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In thermo mechanical members and structures, finite-element analysis (FEA) is typically
invoked to compute displacement and temperature fields from known applied loads and heat
fluxes. FEA has emerged in recent years as an essential resource for mechanical and
structural designers. Its use is often mandated by standards such as the ASME Pressure
Vessel Code, by insurance requirements, and even by law. Its acceptance has benefited from
rapid progress in related computer hardware and software, especially computer-aided design
(CAD) systems. Today, a number of highly developed, user-friendly finite-element codes are
available commercially. The purpose of this chapter is to introduce finite-element theory and
practice. The next three chapters
focus on linear elasticity and thermal response, both static and dynamic, of basic structural
members. After that, nonlinear thermo mechanical response is considered.
In FEA practice, a design file developed using CAD is often “imported” into finite element
codes, from which point little or no additional effort is required to develop the finite-element
model and perform sophisticated thermo mechanical analysis and simulation. CAD integrated
with an analysis tool, such as FEA, is an example of computer-aided engineering (CAE).
CAE is a powerful resource with the potential of identifying design problems much more
efficiently and rapidly than by “trial and error.” A major FEM application is the
determination of stresses and temperatures in a component or member in locations where
failure is thought most likely. If the stresses or temperatures exceed allowable or safe values,
the product can be redesigned and then reanalyzed. Analysis can be diagnostic, supporting
interpretation of product-failure data. Analysis also can be used to assess performance, for
example, by determining whether the design-stiffness coefficient for a rubber spring is
attained.
Consider a thermo elastic body with force and heat applied to its exterior boundary.
The finite-element method serves to determine the displacement vector u(X,t) and the
temperature T( X,t ) as functions of the un deformed position X and time t . The process of
creating a finite-element model to support the design of a mechanical system can be viewed
as having (at least) eight steps:
1. The body is first discretized, i.e., it is modeled as a mesh of finite elements connected
at nodes.
2. Within each element, interpolation models are introduced to provide approximate
expressions for the unknowns, typically u(X,t) and T(X,t), in terms of their nodal
values, which now become the unknowns in the finite-element model.
3. The strain-displacement relation and its thermal analog are applied to the
approximations for u and T to furnish approximations for the (Lagrangian) strain and
the thermal gradient.
4. The stress-strain relation and its thermal analog (Fourier’s Law) are applied to obtain
approximations to stress S and heat flux q in terms of the nodal values of u and T.
5. Equilibrium principles in variational form are applied using the various
approximations within each element, leading to element equilibrium equations.
6. The element equilibrium equations are assembled to provide a global equilibrium
equation
The output is post processed. Initially, the output should be compared to data or benchmarks,
or otherwise validated, to establish that the model correctly represents the underlying
mechanical system. If not satisfied, the analyst can revise the finite-element model and repeat
the computations. When the model is validated, post processing, with heavy reliance on
graphics, then serves to interpret the results, for example, determining whether the underlying
design is satisfactory. If problems with the design are identified, the analyst can then choose
to revise the design. The revised design is modeled, and the process of validation and
interpretation is repeated.
MESH DEVELOPMENT
Finite-element simulation has classically been viewed as having three stages: preprocessing,
analysis, and post processing. The input file developed at the preprocessing stage consists of
several elements:
1. control information (type of analysis, etc.)
2. material properties (e.g., elastic modulus)
3. mesh (element types, nodal coordinates, connectivities)
4. applied force and heat flux data
5. supports and constraints (e.g., prescribed displacements)
6. initial conditions (dynamic problems)
In problems without severe stress concentrations, much of the mesh data can be developed
conveniently using automatic-mesh generation. With the input file developed, the analysis
processor is activated and “raw” output files are generated. The postprocessor module
typically contains (interfaces to) graphical utilities, thus facilitating display of output in the
form chosen by the analyst, for example, contours of the Von Mises stress. Two problems
arise at this stage: Validation and interpretation.
The analyst can use benchmark solutions, special cases, or experimental data to validate the
analysis. With validation, the analyst gains confidence in, for example, the mesh. He or she
still may face problems of interpretation, particularly if the output is voluminous. Fortunately,
current graphical-display systems make interpretation easier and more reliable, such as by
displaying high stress regions in vivid colors. Postprocessors often allow the analyst to “zoom
in” on regions of high interest, for example, where rubber is highly confined. More recent
methods based on virtual-reality technology enable the analyst to fly through and otherwise
become immersed in the model.
The goal of mesh design is to select the number and location of finite-element nodes and
element types so that the associated analyses are sufficiently accurate.
Several methods include automatic-mesh generation with adaptive capabilities, which serve
to produce and iteratively refine the mesh based on a user-selected error tolerance. Even so,
satisfactory meshes are not necessarily obtained, so that model editing by the analyst may be
necessary. Several practical rules are as follows:
1. Nodes should be located where concentrated loads and heat fluxes are applied.
Modeling error ensues from inaccuracies in such input data as the material properties,
boundary conditions, and initial values. In addition, there often are compromises in the mesh,
for example, modeling sharp corners as rounded.
Numerical error is primarily due to truncation and round-off. As a practical matter, error in a
finite-element simulation is often assessed by comparing solutions from two meshes, the
second of which is a refinement of the first.
Types of supports
Degrees of Freedom to be
Sl.
Type of support Restricted
No
Tx Ty Tz Rx Ry Rz
1 Fixed ¥ ¥ ¥ ¥ ¥ ¥
2 Roller ¥ ¥ ¥ ¥
x-y plane
Hinged
3 ¥ ¥ ¥ ¥ ¥
Or pinned x-y plane
4 Simply support ¥ ¥ ¥ ¥
x-y plane
TRUSS
Determine the force in each member of the following truss. Indicate if the member is in
tension or compression. The cross-sectional area of each member is 0.01 m and the Young’s
modulus is 200x109 N/m2 .
Step2: Select the "File: New" command. The "New" dialog will appear. Select the
"FEA Model" icon and press the "New" button.
Step5: Create a new Analysis file truss1 and save-this will open us the Working environment
Step6: Go for Plane 1 <XY-Top> , right click it and select Sketch. Now the Drawing
Environment opens.
Step7: Go for Geometry in the menu bar for the creation of line element.
Step9: Start the line by pressing enter i.e start from 0,0. Then
Y=2.8– Enter
Step 10: Go for Plane 1 <XY-Top> , right click it and select Sketch again to come out of the
Drawing Environment.
Step 11: A New Part 1 Will be generated. In Part1 kindly select Element type and right click
to define it . Select Truss from the list.
Step 12: Select the Element Definition, right click for Modify Element Definition, A new
dialog box opens give cross-sectional area as 0.01m2.
Step13: Select Material, right click to modify material and select AISI !005 Steel from the
List to assign it to the truss
Move the cursor to near the A node and select it. The Node will highlight, then right click in
the screen and select Nodal Boundary condition and select fixed.
.
Select Y Direction and give -2800 as nodal force – ve sign for force acting downwards
Move the cursor to near the C node and select it. The Node will highlight, then right click in
the screen and select Nodal Boundary condition and select all expect TY.
Step15: Go for Analysis in the menu bar and select Parameters. Select all in the output tab.
Step 15: Go for Analysis in the menu bar and select Perform Analysis.
Step16: After analysis completes, Go for Results Element Force And moments –Axial
Forces. The Model will show the results.
FORCE ACTING ON
AB=1700
AC=2000
BC=-2500(Compression)
Step17: After analysis completes, Go for Reaction Vector –Reaction Forces-Y. The Model
will show the results.
Reaction Force
FY: 2800
Repeat for X Direction
FX: 1500
-1500
Exercises on Truss
1) Determine the reaction force, displacement and elemental stress for the truss shown
below.
Given:
Material : Mild steel
E = 209X103N/mm2
A= 100mm2
2) Determine the reaction force displacement and elemental stress for the truss shown below.
Given:
Material : Mild steel
E = 209X103N/mm2
Section A –A : 10X10 Sq
100
3) Determine the reaction force displacement and elemental stress for the truss shown below
Given:
E = 209X103N/mm2
A = 0.01m2
BARS
Determine the Displacement in the direction of force applied for a bar of constant cross
Section area.
Step2: Select the "File: New" command. The "New" dialog will appear. Select the
"FEA Model" icon and press the "New" button.
Step5: Create a new Analysis file Bar 1 and save-this will open us the Working environment.
Step6: To create the bar we need to draw line in YZ plane, to go to drawing environment
right Click the YZ plane and select sketch.
Step 8: Remove the construction only and press enter to start line and enter the value 1m in Y
direction to complete the Line.
Step 10: Assign Beam Element for the Line by right Clicking the Element type.
Step 11: To assign the Cross section, right click the Element definition, select the colum
value –the Cross-Section Libraries iron will appear. Press this icon to get the library. Select
round from the List and assign value 0.1m. Click ok to accept.
Step12: Select Material, right click to modify material and select AISI 1005 Steel from the
List to assign it to the truss
Click on the left side end vertices and right Click to add the constraints. Select Fixed.
Click on the Right side end vertices and Right click to add force
Step 15: Go for Analysis in the menu bar and select Perform Analysis.
Step 16: Now the result window opens. Select the Results- displacement -magnitude to know
the displacement
Exercises on Bars
Case 1: Bars with uniform cross section
1) A circular rod of dia 20 mm and 500 mm long is subjected to a tensile force of 45 KN.
The modulus of elasticity for steel may be taken as 200 KN/mm2. Find stress, strain and
elongation of the bar due to applied load.
2) A bar of 800 mm length is attached rigidly at A and B as shown in figure. Force of 30KN
and 60 KN act as shown on the bar. If E= 200GPa, determine the reactions at the two
ends. If the bar dia is 25 mm, Find the stresses and change in length of each portion.
60KN
30KN
A C D B
4) The composite bar shown in fig is subjected to a tensile force of 30kN. Young’s modulus
of brass and steel are 99777.6N/mm2 and 2x 105 N/mm2 respectively. Find the extension
of the bar.
(Ans: 0.186mm)
400 300
Aluminum
50KN
Steel
500mm
6) A compound bar consist of a circular rod of steel of dia 20 mm rigidly fitted into a copper
tube of internal dia 20 mm and thickness 5 mm. If the bar is subjected to a load of 100
KN, find the stresses developed in two materials. Take Esteel 2X10 5 N/mm2 and Ecopper =
1.2 X10 5 N/mm2. Length of both the bars is 100 mm.
7) A 1.5 meter long steel bar is having uniform dia of 40 mm for a length of 1 m and in the
next 0.5 m its dia gradually reduces from 40 mm to 20 mm. Determine the elongation of
this bar when subjected to an axial tensile load of 160 KN. Given: E = 200GPa.
8) Find the extension of the bar shown in figure under an axial load of 20KN. Take E=
2GPa.
(Ans: extension=0.444mm)
Beams
1) Determine the maximum bending stress and strain developed in the beam and Maximum
deflection of the beam due to applied load. Also plot SFD and BMD for the cantilever
beam shown below. Material used is Steel AISI 4130.
Step2: Select the "File: New" command. The "New" dialog will appear. Select the
"FEA Model" icon and press the "New" button.
Step5: Create a new Analysis file : Cantilever BEAM and save-this will open us the Working
environment.
Step6: To create the bar we need to draw line in XY plane, to go to drawing environment
right Click the XY plane and select sketch.
Step 8: Remove the construction only and press enter to start line and enter the value 1m in X
direction to complete the Line, then enter 2 m in X direction , again enter 3.5 m in X
direction, press ESC twice to exit from sketch.
Or
Step 9: To come out of the drawing double Click the XY plane.
Step 10: Assign Beam Element for the Line by right Clicking the Element type.
Step 11: To assign the Cross section, right click the Element definition, and select the
column value –the Cross-Section Libraries icon will appear.
Press this icon to get the library. Select Rectangular section and enter the values as below.
b=.01m h=.008m
Step12: Select Material, right click to modify material and select AISI 4130 Steel from the
List to assign it to the beam.
Click on the left side end vertices and right Click to add the constraints. Select Fixed.
Click on the 2nd and 3 rd vertices and Right click to add force. Assign the value -20KN in Y
direction. Similarly select 4 th vertices assign -10KN load in Y direction.
Step 15: Go for Analysis in the menu bar and select Perform Analysis.
Step 16: Now the result window opens. Select the Results- displacement -magnitude to know
the displacement
ANSWERS
Displacement: 0.326395m
5) With elements selected go to Inquire >Add shear diagram( axis 2) to get SFD.
6) To get the magnitude of Shear force at required points…..
Results>Element forces and Moments>Local 2 force
7) With rectangular selection ON and Vertices selection ON, Select all vertices >right
click> Add probes to selection.
8) View >display >features.
For BMD
1) Keep the displacement plot in the results area.
2) Results options> Deselect Show displaced model
3) Right click >select vector plot.
4) With Rectangular select ON, select elements- select complete line-
(Selection>shape> rectangle and selection> select> Elements)
5) With elements selected go to Inquire >Add Moment diagram (axis 3) to get BMD.
6) To get the magnitude of bending moment at required points…..
Results>Element forces and Moments>Local 3 moment
7) With rectangular selection ON and Vertices selection ON, Select all vertices >right
click> Add probes to selection.
8) View >display >features.
2) Determine the maximum stress and strain developed in the beam and Maximum
deflection of the beam due to applied load. Also plot SFD and BMD for the beam shown
below. Material used is Steel AISI 4130.
3) Determine the maximum stress and strain developed in the beam and Maximum
deflection of the beam due to applied load. Also plot SFD and BMD for the beam shown
below. Material used is Steel AISI 4130.
4) Determine the maximum stress and strain developed in the beam and Maximum
deflection of the beam due to applied load. Also plot SFD and BMD for the beam
shown below. Material used is Steel AISI 4130.
Determine the maximum stress for a rectangular plate of 50mm x 80mm with hole of 10mm
diameter in the center is loaded in axial tension. Thickness of the plate is 10mm. Take E =
200GPa
Theoretical calculation:
Results Comparison
FEM Theoretical
Deformation 0.009284 mm -
Stress 59.99 N/ mm2 62.5 N / mm2
Procedure:
1) To generate 2-D mesh: Right click >1< XY top> > Create 2D mesh> Enter 500 in the
mesh density tab > Apply,
2) Define Element type (Plate), Element definition >Check design variable> Enter thickness
(10 mm) and Material type (200GPa).
3) To Apply BC and Load: select all nodes in left side > Apply fixed BC > Select all nodes in
right side> Apply Nodal force as shown below. (1000N/ No of nodes)> OK.
4) Perform Analysis.
5) Find out displacement, Maximum stress etc…
Exercises:
Determine the maximum stress for a rectangular plate of 50mm x 80mm with hole of 10mm
diameter in the center is loaded in axial tension. Thickness of the plate is 10mm. Take E =
210GPa. Take Axial Load P = 100KN. Validate your results with theoretical results.
P P
Solution:
Step2: Select the "File: New" command. The "New" dialog will appear. Select the
"FEA Model" icon and press the "New" button.
Step3: Select –Thermal- Steady State Heat Transfer
Step4: Select the New Button on the lower right corner
Step5: Create a new Analysis file THERMAL 1 and save-this will open us the Working
environment
Step6: Go for Plane 1 <YZ-Right>, right click it and select Sketch. Now the Drawing
Environment opens.
Step7: Go for Geometry in the menu bar for the creation of rectangle element. Uncheck the
USE AS CONSTRUCTION BOX. Create a rectangle by pressing enter for the starting corner
and enter the values Z=20 and Y=10 and press enter to complete the rectangle.
Step8: Double click the YZ plane to come out of the drawing environment.
Step9: Right Click the element type and Select Plate.
Step 10: Right Click Element definition and assign 0.1m for the thickness of the plate.
Step11: Right Click Material and assign Alumina material from the material List.
Step 12: Right Click the YZ plane and select create 2D Mesh option and create Mesh; you
can modify the mesh also.
Exercises:
1) A furnace wall is made of inside silica brick (k = 1.5 W/mK) and outside magnesia brick
(k = 4.9 W/mK), each 10 cm thick. The inner and outer surfaces are exposed to fluids at
temperatures of 820°C and 110°C respectively. The contact resistance is 0.001 m2K/W.
The heat transfer coefficient for inner and outside surfaces is equal to 35 W/m2K. Find the
heat flow through the wall per unit area per unit time and temperature distribution across
the wall.
Theoretical calculation:
Dynamic analysis
Step2: Select the "File: New" command. The "New" dialog will appear. Select the
"FEA Model" icon and press the "New" button.
E=2e11 N/m2
Density = 7830 Kg/m3
Step13: Defining boundary condition:
Select the Vertices from Selection-Select from menu bar
Click on the left side end vertices and right Click to add the constraints. Select Fixed.
Step 15: Go for Analysis in the menu bar and select Perform Analysis.
Step 16: Now the result window opens. To get the modes of vibration click the icon as
below.
Results:
Exercises:
Determine the natural frequency and different modes of vibration (Simple Modal Analysis) of
truss shown below.
Given:
E=2e11 N/m2,
Area A = 0.01 m2 , Density = 7830 Kg/m3
Results:
Mode Frequency
1 57.1109
2 107.986
3 141.601
4 196.702
5 231.16