
Play with the View Select (F5 or tool bar pick)
and understand the concept of centroidal
versus nodal stresses.
Contour
C t TType iis about
b t simple
i l versus
intelligent stress contouring.
Data Conversion is how the nodal or
centroidal stresses are averaged. Corner data
= Nodal Data
Element Contour Discontinuities is used for
plate elements and corrects for idealization
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problems with plate elements.

Re
Load Model File: Post Processing / Comparison of Element Types Under Simple Bending.MOD
Movie File: Post Processing / Post-Processing Stress Scalers.avi
87
y options
Default analysis p g
gives y
you
applied loads and reaction loads
(forces/moments at constraints) within the
model.
Internal forces require
q Analysis
y /
Advanced options (see next slide).
Free-body diagrams help you check
evised 2010
your work at a glance.

Re
Free-Body-Diagram / Free-Body-Diagram Beam Elements.mod

88
With this lash-up - you see all the

internal forces acting
g at each node -
this is most useful when you are trying
to debug interfaces or strange
evised 2010
connections.
Re
Free-Body-Diagram /Free-Body-Diagram Beam Elements.mod

89
Another useful thing

about the FBD option is
the ability to check your
RBE2, RBE3 connections
(Multi Point Reaction
(Multi-Point
Loads).
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Re
Free-Body-Diagram / Free-Body-Diagram with RBE3.mod

90
Advanced Femap Modeling Topics:
Mesh Repair
Comments:
Our goal is be able to get any type of solid to
mesh! It is possible! This interface has the tools
to allow you to mesh anything. The trick is to
recognize the steps and to figure out where the
meshing process is failing.
In this exercise - we hand fix a mesh and then
mesh the resulting surface mesh.
Solid meshing is all surfaces, surfaces, surfaces.

Tasks: Solid Mesher Steps:
With the above solid,
solid mesh it using the default 1 Meshes surfaces
1.
sizing, uncheck Suppress Short Edges. 2. Seals surfaces into continuous shell.
Read Meshing Messages and then find the hole 3. Grows surface mesh into a solid tet mesh.
in the surface via View Select / Free Edge.
Find p
problem,, fix-it,, and then create a solid mesh
from the sealed skin.
Fixing:
evised 2010
1. Bad surfaces - wont mesh.

2. Create sealed surface.
Re
3. Play and learn. No easy way.
Adv Femap Topics / Meshing / DETROIT STOKER LINK MESH

EXAMPLE.X_T / Mesh Repair.avi
91
Hex Meshing
Comments:
Hex meshing is ideal for easy solids since one
brick is equivalent to five tetrahedrals (8 nodes
versus six 10-node tetrahedrals (27 nodes)
The concept is to break the solid down into
eight-sided meshable solids. Think of slicing and
embedding faces.
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Re
Import Geometry File: Adv Femap Topics / Hex Meshing / Hex Mesh Geometry.x_t
Movie File: Adv Femap Topics/ Hex Meshing/ Hex Meshing Geometry.avi
92
Surfaces as Infitisimally thin solids
Introduction: Before the age of modern CAD, we had simple

surfacing techniques (a.k.a., dumb surfaces). These simple
surfaces could not be manipulated downstream once they
were created. Nowadays, the only legacy simple surface
th t one can create
that t is
i the
th boundary
b d surface
f from
f curves.

Femap now uses the parasolid geometric kernal to creates
geometric surfaces and solids. Manipulation of geometric
solids within Femap is native to most CAD users and needs
little explanation.
explanation The converse is true when one induces the
concept of surface modeling within Femap and thinking
about surfaces as infitisimally thin solids.
In Femap, surfaces are treated as very thin solids -- like
infitisimally thin solids.
solids What you can do with geometric
(parasolid) solids you can also do with surfaces. My favorite
trick is to create manifold skins from disparate but contiguous
individual surfaces. This trick is under Geometry / Solid /
Stitch. Once you have this stiched up skin, you can then
treat it as a collection of surfaces within one infitisimally thin
solid. A little tutorial is provided showing these featues.
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Work Flow: Run tutorial and then try to create the work flow
pattern at your own pace.
Re
Adv Femap Topics / Surface_Concepts / New

Model - Nothing to load / Surface_Concepts.avi
93
Surfaces as Infitisimally thin solids
Comments:
This sections expands upon working with smart
surfaces (parasolid based infitisimally thin solids)
within Femap.
Many commands from the Geometry / Solid
menu can be used within Femap. For example,
one can fillet surfaces and remove faces much
as you do for solids (likewise you can also
remove holes in surfaces).
We also explore mapping a perfect quad
mesh onto a not-so-perfect warped geometry
via Boundary Surface / Surface on Solids to
create one surface and then using Mesh /
Surface_Manipulation.avi
Mesh Control / Approach on Surface.
Work Flow Tips:

Open model file and set the mesh sizing via
Mesh / Mesh Control / Size on Surface. Mesh the
surfaces and note the quality of the elements.
Create boundary surface using the underlying
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surfaces. Repeat the steps above.

Create mapped surface via Mesh / Mesh
C t l / Approach
Control A h on Surface.
S f Repeat.
R t
Re
Adv Femap Topics / Surface_as_Solid / Cargo

Net_Start.mod / Surface_as_Solid.avi
Advanced Analysis Topics 94
F
Force = Mass
M Radius
R di 2
Rotation motion,
although might be
consider dynamic is
actually a static body
load.
The same might be
said about gravity.
gravity
Gravity is actually
enforced as an
acceleration. A force is
generated based on F =
m*a.
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Re
2u u
m +c + ku = r ( t )
t 2 t
Linear dynamic systems are

wonderfully well behaved and
can be simulated extremely
accurately.
As in all modeling, start simple
with a linear, elastic solution, then
progress to a modal solution, and
then kick in the full transient.
Geometric and material
nonlinearities can be included
but they should be added after
you have a good dynamic run.
Generate a history of results and
youll convince yourself and
others that what you are seeing is
real and not a modeling gasim.
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Re
Eigenvalue problem: undamped free vibration
2u
m 2 + ku = 0
t
Assuming a solution of the form: u = u o sin t
Then:
[k m ]{u
2
o }=0
For non-trivial solutions (i.e., solutions that are more than just zeros):
[ ]
k 2m = 0 giving us the well know frequency relationship: =
k
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m
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Normal Modes / Eigenvalue problem: undamped free vibration
llet:
t
k Kvertical=1000/0.0435
m=100
k 23,000
= = = 15.16rad
sec
m 100
NX Nastran reports frequencies in cycles per
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second. Hence, 15.16 radians/sec is equal

to 2.41 cycles/sec.
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Comments:
Analysis Manager
Vibration - Normal Modes
Optimization
Tasks:
Model has already been constructed -
create new analysis set (Model / Analysis /
New). Set model up for Normal Modes run
and only analyze the first three modes. For
output youll only need displacements.
Analyze and animate the mode shape.
Play with the animation settings (View
Options / Category - Post-Processing).
Optimize
Optimize structure by increasing the Cross
Rod diameter from 2.54 to 25.4 mm.
Analyze again...
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Open Model File: Vibration / Coors Tek Forming Board.mod

2u u
m 2 +c + ku = r ( t ) sin( t )
t t
Details,
D t il d details,
t il
details, details will kill
you.
Data management
is a big issue when
doing dynamics.
Small models will
make or break you.
Simple but
effective dynamic
models are created
by dedicated, brutal
modelers that are
willing to make and
take big assumptions
th t are valid.
that lid
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Re
Stress S
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101
NX Nastran Error Messages
Unsuccessful Analysis (from the Femap V9.3 help section)

There may be times when your analysis is unsuccessful. NX Nastran for FEMAP will indicate an
error in the solver in the Message Review Dialog Box. By pressing "Show Details" you can review
the individual messages from the NASTRAN printed output file
file. While reviewing each detailed
message, you can press the Help button and jump into this help file directly to the appropriate
message and review any additional information that may be available.
Common causes of analysis errors include:
Not merging coincident nodes. Coincident nodes are multiple nodes that share the same
coordinates. While coincident nodes may be desired due to the type of model being made,
they improperly occur when nodes and elements are generated around an enclosed surface. It
is a good idea to do a coincident node and element check prior to performing the analysis.
Not having mass in the model. Normal modes analysis requires that the structure contain mass.
Similarly, when performing static analysis with a gravity load the structures mass is required, or
else the applied loads will be zero. It is a good idea to always make sure that mass density has
been entered for the properties.
Nott constraining
N t i i the
th model
d l properly.
l Static
St ti analysis
l i requires
i that
th t th
the model
d l be
b constrained
t i d
against rigid-body motion (translation and rotation). Note that many textbook type problems
show an incomplete set of constraints because they are working in 2D as opposed to 3D. NX
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Nastran for FEMAP assumes 3D, and you must properly constrain your model.
Re
NX Nastran Error Messages 102
Solver Error/Warning Messages:

There may be times when the analysis fails, and gives you messages in the Message Review window. Most often analysis failure happens when NX
Nastran finds an error. Errors can vary from problems in the input data definition to problems with your operating system and there are many possible
error messages. Some of the more common error messages that you might encounter are listed below:
MESSAGE 3060,, SUBROUTINE MODEL OPTION NAST NOT IN APPROVED LIST.
This error message indicates a problem with NX Nastran security on your system. You have either a bad security device or an invalid authorization key.
Check the device and/or request another EDS PLM Solutions authorization key. Be sure to enter the correct EDS PLM Solutions ID and Model Number
in the EDS PLM Solutions Authorization Key Request form.
MESSAGE 9050 (SEKRRS) - RUN TERMINATED DUE TO EXCESSIVE PIVOT RATIOS
This error happens when the model has not been restrained properly. In linear static analysis, you must restrain the body sufficiently to prevent rigid
b d motion.
body ti Ch k the
Check th applied
li d constraints
t i t and
d correctt them.
th
USER FATAL MESSAGE 4276 Error Code xxx.
This error also indicates insufficient resources during the simulation process. Try to increase the virtual memory setting on your computer. Refer to the
Installation and Operations Guide for the recommended swap space settings.
USER FATAL MESSAGE 5271. The ratio of the longest edge to the shortest altitude exceeds 100.
This error shows
Thi h th
thatt the
th quality
lit off one or more elements
l t iin th
the simulation
i l ti model
d l iis unacceptable
t bl tto th
the NX N
Nastran.Nastran
t N t solver.
l T re-meshing
Try hi th
the
model with a different average element size.
USER FATAL MESSAGE 316 - Illegal data on Bulk Data Card XXXX
This will occur whenever you have "bad" data in your model definition. One common example is the incorrect definition of material or property data,
such as defining a Young's Modulus of 0.0.
USER WARNING MESSAGE 2148 - SPCD on a Point not in the S-set
This will occur when you are using Displacement loads that are not accompanied by a nodal constraint. The nodes which have displacement loads
must have a constraint on the same Degrees of Freedom as the displacement load, otherwise the displacement loads are skipped.
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Warning Message 4420 - The following degrees of freedom are potentially singular
If you get this message, you will not get any results, even though it may not be accompanied by any FATAL messages. This message could occur
because your model is underconstrain, or you may have rigid body motion in your model.
Re
MESSAGE 9050 (SEKRRS) - RUN TERMINATED DUE TO EXCESSIVE PIVOT RATIOS
This is one trick - Solve model for first

six modes (an eigenvalue solution).
solution)
Eigenvalue
u 2
solutions dont
m 2 + ku = 0 require loads
t
or constraints.
This is one of the most powerful
model debugging tools that I know
to figure out where parts of your
y g off into space.
model are flying p
You can also force your model to
solution by setting the
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PARAM,BAILOUT,-1 in the Nastran bulk

data deck (see Analysis Manager -
Bulk Data Options / Start Text
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104
How accurate are the loads? Model to the accuracy of the loads.
Verify the FEA applied load against the calculated load.
Is the pull of gravity important?
Check a few key y dimensions of y your structure. Do they y make sense?
Plate models have top and bottom surfaces. When you apply
pressure loads on plate elements verify that the load direction is in the
right direction.
Playy with y
your constraints. An overconstrained model will under
report the true stress state.
Convergence checking is as simple as comparing the centroidal
stress against the adjacent nodal stress. If they are within 30% you can
be assured of g good convergence.
g An even simpler
p check is to look at
the element shapes and the contour gradations, if they look good
then the stress results will most likely be good. These convergence
checks are superior to a software based solution.
Cant g get the model to run without negative
g pivot
p ratios? Run the
model as a Normal modes / Eigenvalue job and animate the near zero
frequencies. The near zero frequencies are rigid body motions!
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Another technique is to insert the PARAM,BAILOUT,-1 into the Nastran

Bulk Data Options
p as a Manual Control / Start Text / then p place the
Re
above param control card.

105
Remember - loads, forces, gravity, etc, are not used in an Eigenvalue

analysis.
The first three modes or Eigenvalues represent the dominant
vibrational response of your structure. Their corresponding mode
shapes indicate how the structure will vibrate but give you no idea of
the magnitude of the vibration.
The mass of the FEA model should be close (say within 5%) of the
structure that you are modeling. If you are working in U.S. units
remember to multiple the mass of the FEA model by 386 to obtain its
corresponding weight.
Eigenvalue analysis can be quite handy in debugging linear
linear, elastic
elastic,
static models that are not fully constrained.
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Re
106
Follow all the steps for an Eigenvalue analysis FIRST. I know this sounds
a little redundant but it will save tons of time in the long run.
You will need two functions for a Modal Frequency Analysis (MFA): 1)
A function for the driving force (scaler versus Hz) and a function that
defines the solutions that you are interested in obtaining information
about.
See examples in tutorial book and run then before proceeding with
your first MFA.
In a MFA, you are obtaining X0 where X = X0*sin(t-). To see the full
field solution you need to expand your solution using the absolute
magnitude (X0) at a particular frequency () and phase angle (). () This
holds true for all displacement, stresses, etc.
Extremely accurate form of dynamic analysis since it is basically a
form of a linear, elastic, static solution.
Damping dominantly affects only the magnitude of the response
and not its frequency.
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Re

Industrial FEA Modeling Course 2010

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1

Industrial Finite Element Analysis

Industrial Finite Element Analysis

An introduction to Femap and NX Nastran using a blend of

Course Outline (continued):

i) Theory on the application of symmetry: geometry and loads

Course Outline (continued):

Course Outline (continued):

e.) Application Programming Interface (API)

ii) Workshop Create simple API and place in user-defined toolbar.

Course Outline (continued):

d.) Open discussion / Comments

Finite Element Analysis:

solutions to a wide range of problems in mathematical physics. The method has

From McGraw-Hill Science and Technology Encyclopedia, 5th Ed.

Four things to know about FEA:

Finite Element Analysis Concepts:

Linear, Elastic, Static Analysis (99% of the world)

Stresses can be scaled as a linear

With a little work

We typically know something about forces and / or displacements.

Step 1: Satisfy static equilibrium

Step 2: Relate strain to displacements

Step 4: Relate force to stress

The minus sign is required since a positive tensile stress

Step 5: Relate force to displacement

Using the prior equations and performing a little substitution yields:

Step 6: Assemble matrix

* If u1 and u2 are non

stiffness terms. Off

F1 2 2 0 u1 In this form, K is singular! One

F1 is solved as a reaction force at

Analysis Script: Geo,

general analysis outline.

Import Geometry File: Introduction to Femap / Part I / LANDING GEAR LINK.X_T

Import Geometry File: Introduction to Femap / Part II / Avionics Instrumentation Turret.X_T

2D Beam model: The big difference is rotation. In

The equations for this 2D beam can be developed

M 3L L2 3L 2L2 the matrix look?

beam element have?

Beam orientation is often

Beams can be offset from

their neutral axis and/or

The beam orientation vector is

Open Model File: Beam Modeling / Part II / Beam-Thruster Structure - Start.MOD

Post-Processing: Beam Stresses

^^^ USER ACTION: CONSTRAIN MECHANISMS WITH SPCI OR

box needs to be checked.

General All Purpose Elements: Isoparametric Elements

Isoparametric elements can

General All Purpose Elements: Isoparametric Elements

In order to develop stiffness equations, we must be able to map

Ni is known as the shape function,

General All Purpose Elements: Isoparametric Elements

The development of an element stiffness matrix

Step 1: Satisfy static equilibrium F = 0

Step 2: Relate strain to displacements - simple 2D example

General All Purpose Elements: Isoparametric Elements

Step 2: Relate strain to displacements - simple 2D example

General All Purpose Elements: Isoparametric Elements

Step 2: Relate strain to displacements - simple 2D example

Step 4 and 5: Relate force to stress and then force to displacement

General All Purpose Elements: Isoparametric Elements

{k} = [B ] [E][B ]dxdy