16.810 (16.

682)
16.810 (16.682)
Engineering Design and Rapid Prototyping
Engineering Design and Rapid Prototyping
Instructor(s)
Finite Element Method
January 12, 2004
Prof. Olivier de Weck Dr. Il Yong Kim
deweck@mit.edu kiy@mit.edu
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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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Course Concept
today
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Course Flow Diagram
CAD/CAM/CAE Intro
FEM/Solid Mechanics
Overview
Manufacturing
Training
Structural Test
Training
Design Optimization
Hand sketching
CAD design
FEM analysis
Produce Part 1
Test
Produce Part 2
Optimization
Problem statement
Final Review
Test
Learning/Review Deliverables
Design Sketch v1
Analysis output v1
Part v1
Experiment data v1
Design/Analysis
output v2
Part v2
Experiment data v2
Drawing v1
Design Intro
due today
today
Wednesday
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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?
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.
FEM: Method for numerical solution of field problems.
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)
Elastic problems
Thermal problems
Fluid flow
Electrostatics
etc.
Many engineering phenomena can be expressed by
governing equations and boundary conditions
Governing Equation
(Differential equation)
( ) 0 L f + =
Boundary Conditions
( ) 0 B g + =
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Elastic deformation
Thermal behavior
etc.
Governing
Equation:
( ) 0 L f + =
Boundary
Conditions:
( ) 0 B g + =
[ ]{ } { } = K u F
A set of simultaneous
algebraic equations
FEM
Approximate!
Fundamental Concepts (2)
Example: Vertical machining center
Geometry is
very complex!
You know all the equations, but
you cannot solve it by hand
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[ ]{ } { } = K u F
1
{ } [ ] { }

= u K F
Property
Behavior
Action
Elastic
Thermal
Fluid
Electrostatic
Behavior { } u Property [ ] K Action { } F
stiffness
displacement
force
conductivity temperature heat source
viscosity
velocity
body force
dialectri permittivity electric potential
charge
Unknown
Fundamental Concepts (3)
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It is very difficult to make the algebraic equations for the entire domain
Divide the domain into a number of small, simple elements
Adjacent elements share the DOF at connecting nodes
Fundamental Concepts (4)
Finite element: Small piece of structure
A field quantity is interpolated by a polynomial over an element
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Obtain the algebraic equations for each element (this is easy!)
Put all the element equations together
[ ]{ } { } = K u F
[ ]{ } { }
E E E
= K u F [ ]{ } { }
E E E
= K u F [ ]{ } { }
E E E
= K u F
[ ]{ } { }
E E E
= K u F [ ]{ } { }
E E E
= K u F [ ]{ } { }
E E E
= K u F
[ ]{ } { }
E E E
= K u F [ ]{ } { }
E E E
= K u F
[ ]{ } { }
E E E
= K u F
Fundamental Concepts (5)
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[ ]{ } { } = K u F
1
{ } [ ] { }

= u K F
Solve the equations, obtaining unknown variabless at nodes.
Fundamental Concepts (6)
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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.
[ ]{ } { } = K u F
Property
Behavior
Action
K: Stiffness matrix
x: Displacement
F: Load
Kx F =
K
F
x
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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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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 load (pressure, thermal, inertial forces)
- Time or frequency dependent loading
Advantages of the FEM
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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 be fatal.
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Typical FEA Procedure by
Commercial Software
Preprocess
Process
Postprocess
User
User
Computer
Build a FE model
Conduct numerical analysis
See results
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[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
3-D
Linear
Quadratic
Beam
Truss
Shell
Solid
Plate
[3] Material properties , , , , E
Preprocess (1)
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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
- Solve the boundary value problem
[7] Process
- See the results
[8] Postprocess
Displacement
Stress
Strain
Natural frequency
Temperature
Time history
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Responsibility of the user
Results obtained from ten reputable
FEM codes and by users regarded as
expert.*
BC: Hinged supports
Load: Pressure pulse
* R. D. Cook, Finite Element Modeling for Stress Analysis, John
Wiley & Sons, 1995
Fancy, colorful contours can
be produced by any model,
good or bad!!
D
i
s
p
l
a
c
e
m
e
n
t


(
m
m
)
Time (ms)
1 ms pressure pulse
200 mm
Unknown: Lateral mid point
displacement in the time domain
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Errors Inherent in FEM Formulation
Quadratic element Cubic element
- Field quantity is assumed to be a polynomial over an element. (which is not true)
True deformation
- Geometry is simplified.
Domain
Approximated
domain
FEM
Linear element
FEM
- Use very simple integration techniques (Gauss Quadrature)
x
f(x)
1
-1
1
1
1 1
Area: ( )
3 3
f x dx f f

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- The computer carries only a finite number of digits.
- Numerical Difficulties
e.g.) Very large stiffness difference
e.g.) 2 1.41421356, 3.14159265 = =
1 2 2
, 0 k k k
1 2 2 2 2
2
[( ) ]
0
P P
k k k u P u
k
+ = =
Errors Inherent in Computing
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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 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), http://cee.ce.uiuc.edu/paulino
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, http://210.17.155.47 (in Korean)
J. Tinsley Oden et al., Finite Elements An Introduction, Prentice Hall, 1981