Modelling and Simulation

Mechanical Engineering Project

Management
Contents
1. Introduction

2. 3D Design

3. BIM Methodology

4. Finite Element Analysis

5. 3D Printing

6. Bibliography

Introduction
Several tools are used in the modelling and simulation
process, the most common of which can be classified
into the following groups:
• 3D Design
• BIM Methodology
• Finite Element Analysis
• 3D Printing
3D Design
Computer Aided Design - CAD in three dimensions refers
to the use of computers to obtain a three-dimensional
model of a mechanical element, in an imaginary space,
visually displaying its physical properties, such as
dimensions, material, or colour.
The use of 3D CAD provides benefits such as:
• Visualisation: allows you to create and visualise
3D objects and make modifications as required.
In addition, it is possible to create photorealistic
images by rendering.
• Detail: the representation is very close to the final
result, with the necessary precision and details that
may be different for each part of the model.
• Optimisation: showing failures of the design
process, even allowing simulations and kinematic,
dynamic, stress, deformation, vibration, temperature
or fluid flow tests.
• Specialisation: with specific applications and
functions for each sector, such as calculating the
total mass, estimating manufacturing times and
costs and calculating the carbon footprint of their
manufacture.
• Realisation: giving the possibility to transform it into
a real physical model in a simple and inexpensive
way.
There are two traditional approaches to creating 3D
geometry, the so-called history-based approach, where
the structure and order of features controls how models
react to changes or edits, creating predictable models
based on a sketch; and direct modelling, where no history
or sketch is maintained, and editing is done directly by
selecting what is to be modified and applying values.
The latest trend is towards the use of a synchronous
approach, which combines the two approaches to allow
changes to the design to be made intuitively by modifying
dimensions, relationships, and constraints.
Modelling and Simulation 3
Figure 1. Modelling vectors.
BIM Methodology
BIM, Building Information Modelling, is a collaborative
work methodology that documents the entire life cycle of
a building or infrastructure, using a computer tool, in such
a way that a single repository of all useful information is
generated.
It can be defined as a set of work methodologies and
tools, characterised by the use of information in a
coordinated, coherent, computable, and continuous way,
using one or several compatible databases that contain
all the information relating to the element to be designed,
built, and operated.
BIM promotes new ways of thinking and acting, moving
from a short-term vision, focused on the partial vision of
one of the stages of the element's life cycle, to a long-
term, multidisciplinary vision that includes the entire life
cycle.
The use of BIM is an evolution of traditional designs,
going beyond the definition and design phases based on
3D geometry, to include new dimensions:
• 4D: scheduling, such as simulations of project
phases, implementation of Lean methodology and
Just-in-Time systems and visual validations for
payment approvals.
• 5D: cost estimating, including cost planning,
procurement verifications, earned value, and
solution analysis.
• 6D: sustainability, including energy analysis,
element traceability, and LEED and BREAM
certifications.
• 7D: infrastructure management, including life cycle
strategies, and operations and maintenance plans
and programmes.
• 8D: relating to occupational safety plans in the
construction process.

The digital model provided by BIM is a virtual prototype
that digitally reproduces what is intended to be built and
exploited in reality. Its elements contain information
relating to the data of all the elements that are
represented, in the form of a figure in 3 dimensions,
which allows interactive visualisation, that facilitates
communication between the agents involved and
centralises the knowledge used.
This database requires the definition of Levels of
Development (LOD), which is the way to measure the
degree of information contained in each element, which
goes beyond the accuracy and detail of the graphic
representation, becoming a measure of the increase of
information in the model.
The most commonly used Level of Development model
is the BIMForum Specs model, which creates a scale
from LOD 100 to LOD 500 with the following definitions:
• LOD 100: graphical representation of the element.
• LOD 200: graphic representation accompanied by
approximate quantities, sizes, shapes, locations,
and orientations.
• LOD 300: graphical representation accompanied
by exact quantities, sizes, shapes, locations, and
orientations.
• LOD 350: graphical representation accompanied
by quantities, sizes, shapes, shapes, locations,
orientations, as well as interfaces to other systems
and elements.
• LOD 400: graphical representation accompanied
by quantities, sizes, shapes, locations, and
orientations, as well as manufacturing, assembly,
and installation details and information.
• LOD 500: is a field-verified representation of the
element, with all its data.
3D 4D 5D
• Cost estimates
• Programming
• Graphical • Verifications
• Lean
representation • Earned value
• Validations
• Solution analysis
Figure 2. Dimensions of the process.
Modelling and Simulation 4
Finite Elements
A mechanical component is nothing more than a
continuous elastic structure. The Finite Element Analysis
(FEA) methodology consists of dividing, i.e. discretising
this structure into small substructures, called elements,
which are elastic and perfectly defined, but of finite size.
These elements can be linear, with 2 nodes, superficial,
with 3-8 nodes, or in the form of a solid, with 4 or more
nodes; to which are added special elements such as
gaps, connections, and rigid joints, with a minimum of 2
nodes each.
It can be defined as the methodology that poses and
solves a system of equations that considers the loads
and deformations for each of these elements.
By employing polynomial functions, the continuous
elastic behaviour of each element is developed in terms
of the material and geometric properties of the element.
Loads can be applied within the element (gravity,
dynamic, thermal, etc.), at the element surface or at
element nodes.
The analysis process consists of three phases: Pre-
processing, processing, and post-processing.
Pre-processing
consists of modelling the geometry using a graphical
interface or, better yet, a 3D CAD program, and then
transferring the model to the finite element software.
This step may require adjustments to the model, which
may be a simplification, or ensuring that the shapes are
closed and continuous.
The next step is the meshing of the model, which,
as indicated, consists of discretising the model into
elements. This is the most important part because the
accuracy of the result will depend on it. It is advisable to
be especially careful and reduce the size of the elements
around the stress concentration points of the structure.
On the other hand, an element that is too small in size
slows down the whole calculation process.
6D 7D
• Infrastructure
• Sustainability Management
• Energy analysis • Strategies
• Traceability • O&M Plans
• Certifications • O&M
Programmes

Material properties are assigned to the different elements
of the structure, such as density, Young's Modulus,
Shear Modulus and Poisson's Ratio for mechanical
calculations, and others such as, Coefficient of Thermal
Dilatation, Coefficient of Thermal Conductivity, Electrical
Conductivity, etc., depending on the type of calculation to
be carried out.
Finally, the boundary conditions are assigned, such as
the restrictions of movement in the elements and nodes,
as appropriate, and the loads to which the structure is
subjected are applied, without forgetting about the value
and direction of gravity.
Process
It consists of the development of a set of systems of
discrete equations, based on each of the elements of the
mesh. The equations can be developed based on various
principles, such as energy conservation principles,
Hamilton's Principle, the Weighted Residual Method, or
Taylor Series.
Systems of equations are solved either by direct methods,
suitable for a small number of elements, such as
Gaussian elimination or L U factorisation; or by iterative
methods, more suitable for systems with a large number
of equations, such as Jacobi's method, the Gauss-Seidel
method, the SOR method, etc.
For systems of non-linear equations, several iterative
resolution cycles must be carried out.
Post-processing
The result of the calculation is a large volume of data
that is very difficult to process, so it is essential to
transform this data into 3D images with colour scales,
which are much easier to interpret and analyse, to which
iso-surfaces, vector fields, and animations that simulate
dynamic behaviour can be added.
Virtual reality solutions are currently being developed
that allow a more in-depth analysis of the solutions.
• Geometric modelling
• Transfer to FEA
• Meshing (discretisation)
Pre-processing • Material properties
• Boundary conditions
• Loads
• Development of systems of equations
Process • Solving systems of equations
Post-
• 3D Images
processing
Figure 3. Stages of the Process.
Modelling and Simulation 5
3D Printing
The principle of 3D printing is that a digital model, made
in 3D CAD, is converted into a three-dimensional physical
model by adding material. This is why it is also called
Additive Manufacturing, as opposed to subtractive
manufacturing, which would be obtained by machining
or cutting, and conformal manufacturing, which would be
obtained by moulding or confirmed moulding.
3D printing software transforms the digital model into
a series of 2-dimensional "slices" that are printed and
placed on top of each other, adding the third dimension
to the whole.
FDM
SLA &
SL/LOM
DLP
3D Printing
SLS/
DED SMLS/
SLM
BJ MJ
Figure 4. Types of technology used in 3D printing.
There are several 3D printing technologies, which are
classified into 7 types:
• Fused Deposition Modelling (FDM), which uses a
filament spool that feeds an extrusion head with
a high temperature nozzle, in which the the head
deposits molten material in precise locations, and
then cools and solidifies creating a rigid part.
• Vat Polymerisation (Stereolithography & Digital
Light Processing - SLA & DLP) uses ultraviolet
light to cure a liquid resin, deposited in a vat, that
solidifies it, layer by layer. SLA uses a single laser
beam, while DLP projects a two-dimensional image
for each layer.
• Powder Bed Melting (Selective Laser Sintering/
Direct Metal Laser Sintering/ Selective Laser
Melting - SLS/ DMLS/ SLM), the process starts by
preheating a deposit of polymer powder just before
its melting point, a roller deposits a very thin layer
of this powder, and a laser light sinters exactly the
powder particles that form the part. In DMLS and
SLM, metal powder is used.
 Modelling and Simulation 6

• Material Jetting (MJ), works in a similar way to

an inkjet printer; only the head injects a layer of Bibliography
material, and once it has been deposited and cured [1] R. Budynas, K. Nisbett. (2012). Mechanical
under UV light the platform is lowered for another engineering design. McGraw-Hill Interamericana de
layer to be deposited. The speed of the process can España, S.L.
be increased by using several heads.
[2] G.R. Liu, S.S. Quek (2003). Finite Element Method: A
• Binder Jetting (BJ), a bed of material is deposited, Practical Course. Elsevier Science & Technology
which can be metallic, acrylic, or powder; a head
[3] B.Redwood, F.Schöffer, B.Garret (2017). The 3D
injects adhesive material forming layers of the final
printing handbook. 3D hubs B.V.
part; finally, the part is separated from the bed of
material and cleaned. [4] es.BIM (2016). BIM in 8 points
• Directed Energy Deposition (DED), which uses a
head that deposits layers of molten material, which
solidify to form the part.
• Lamination (Sheet Lamination/ Laminated Object
Manufacturing - SL/ LOM), which consists of
overlapping sheets of material, these sheets are cut
to the exact shape using a laser cutter.

The use of 3D printing is interesting because it allows

prototyping at very low cost, reducing design time,
allowing the use of a wide variety of materials and the
manufacture of parts of great geometric complexity.

However, it has limitations as the materials used are

usually anisotropic and have low structural strength,
require post-treatment, and do not allow a high degree
of precision, so these factors must be considered when
validating the prototype.