en to Use 3-d Elements 100 100~ 200 ~50 ns are comparable pe-Tetra, penta, hex, pyramid data from user ~ Nothing Solid : Gear box, engine block, crankshaft etc. Crank Shaft Tetra Meshing (image Source: Altair Calendar 2006, ‘6oylinder crankcase brick mesh Courtesy : Bharat Forge Ltd.)ner) t m 3 DMeshing 112 3-d Element types: 3-d Elements z— Penta or Wedge Se \, | Linear Tetra a ds Parabolic Parabolic Penta 15 Tetra 10 8.2 DOFs For Solid Elements ] Hex or Brick Eg Linear Hex 8 ae Parabolic Hex 20 Pyramid N Linear Pyram 5 Not supported by all softwares za Parabolic Pyram 13 2-4 thin shell and 1-d beam element supports 6 dofs, but all solid elements have only translational dofs (no rotational dof) i.e. a 10 noded tetra element has total 10 x 3 = 30 dofs Why solid have only 3 translations & no rotational dofs (Physical interpretation)? Consider a piece of paper (2-d geometry) or long steel scale (1-d geometry), it could be easi bended and twisted (rotational dof) but now consider a solid object like duster or paper weight it could not be i.e. very high bending and torsion stiffness. Hence solid elements have been formulated with 3 translational dofs and no rotational dofs.Practical Finite Element Analysis Meshing Techniques f two methods of tetra meshing ic mesh : This approach is limited to simple geometries and pre-requisite is error free User has to just select the volume and software automatically carries out meshing as ied element length, quality criteria etc. Very quick, no meshing efforts :Results in very high number of nodes and elements. There is no control on mesh ind specific mesh pattern requirement (like bolted, welded joints or contact surface Iria) to 3d (Tetra) : Most commonly used method. Quad or tria meshing is carried out on surfaces of the geometry, quads split to trias and then converted to tetras. -d (Tria) to 3-d (Tetra) mesh generation : ) Study the geometry Separate (isolate) surfaces, split the job among engineers (if there is time constraint) wineer 1| 3D 114 ‘Meshing b. CAE engineer 2 Step 3) Combine the mesh Step 4) Quality checks for triangular element (Min. tria angle > 15°, Max. tria angle < 1 Jacobian > 0.6), zero free edges, no T-connection Step 5) Convert Tria mesh to Tetra Step 6) Quality checks for tetra elements (tet collapse > 0.1, Jacobian & distortion > 0.5, st > 0.2 etc.). Improve quality of mesh if required. Step 7) Free-Free run or otherwise linear static analysis with dummy BC's. Common algorithms for Tria to Tetra Conversio 1) Advancing Front : Very powerful and most commonly used algorithm 2) Delaunay Algorithm 3) Tria-Quad mesh All Algorithms provide following two options for Tria to Tetra conversion 1) Floating trias : Not recommended, original tria mesh generated by user on outer sur might not match with software produced tetra. Selection of this algorithm gives freedom software to change the triangular mesh pattern (in case of any problem in tetra mesh generatiPractical Finite Element Analysis uld be used for meshing of general components or areas (not high stress, used for ng stiffness or mass etc.). as: Recommended. Original tria mesh and generated tetra mesh pattern matches. Original tria Tria & Tetra mesh togather Tria & Tetra togather mesh (floating tria method) Tria & tetra mesh same Tria & Tetra mesh not same (fixed tria method) (at cross pattern of mesh) if you are getting the job done from a service provider, always request for 2d shell long with 3d tetra. Checks for Tetra Meshing le= 1.0 (Acceptable > 0.1) apse= h*1.24/A ed as distance of node from opposite face ‘area of the face multiplied by 1.24) ere passing through corner nodes of ideal (equilateral) tetra in it. Find volume d actual tetra elements. (Acceptable < 0.7) WV, 1 teat Vac Skew eat 153D Meshing Stretch: Ideal value = 1.0 (Acceptable > 0.2) Stretch = R* 24 /L,.. R = Radius of largest possible sphere inside given tetra element. Distortion: Ideal value = 1.0 (Acceptable > 0.5) Distortion = |J|* Vol", /Vol" seg LCS - Local Coordinate System GCS - Global Coordinate System Jacobiai Ideal value .0 (Acceptable > 0.5) In simple language, jacobian is a scale factor arising because of transformation of co-ordi system. Elements are transformed from global co-ordinates to local co-ordinates for reduci solution time 8.5 Other Checks for Tetra Meshing 1) Quality checks for 2-d tria elements: Before converting trias to tetras all the quality che discussed in chapter 7 should be applied. 2) Free edges: Conversion from tria to tetra is possible only when there is no free edge. No edge indicates mesh is forming enclosed volume. 3) T-connections : Mesh model should not contain any T-connection. T-connection is int (volume) loop formation in the outer enclosed volume. Geometry T-connection, not acceptable Green elements should not be there in the modelNo T-connection correct mesh ‘Shell normals : Before converting trias to tetras, shell normals should be corrected. ftwares do not allow shell to solid conversion unless normals of all the elements are ligned. netry deviation : After completion of meshing, geometry as well as mesh should be ‘quality improvement (in particular for distortion/jacobian on curved surfaces or fillets) es nodes get translated too far away from the geometry and not acceptable. elements should be deleted before final submission : It's a common mistake to shell elements along with tetra mesh as final delivery. to improve quality of tetra mes! provide auto algorithms / localized remesh facility for improving mesh quality. These simprove most of the elements but some might remain as itis. For such elements quality ent is carried out via manual shifting / translation of nodes. Unlike 2-d shell elements, ode'facility is not available for 3-d elements. Vs. Parabolic Tetra Elements : ra elements not recommended for structural analysis. They are very stiff & inaccurate in son to parabolic elements. ‘tetras are not recommended for structural analysis then why this option is provided nercial FEA softwares? structural analysis of very big assemblies, to reduce overall dofs, components away critical areas are meshed with linear tetras. thermal analysis linear tetra is convenient since temperature is the only variable (1 dof like 3 for structural) use of tetra 10 would unnecessarily increase dofs. CFD calculations are mostly based on linear elements. Mould flow analysis Practical Finite Element Analysis 1173D Meshing 8.6 Brick Meshing Brick meshing (also known as Hex meshing) is all about planning, hard work & patience. Brid meshing support only manual and semi automatic command options. Automatic meshing of option like quad to brick (tria to tetra) is not supported by commercial softwares. Rear axle assembly with brake drum and wheel hub, Brick mesh (Image Source : Altair Calendar 2006, Courtesy : Ashok Leyland ) Procedure for brick meshing of complicated parts is to shell mesh the surfaces and then convet tohex by using commands extrude, spin, sweep, linear solid etc. Free face checkis very importa after completion of hex meshing. Extrude / drag usPractical Finite Element Analysis 1193D Meshing Tips for brick meshing: Even experienced engineers fear and do not willingly accept job of brick meshing. Don’t you believe, ok let us have some fun, try it on 1* of April, tell your experienced company colleague that just now in the meeting he has been assigned job of engine block brick meshing and observe expressions on his face. It will tell entire story about brick meshing. In philosophy they say “know the One (God) & you will know every thing of this world” Philosophy for meshing would be “Know the brick meshing & you will know all about meshing” No book or consultant or university can teach you brick meshing, The real teacher is determined approach & hours of sitting in front of the computer, making mistakes and learning from the mistakes, Are you ready .... Here are some tips for brick meshing 1) Proper planning before starting the job : Sufficient time should be spent in studying the geometry & meshing should not be started unless and until meshing steps and how to proceed is visualized in the mind. Symmetry, sub symmetry or repetitive features if any could save time. 2) 2-d quad mesh should be systematic (ruled or mapped), avoid 2-d auto mesh : Flow lines should be maintained with minimum trias, diamond or rotating quads should be avoided. Use of auto mesh on surfaces results in zig-zag or random mesh which might lead to unexpected problems later. 3) Do not hurry to convert the shell mesh to brick: One should not convert 2-d mesh to 3-d immediately instead, proceeding further with quads and checking for any possible problem with the current pattern is recommended. 4) Start from the complicated feature and not the simple one or corner of the part: During the exams for effective time management basic thumb rule told to students is “Attack simple problems first and then the complicated one.’Thumb rule for brick meshing is exactly reverse i.e. “Attack complicated features first and then simple ones”, Beginners make a common mistake to mesh the simple and outer corners of the part first. 5) Use linear solid command: Linear solid and morph are very powerful commands for brick meshing and should be utilized. > Brick and Tetra meshing comparison * No.of elements &nodes generated by brick mesh are of the order of 1/2 to 1/50 in comparison to tetra mesh. Brick mesh reduces solution time and results in ease of handling the model on workstation (pre & post display).Practical Finite Element Analysis [Analysis types like crash or nonlinear give preference to brick mesh due to no. of nodes & mesh flow lines. Previously all the organizations used to brick mesh solid parts. So in case if objective is to compare existing model with the previous one then it has to be modelled using same type ‘of element and length for a logical conclusion. Time consumed in brick meshing is more & requires experience, hard work & lot of patience ‘too! ‘Over the years algorithm for tetra has improved & accuracy wise there is not much difference in tetra 10 & brick 8 elements. Brick Mesh Quality Checks leal shape for brick element is cube. Various quality criteria check how far a given element sviate from ideal shape. rp angle: Ideal value = 0 (Acceptable <30°) rp angle is calculated on faces (quadrilateral) of hex element. It is angle between the planes form by splitting quad element. Ideal value = 1.0 (Acceptable > 0.5) In simple language, jacobian is a scale factor arising because of transformation of co-ordinate ystem. Elements are transformed from global to local coordinates for reducing solution time. Distortion = |J |*Vol" eg / VOI Ges ‘LCS Local Coordinate System GCS - Global Coordinate System Stretch: Ideal value = 1.0 (Acceptable > 0.20) Stretch = min. edge length * V 3 / max. diagonal length Aspect rati Ideal value =1.0 (Acceptable < 5) Aspect ratio = max. edge length / minimum edge length. Skew: Ideal value = 0° (Acceptable < 45°) Skew is checked on all the faces (quadrilateral). For skew definition please refer chapter 7. Quad face included angles: 45° < @ < 135° Tria face (wedge / penta elements) included angles: 20° < @ < 120° % of Pentas : Acceptable < 5% 1213D Meshing 8.8 Other Checks for Brick Mes Free faces: Free face check is the most important check for brick meshing. A single brick element has 6 free faces. Free faces of the mesh should match with outer surfaces (skin) of solid part. Any extra (inside) faces indicates either nodes are not connected properly or otherwise mismatching elements. Brick mesh Free faces Outer layer elements displayed in line made to check internal faces Converting free faces to tetras For complicated geometries checking internal free faces could consume lot of time, a quick shortcut is to convert free faces (split quads to trias) to tetra mesh. Successful conversion indicates brick meshing is ok and there are no internal faces. 122Practical Finite Element Analysis line or dynamic viewing option : Line mode Hidden line mode displaying the brick mesh model in hidden line or fast dynamic viewing mode one can jediately recognize node / element connectivity problem if any. from above listed checks other checks (like duplicate elements, duplicate nodes, delete Ip. / free nodes etc.) as discussed in chapter 7, should also be applied. .9 How Not to Mesh Mid nodes should lie exactly on the geometry : Not acceptable Recommended parabolic tetra meshing task, many CAE engineers prefer to start with linear tria (instead of 1233D Meshing parabolic) meshing and then covert it to parabolic. In the conversion process mid nodes might Not get projected automatically on the curved surfaces and fillets, Ifso, it should be projected on corresponding surfaces before conversion to tetras, 2)When the job is split among several engineers, element length and over all mesh pattern should be consistent. Above job was split among 3 engineers due very short duration provided by the client. Same mesh size and pattern was not followed by engineers working independently on sub parts of geometry. 3) Minimum 2 elements on the fillets for tetra meshing: Elements at fillets and curved surfaces usually fail in jacobian/distortion. Manual adjustment for improving the quality results in mesh deviation from geometry and visible kinks. This could be avoided by modeling the fillets with 2 or more elements, 4) For brick meshing minimum 2 elements across the thickness: Single element lead to poor interpolation & thus affect accuracy of results. Minimum 2 elements. 124Practical Finite Element Analysis s any thickness is recommended. Exception is NVH applications where not the stress but sentation of mass and stiffness (with least dofs) is main criteria. ‘Use of tetra / pyramid elements while brick meshing : Pyramid Tetra Some clients allow few tetra elements for brick meshing. Also some softwares and analysis types support pyramid elements. Use of tetra and pyramid can make life of brick mesher tolerable if not easy! It's a good practice to clarify instructions for use of these elements from the client. 6) Modeling a sheet metal part with 3-d elements : For sheet metal or very small thickness parts 2-d shell elements are better suited and | recommended. Its not like we can not use 3-d mesh at all, but it will result in very high number of nodes & elements. Consider following sheet metal part 200 x 200 x 2 mm. We will mesh the same part with 3-d parabolic tetra elements and 2-d quad-4 (linear) elements using same element length and compare number of nodes and elements. 1253D Meshing ; 3-d Tetra mesh 2-dquad-4 mesh i Nodes = 1496 Nodes = 121 Elements = 689 Elements =100 7) Limitation of 1-d element and advantage of 3-d meshing: Fillets, cutouts and complicated geometry features can not be represented accurately by 1-4 element. 3-d elements because of 3 dimensions can capture all the minute details accurately. For example consider following shaft. It is very difficult to capture key way slot and variable fillet via 1-4 elements, instead 3-d meshing is recommended for such applications. 126