FE Analysis Steps

CE 264
Non-linear Finite Element Modeling and Simulation

Development of a model (Geometry discretization)

Formulation of the governing equations
Discretization
sc et at o o
of tthe
e equat
equations
o s
Solution of the equations
Interpretation of the results
Typicallly within
the code

Finite Element Modeling and

Mesh Quality Checks
Lecture - 2

Engineer is responsible

CE 264, Lecture 2

Mesh Descriptions

Finite Element Modeling Process

Lagrangian Mesh

Nodes are coincident with the material points

Obtain CAD data (catia, unigraphics etc.,) for each part

Clean up geometry and prepare for meshing
Determine connections between adjacent parts and setup
same mesh pattern along flanges
Create the FE mesh and check model quality

Original

Deformed

Eulerian Mesh

Original

CE 264, Lecture 2

Slide #2

Deformed

Slide #3

10 15 mm element size is recommended for modeling main

structural areas
20 25 mm element size is recommended for modeling nonstructural areas

Avoid fast transitions from small elements to large elements

Assemble the meshed parts to define a complete finite

element model
Check model for free nodes, free edges, undesired mesh
overlap between parts, etc.

CE 264, Lecture 2

Slide #4

Modeling Guidelines General

The element mesh should be orthogonal to the centerline

of the part
The element mesh should be on the mid-plane of the
cross section of the component thickness

Modeling Guidelines General

No component thickness penetration or part intersection

is allowed
Element size should be uniform whenever possible
Maintain a smooth transition from Coarse to Fine Mesh

Slide #5

Modeling Guidelines Flanges

Element mesh is to be orthogonal to the centerline of the part

Transition Mesh

The mid-plane is established by offsetting the geometry by

1/2 of the gage thickness in the direction that the material is
shown in the cross section of the drawing

CE 264, Lecture 2

Slide #6

Modeling Guidelines Flanges

Flanges of Crash models are to be modeled with

three (3) elements across the flange
Two (2) elements can be used if the flange width is
l
less
th
than 15 mm

CE 264, Lecture 2

CE 264, Lecture 2

Slide #7

Bend radii less than 8mm are to be modeled as a

sharp corner angle
Bend Radii greater than 8mm are to have a minimum
of 2 elements
elements, 1 node,
node following the geometry

CE 264, Lecture 2

Slide #8

Modeling Guidelines Beads and Ribs

Modeling Guidelines Holes

Heights less than 3mm

ignore and mesh as flat
Heights between 3-5mm
increase the height to 5mm
Heights greater than 5mm
mesh as 3 equal length sides on the geometry

Holes

Holes with a diameter less

than 10 mm are ignored
Holes with a diameter
greater than
h 10 mm are to
be included
When meshing around
holes, a minimum of 6
elements is required

d < 10 mm

d > 10 mm

CE 264, Lecture 2

Slide #9

Modeling Guidelines Notches

Notches greater than 20 mm

l < 20 mm

Mesh Transition

Keep notch and split

element to a minimum of 2
across the width

eliminate and replace with 2

triangular elements

Notches less than 6 mm

eliminate and replace with 2
g
elements ((larger
g
triangular
than 6 mm)

CE 264, Lecture 2

Slide #10

Modeling Guidelines Transitions

Notches less than 20 mm

CE 264, Lecture 2

l < 6 mm

Triangular elements are

stiffer than quad elements,
particularly for coarse mesh

Slide #11

Use triangular elements to

transition
Check aspect ratio of
triangular elements

Mesh Transition

Use Co option in LS-DYNA

(*CONTROL_SHELL, full
sorting)
ti )
Triangular elements.
should be less than 10% of
total elements

CE 264, Lecture 2

Slide #12

Modeling Guidelines Transitions

Modeling Guidelines Special Shapes

2-D and 3-D Elements

2-D and 3-D Elements

Special Mesh Shape

It is possible to use quad
elements for triangular
meshes

Triangular Mesh
1-2 Transition

1-3 Transition
Trapezoidal Mesh

CE 264, Lecture 2

Slide #13

Modeling Guidelines Special Shapes

CE 264, Lecture 2

Modeling Guidelines General

2-D and 3-D Elements

2D and 3-D Elements

When modeling a sectional structure component

NOT DESIRABLE
CE 264, Lecture 2

Slide #14

Use a minimum of 3 rows of elements to get a good in-plane

b di
bending
Use a minimum of 5 elements for a buckle

DESIRABLE

Slide #15

CE 264, Lecture 2

Slide #16

Modeling Guidelines Solids

Element Quality Check

3-D Elements

Solid Element Selection

Warpage

Regular shaped 8-node brick is recommended (hexa)

Avoid 4, 5 and 7 node solid elements

Aspect Ratio

Skew

Jacobian

Slide #17

Element Quality Check - Warpage

CE 264, Lecture 2

Ratio of the longest edge of an element to its shortest edge

Should be less than 5:1

CE 264, Lecture 2

Amount by which an element or element face (solid elements)

deviates from being planar
Should be less than 150

Should be less than 600

Measure of the deviation of an element from an ideally shaped
element
Ranges from 0 to 1.0, where 1.0 represents a perfectly shaped
element
Should be greater than 0.6

CE 264, Lecture 2

Slide #18

Element Quality Check - Skew

Slide #19

CE 264, Lecture 2

Slide #20

Final Quality Checks Shells

CE 264, Lecture 2

Final Quality Checks Solids

Slide #21

Final Quality Checks

SHELL ELEMENTS: No SPLITS or CRACKS allowed

in the mesh
SOLID ELEMENTS: No interior SPLITS or CRACKS
allowed in the mesh

Check for and eliminate DUPLICATE ELEMENTS

Check for and eliminate FREE 1-D ELEMENTS
Check for and eliminate RIGID DEPENDENCIES
and RIGID LOOPS or CIRCULAR DEPENDENCIES

CE 264, Lecture 2

Slide #22

Homework

Align element NORMALS for each component in 1

direction
BOUNDARY CHECK

CE 264, Lecture 2

Slide #23

http://crash.ncac.gwu.edu/pradeep/
Select CE-264
Download Homework No
No. 1 (HM file)
Mesh file using Hypermesh
Use element size of 10 mm
Check Mesh Quality
Homework due Feb 24, 2009
E mail Hypermesh (.hm)
E-mail
( hm) file and Mesh Quality Form
to pradeep@ncac.gwu.edu.

CE 264, Lecture 2

Slide #24