BMCG 3333: MECHANICAL DESIGN

CHAPTER 7-1: FINITE ELEMENT

METHOD

Rev: 03.12.2018
Chapter Outcome:
• At the end of this chapter, students should be able to:-
i. Define and describe the concept of Finite Element Methods and
Analysis (FEM/FEA)
ii. Describe the methodology use in FEA
iii. Apply commercial FEA tools for engineering applications
Introduction to Finite Element Methods
and Analysis (FEM/FEA)

What is FEM/FEA?

 The finite element method (FEM) is a numerical technique for

finding approximate solutions to boundary value problems for
partial differential equations. It is also referred to as finite element
analysis (FEA) (Wikipedia, 2016)

 Finite element analysis (FEA) is a computerized method for

predicting how a product reacts to real-world forces, vibration, heat,
fluid flow, and other physical effects. Finite element
analysis shows whether a product will break, wear out, or work the
way it was designed (Autodesk, 2016)
Fundamental Concept of FEM
• A continuous field of a certain domain having infinite
degrees of freedom is approximated by a set of piecewise
continuous models with a number of finite regions called
elements. The number of unknowns defined as nodes are
determined using a given relationship i.e.{F}=[K]*{d}.
Fundamental Concept of FEM

Domain 
x


• Red line-Continuous
Domain with degrees of freedom
field over the entire
domain.
x
• Blue line-Finite

number of linear
 Subdomain e
x
approximations with
Domain divided with subdomains
the finite number of
with degrees of freedom
elements
1

2
5 6
3
4
x
General Steps
1) Discretize the domain
a) Divide domain into finite elements using
appropriate element types (1-D, 2-D, 3-D, or
Axisymmetric)
2) Select a Displacement Function
a) Define a function within each element using the
nodal values
3) Define the Strain/Displacement and
Stress/strain Relationships
4) Derive the Element Stiffness Matrix and
Equations
a)Derive the equations within each element
General Steps
5) Assemble the Element Equations to Obtain the
Global or Total Equations and Introduce
Boundary Conditions
a)Add element equations by method of superposition
to obtain global equation
6) Solve for the Unknown Degrees of Freedom
(i.e primary unknowns)
7) Solve for the Element Strains and Stresses
8) Interpret the Results
Applications
• Stress Analysis
• Truss and frame
analysis
• Stress concentration
• Buckling
• Vibration analysis
• Heat transfer
• Fluid flow
Advantages of FEM
• Model irregularly shaped bodies
• Compute General load conditions
• Model bodies composed of different materials
• Solve unlimited numbers and kinds of boundary
conditions
• Able to use different element sizes in places
where loads or stresses are concentrated
• Handle non-linear behavior using linear
approximations
• Reduce System Cost
FEM Packages
• Large Commercial Programs
• Designed to solve many types of problems
• Can be upgraded fairly easily
• Initial Cost is high
• Less efficient
• Special-purpose programs
• Relatively short, low development costs
• Additions can be made quickly
• Efficient in solving their specific types of problems
• Can’t solve different types of problems
FEM Packages
• Algor
• ANSYS
• COSMOS/M
• STARDYNE
• IMAGES-3D
• MSC/NASTRAN
• SAP90
• GT-STRUDL
• HyperWorks
Note on Stiffness matrix
For a 1-D bar, the stiffness matrix is derived from the
stress/strain relationship in Hooke’s law and the definitions
of stress and strain.

σx = Eεx. ; σx = P/A ; εx = du/dx = (d2x – d1x)/L

By substitution: -f1x = EA (d2x – d1x) L E

L A
f1x = EA (d1x – d2x) f1 f2
L d1x d2x
Similarly for f2x: f2x = EA (d2x – d1x)
L
Combining into matrix form, the stiffness matrix is defined
as
[k] = EA 1 -1
L
-1 1
 Note on the displacement function
•For a given set of nodes there exists a function that approximates
the displacement at any position along the bar.
•This function, called the displacement function, is derived from
Pascal’s Triangle.
•A new constant is introduced into the function for every node in
the discretized domain.

For 1-D u(x) = a1 + a2x + a3x2 + …

Note on the displacement function
If a 1-D bar is broken into 2 elements, the displacement function
would be u(x) = a + a x + a x2.
1 2 3

Putting it into matrix notation: u(x) = [1 x x2] a1

a2
By knowing the distances to the nodes a3
and the displacements at those nodes, the
equation becomes: u1 1 0 0 a1
u2 1 x x 2
a2 , where
= 2 2
u3 1 x 3 x32 a3

x1 = 0, x2 and x3 are the distances to the nodes and u1, u2, and u3 are the displacements

The coefficients are found by solving the equation.

Example
E 2E

a A b A P

L L

Determine displacements of materials a and b if

the load P is applied to the end of the bar given
the above information.
Example con’t.
1) Discretize the domain with appropriate elements.

Element a Element b

f1 f3 = P
1 2 3
u1 u2 u3

f1 1 2 f21 f22 2 3 f3 = P

u1 u2 u2 u3
Example con’t.

2) Select a displacement function

There will be new term for each element, and the terms are
derived from Pascal’s triangle.
1 2 3
u1 u2 u3

u(x) = a1 + a2x + a3x2

Example con’t.
3) Define stress/displacement and stress/strain relationships
σx = Eεx εx = du/dx
4) Derive the element stiffness matrix and element equations
{F} = [k]{d} [k] = stiffness matrix

{F} = Force [k] = EA 1 -1

L
{d} = displacement -1 1
a b
f1 EA 1 -1 u1 f22 EA 2 -2 u2
f21 = L , = L
-1 1 u2 f3 u3
-2 2
Example con’t.
5) Construct Global equation and introduce boundary
conditions and known variables.

f1 1 -1 0
= EA u1 Global Equation
f21+f22 L -1 3 -2 u2
f3 u3
0 -2 2

B.C.: (x =0) u1 = 0
Known variables: f3 = P and f2 = f21+f22 = 0
Example con’t.
6) Solve for unknowns.

f1 1 -1 0
= EA 0
0 L -1 3 -2 u2
P u3
0 -2 2

f1 = -EAu2 0 = EA(3u2-2u3) P = EA(2u3-2u2)

L L L

u2 = PL u3 = 3PL
EA f1 = -P
2EA
Example con’t.

7) Solve for the element strains and stresses.

εa = P = u2 σa = Eεa = P
EA L A
εb = 3P = u3 σa = 2E εb = P
2EA L 3 A

8) Interpret the Results

•After solving for the displacements, the coefficients of the

displacement function can be determined.
 FEA Methodology (based on FEM
Packages)

Create Define load

Assign
geometry and boundary
material
model conditions

Pre-processing

View results Run Meshing

Post-processing Processing
FEA Applications
• Example of FEM package in market =
CATIA V5 Generative Structural
Analysis workbench  for simplified
finite element analysis of structures
• In static and dynamics loading
conditions
• Analyze single part and assembly
• Able to simulate the behavior of
structures subjected to various type of
loadings
• Advantage: easy procedure to conduct
the FEA, user friendly, able to integrate
part model generated from other CAD
software (CATPart, IGS, STP etc.),
provide visual info
• Limitation: Accuracy
CATIA V5 GSA process flow for static structural
analysis
Step Procedure
1 Open or Create the part that to be simulated.
2 Apply a material.
Note: Very important to know to find the Properties of a material. To find the
material proprieties in CATIA, double click on the material selected on the Tree
and go to Analysis Tab.
3 Open the CATIA Analysis and simulation -> General Structural
Analysis module from Start Menu and select Static Analysis and click OK
4 Meshing.
Define “size” (green) and “sag” (blue). A smaller element size lead to more
accurate results at the expense of a larger computation time. The “sag”
terminology is unique to CATIA. A smaller “sag” value could lead to better
results.
To change the value of these two elements you can double click on OCTREE
Tetrahedron Mesh or double click on the elements that appear on the part.
To see the Mesh go to the Tree -> Finite Element Model.1 -> Right click on
Nodes and Elements and click Mesh Visualization.
 2
4

2
CATIA V5 GSA process flow for static
structural analysis
Step Procedure
5 Applying Boundary Conditions / Restraints in CATIA analysis and simulation.
In FEA, restrains refer to applying displacement boundary condition which is
achieved through the Restraint toolbar. i.e.Clamp conditions mean that the
displacements in all three directions are zero.
6 Applying Loads.
In FEA, loads refer to forces. The Loads toolbar is used for this purpose, i.e.
Distributed Force
7 Launching the Solver (Compute)
To run the analysis, use the Compute toolbar by selecting the Compute icon
8 Postprocessing.
The main postprocessing toolbar is called Image. Type of views: i)
Deformation, ii) Displacement, and iii) Von Mises Stress
5

7
 8

DEFORMATION
8

STRESS

RESULTS INTERPRETATION
Distribution, maximum and
minimum value, location of max.
and min. value
DISPLACEMENT
Ref: http://catiav5v6tutorials.com/catia-v5-tutorials/general-structural-
analysis/first-steps-in-catia-general-structural-analysis-beginner-tutorial/
Video Tutorial
Challenge Your Understandings
a) What is boundary conditions?
b) What is geometry model?
c) What postprocessing?
d) What are the advantages of using commercial software
such as CATIA for performing FEA?
Assignment
• Form a group (max. 5 students per group)
• Select a household product as topic
• Conduct load analysis
• Create 3D part model
• Perform FEA using CATIA V5/Solidworks/Fusion/Inventor
• Analyze the results
• Propose design improvements for the product
• Create assignment report

• Submission date: 2 weeks from the date of assignment

briefing
Case Study: Static Structural Analysis of Curtain Rail
Bracket Using Finite Element Method
• Product selected: Curtain rail bracket
• FEA software used: Autodesk Fusion 360
• Load analysis: 50N distributed bending load
• Bracket material: Aluminium alloy (Sy= 7.28 MPa)
• Analysis type: static bending

Picture of actual curtain rail bracket

 Geometry Assign Define load
model material and BC

• Material type: Aluminium alloy (select from software library)

• Finite element model properties : element type = OCTREE
Tetrahedral linear element; no. of element = 36048 elements; no. of
nodes= 57360 nodes; load type applied: static bending load;
boundary condition/constraint type = fix

Curtain rail bracket 3D View of load and boundary condition

geometry model produced
using Autodesk Fusion
 Post Result 1: Result 2: Results
processing stress displacement interpretation

Result 1: Max. stress and stress Result 2: max. displacement and

distribution displacement distribution

i. Max.stress = 0.4851 MPa; location?

Results
ii. Max.deformation = 0.1038 mm; location?
interpretation
iii. F.O.S ~ 15.0;
iv. Theoretical product weight ~250grams (from
CAD model)
FEA WITH CATIA V5
• Static Analysis: https://www.youtube.com/watch?v=9glRJyWWXZw

https://www.youtube.com/watch?v=aI3I4Tl3He4

• Static on an Assembly: https://www.youtube.com/watch?v=Whr6bu2n1iY

FEA WITH FUSION 360

Static stress analysis using Autodesk Fusion 360
https://www.youtube.com/watch?v=r6dA6QjBF0k

Getting started with FEA in Fusion 360

https://www.youtube.com/watch?v=hXeFsNDnHk4
Bibliography
• Logan, Daryl L. A First Course in the Finite Element
Method Using Algor. Brooks/Cole, Pacific Grove,
CA. 2001
• http://www.finite-element-method.info
• http://www.eng.fsu.edu/~chandra/courses/eml4536/
• http://urbana.mie.uc.edu/yliu/FEM-
525/FEM_Lecture_Notes_Liu_UC.pdf
The End – Thank You