Finite Element Analysis Lab

7th SEMESTER

Submitted by Arqam Ahmad

Class / Section ME 12 C
CMS ID 334444
Submitted to LE Ibrahim Khan

School of Mechanical and Manufacturing Engineering

 Abstract

The document demonstrates the FEM analysis on one problem analyzed

using COMSOL. This problem includes shape optimization of a wrench. The
analysis outlines the Von mises and 1st Principal strain. Changing mesh
size varies the overall stress in the model converging the stress distribution
to the regions undergoing the re-entrant corner.

Introduction

Introduction to FEA
Finite Element Analysis (FEA) is a powerful numerical technique that has revolutionized the field of engineering and
computational science. It serves as a virtual laboratory, enabling engineers and researchers to simulate and analyze
complex physical phenomena across various disciplines, from structural mechanics and heat transfer to fluid dynamics and
electromagnetics. FEA breaks down intricate real-world systems into smaller, manageable elements, allowing for the
accurate prediction of how these systems will behave under different conditions. As a cornerstone of modern engineering
design and analysis, FEA empowers professionals to optimize structures, products, and processes, ultimately leading to
safer, more efficient, and cost-effective solutions in an ever-evolving technological landscape. In this exploration of Finite
Element Analysis, we delve into its principles, applications, and the profound impact it has had on the way we conceive,
design, and innovate in the world of engineering.

Shape Optimization of a Wrench

An established product's geometry can be changed using shape optimization to boost performance. The Deformed
Geometry interface can be used to accomplish this, but one must choose which shape deformations to permit. It's critical
to enforce some constraint placed on the optimization process to protect mesh quality. One approach is to use the
Helmholtz filter to introduce a length scale which (when combined with a maximum displacement parameter) limits the
slope of the shape variations. This type of regularized shape optimization can be set up using equations-based modeling,
but it is also built into the Free Shape Boundary feature. This model applies the feature to a CAD representation of a
wrench, but the initial geometry equations can also come from topology optimization.

Von-Mises Stress
Von Mises stress is particularly useful for predicting the failure of ductile
materials, which deform plastically rather than fracturing when subjected
to stress. Ductile materials, such as many metals, can withstand a certain
amount of plastic deformation before failing. The von Mises stress criterion
provides a way to assess this plastic deformation and predict when it will
occur. Engineers and materials scientists use von Mises stress calculations
to design structures and components to ensure they can withstand the
expected loads and avoid plastic deformation or failure.
1st Principal Strain
The first principal strain, often denoted as 𝜀₁, is a measure of the largest deformation or elongation that occurs in a material
or structural element due to applied loads or stress. Principal strains represent the directions in which the material is either
stretching or contracting the most, and they are important for understanding how materials respond to mechanical loads.

Methodology

The geometry of the wrench was constructed according to the dimensions provided. The material was selected as
“Structural Steel”. The constraints were set with a fixed boundary (boundary 35) and a boundary load of 150 𝑁 (negative)
acting vertically downwards at boundary 111.

Furthermore, the analysis was performed using four different mesh sizes which are shown below:

Figure 1: Coarser Mesh

 Figure 2: Normal Mesh

Figure 3: Fine Mesh

Figure 4: Finer Mesh

All meshes were “Physics controlled mesh”.

 Results and Discussions

Here is the plot obtained for von-Mises stress for all four meshes:

Figure 5: Coarser Mesh

Figure 6: Normal Mesh

Figure 7: Fine Mesh

 Figure 8: Finer Mesh

Based on these plots, here are the results obtained:

Maximum Stress Minimum Stress

Type of Mesh
(𝑴𝑷𝒂) (𝑴𝑷𝒂)
Coarser 605 0.814
Normal 450 0.324
Fine 401 0.218
Finer 483 0.0913

Similarly, here are the plots for 1st principal strain for these meshes:

Figure 9: Coarser Mesh

Figure 10: Normal Mesh

Figure 11: Fine Mesh

Figure 12: Finer Mesh

Based on these plots, here are the results obtained:

Maximum Strain Minimum Strain

Type of Mesh
(%) (%)
Coarser 0.21 −1.43 × 10−3
Normal 0.187 9.79 × 10−5
Fine 0.186 5.18 × 10−5
Finer 0.205 −6.73 × 10−6

We have observed that for each type of mesh, we acquire different set of maxima and mimima of values for von-Mises
stress and 1st principal strain. Coarser mesh (larger elements with fewer nodes) provides a less detailed representation of
the object’s shape. Normal mesh (elements of moderate size and density) is used when required level of accuracy is not
known. Fine mesh (small elements with higher node density) yields more accurate stress distributions but requires
computational resources. Finer mesh (even smaller elements with even higher node density) provides the most accurate
stress distributions. This means that the choice of mesh type depends on the specific requirements of your FEA analysis.

We can notice that the maximum stress is being applied at the point of rotation. This is because all the torque is distributed
on the point of rotation causing the wrench to bend and rotate the nut. It's common to see a stress concentration near
the point of rotation because that's where the mechanical action (torque) is concentrated, leading to the highest
deformation and stress levels.

Conclusion

The FEM analysis performed on the shape optimization of the wrench undergoing various types of natural and essential
boundary conditions gives us an understanding regarding the von-Mises stress distribution and 1st principal strain
distribution of the wrench. The contour plots in 2D gives an overall understanding of the structure’s deformity and the
behavior of induced stresses along the stress planes.