Application of Finite Elements

Ramanan L
Principal Engineer
GE Healthcare GTO India
Body Structure – Loco, Car, Plane …
FE Application to Rail Car Body

1 CAE Simulation of Rail Car … Ramanan. L et. al..

FE Application - Rail Car Bogie
Chassis

2 Bogie Frame Car … Ramanan. L et. al..

FE Application - Rail Wheel & Tyre

3 Thermo Mechanical FE Analysis l. Ramanan et al. IJMS

4 Thermo Mechanical FE Analysis l. Ramanan et al. NAFEM

5 Submodeling FE Analysis l. Ramanan et al. ABAQUS

FE Application – For FASTER to
MARKET

3 Thermo Mechanical FE Analysis l. Ramanan et al. IJMS

4 Thermo Mechanical FE Analysis l. Ramanan et al. NAFEM

5 Submodeling FE Analysis l. Ramanan et al. ABAQUS

FE Application – Safety Critical Joints

6 Rotating Anodes X Ray Tube Using Interference Fit, US

Patent – 4089612, GE

7 Thermo Mechanical FE Analysis l. Ramanan et al. NAFEMS

8 Mechanical Joint with Interference Fit for Use in Hand

Rail of Patient Table … IP Publication in IP.com..
FE Application – Safety Critical Medical Device

Power Requirement
X-Ray On Detector

6 Altair User Conference

7 Manipal Bio Med Conference

FE Application – Design for Usability in Medical

US Patent Application No: 11/530656 – Shock Transferor

8 in Patient Tables, L Ramanan & Kiran Kumar – General
Electric
FE Application – Flow in Electronics Cabinets

US Patent Application No: 11/530656 – Shock Transferor

8 in Patient Tables, L Ramanan & Kiran Kumar – General
Electric
FE Application – Blood & Artery Interaction

Fluid Structure Interactions – In Blood

Vessels

9 Coupling of FEA to CFD for investigating the shear effects of pulsating blood flow on the
Dilation of Artery Walls – Eric M, Rachel Fu and Subham Sett
FE Application – Micro Mechanics
FE Application – Human Body Structure
FE Application – Human Body

Simulation of Rubber O Ring – Hyper Elastic , Aruda –Boyce / Mooney

Revlin Material Model. “Simulation of Non Linear Material Model”
10 Bearings
Simulation of Polymer 11 with Glass Balls - Contact Pressures,
Wear Pattern Correlations etc.
1
Simulation of Facial Tissues – A Finite Element model of the face soft
tissue with Linear and Hyper Elastic Material Mooney Rivlin Material
Model – Maxillofacial surgery and correction of face dismorphosis

12

10 Simulation of Non-Linear Material Model in ANSYS, L, Ramanan, 2006 India Users Conference

11 Behavior of Rubber O Ring in Oil Grove using Hyper Elastic Material Model in ANSYS, L,
Ramanan, 2007, ANSYS India Users Conference
Comparison of linear and non-linear soft tissue models with post-operative CT scan in
12 maxillofacial surgery - M. Chabanas, Y. Payan, Ch. Marécaux, P. Swider and F. Boutault –
Medical Simulation 2004
Business Impact of Predictive Design
Safer & Robust Product

Time to Market – Faster Turn Around

Less Proto-Type - First Time Right Product

Lower Cost in Product development

Multiple Design Concepts & Validation

Drives Design Decisions

Statistical Aspect to Engineering
Little Complex TF – Predict Compression Ratio

Pl. Answer

Factors - 2 /3/4/5 ?

Response - ?

Transfer Function - ?

Key - Transfer function

Address Variations
Principle of Tolerancing
Tolerance is the range of variation allowable in X such that the
requirements for the Y are still met.
We need to understand the relationship (transfer function) that
exists between Xs (factors) and the Y (response).
Rod Dia x1
25.349 to 25.4

End Bore X2 Radial Gap Y = (X2-X1)/2

25.4 to 25.502

Rod End Cap

O-Ring
Inner Dia
PTFE Seal
Interference = (Grove rad+Ring
dia+PTFE – Rod radius)
End grove Dia
Success Depends on Predictive Design
A New Direction for Medicine

Late Early
Disease Health
Symptom Based Prevention/Predic
Data Detailed
tion
Managing
Starved Early
Patient Info
Average
Illness Targeted
Diagnosis
Therapies Therapies
Evolution of Bio-Medical Product
Product
Launch
Clinical
Trails
Regulatory
Approvals
Verification,
Validation &
Product Exhibited in RSNA Proto-Type &
Reliability
Correlation of
Tests
Prediction &
Measurement

Finalise ti on
Concept v olu
E
uct
Concept Prod
al
Analysis
Me dic CAE
Concept
Simulations
Customer
Voice for Early
Health
Integration of Technology & Science
Interventi
onal
Clini
Informati
cal
on System

Electrical &
Mechanical Electronics Life
Sciences
VCT

Communication Industrial

Ch
s
sic
Networking Design

em
y
Medical

Ph

ist
ry
Devices Monitoring

Biology
MRI
Digital Safety
Imaging Ergonomics
Sensing

Computer ECG
HW & SW

Imagi
ng PET

Ultra
Sound
Predictive Approach to Safety
Safer Product “Quality is Patient Safety”

Design for Safety – CPR, CTS, SPoF

Robust Design “Factor of Safety & Regulation”

Fatigue Life Predictions - “Reliability”

Design for Usability–“User Centric Approach”

Risk Mitigation in Early Design Stages

Prediction in Design for Safety

Critical to Safety Parts Bolted Joint-Safety

X-Ray On
Detector- Safety
Prediction for Safety Critical Joints

3
Interference Fits – Force Fit Mechanical Joints 7

4 5

Fasteners – Mechanical Bolted Joints

1 Stress, Deformation and Strain Predictions Due to

the Joint

3 Rotating Anodes X Ray Tube Using Interference Fit, US Patent – 4089612, GE

4 “Finite Element Analysis in Manufacturing Simulation” – L Ramanan et. al

Proceedings of the 15th International Conference on CAD/CAM
5 “Heat Shrinking Approach to Accessory Rails to Positioners” L Ramanan & S Baskar,
IP Publications
6
6 “Influence of Interference Fit on the Strain Distribution in the Implanted Proximal
Femur” AS Wong, AMR New, A.Ritchie, and M Taylor

7 “Thermo-Mechanical Finite Element Analysis of a Rail Wheel” L Ramanan et.al,

International Journal of Mechanical Sciences, 41, 1999, Elsevier Sciences Ltd.,
Structural Prediction
System Level to Component Level Predictions

Stress and Deflections – Static & Dynamics

Image Quality & Comforts – Noise & Vibration

Design Evolution – Innovative Concepts

Inputs to Other Domains – Integration

1
Material Modeling – Isotropic & Anisotropic

1 Role of CAE in Predictive Design of Medical Equipments & Devices, L Ramanan, 2007
India / S.Asia Altair CAE User’s Conference
2 Application of CAE in Bio-Medical Engineering using ABAQUS, Web-seminar, 2006
Predictive Approach to Performance
System Level to Component Level Predictions

Performance in – Static & Dynamics

Image Quality & Comforts – Noise & Vibration

Design Evolution – Innovative Concepts

Performance after - Drop & Impact

Inputs to Other Domains – Integration

Material – Isotropic & Anisotropic

Examples for Performance Prediction

PLmodLOW1-PulseG
eometry-027 Mo...

Power Prediction Frequency Prediction Life Prediction

Mechanism & Motion Deformation

Prediction in Mechanism and Motion

Simulation of Motion – Understand Mechanism, Forces in the joint

Power Prediction
1
Rigid Body Dynamics – Frequency, Power predictions.

Simulation of Human Joints – Toward Memory-Based Human

Motion Simulation: Development and Validation of a Motion
Modification Algorithm

13
Toward Memory-Based Human Motion Simulation: Development and Validation of a
13 Motion Modification Algorithm - Woojin Park, Don B. Chaffin, and Bernard J. Martin,
376 IEEE TRANSACTIONS ON SYSTEMS, MAN, AND CYBERNETICS—PART
A: SYSTEMS AND HUMANS, VOL. 34, NO. 3, MAY 2004
Predictive Design for Usability Conditions

Low energy Impacts – Un-Intentional

Shocks – Due to Unintentional Drop

8

Usage Patterns – Hand Rails

8 US Patent Application No: 11/530656 – Shock Transferor in Patient Tables, L Ramanan &
Kiran Kumar – General Electric
Predictive Approach in Electronics

System Level Fluid Flow Prediction

Fan Selection & Validation of Operating Range

Sub-System Level Flow & Thermal Prediction

“PC Board Level Trace Heating” Predictions

Thermal Packaging & Heat Sink Optimization

Prediction of Fluid Structure Interaction

Fluid Structure Interactions – In Blood Vessels

9 Coupling of FEA to CFD for investigating the shear effects of pulsating blood flow on the
Dilation of Artery Walls – Eric M, Rachel Fu and Subham Sett
Predictive Approach in Physics
Macro to Micro Level Predictions

Behavior of O Ring in Oil Groove

Effect of Interference Fit in Assembly

Behavior of Bearing Under Radial Load

Elastic & Hyper Elastic Material Behavior

Non-Linear Effects – Material, Boundary & Geometry

Pre-Tension Effects in Bolted Joints of Assembly

Prediction of Material Behavior

Simulation of Rubber O Ring – Hyper Elastic , Aruda –Boyce / Mooney

Revlin Material Model. “Simulation of Non Linear Material Model”
10 Bearings
Simulation of Polymer 11 with Glass Balls - Contact Pressures,
Wear Pattern Correlations etc.
1
Simulation of Facial Tissues – A Finite Element model of the face soft
tissue with Linear and Hyper Elastic Material Mooney Rivlin Material
Model – Maxillofacial surgery and correction of face dismorphosis

12

10 Simulation of Non-Linear Material Model in ANSYS, L, Ramanan, 2006 India Users Conference

11 Behavior of Rubber O Ring in Oil Grove using Hyper Elastic Material Model in ANSYS, L,
Ramanan, 2007, ANSYS India Users Conference
Comparison of linear and non-linear soft tissue models with post-operative CT scan in
12 maxillofacial surgery - M. Chabanas, Y. Payan, Ch. Marécaux, P. Swider and F. Boutault –
Medical Simulation 2004
Summary
Predictive & Robust Engineering Ensures Safer Product – Mitigates Risk Early

Impacts the Business - Aids Early to Market

Reduces Product Development Cost – Proto

Drives Innovation – Validates Concept

Fore Runner to DFR - Not a Substitute

Models Physics – Helps in Living Useful Life

Note
This Material was presented as a “Key Note
Address” in Vellore Institute of Technology
University on 15th November 2007, to explain
the usage of Predictive in Design in
Engineering for the benefit of student
community for academic purpose.

Any other interpretation or inferences can not

be made, apart from appreciating the usage of
CAE Technology & Tools in Design