Finite Element Analysis in y Practice

Introduction

Overview

This course is taught with a mix of theoretical information and applied th ti l i f ti d li d finite element analysis (FEA). Concepts are ill t t d with simple, C t illustrated ith i l hands-on exercises. Models are created which illustrate a broad range of topics including theory, element types, analysis types, meshing techniques, results evaluation and more.

What is FEA?

FEA is a mathematical solution to engineering l ti t i i problems where a physical model is divided into discrete components. p FEA models are defined by nodes and elements (commonly called a mesh).

What is FEA?

Basic engineering equations, such as Hookes ti h H k law, are solved at the nodes and elements. A matrix equation with terms from each element is solved. solved

What is FEA?

Predicts change within the element (e.g., deformation, l t( d f ti stress). The results are plotted on the model by color to show the lowest and highest values. values

Why Use FEA?

Provides a non-destructive means of t ti products. f testing d t Faster prototyping for p yp g what if scenarios. Design optimization. optimization Speed up time to market by shortening the design cycle.

Best Practices

FEA requires engineering judgment. In the best case, you should know the approximate answer before you begin. Proper selection of elements materials elements, materials, loads, constraints and analysis parameters comes from experience experience.

Best Practices

Understand that the computer model never matches reality (its (it s only an approximation). The surest route to failure in FEA is to underestimate the complexity of the technology. technology

FEA in Different Industries

Aerospace Industry Orbital Technologies Corporation

The above illustration shows how engineers
analyzed a Biomass Production System to conduct biotechnology plant research. d t bi t h l l t h

FEA in Different Industries

Automotive Industry Danly Engineering Services, Division of Services Enprotech Mechanical Services, Inc.
The above illustration shows how engineers analyzed
a power press with additional cutouts.

FEA in Different Industries

Biomedical Industry Ophthalmic Consultants of Boston and the Tufts University School of Medicine y
The above illustration shows stresses on an eye as it
underwent a 30 saccadic eye movement. This was modeled to help understand why retinal detachments occur.

FEA in Different Industries

Power/Utility Industry Cronulla Sewage Treatment Plant

The above illustration shows how engineers modeled a
piping system to verify that the number of bellows could safely be reduced by using lightweight, spiral-wound y y g g g , p stainless steel. This allowed them to keep a $90 million sewage treatment plant upgrade on budget.

FEA Overview O i and Examples

The Basic Steps of FEA

Build/Mesh a Model

Define FEA Model Analysis and Element Types Define Loads and Constraints

Analyze Model (Solve)

Review Results and Create Presentations

Example Using ALGOR

Create Mesh in CAD Solid Model or FEA Editor Environment Setup Analysis Type, Element Type and Materials in the FEA Editor Environment Apply Loads and Constraints in the FEA Editor Environment Analyze Model (Solve)

F E M P R O

Review Results in the Results Environment and Create an HTML Report in the Report p p Environment

FEMPRO Interface
A. Title bar B. Menu bar C. Toolbars D. Tree view E. Working area F. Miniaxis G. G Design scenario toolbar H. Status bar

Create Mesh

CAD Solid M d l S lid Model Environment Open and mesh

models from CAD solid modelers or universal files.

FEA Editor Edit Environment Generate 2 D and 3 D 2-D 3-D

meshes from sketches. Add lines to existing meshes.

Assign FEA Parameters

FEA Editor Environment Assign element types and parameters. Assign material properties. Apply loads and constraints. Assign analysis parameters. Analyze the model.

Review Results

R Results E i lt Environment t Review the model setup. Review the analysis results results. Create images or animations of results.

Present Results

R Report E i t Environment t Generate a report of the analysis for presentation

purposes. purposes Add images or animations in an appendix. View summary and log files from the analysis. y g y

Introduction Example

Opening the Model

Select File: Open.... p Change the file type to IGES (*.igs, ( .igs, *.iges). Select MotorMount.IGS.

Creating a Mesh Create a mesh by pressing the Mesh g model button in the Model Mesh Settings dialog. S tti di l

Applying the Materials Select all three parts by clicking on the y g part names in the tree view while holding d h ldi down the th <Ctrl> key. Right click on the name and select Modify: Modify: Materials.... Select Steel (ASTMSteel (ASTM A36) from the list.

Applying the Loads Use the surface selection option. Select the two top surfaces of the brackets. After the surfaces are selected, right click and select Add: Surface Pressure/Tractions.... Enter a pressure of 20 psi.

Applying the Constraints Select the surfaces in the holes of the shaft. After the surfaces are selected, right click and select Add: S rface Add Surface Boundary Conditions... Conditions . Press the Fixed button and then the OK button.

Reviewing the Results Run the analysis by selecting Analysis: g y Perform Analysis.... Once the analysis is complete, the von Mises stress results will appear. ill appear

Creating a Report Select the Report tab at the bottom of the screen. Select the HTML Report heading. Right click and select the Report Wizard command. Thi will take you This ill t k through a five-step wizard and produce an HTML report.

Presentation of Results

Refer to the Presentation of Results Tutorial T t i l available at il bl t

www.algor.com/service_support/tutorials

for more information on generating p reports.

FEA Concepts

What is a DOF? The unknowns in a finite element problem are referred to as degrees of freedom (DOF). g ( ) Degrees of freedom vary by element and analysis type.

DOF Type Displacement p Temperature

Action Force Heat Flow Rate

Application Structural Thermal

What is a DOF?
Uy

Rot y

Node
Rot z Uz

Rot x Ux

Node

A node is a coordinate location in space where the DOF are defined. Th d fi d The DOF of this point f thi i t represent the possible response at this point due to the loading of the structure.

Element

An element is a mathematical relation that defines how the DOF of a node relate to the f d l t t th next. These elements can be lines (beams), areas ( (2-D or 3-D plates) or solids p ) (bricks and tetrahedrals).

Nodes and Elements

A node has a given set of DOF, which characterize the response. For structural p analyses, these DOF include translations and rotations in the three global directions. The type of element being used will also characterize which type of DOF a node will yp have. Some analysis types have only one DOF at a y yp y node. Examples of these analysis types are temperature in a heat transfer analysis and velocity in a fluid flow analysis.

Element Connectivity

Elements can only transfer loads to one another via common nodes.
No Communication Between the Elements Communication Between the Elements

Stress and Strain Review

The basic stress and strain equations:

= E

F A

L 0

dx

FL = E

Stress Basic equations do not require the use of a computer to solve. solve Computer-based analysis is needed when complexity is added as follows: Geometric complexity makes the elasticity
equation difficult or impossible to solve. q p Variations in material properties exist throughout the part.

Multiple load cases and complex or combined

loading exists.

Dynamics are of interest interest.

General Case

The DOF components of each element combine to form a matrix equation:

[K] {d} = {A}

[K] = element stiffness components {d} = DOF results (unknown) {A} = action value (e.g., force, temperature)

Structural FEA Equation

To determine the displacement of a simple linear spring under load, the relevant equation is:

{f} = [K] {d}

Known
where {f} = force vector [K] = stiffness matrix {d} = displacement vector

Unknown

FEA Equation Solution

This can be solved with matrix algebra by rearranging the equation as follows:

{d} = [K] {f}

-1 1

Calculation of and

Strains are computed based on p the classical differential q p y equations previously discussed. Stress can then be obtained from the strains using Hooke s Hookes law (F = kx).

Dynamic Equation For a more complex analysis, more terms are needed. This is true in a dynamic analysis, which is defined by the following equation:

{f} = [K] {d} + [c] {v} + [m] {a}

where {f} = force vector {} [K] = stiffness matrix {d} = displacement vector [c] = damping matrix {v} = velocity vector [m] = mass matrix {a} = acceleration vector

Other Applications

FEA can be applied to a wide variety pp of applications such as:

Dynamics Nonlinear Materials Heat Transfer Fluid Flow Electrostatics Piping Design and Analysis

Exercise A - FEA Example by Hand

F = 10,000 lb A = 2 in2 E = 30 x 106 psi L = 10 ft = 45

1 4

F L

Element 1

0 0 0 1 6 30 x10 (2 ) k= 0 0 120 0 1

0 0 1 0 0 0 1

Element 2

0 .5 0 .5 0 .5 0 .5 0 .5 0 .5 0 .5 30 x10 6 (2) 0.5 k= 0 .5 0 .5 0 .5 0 .5 120 x 2 0 .5 0 .5 0 .5 0 .5

Element 3

1 30 x106 (2 ) 0 k= 1 120 0

0 1 0 0 0 1 0 0

0 0 0 0

F L

Total Stiffness Matrix

0.354 1.354 0.354 1.354 0 0 1 0 k = (500,000 ) 0.354 0.354 0.354 0.354 1 0 0 0

0 0 0.354 0.354 1 0 0 1 0.354 0.354 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0.354 0.354 0 0 0 0 0.354 0.354 0 0 0 0 0 0 1 0 0 0 0 0 0 0

Force and Displacement Vectors

0 10,000 F2 x F2 y F= F3 x F3 y F 4x F4 y

D1x D 1y 0 0 D= 0 0 0 0

Displacement and Stress Results

D1x = 0.414 x10 i in 2 D1 y = 1.59 x10 in

1 = 3965 psi 2 = 1471 psi 3 = 1035 psi

ALGOR Model

ALGOR Results

D1x = 0.414 x10 in 2 D1 y = 1.59 x10 in

1 = 3964 psi 2 = 1464 psi 3 = 1036 psi i

Analysis Options

Choosing an Analysis Type

The first decision in the FEA process is to decide what type of analysis you need to run. The analysis type will dictate what yp y type of results you will obtain. For example, if you need the displacement of your part, then you will need to run a structural analysis.

Analysis Options

Linear

Linear static Linear dynamics

Electrostatic
C Current and voltage d l Field strength and voltage

Fatigue Nonlinear Thermal

Multiphysics u t p ys cs
Steady coupled fluid flow and
thermal

Nonlinear static MES Steady-state heat transfer Transient heat transfer Steady fluid flow Unsteady f fluid f flow Flow through porous media

Piping Design and Analysis

Fluid Flow

Structural

Linear static Small changes in stiffness. No changes in loading

direction. Material remains in the linear e ast c a ge elastic range. Small deformation and strain.

Structural

Linear dynamics

N t l frequency (modal) Natural f ( d l) Response spectrum Random vibration Frequency response Transient stress (direct integration) Transient stress (modal superposition) Critical buckling load Dynamic Design Analysis Method
(DDAM)

Structural

Fatigue

Product life cycle simulation (failure). (failure) Stress-based fatigue life calculation. Strain based fatigue life calculation. Strain-based calculation

Structural

Nonlinear/MES
Li Linear and nonlinear material models. d li t i l d l Large deformation and strain. Failure due to:
yielding. Local and structural buckling. Permanent deformation residual stress. Large-scale motion.
Material

Structural

Nonlinear/MES
S f Surface-to-surface contact t f t t Impact C Creep

Thermal

Steady-state heat t St d t t h t transfer f

Steady-state conditions Steady state

Transient heat transfer

Time-varying conditions

Fluid Flow

Steady fluid flow Unsteady fluid flow Flow through porous media

Electrostatic

Electrostatic current and voltage Electrostatic field strength and voltage lt

Element Options p

Choosing an Element Type

Selecting the type of element will depend on the following:

Analysis type selected. How you create y y your mesh. Assumptions you can make
about geometric properties properties.

Element Categories

Line Elements: A line connecting 2 nodes (beams, trusses, springs, actuators, pipes, etc.) Area (2-D) Elements: A cross-section p of a part. Must be 3 or 4 lines enclosing an area.

Element Categories

Area (3-D Planar) Elements: Midplane of a part in space. Must be 3 or 4 lines enclosing an area. 3-D Solid Elements: Must be 4, 5, 6 g or 8 nodes enclosing a volume.

Meshing and M hi d Modeling

Proper Modeling Techniques

For any region (3, 4, 5, 6 or 8-nodes) to be a valid element, it must:

Consist of either three (triangular) or

four (quadrilateral) undivided line segments. If a side consists of multiple line segments, the region is invalid. segments invalid

Not have curved or arched sides.

Proper Modeling Techniques

Certain shapes can create elements p which are not recommended for FEA y g g analysis. The following regions will be eliminated:
Regions eg o s

with a y co ea o t any collinear or concave sides. with a highly nonflat curvature in a 3-D drawing.

Regions

Proper Modeling Techniques

Valid and Invalid Regions

Meshing Guidelines

Meshing can be completed either by using automatic mesh engines or by creating a mesh by hand. Automatic mesh generation is usually p completed on CAD solid models. Hand meshing is usually done on simple models that require a structured mesh.

Hand Meshing

There are two types of hand meshing: building from scratch and building from a wireframe. Building from scratch: Draw the elements by hand one at a time to create a structured mesh. Building from a wireframe: Build a 2-D or 3-D wireframe of the model and use an unstructured mesh engine to d t t d h i t generate the internal elements.

Loads d L d and Constraints

Introduction to Loads and Constraints

You will have to decide what type of loads and constraints will properly define the engineering criteria for the model. model In FEA, there are different types of loads and constraints for each analysis type type. Applying the proper loads and constraints is one of the most important factors in getting the correct answer. Always double check your model model.

Types of Loads and Constraints

There are multiple ways to p y apply different loads and constraints to a model: Nodal Edge Surface Element

Structural Nodal Loads

Displacements p Forces Moments Temperatures (thermal stress) Voltages (piezoelectric materials)

Structural Nodal Constraints

Boundary Conditions: y Prevent specified DOF from g g undergoing translation or rotation in a specified direction. Boundary Elements: Act like a spring with a specified stiffness along a specified direction.

Structural Nodal Constraints

Using Boundary Conditions to Model Symmetry

Along

the line of symmetry, boundary conditions must be applied to represent the symmetrical part:
Out-of-plane displacement = 0 Two in-plane rotations = 0 T i l t ti

Structural Nodal Constraints

P P P

Line of Symmetry

Plane of S Pl f Symmetry

Boundary Conditions

Proper boundary conditions are necessary for an accurate analysis. The global stiffness of the system must be modeled correctly for any local behavior to be captured correctly.

Boundary Conditions

The two most unwanted FEA effects to watch out for are:

Overstiffening Understiffening Unlike the real-world equivalent, constraints in FEA are perfect perfect.

Linear Surface Loads

Uniform or Hydrostatic Pressure y and Traction

Applied

to the face of plate, composite and brick elements. Applied to the edge of 2-D and membrane elements elements.

Surface Force
Can

specify magnitude and direction of a force that will be evenly distributed over a given surface.

Linear Surface Loads

Variable Pressure or Traction

Define

a function of the position that controls the magnitude of the load over the surface surface.

Linear Element Loads

Gravity y
Can

specify gravitational value and direction. You must have a mass density defined for each part. part center of rotation angular velocity rotation, and acceleration values.

Centrifugal Loads
Specify

Distributed Loads
Specify

the magnitude and direction at each end of beam elements.

Truss Elements

Truss Elements
Truss elements are two-node members, members which allow arbitrary orientation in the X, Y, Z system. The truss transmits axial force only, and in general, is a three DOF element (i.e., three global l t (i th l b l translation components at each end of the member). Trusses are used to model structures such as towers, bridges and buildings. b ildi

Truss Elements

Guidelines for using truss elements: t l t

The length of the element is much
greater than the width or depth (approximately 8-10 times).

It is connected to the rest of the model

with hinges that do not transfer moments. t

The external applied forces are only at

joints. j i t

Exercise B - Truss Frame Model

Objective: Construct and analyze a frame of truss elements loaded with 2 nodal forces. Geometry: Cross-sectional area = 1 in2. Material: Aluminum (6061-T6). Loads: Nodal forces as shown in the image to the right. Constraints: Fully fixed at Point A. A Ty and Tz constrained at Point G. The rest of the model will have Tz constrained.

Beam Elements

Beam Elements
Beam elements are slender structural members that offer resistance to forces and bending under applied loads. B Beams are f found i building d in b ildi frames, transmission towers and bridges. bridges A beam differs from a truss in that a beam resists moments (twisting and bending) at the connections.

Beam Elements

Beams use a third node to define the orientation. Cross-sectional properties Cross sectional are defined for bending about both the strong and weak axes.

Beam Elements

Guidelines for using beam elements: g

The

length of the element is much greater than the width or depth. g p element has constant crosssectional properties. p p element must be able to transfer moments. element must be able to handle a load distributed along its length. g g

The The The

Exercise C - Support Beam Under Gravity

Objective: Determine the maximum deflection of the beam due to its own weight. Geometry: W10 x 100 crosssection. Material: Steel (AISI 4130). Loads: Gravity in the -Y direction. Constraints: Each end has constraints against all DOF except for Rz.

2-D Elements

2-D Elements

Two-dimensional elements are three- or l t th four-node elements that are f formulated in the Y-Z l t d i th Y Z plane. They are used to model and analyze d l d l objects such as bearings, seals or structures such l t t h as dams.

2-D Elements

2-D Geometry Types

Axisymmetric: For parts that are

revolved about an axis. Plane strain: No deflection normal to the cross-section (e.g., a large dam). Plane stress: No stress normal to the cross-section (e.g., a plate under axial load). load)

2-D Elements

Create wireframe sketches for each part in the FEA Editor environment. Use the 2-D mesh engine to generate the 2-D elements elements.

Exercise D - Axisymmetric Thick-walled Cylinder

Objective: Determine the hoop stress at the inner radius of the cylinder from the applied pressure load. Material: Steel (AISI 4130). Loads: Uniform internal pressure of 10,000 psi. Constraints: The bottom edge g will have Tz constraints.

Plate Elements

Plate/Shell Elements

Plate/shell elements are three- or four-node four node elements formulated in three-dimensional space. These elements are used to model and analyze objects such as pressure vessels and automotive body parts. A thickness is assigned to the elements. Stresses will vary linearly through the thickness. h hi k

Plate/Shell Elements

Guidelines for using plate/shell elements:

The thickness is small in relation to

the length and width (about 1/10). g ( )

Good for small displacements and

rotations.

Elements remain planar (i.e., no

warpage). p g )

No rotation about the direction normal

to the element.

Membrane Elements

Three- or four-node elements formulated in three-dimensional three dimensional space. Used to model "fabric-like" objects such as tents or cots, or structures such as the roof of a sports stadium. Model solids of a specified thickness, which exhibit no thi k hi h hibit stress normal to the thickness.

Composite Elements

There are two types of composite elements: it l t thin or thick. Each element can have multiple lamina with different material properties and fiber orientations. Multiple failure criteria are available.

Exercise E - Plate Under Uniform Pressure

Objective: Determine the maximum stress in the plate from the applied pressure load. Geometry: The plate is 10 x 5 x 0.25. Material: Steel (AISI 4130). Loads: Uniform pressure of 50 p psi. Constraints: The two long edges will have Ty and Tz constraints. constraints One short edge will have Tx and Tz constraints.

Brick Elements

Brick Elements

Brick elements are four-, five-, four- five- six- or eight-node elements formulated in threedimensional space. Brick elements should be used when the stress through the thickness of a part is important. important

Exercise F - Cantilever Beam Model

Objective: Determine the maximum bending stress in the beam from the applied load. Material: Steel (4130). Loads: 10,000 pounds , p distributed across the free end. Constraints: The center row of nodes at the fixed end will be fully constrained. The rest of the nodes at the fixed end will have Tx constraints.

Comparing Element Types

Exercise G - Comparing Element Types

Objective: Analyze a beam model using different element types and compare the results. Material: Steel (AISI 4130). Loads: 100 psi in the -Z direction on the top of the beam. Constraints: Fixed at the left end and simply supported at the right. Elements

Beam: Convert the 100 psi

load over the 0.25 width to a 25 lb/in distributed load.

2-D: Apply a 100 psi pressure to p g the top edge. Plate: Model the 10 x 0.5 dimensions with a thickness of 0.25. Apply nodal forces equivalent to the pressure load. i l t t th l d The forces at the end nodes should be half the magnitude of the forces at the interior nodes. Plate: Model the 10 x 0.25 dimensions with a thickness of 0.5. Apply a 100 psi pressure load t th t l d to the top. Brick: Apply a 100 psi pressure to the top surface.

Comparison of Results

Element Type Beam 2-D Plate 0.25 Thick Plate 0.5 Thick Brick

Deflection (inch) 0.01758 0.01758 0.01757 0.01726 0.01753

Moment (in-lb) 312

Shear (lb) 156.2

(psi)

xy y

(psi)

y (near

29950 30348 3034 32742 31917

1780

center) (psi) 16889 16897 16896 16845

341

2363

16875

Mesh Convergence

Mesh Convergence

For mesh convergence testing, it is suggested that you run at least three analyses at different mesh sizes:

Coarse Fine Somewhere in between coarse

and fine

Mesh Convergence

Usually, you will not see the direct equation solutions (such as displacements) change with the different mesh sizes. You will see the numerical method answers (such as ) g stresses) converge to an answer as the mesh gets finer.

Exercise H - Mesh Convergence

Objective: To perform a 2-D analysis using plane stress elements on a classical problem l t l i l bl by utilizing different meshes of 200, 400, 800, 1600 and 3200 elements. elements Geometry: Thickness = 1.0. Material: Stainless steel (AISI 302) cold-rolled. ld ll d Loads: 1000 psi on one edge as shown in the image. Constraints: Fixed at opposite end as shown in the image.

Examples of Mesh Convergence

Mesh Density 200 400 800 1600 3200

y max (psi)
3460.58 3448.13 3502.20 3538.23 3556.18

Reference (psi) 3550 3550 3550 3550 3550

% difference 2.52 2.87 1.35 0.33 0.17

Meshing CAD Solid Models

Meshing CAD Models

Build a solid model in any CAD solid modeler. Using direct CAD/CAE data g exchange or a universal file (IGES, , ), p STEP, ACIS), open the model. Create a mesh on the model.

Mesh Refinement

To optimize solution time, it is useful to create a fine mesh in areas where the results are critical and a coarser mesh in areas where the results will not be as high. You can add refinement points p to achieve localized refinement.

Exercise I - Bracket Model

Objective: Determine the maximum stress in the bracket from a load applied at the hole. Material: Steel (ASTM - A514). Loads: 40 pounds in the -Y p direction at the hole. Constraints: The back surface is fully constrained. y

Midplane Meshing

Refer to the Midplane Meshing Tutorial available at il bl t

www.algor.com/service_support/tutorials

for information on creating plate element models from CAD solid models.

Assembly Meshing

When working with multiple parts in an assembly, it is critical that the assembly meshes match between the parts if they are bonded together. together If the area where the parts come together should not be bonded, t th h ld t b b d d then contact should be used to account f th i interaction. t for their i t ti

Exercise J - Hanger Assembly Model

Objective: Determine the maximum stress in the hanger assembly from a load applied at the center of the shaft. Material: Brackets: Steel (4130) Shaft: Iron Loads: 100 pounds in the -Y direction at the center of the shaft. Constraints: The bottom surfaces of both brackets are fully constrained.

Combining Element Types

Any combination of element types is possible in an assembly. y Nodes must be matched where the parts meet in order for loads to be transferred. The available DOF of the element types that are connected must be considered to avoid unstable geometry.

Combining Element Types

Refer to the Combining Beam Elements with CAD S lid Models Tutorial ith Solid M d l T t i l available at
www.algor.com/service_support/tutorials

for information on combining element g types.

Contact
Select surfaces in the CAD Solid Model environment and specify that contact be considered. The nodes on the surfaces will be able to move apart from each other with no restrictions. The nodes will translate loads when they move together. An iterative solution is used to determine which nodes are in contact. Contact is not considered during the first iteration. Therefore, it may be necessary to apply weak elastic boundary elements to ensure stability. stability

Exercise K - Linear Contact Model

Obj ti Objective: Determine the stress in D t i th t i the assembly for a maximum clamping load of 1,000 pounds applied at the end of the lever. Material: Handle, base and lever: Iron Pins: Steel (ASTM - A36) Constraints: Four bolt holes are fully constrained. Top of the handle is fully constrained. t i d One surface of the lever is constrained against the Z translation. Weak elastic boundary elements in the X and Y directions should be applied to a surface on the lever.

Loads: 1,000 pounds will be applied in the Y direction at the end of the lever. Surface contact should be defined between the handle and the lever, the handle and the pins and the lever and p the pins.

Solving Options

Introduction to Solvers

There are many different ways to solve the matrices that were discussed earlier. As computers get faster new faster, technologies are used that create faster processing of the equations. equations You should usually accept the default settings, which are optimized for the fastest processing.

Solver Options

Sparse

Solves only non zero equations non-zero Skyline Variable bandwidth Banded Fixed bandwidth Iterative Requires a tolerance and initial
conditions

Results Evaluation

Result Options

The types of results depend on the type of analysis that is performed. For example, a structural analysis g y p will give you displacement and stress results while a thermal y give you temperature y p analysis will g and heat flux results.

How Results are Calculated

The results are either calculated directly through linear equations g or calculated through numerical integration methods. For example, displacements are calculated directly from Hookes law, but strains are calculated through numerical methods.

How to Justify Your Results

The best method for justification is to run the model with different mesh sizes. R Remember, you are approximating an b i ti area or volume with the elements. The better the quality of the elements, the better the results. Usually a fine mesh will give more accurate answers than a coarse mesh.

Structural Results

Displacement Stress Strain Reaction forces I t Internal forces lf Motion

Presentation P i of Results

Presentation Guidelines

Use colors that will stand out from each other. other Make presentations that everyone can understand. understand Remember that many people looking at engineering reports are not engineers. Have a standard template. Include 3 D representations with 3-D charts and graphs.

Presentation Options

Contour images g Animations Time-dependent plots Report generation

Contour Images

Animations

Time-Dependent Plots

Report Generation

Other Analysis Types

Thermal Elements

The thermal rod, 2 D, plate 2-D, and brick elements are geometrically identical to the structural elements.

Thermal Nodal Loads

Initial Temperature
Specify

a certain temperature that an area will begin the analysis at (transient analysis).

Applied Temperature
Specify

a certain temperature that a node is kept at due to a heat source.

Thermal Surface Loads

Convection
Assign

a convection coefficient and the ambient temperature. the radiation function and the th ambient temperature. bi t t t the amount of heat added or removed per unit area.

Radiation
Assign

Heat Flux
Assign

Thermal Element Loads

Heat Generation
Enter

the amount of volumetric heat generated in a given part.

Body-to-Body Radiation

Select the surfaces that will exchange heat through g radiation and assign an emissivity value. The processor will automatically calculate the view factors between elements.

Thermal Contact

Used to simulate imperfect thermal conduction between two parts or a substance between two parts that is not modeled (i.e., epoxy). Define contact pairs in the CAD Solid Model environment environment. Define the resistance value between the surfaces. f

Forced Convection

Perform a fluid flow analysis. Apply the velocity profile as input for the heat transfer analysis. Th convection generated by the The ti t d b th velocity profile will be applied to the model during the analysis. d l d i th l i

Thermal Results

Temperature Heat flux Total heat flow

Exercise L - Thermal Model

Objective: Analyze the thermal effects of a material containing hot and cold water pipes. Material: Steel (ASTM - A514) Loads: in lbs Small hole: Convection coefficient = 93,380 in sec F Ambient temperature = 180F in lbs Large hole: Convection coefficient = 46 690 sec F 46,690 in i Ambient temperature= 45F
2 2

Electrostatic Elements

The electrostatic 2 D and brick 2-D elements are geometrically identical to the structural elements.

Electrostatic Nodal Loads

Applied Voltages pp g

Specify a certain voltage that

a node is kept at due to a voltage source.

Temperatures p

Specify temperature of a node

for temperature-dependent material properties.

Electrostatic Results

Voltage Current Current flow Electric field

Electrostatic Analysis

Refer to the Electrostatic and MEMS Tutorial T t i l available at il bl t

www.algor.com/service_support/tutorials

for information on performing an y electrostatic analysis.

Fluid Flow Elements

The fluid flow 2 D and brick 2-D elements are geometrically identical to the structural elements.

Fluid Flow Loads

Prescribed Velocity C b used to specify an inlet Can be dt if i l t F Curves Fan C Can be used to model flow

velocity or zero velocity along a wall. generated by intake, exhaust or internal fans. i t lf rotating machinery.

Rotating Reference Frames Can be used to model flow in

Fluid Flow Loads

Pressure

Applied normal to the edge of

2-D elements. Applied normal to the face of 3-D elements.

Gravity Natural Convection

Uses thermal results from a

steady state steady-state heat transfer analysis.

Fluid Flow Results

Velocity Pressure Stress tensors Reaction forces

Fluid Flow Analysis

Refer to the 3-D Unsteady Fluid Flow Tutorial T t i l available at il bl t

www.algor.com/service_support/tutorials

for information on performing a fluid flow y analysis.

Examples of Combining Analysis Types

Multiphysics

A multiphysics analysis combines the effects of multiple analysis types. y y The original analysis is performed. Another analysis is set up using the results y p g from the original analysis as the loading in the subsequent analysis. For some analyses, iterations are required to reach a steady solution. Steady coupled fluid flow and thermal analysis solves for fluid and thermal results simultaneously. i lt l

Examples of Combining Analysis Types

Apply temperature results from a heat transfer analysis to a stress analysis to analyze thermal stress. l th l t Apply current results from an electrostatic analysis to a heat transfer analysis to analyze Joule heating. Apply velocity results from a fluid flow pp y y analysis to a heat transfer analysis to analyze forced convection. A l t Apply temperature results from a heat t lt f h t transfer analysis to a fluid flow analysis for natural convection.

Thermal Stress Analysis

Refer to the Static Stress with Linear Material M d l /M lti h i T t i l M t i l Models/Multiphysics Tutorial available at
www.algor.com/service_support/tutorials

for information on performing a thermal p g stress analysis.

Material Models

Background on Material Models

Material models are subsets of the element types. types These properties allow you to make decisions on what type of material properties will be used for each part in the model. For example, if a part will see the plastic region of a stress versus strain curve, you should select one of the von Mises material models for an elastic/plastic analysis. l i

Isotropic

This is the standard material model. The material properties d l Th t i l ti are independent of direction.

Orthotropic

This material model can have different properties i th th diff t ti in the three orthogonal directions. The required properties are identical to the isotropic material model. However, you enter separate values for the three directions.

Temperature-Dependent

For some elements, the properties for both isotropic ti f b th i t i and orthotropic materials can b defined on a be d fi d temperature basis. The values are linearly interpolated between the temperature points.

Elastic-Plastic (von Mises)

These material models allow you to specify a bilinear curve. A modulus if bili d l for the elastic region, a yield point and a modulus for the plastic region d d l f th l ti i will be defined. These material models also allow you to define a stress-strain curve if the material cannot be modeled with a bilinear curve.

Ogden, Mooney-Rivlin and Hyperfoam

These material models are used to simulate rubberdt i l t bb (hyperelastic) and foam-like materials. t i l The hyperfoam model will include compressibility effects.

Drucker-Prager

This material model is used to t model soils and concrete. d l il d t

Viscoelastic and Viscoplastic

These material models are used t account for rated to tf t dependent material behavior due t di i ti l d to dissipative losses due d to viscous effects. These material models can be used to model thermal creep.

Thermoelastic and Thermoplastic

These material models are used for thermal stress d f th l t analyses.

Piezoelectric

This material model is used to t model parts that d l t th t experience stress due to a voltage distribution. lt di t ib ti

Curve

This material model allows you t i to input a bulk modulus t b lk d l versus strain curve to control the behavior of the t l th b h i f th part.

Exercise M - Nonlinear Material Model

Objective: Analyze a cantilever beam with an elastic material model. Determine if yielding occurs. If yielding occurs, analyze the model with a plastic material model. t i l d l Geometry: The beam is 10 long and is 5 x 5 square. Material: Steel (ASTM - A36) Loads: 7,000 pounds in the Load curve -Y direction at the free end. Time Multiplier M lti li (s) Constraints: The fixed end is 0 0 fully constrained. 10 1 Duration: 10 seconds. Capture rate: 1 step per second.

Nonlinear Material Models

Refer to the Static Stress with Nonlinear Material M d l T t i l M t i l Models Tutorial available at il bl t
www.algor.com/service_support/tutorials

for information on performing an analysis with nonlinear material models.

Mechanical E M h i l Event Simulation t Si l ti (MES)

Kinematic Elements

Kinematic elements can be either 2- or 3 D elements. 3-D elements Kinematic elements do not experience strains and do not report stresses stresses. Otherwise, these elements behave just like flexible brick elements. They have an advantage over flexible brick elements because of their small contribution to the size of the global stiffness matrix. This results in faster run times.

Contact Elements

Contact elements can have different stiffness values in compression and tension. tension These elements can also have a breaking stress at which point the stiffness will be zero zero. These elements can be used to simulate cables.

Coupling Elements

Coupling elements aid in the simulation of parts that "couple" at a known length. Thi coupling is modeled This li i d l d by introducing a stiffness when it reaches this l h h thi length. th This stiffness is calculated using the modulus of i th d l f elasticity, a coupling area and the length of the d th l th f th element.

Dashpot Elements

Dashpot elements can be used to apply local damping to a model. You can specify a p g damping coefficient that will control how much these elements affect motion.

Actuator Elements

Actuator elements are line elements whose lengths can change over time time. They are used to simulate defined movement of a part (e g (e.g., hydraulic cylinders or solenoids).

Slider Elements

A slider element consists of two collinear lines connected at one node. The node in the middle will be allowed to move along the line defined by the other two points, letting the node slide slide such as a slot.

Pulley Elements

Pulley elements consist of three nodes: driver, pivot and slack. As the driver node moves toward or away f from th pivot, the i t the slack node will move in the opposite direction by a set relationship. relationship

Pipe Elements

Pipe elements allow you to model piping systems under internal pressure loads. The pipe elements can be either straight sections or bends.

Hydrodynamic Elements

Hydrodynamic elements can be either 2- or 3-D elements. Th These elements allow l t ll for the simulation of the i t th interaction of fluids ti f fl id with solids without considering the details id i th d t il of the flow.

Impact Planes

Specify a wall or floor parallel to the global X, Y and Z axes. Objects will not be able to pass through this plane.

Surface-to-Surface Contact

Specify two or more surfaces that may come into contact during the event duration. Can include static and dynamic friction effects effects.

Mechanical Event Simulation

Refer to the following tutorials available at

www.algor.com/service_support/tutorials

for information on performing a Mechanical Event Simulation: Mechanical Event Simulation with Linear Material Models Tutorial Mechanical Event Simulation with Nonlinear Material Models Tutorial Tutorial