Wh t I N d d T What Is Needed To What Is Needed To
Element Analysis? Element Analysis? Element Analysis? This chapter includes material from the book Practical Fin s c apte c udes ate a o t e boo act ca additional material included by Matthias Goelke and Jan Gras additional material included by Matthias Goelke and Jan Gras Basic Information Needed To Run A Finite Basic Information Needed To Run A Finite n a high level summary, the working steps involved in a finite e g y, g p Modeling (pre-processing) Modeling (pre processing) Solution Solution Vi li ti f l ti lt ( t i ) Visualization of solution results (post-processing) This image depicts the three elementary working steps involved This image depicts the three elementary working steps involved summarized below summarized below. 2 M d li g / P P i g 2. Modeling / Pre-Processing g / g CAD D t CAD Data Most commonly, an FEM simulation process starts with the impor y, p p UG IGES solidThinking etc.) into the pre-processor i.e. HyperMes UG, IGES, solidThinking, etc.) into the pre processor i.e. HyperMes In many cases the imported geometry is not ready for meshing Qu In many cases, the imported geometry is not ready for meshing. Qu b k f broken surfaces surfaces which are not stitched together g redundant (multiple) surfaces redundant (multiple) surfaces surfaces which are too small to be meshed in a reas surfaces which are too small to be meshed in a reas 1 Fi it El t A l i ? Finite Element Analysis? - R A Fi it o Run A Finite o Run A Finite ??? ite Element Analysis. It also has been reviewed and has te e e t a ys s t a so as bee e e ed a d as smannsdorf smannsdorf. Element Analysis Element Analysis element analysis may be categorized as: y y g in a FEM analysis Some details about the individual steps are in a FEM analysis. Some details about the individual steps are rt of the components (or parts) CADgeometry (e.g. CATIA, STEP, p ( p ) g y ( g , , sh sh uite often the geometry needs a cleanup first due to uite often the geometry needs a cleanup first due to sonable way later on sonable way later on Wh t I N d d T R A F - What Is Needed To Run A F Another issue related to geometry is depicted in the following ima g y p g In the image on the left, the imported geometry is shown. Note t y green) do not meet at a single point i.e. there is a very small lat green) do not meet at a single point i.e. there is a very small lat respect to the surfaces this small offset will be automatically take respect to the surfaces, this small offset will be automatically take lit l t Th i i th iddl d i t th very poor quality elements. The image in the middle depicts the m The updated (cleaned) and meshed geometry is shown on the righ p ( ) g y g H r th rf dg (i gr ) d t t i i gl i t i Here, the surface edges (in green) do not meet in a single point, i. meshing is carried out with respect to the surfaces, this small offs g p which, unfortunately will result in very poor quality elements. which, unfortunately will result in very poor quality elements. O h h dl d d k h h ll Once these hurdles are mastered, one needs to ask whether all and rounds, tiny holes or even company logos which can often be a d ou ds, t y o es o e e co pa y ogos c ca o te be performance of the component? performance of the component? Meshing g Once the geometry is in an appropriate state a mesh is create Once the geometry is in an appropriate state, a mesh is create h (2D) lid h (3D) ill b t d Thi hi t mesh (2D) or a solid mesh (3D) will be created. This meshing step directly reflects on the quality of the results generated. At the sa y q y g computation time That is the reason why in certain cases a 2D computation time. That is the reason why in certain cases a 2D metals a 2D appro imation of the str ct re ses m ch less elem metals a 2D approximation of the structure uses much less elem are waiting for your results). g y ) See the picture above for structures that are typically meshed w p yp y choose for which part? choose for which part? 2 Fi it El t A l i ? Finite Element Analysis? - age: g the lateral offset of the green edges. Here, the surface edges (in teral offset of the surface edges. As meshing is carried out with teral offset of the surface edges. As meshing is carried out with en into account during meshing which unfortunately will result in en into account during meshing, which, unfortunately will result in h d i iti l t N t h th h i l ll di t t d meshed initial geometry. Note how the mesh is locally distorted. ht. th r i r ll l t r l ff t f th rf dg A .e. there is a very small lateral offset of the surface edges. As set will be automatically taken into account during meshing, y g g l h CAD i f i i ll d d Wh b li l fill l the CAD information is really needed. What about little fillets found in CAD data? Do they really contribute to the overall ou d C data o t ey ea y co t bute to t e o e a ed to approximate the geometry Either a beam mesh (1D) shell ed to approximate the geometry. Either a beam mesh (1D), shell i i l t th fi it l t l i th lit f th h p is crucial to the finite element analysis as the quality of the mesh me time, the number of elements (number of nodes) affects the , ( ) and 1D mesh is preferred over 3D mesh For example in sheet and 1D mesh is preferred over 3D mesh. For example, in sheet ments and th s red ces the CPU time ( hich is the time hile o ments and thus reduces the CPU time (which is the time while you with 1D, 2D and 3D elements. Which element type would you , yp y Wh t I N d d T R A F - What Is Needed To Run A F Despite the fact that meshing is (at least optionally) a highly auto p g ( p y) g y and element normals needs to be checked. If necessary, these e and element normals needs to be checked. If necessary, these e the underlying geometry or by editing single elements the underlying geometry or by editing single elements. Material And Property Information p y After meshing is completed material (e g Youngs Modulus) and After meshing is completed, material (e.g. Youngs Modulus) and elements. Loads Constraints And Solver Information Loads, Constraints And Solver Information Various loads and constraints are added to the model to repr p Different load cases can be defined to represent different loading Different load cases can be defined to represent different loading to tell the solver what kind of analysis is being run which results t to tell the solver what kind of analysis is being run, which results t To determine your relevant loads, your engineering skills are nee To determine your relevant loads, your engineering skills are nee structure and decide whether you want to use them in your sim structure and decide whether you want to use them in your sim t M ltib d Si l ti (MBD) ight b h l f l event, a Multibody Simulation (MBD) might be helpful. The FEM model (consisting of nodes elements material propert The FEM model (consisting of nodes, elements, material propert processor HyperMesh The exported FEM model typically called processor HyperMesh. The exported FEM model, typically called f OSS O S the FEM solver chosen for the analysis (e.g. RADIOSS or OptiStru figure below. figure below. As you will see, the bulk of information stored in the analysis file defined by its nodal number (ID) and its x-, y- and z coordinates. defined by its nodal number (ID) and its x , y and z coordinates. nodes (IDs are referenced) This completes the pre processing ph nodes (IDs are referenced). This completes the pre-processing ph 3 Fi it El t A l i ? Finite Element Analysis? - omated process, mesh quality, its connectivity (i.e. compatibility), p q y y ( p y) element issues may need to be improved by updating (altering) element issues may need to be improved by updating (altering) d property information (e g thickness values) are assigned to the d property information (e.g. thickness values) are assigned to the resent the loading conditions that the part(s) are subjected to. g p ( ) j g conditions on the same model Solver information is also added g conditions on the same model. Solver information is also added to export etc to export, etc. eded. Think of all kinds of load situations that can occur on your eded. Think of all kinds of load situations that can occur on your mulation or not To determine the load from a static or dynamic mulation or not. To determine the load from a static or dynamic ties loads and constraints) is then exported from within the pre- ties, loads and constraints) is then exported from within the pre solver input deck is an ASCII file based on the specific syntax of solver input deck, is an ASCII file based on the specific syntax of f O S uct). A section out of an OptiStruct solver deck is depicted in the is related to the definition of nodes (or grids). Each single node is Each element is then defined by its element number (ID) and its Each element is then defined by its element number (ID) and its hase hase. Wh t I N d d T R A F - What Is Needed To Run A F 3. Solution 3. Solution f During the solution phase of a simple linear static analysis or an e settings of the Finite Element program do handle these classes o settings of the Finite Element program do handle these classes o process is aborted by an error it is due to mistakes you have ma process is aborted by an error , it is due to mistakes you have ma errors: Element quality (http://altair-2 wistia com/medias/rm Element quality (http://altair 2.wistia.com/medias/rm Invalid material properties Invalid material properties Material property not assigned to the elements Material property not assigned to the elements I ffi i tl t i d d l (th d l h Insufficiently constrained model (the model shows a r Some of these model issues are discussed in a free video series Some of these model issues are discussed in a free video series l i i i / l i /b l i 2/h h l d/f altairuniversity.com/e-learning/by-altair-_2/hypermesh-related/fr 4 4 Vi li ti / P t P i g 4.4 Visualization / Post-Processing / g Once the solution has ended successfully post-processing (in H Once the solution has ended successfully, post-processing (in H th i l ti lt i d t St t i d d f the simulation results is done next. Stresses, strains, and deform to the various loading conditions. Based on the results, modificat g , examine howthe modifications affected the part examine howthe modifications affected the part. This eventually completes the FEM process This eventually completes the FEM process. Remarks Practice will show, that in many projects, the above depicted Practice will show, that in many projects, the above depicted indicate that the part is not performing as requested indicate that the part is not performing as requested. It i it b i th t i b k t CAD (t l h ) It is quite obvious that going back to CAD (to apply changes) a Avery efficient (and exciting) technology to speed up this process i Avery efficient (and exciting) technology to speed up this process i to modify the geometry of the FEM model e g change radii thickn to modify the geometry of the FEM model, e.g. change radii, thickn 4 Fi it El t A l i ? Finite Element Analysis? - f f f eigenfrequency study, there is not much for you to do. The default of problems pretty well. Practice will show you that if the solution of problems pretty well. Practice will show you that if the solution ade during the model building phase Just to mention a fewtypical ade during the model building phase. Just to mention a fewtypical mretoumym) mretoumym) i id b d ti d t t l l d ) rigid body motion due to external loads) s available on the Academic Training Center (http://training s available on the Academic Training Center (http://training. h k ki id i /) ree-hyperworks-starter-kit-video-series/) HyperView for contour plots and HyperGraph for 2D/3D plots) of HyperView for contour plots and HyperGraph for 2D/3D plots) of ti l tt d d i d t h th t d d mations are plotted and examined to see how the part responded tions may be made to the part and a new analysis may be run to y p y y d process must be re-entered again, because simulation results d process must be re entered again, because simulation results d ki th h th ti FEM b t di and working through the entire FEM process becomes tedious. is called Morphing Employing morphing allows the CAE engineer is called Morphing. Employing morphing allows the CAE engineer ness of ribs shape of hard corners etc Quite often the morphed ness of ribs, shape of hard corners, etc. Quite often the morphed Wh t I N d d T R A F - What Is Needed To Run A F FEM model can be exported instantaneously (without any reme p y ( y modified part on the fly. modified part on the fly. An example of morphing a given finite element model is depicted An example of morphing a given finite element model is depicted A nice introduction in morphing is given in the video below (http:// A nice introduction in morphing is given in the video below (http:// Note: Note: Th i di id l ki t f th FEM t l b The individual working steps of the FEM process are not only sub loads. A lot of attention must also be paid to the chosen modelin p element type and size etc ) Even though the FEM solver may d element type and size, etc.). Even though the FEM solver may d res lts ha e b passed errors is high results have bypassed errors is high. The following chapters aimat creating awareness about FEM cha The following chapters aimat creating awareness about FEM cha 5 Fi it El t A l i ? Finite Element Analysis? - eshing) allowing the CAE engineer to re-run the analysis of the g) g g y below (http://altair 2 wistia com/medias/dp9q29f3jn) below (http://altair-2.wistia.com/medias/dp9q29f3jn) /altair-2.wistia.com/medias/xycj10c4y2). /altair 2.wistia.com/medias/xycj10c4y2). bj t d t t hil d fi i t i l bjected to many user errors e.g. typo while defining material or ng assumptions (for instance, simplification of geometry, chosen g p ( , p g y, detect some of the most striking errors the likelihood that your detect some of the most striking errors, the likelihood that your llenges and pitfalls. llenges and pitfalls.