16.

810
16.810

Engineering Design and Rapid Prototyping

Prototyping

CAE -Finite Element Method

Instructor(s)

Prof. Olivier de Weck

January 11, 2005

 Plan for Today

„ Hand Calculations Aero Æ Structures

„ FEM Lecture (ca. 45 min)
„ FEM fundamental concepts, analysis procedure
„ Errors, Mistakes, and Accuracy

„ Cosmos Introduction (ca. 30 min)

„ Given by TA
„ Follow along step-by-step

„ Work on CAD and conduct FEA in teams(ca. 90 min)

„ Work in teams of two
„ First conduct an analysis of your CAD design
„ You are free to make modifications to your original model

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 Course Concept

today

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 Course Flow Diagram (2005)

Learning/Review Problem statement Deliverables

Design Intro / Sketch Hand sketching (A) Hand Sketch

CAD Introduction CAD design (B) Initial Airfoil

FEM/Solid Mechanics FEM/Xfoil analysis (C) Initial Design

Xfoil Airfoil Analysis

Design Optimization Optimization optional

CAM Manufacturing Revise CAD design (D) Final Design

Training
Parts Fabrication (E) Completed Wing
Structural & Wind
Assembly
Tunnel Testing Assembly
(F) Test Data &
Test Cost Estimation

Final Review (G) CDR Package

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 Numerical Method

Finite Element Method

Boundary Element Method

Finite Difference Method

Finite Volume Method

Meshless Method

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 What is the FEM?

FEM: Method for numerical solution of field problems.

Description
- FEM cuts a structure into several elements (pieces of the structure).
- Then reconnects elements at “nodes” as if nodes were pins or drops

of glue that hold elements together.

- This process results in a set of simultaneous algebraic equations.

Number of degrees-of-freedom (DOF)

Continuum: Infinite

FEM: Finite

(This is the origin of the name,

Finite Element Method)

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 Fundamental Concepts (1)

Many engineering phenomena can be expressed by

“governing equations” and “boundary conditions”

Governing Equation
Elastic problems
(Differential equation)
Thermal problems L(φ ) +
f = 0

Fluid flow

Electrostatics Boundary Conditions

etc. B(φ ) + g = 0

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 Fundamental Concepts (2)

Example: Vertical machining center

Geometry is
Elastic deformation very complex!
Thermal behavior
etc.

A set of simultaneous
FEM algebraic equations
Governing
Equation: L(φ ) + f = 0
Boundary
Conditions: B(φ ) + g = 0 Approximate!
[K ]{u} = {F}
You know all the equations, but
you cannot solve it by hand

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 Fundamental Concepts (3)

[K ]{u} = {F} {u} = [K]−1{F}

Property Action
Behavior
Unknown

Property [K ] Behavior {u} Action {F}

Elastic stiffness displacement force

Thermal conductivity temperature heat source

Fluid viscosity velocity body force

Electrostatic Dielectric permittivity electric potential charge

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 Fundamental Concepts (4)

It is very difficult to solve the algebraic equations for the entire domain
Divide the domain into a number of small, simple elements

A field quantity is interpolated by a polynomial over an element

Adjacent elements share the DOF at connecting nodes

Finite element: Small piece of structure

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 Fundamental Concepts (5)

Obtain the algebraic equations for each element (this is easy!)

Put all the element equations together

[K E ]{u E } = {F E } [K E ]{u E } = {F E } [K E ]{u E } = {F E }

[K E ]{u E } = {F E } [K E ]{u E } = {F E } [K E ]{u E } = {F E }

[K E ]{u E } = {F E } [K E ]{u E } = {F E } [K E ]{u E } = {F E }

[K ]{u} = {F}

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 Fundamental Concepts (6)

Solve the equations, obtaining unknown variabless at nodes.

[K ]{u} = {F
} {u} = [K]−1{F}

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 Concepts - Summary

- FEM uses the concept of piecewise polynomial interpolation.

- By connecting elements together, the field quantity becomes interpolated

over the entire structure in piecewise fashion.

- A set of simultaneous algebraic equations at nodes.

Kx = F

[K ]{u} = {F} K: Stiffness matrix

x: Displacement
K
Property F: Load
Action
Behavior
x
F

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 Brief History

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

- The first book on the FEM by Zienkiewicz and Chung was published in

1967.

- In the late 1960s and early 1970s, the FEM was applied to a wide variety

of engineering problems.

- Most commercial FEM software packages originated in the 1970s.

(Abaqus, Adina, Ansys, etc.)

- Klaus-Jurgen Bathe in ME at MIT

Reference [2]
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 Advantages of the FEM

Can readily handle very complex geometry:

- The heart and power of the FEM

Can handle a wide variety of engineering problems

- Solid mechanics - Dynamics - Heat problems
- Fluids - Electrostatic problems

Can handle complex restraints

- Indeterminate structures can be solved.

Can handle complex loading

- Nodal load (point loads)

- Element loads - distributed (pressure, thermal, inertial forces)

- Time or frequency dependent loading

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 Disadvantages of the FEM

A general closed-form solution, which would permit one

to examine system response to changes in various
parameters, is not produced.

The FEM obtains only "approximate" solutions.

The FEM has "inherent" errors.

Mistakes by users can remain undetected.

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 Typical FEA Procedure by

Commercial Software

User Preprocess Build a FE model

Computer Process Conduct numerical analysis

User Postprocess See results

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 Preprocess (1)

[1] Select analysis type - Structural Static Analysis

- Modal Analysis
- Transient Dynamic Analysis
- Buckling Analysis
- Contact
- Steady-state Thermal Analysis
- Transient Thermal Analysis

[2] Select element type 2-D Linear Truss

Quadratic Beam
3-D
Shell
Plate

E, ν , ρ , α , L
Solid
[3] Material properties

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 Preprocess (2)

[4] Make nodes

[5] Build elements by assigning

connectivity

[6] Apply boundary conditions

and loads

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 Process and Postprocess

[7] Process
- Solve the boundary value problem

[8] Postprocess
- See the results Displacement
Stress
Strain
Natural frequency
Temperature
Time history

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 Responsibility of the user

200 mm Fancy, colorful contours can

be produced by any model,
good or bad!!
1 ms pressure pulse

Displacement (mm)
BC: Hinged supports

Load: Pressure pulse

Unknown: Lateral mid point

displacement in the time domain

Results obtained from ten reputable

FEM codes and by users regarded as
expert.*

Time (ms)
* R. D. Cook, Finite Element Modeling for Stress Analysis, John
Wiley & Sons, 1995

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 Errors Inherent in FEM Formulation

Approximated
Domain
- Geometry is simplified. domain

FEM

- Field quantity is assumed to be a polynomial over an element. (which is not true)

True deformation
Linear element Quadratic element Cubic element

FEM

- Use very simple integration techniques (Gauss Quadrature)

f(x)
1 ⎛ 1 ⎞ ⎛ 1 ⎞
Area: ∫−1 f ( x ) dx ≈ f ⎜
⎝ 3⎠
⎟ + f ⎜−
⎝
⎟
3⎠
x
-1 1

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 2-D vs. 3-D

In reality, everything is 3-D.

But some problems can be simplified to 2-D (in structures, plane stress and
plane strain).
Plane Stress Plane Strain

σz = 0 εz = 0
thickness ≈ 0 thickness ≈ ∞
z
sheet
dam
3-D z

2-D

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 Truss vs. Beam

Truss Beam

Only supports axial loads Supports axial loads and

bending loads

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 Errors Inherent in Computing

- The computer carries only a finite number of digits.

e.g.) 2 = 1.41421356, π = 3.14159265

- Numerical Difficulties
e.g.) Very large stiffness difference

k1 >> k2 , k2 ≈ 0

P P
[(k1 + k2 ) − k2 ]u2 = P ⇒ u2 = ≈
k2 0

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 Mistakes by Users

- Elements are of the wrong type

e.g) Shell elements are used where solid elements are needed

- Distorted elements

- Supports are insufficient to prevent all rigid-body motions

- Inconsistent units (e.g. E=200 GPa, Force = 100 lbs)

- Too large stiffness differences Æ Numerical difficulties

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 Plan for Today

„ FEM Lecture (ca. 50 min)

„ FEM fundamental concepts, analysis procedure
„ Errors, Mistakes, and Accuracy

„ Cosmos Introduction (ca. 30 min)

„ Follow along step-by-step

„ Conduct FEA of your part (ca. 90 min)

„ Work in teams of two
„ First conduct an analysis of your CAD design
„ You are free to make modifications to your original model

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 References

Glaucio H. Paulino, Introduction to FEM (History, Advantages and

Disadvantages)

Robert Cook et al., Concepts and Applications of Finite Element Analysis, John
Wiley & Sons, 1989

Robert Cook, Finite Element Modeling For Stress Analysis, John Wiley & Sons,
1995

Introduction to Finite Element Method

J. Tinsley Oden et al., Finite Elements – An Introduction, Prentice Hall, 1981

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