Get Into FEA - Amit Belvekar

An Autonomous Institute Affiliated to SPPU Alandi (D), Pune,
India
School of Civil & Mechanical Engineering
UNIT 1 : GET INTO FEA
By
Prof. A.B. Belvekar-Patil 1
SYLLABUS REV 00
Basics of Solid Mechanics, Basic equations of elasticity, Equilibrium equation in

elasticity, plane stress, plane strains, Solution methodologies to solve engineering
problem, Failure Analysis of product, Review of Theories of Failures, CAE driven
design process, Past, Present & Future of FEA, FEA Terminology, General
Procedure of FEA, Introduction to Types of Analysis.
2
Prof. Amit Belvekar-Patil FINITE ELEMENT ANALYSIS
Solution Methodologies to solve Engineering Problem REV 00
Solution Methodologies to solve Engineering Problem
ANALYTICAL METHOD NUMERICAL METHOD EXPERIMETAL METHOD
➢ Classical Approach ➢ Mathematical ➢ Actual measurement

Representation
➢ Use of equations ➢ Experimental setup &
➢ Use of iterations
➢ Gives 100% accurate results Specimens required
➢ Gives approximate
➢ Applicable to only simple ➢ More time required
results
problems.
➢ Results can not believed blindly ➢ UTM, FFT, strain gauges etc
➢ Ex. Bending Equation,
& must be verified by
Torsion equation etc.
experimental or analytical
method.
➢ Applicable to all complex, real
life problems.
➢ Ex. Finite Element
Method, FVM, BEM.
3
FINITE ELEMENT ANALYSIS/METHOD REV 00
➢ FINITE:
➢ ELEMENT:
➢ METHOD/ ANALYSIS
4
FINITE ELEMENT ANALYSIS/METHOD REV 00
Definition:
FEM/FEA is a numerical Method in which infinite DOF is converted into
finite DOF by the discretization method, all the calculations are done on
points called as nodes and finally results are interpolated.
Or
FEM/FEA is a computer simulation technique used in engineering analysis.

It uses a numerical technique/ method
5
HOW RESULTS ARE INTERPOLATED REV 00
ELEMENT:
U= a0+a1x+a2y U= a0+a1x+a2y+a3xy
6
HOW ABOUT ACCURACY IF WE INCREASE NO. OF CALCULATIONS REV 00
ERROR
7
FEA Terminologies REV 00
1. Continuum or Domain
8
2. Node: A node is specific point in the finite element at which all the calculations are done and values of
field variable is to be determined
3. Element: It is the entity which joins the nodes and form specific shape
4. Degree of Freedom:
9
4. Degree of Freedom: Minimum number of parameters required to define position of any object in space
completely
10
BASICS OF SOLID MECHANICS REV 00
FORCE & ITS TYPES
1. BASED ON APPLIED DIRECTION

✓ Only three forces Fx, Fy, Fz
✓ If inclined we can resolve into two directions.
Force
2. BASED ON REGION OF FORCES APPLICATION
POINT AREA LINE VOLUME

Y
PERPENDIC GRAVITATI CENTRIFUG
PARALLEL
ULAR ONAL AL
11
Point Load
Line/ Uniformly Distributed Load (UDL)
12
6. Constraints: (To keep the structure or system in equilibrium)

a. Homogeneous Boundary Conditions
b. Nonhomogeneous Boundary Conditions
13
Types of Moments REV 00
Moments
Mx My Mz
Torsion Bending Bending
Y
Shear Stress Normal Stress Normal Stress
X
Z
What is torque?
Is it Force or Moment?
14
Basics of FEA REV 00
What is Stress?
Internal Resistance to external force. Internal resistance force per unit area
NO
15
Stress
Normal Shear
inclined
Stress Stress
16
Normal Stress Normal stress causes elongation/compression
Shear Stress Shear stress causes Distortion
17
REV 00
Task to You
What is Von mises stress?
18
PAST, PRESENT & FUTURE OF FEA REV 00
➢ 1906 : Civil engineering applications, structures analyzed by 1D beams (hand calculations)

➢ 1909 : Ritz gives Variational method
➢ 1915 : Galerkin gives Weighted method
➢ 1940’s : Courant gives mathematical foundation for present form of FEA
➢ 1950’s : Turner formulated stiffness equations for aerospace industry.
➢ 1960 : Ray Clough coined the name Finite Element Method.
➢ 1967: First book on FEM was published by Zienkiewicz
➢ 1960: NASTRAN was the first software code developed
➢ Late 1960 : Mechanical industry recognized useful tool for solving real life problems
➢ 1970: ANSYS, ABAQUS softwares launched in market.
➢ 1980: Algorithm on Electromagnetic applications, fluid flow and thermal analysis were developed with the
use of FE program.
19
REV 00
➢ 1990: Coupled solutions of fluid flows with structural interactions, biomechanics

➢ Late 1990: FEA adopted by mid & small scale industries
1. At present many commercial softwares like ANSYS, FEAST, ABACUS, LS- Dyna are developed.
2. Due to advancement of these softwares codes FEM can be used in static , dynamic, heat transfer, fluid flow,
electrostatics, biomedical etc
1. Mesh less Analysis

2. Generative Shape design along with Analysis
20
Advantages of FEM REV 00
1. The physical properties, which are intractable and complex for any closed bound solution, can be
analyzed by this method.
2. It can take care of any geometry (may be regular or irregular).
3. It can take care of any boundary conditions.
4. Material anisotropy and non-homogeneity can be catered without much difficulty.
5. It can take care of any type of loading conditions.
6. This method is superior to other approximate methods like Galerkine and Rayleigh-Ritz methods.
7. In this method approximations are confined to small sub domains.
8. Enable to computer programming.
21
Disadvantages of FEM REV 00
1. Proper engineering judgment is to be exercised to interpret results.
2. It requires large computer memory and computational time to obtain intend results.
3. There are certain categories of problems where other methods are more effective, e.g., fluid
problems having boundaries at infinity are better treated by the boundary element method.
4. For some problems, there may be a considerable amount of input data.
22
FUTURE OF FEM REV 00
1. Reducing Analysis time,
2. Improving mesh quality
3. Good automesh tools
4. NVH, CFD, Fatigue, crash
5. Mesh free analysis/ meshless analysis
6. Integrate CAD & solutions steps directly
23
For linear static analysis stress is independent of material & depends only on geometry
St Al Br
Same C/s & length with
different materials
Same force
What @ Stress?
What @ Displacement?
𝑃
𝜎=
𝐴
𝑃𝐿
𝜕=
𝐴𝐸
24
What is Tensor ?? REV 00
 xx  xy  xz 
 
 yx  yy  yz 
 zx  zy  zz 
 
25
Scalar, Vector & Tensor REV 00
3No.ofadditionalparameters 30
Scalar Magnitude defines the scalar
completely =1
e.g. Mass, distance
 Fx 
Vector
3No.ofadditionalparameters 31 =3  Fy
Apart from Magnitude one more  
additional data i.e. direction is required  Fz 
defines the vector completely
e.g. force, velocity
Tensor  xx  xy  xz 
32  
Apart from Magnitude two additional
3No.ofadditionalparameters =9   
 yx yy yz 
data i.e. Plane on which its acting and
 zx  zy  zz 
the direction  
e.g. Stress, strain, magnetic flux
26
POLL
Q. Following are the entities required to define Tensor
Magnitude
Direction
Magnitude, Plane on which its acting and the direction
27
Practical Procedure of FEA REV 00
1. Preprocessor:
2. Processor:
3. Postprocessor:
28
Practical Procedure of FEA REV 00
Procedure of Finite Element Analysis
Preprocessing Post-processing
Solution Phase
Select/Draw Meshing/ Graphical Output Numerical Output

Geometry Defining Property
of Given Material Defining Type of
Geometry Parameters Element
Domain Shape & Size
29
Stiffness REV 00
Stiffness is like Password or PIN for the treasury of FEA
Force required to produce unit displacement
Which
shaft is
more
stiffer?
Steel Al Steel Steel

30
GENERAL PROCEDURE OF FEM (Theoretical) REV 00
STEP 1.- DESCRETIZATION OF THE GIVEN CONTINUUM:
STEP 2 -:SELECTION OF APPROXIMATING FUNCTIONS:

(Approximating functions are also known as displacement function or interpolation function)
The displacement model selected is governed by three conditions:
1.Type & order of Element
2. Should satisfy convergence criteria.
31
STEP 3.-: FORMATION OF ELEMENT STIFFNESS MATRIX:
STEP 4.-: FORMATION OF OVERALL STIFFNESS MATRIX:
STEP 5.-: FORMATION OF ELEMENT LOADING MATRIX:
STEP 6.-: FORMATION OF OVERALL LOADING MATRIX:
32
STEP 7.-: FORMATION OF OVERALL EQUILIBRIUM EQUATION:
STEP 8.-: APPLY BOUNDARY CONDITIONS:
STEP 9.-: CALCULATION OF UNKNOWN NODAL DISPLACEMENT:
STEP 10.-: CALCULATION OF STRAIN & STRESS:
33
Equilibrium Equation in 3D Elasticity(Differential Equation of equilibrium) REV 00
 xx  xy  xz 
 
 yx  yy  yz 
 zx  zy  zz 
 
34
Equilibrium Equation in 3D Elasticity(Differential Equation of equilibrium) REV 00
35
Equilibrium Equation in 3D Elasticity REV 00
The conditions of equilibrium are
F x =0 Fy =0 F Z =0
F x =0
  x 
−  x .d y d z +  x + .d x d y d z
 x 
  
−  xy .d x d z +  xy + xy .d y d x d z
 y 
  
−  xz .d x d y +  xz + xz .d z d x d y + Fx.d x d y d z = 0
 z 
36
 x 
−  x .d y d z +  x .d y d z + .d x d y d z −  xy .d x d z +  xy .d x d z + xy .d x d y d z
x y

−  xz .d x d y +  xz .d x d y + xz .d x d y d z + Fx.d x d y d z = 0
y
 x  
.d x d y d z + xy .d x d y d z + xz .d x d y d z + Fx.d x d y d z = 0
x y y
 x  xy  xz
+ + + Fx. = 0
x y y
37
F y =0 F
Z =0
 xy  y  yz
+ + + Fy. = 0
x y z
 xz  yz  z
+ + + Fz. = 0
z y z
38
 x  xy  xz
+ + +X =0
x y z
 y  yx  yz
+ + +Y = 0
y x z
 z  zx  zy
+ + +Z =0
z x y
39
Task to You?
40
Plane Stress & Plane Strain REV 00
PLANE STRESS: Only the in-plane stress components are nonzero

Area
Nonzero stress components  x , y , xy
element dA t
 xy y  xx  xy  xz 
 xy
x  
 yx  yy  yz 
D  zx  zy  zz 
y  
Assumptions:
1. t<<D
x 2. Top and bottom surfaces are free from traction
41
DOF for Plane Stress REV 00
42
PLANE STRESS Examples:

1. Thin plate with a hole y
 xy Sheet Metal Parts
 xy
x Automobile/ aircraft bodies,
Narrow beams
2. Thin cantilever plate
43
PLANE STRESS REV 00
Nonzero stresses:  x , y , xy
Isotropic linear elastic stress-strain law  = D
 x  1  0    x 
 
 
 y  =
E
 1 
0   y 

z = −
1 −
( +y )
  1 −  1 −  
x
2
 
 xy  0 0   xy 
 2 
Hence, the D matrix for the plane stress case is

1  0 
E  
D=  1 0 
1 − 2
1 − 
0 0 
 2 
44
PLANE STRAIN REV 00
Only the in-plane strain components are nonzero

Nonzero strain components  x ,  y ,  xy
Area element dA
 xy y
 xy
x
Assumptions:
y 1. Displacement components u,v functions of (x,y) only and
w=0
2. Top and bottom surfaces are fixed
x
45
DOF for Plane Strain REV 00
46
PLANE STRAIN
REV 00
1. Dam
Slice of unit Underground
1 thickness Pipes, wide beams,
Dam wall
 xy y
y  xy
z x
x
z
2. Long cylindrical pressure vessel subjected to internal/external pressure and constrained at the ends
Prof. Amit Belvekar-Patil 47ANALYSIS

FINITE ELEMENT
PLANE STRAIN REV 00
Nonzero strain components:  x ,  y ,  xy

Isotropic linear elastic stress-strain law
 = D
 
 x  1 −  0  x 
  E     z =  ( x +  y )
 y  =   1 − 0   y 
  (1 +  )(1 − 2 )  1 − 2   xy 
 xy   0 0   
 2 
Hence, the D matrix for the plane strain case is
1 −   0 
E 
D=   1 − 0 
(1 +  )(1 − 2 )  1 − 2 
 0 0 
 2 
Prof. Amit Belvekar-Patil FINITE ELEMENT ANALYSIS 48

POLL
Q.1 Analysis of DAM can be considered as type of
Plane Stress
Plane Strain
49
POLL
Q.2 Analysis of Fig. shown can be considered as type of
Plane Stress
Plane Strain
50
51
52
Practical Applications REV 00
Practical Applications
1. New Design
2. Cost Cutting/ optimization
3. Failure Analysis
1. New Design
53
2. Cost Cutting/ optimization
54
Design For Infinite life Design For Finite life

➢ Survival for years ➢ Use & Throw concepts
➢ Heavy & oversized components ➢ Life just grater than warranty offered
➢ Noisy & rough operations ➢ Additional source of income, after sale service
➢ High Cost ➢ Light weight
➢ Low cost
55
FAILURE ANALYSIS REV 00
3. FAILURE ANALYSIS
1. Climatic Conditions:
2. Manufacturing Defects
3. Road Conditions
4. Design Abuse
56
Design Abuse REV 00
57
REV 00
58
REV 00
59
Theories of Failure REV 00
60
61
62
REV 00
THEORIES OF FAILURE
63
64
Theories of failure are those theories which help us to determine the safe dimensions of a machine
component when it is subjected to combined stresses due to various loads acting on it during its
functionality.
Some examples of such components are as follows:
1. I.C. engine crankshaft
2. Shaft used in power transmission
3. Spindle of a screw jaw
4. Bolted and welded joints used under eccentric loading
5. Ceiling fan rod
Theories of failure are employed in the design of a machine component due to the unavailability of
failure stresses under combined loading conditions.
Theories of failure play a key role in establishing the relationship between stresses induced under
combined loading conditions and properties obtained from tension test like ultimate tensile
strength (Sut) and yield strength (Syt).
65
Maximum Principal Stress Theory REV 00
When the maximum principal stress induced in a material under complex load condition exceeds
the maximum normal strength in a simple tension test the material fails
Good for brittle materials
66
Maximum Principal Stress Theory REV 00
67
Maximum Shear Stress theory REV 00
When the maximum shear stress in actual case exceeds

maximum allowable shear strength in simple tension test the
material case.
Good for ductile materials
68
69
70
Maximum Distortion Energy Theory (Von Mises Theory) REV 00
When the shear strain energy in the actual case exceeds shear strain energy
in simple tension test at the time of failure the material fails
Highly recommended
71
72
73
74
75
76
Von Mises Stress
Ssy=0.577Syt
77
TYPES OF ANALYSIS REV 00
1. Linear Static Analysis

2. Nonlinear analysis
3. Dynamic Analysis
4. Linear Buckling
5. Thermal Analysis
6. Fatigue Analysis
7. Optimization
8. Computational Fluid Dynamics
9. Crash Analysis
78
TYPES OF ANALYSIS_ Linear Static Analysis REV 00
Linear
Linear means straight line. σ=e E is equation of straight line (y = m x) passing
through origin. "E" Elastic Modulus is slope of the curve & is a constant. In real
life after crossing yield point material follows non linear curve but software
follows same straight line. Component brake into two separate pieces after
crossing ultimate stress but software based analysis never show failure in this
fashion. It shows single unbroken part with red color zone at the location of
failure. Analyst has to conclude whether the component is safe or failed by
comparing the maximum stress value with yield or ultimate stress.
In linear analysis, the deflection considered is small.
Static
The material used is isotropic and stress-strain lies within elastic region i.e.
1. Force is static have linear relationship
2. Satisfies all equilibrium equations
Practical Applications
Most commonly used analysis. All Aerospace, Automobile, Civil engineering industries
79
REV 00
80
Non Linear Analysis REV 00
•Force (stress) Vs. Displacement [strain) curve non linear (polynomial).

•Deals with true stress & strain (unlike engineering stress & strain in linear static analysis).
•Non-linearity due to material involves the stress-strain going beyond elastic region, i.e. the part undergoes plastic
deformation.
•Non-linearity due to geometry is due to large deflections involved in the analysis. Though component is within the
elastic limit but due to very large length even small force causes large deformation. Regular formulas of strength of
material like deflection.6 = PL3/3 El, not applicable as these are based on small displacement assumption.
•Analysis involving contacts comes under non-linear analysis as contact area keeps changing. (stress=load/contact
area).
•Non linearity due to Contact: To simulate physical gap between two parts. E.g. Bearing & shaft
81
Non Linear Analysis REV 00
82
DYNAMIC ANALYSIS REV 00
Vibration Analysis / Modal Analysis
83
LINEAR BUCKLING ANALYSIS REV 00
• Applicable only for compressive load

• Slender beam / Column
• Bending stiffness <<<<< Axial Stiffness
84
THERMAL ANALYSIS REV 00
MODE OF HEAT TRANSFER
CONDUCTION CONVECTION RADIATION
Steady state Un Steady state

Conduction Conduction
Applications:
Engine, Radiator, Exhaust
System, Heat exchanger,
satellite design
85
FATIGUE ANALYSIS REV 00
Calculation of life of the structure when subjected to fluctuating load.

S-N Curve is the base for fatigue calculation.
86
OPTIMIZATION REV 00
Geometrical Parameters Shape Optimization
87
COMPUTATIONAL FLUID DYNAMICS(CFD) REV 00
A Fluid is a substance that continuously deforms under an applied shear stress regardless of magnitude of
applied stress. Gas & liquid are fluid. Fluid mechanics deals with study of fluid, its properties and behavior.
Fluid Mechanics
Fluid Statics (Hydrostatics) Fluid Dynamics

1. Fluid at rest 1. Fluid in motion
2. Easy from calculation point view 2. Calculation are more complex
3. No variation w.r.t. time 3. Variation w.r.t. time
4. Linear equations 4. Non Linear equations
5. E.g. Dam Design 5. E.g. Aerospace, automobile
CFD is a branch of fluid mechanics which uses numerical methods to analysis fluid dynamics problems. It
is based on Naviour Stoke equations.
88
CRASH ANALYSIS REV 00
Structural Crashworthiness:
- To find Deformation, stress & energy absorbing capacity of various structural components of a vehicle
hitting a stationary or moving object.
- The components is said to be crashworthy (safe) if it meets the plastic strain and energy targets.
- Applications: Frontal Side, Rear, Roof crush, car hitting a pole/ wall.
89
Drop test Simulation:

- It is a free fall test carried out to check the structural integrity of the component.
- Application: Black box of an aircraft, mobile phone, TV, fridge.
90
Occupant Safety:
- To find the effects of crash on human body and making the ride safe for driver as well as passengers.
- Several regulations have come across in different countries to ensure proper certification.
- ARAI is setting standards in India.
- Economic commission of Europe.
91
Thank You!
92

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An Autonomous Institute Affiliated to SPPU Alandi (D), Pune,

School of Civil & Mechanical Engineering

UNIT 1 : GET INTO FEA

Basics of Solid Mechanics, Basic equations of elasticity, Equilibrium equation in

Solution Methodologies to solve Engineering Problem

ANALYTICAL METHOD NUMERICAL METHOD EXPERIMETAL METHOD

➢ Classical Approach ➢ Mathematical ➢ Actual measurement

FEM/FEA is a computer simulation technique used in engineering analysis.

FORCE & ITS TYPES

1. BASED ON APPLIED DIRECTION

POINT AREA LINE VOLUME

Line/ Uniformly Distributed Load (UDL)

6. Constraints: (To keep the structure or system in equilibrium)

b. Nonhomogeneous Boundary Conditions

Normal Stress Normal stress causes elongation/compression

Shear Stress Shear stress causes Distortion

What is Von mises stress?

➢ 1906 : Civil engineering applications, structures analyzed by 1D beams (hand calculations)

➢ 1990: Coupled solutions of fluid flows with structural interactions, biomechanics

1. Mesh less Analysis

1. Proper engineering judgment is to be exercised to interpret results.

4. For some problems, there may be a considerable amount of input data.

1. Reducing Analysis time,

2. Improving mesh quality

3. Good automesh tools

4. NVH, CFD, Fatigue, crash

5. Mesh free analysis/ meshless analysis

6. Integrate CAD & solutions steps directly

Q. Following are the entities required to define Tensor

Magnitude, Plane on which its acting and the direction

Procedure of Finite Element Analysis

Select/Draw Meshing/ Graphical Output Numerical Output

Stiffness is like Password or PIN for the treasury of FEA

Force required to produce unit displacement

Steel Al Steel Steel

STEP 1.- DESCRETIZATION OF THE GIVEN CONTINUUM:

STEP 2 -:SELECTION OF APPROXIMATING FUNCTIONS:

STEP 3.-: FORMATION OF ELEMENT STIFFNESS MATRIX:

STEP 4.-: FORMATION OF OVERALL STIFFNESS MATRIX:

STEP 5.-: FORMATION OF ELEMENT LOADING MATRIX:

STEP 6.-: FORMATION OF OVERALL LOADING MATRIX:

STEP 7.-: FORMATION OF OVERALL EQUILIBRIUM EQUATION:

STEP 8.-: APPLY BOUNDARY CONDITIONS:

STEP 9.-: CALCULATION OF UNKNOWN NODAL DISPLACEMENT:

STEP 10.-: CALCULATION OF STRAIN & STRESS:

The conditions of equilibrium are

PLANE STRESS: Only the in-plane stress components are nonzero

PLANE STRESS Examples:

2. Thin cantilever plate

Isotropic linear elastic stress-strain law  = D

Hence, the D matrix for the plane stress case is

Only the in-plane strain components are nonzero

Prof. Amit Belvekar-Patil 47ANALYSIS

Nonzero strain components:  x ,  y ,  xy

Prof. Amit Belvekar-Patil FINITE ELEMENT ANALYSIS 48

Q.1 Analysis of DAM can be considered as type of

Q.2 Analysis of Fig. shown can be considered as type of

2. Cost Cutting/ optimization

Design For Infinite life Design For Finite life

Good for brittle materials

When the maximum shear stress in actual case exceeds

Von Mises Stress

1. Linear Static Analysis