Finite Element Modeling

and Analysis with

ANSYS

Subhash G., M.Tech.

Mechanical Engineering

Bangalore
July 09, 2022
Presentation overview
 Finite Element Modeling  ANSYS Application
 Geometry Clean Up  Objective
 Elements  Finite element modeling
 Meshing  Initial analysis
 Materials  Discussion
 Boundary conditions and
loads
 Solution process
 Analyzing results
Pre-requisites (Optional)
 Review of Basic Statics and Mechanics of Materials
 Static equilibrium conditions/free-body diagram
 Stress, strain and deformation
 Constitutive law – Hooke’s law
 Analysis of axially loaded bar, truss, beam and frame
 2-D elasticity

 Review of Matrix Algebra

 Matrix operation: addition, subtraction, multiplication
 Basic definitions and properties of matrix
 Inverse of matrix and solution of linear equations
 Etc..
Finite Element Modeling (FEM)
 What is finite element modeling?
 It involves taking a continuous structure and “cutting” it into
several smaller elements and describing each of these small
elements by simple algebraic equations. These equations are
then assembled for the structure and the field quantity
(displacement) is solved.

 In which fields can it be used?

 Stresses
 Heat transfer
 Fluid flow
 Electromagnetics
FEM: Applications
 Determine the displacement at the material interfaces
 Structural & Stress Analysis
 Thermal Analysis
 Dynamic Analysis
 Acoustic Analysis
 Electro-Magnetic Analysis
 Manufacturing Processes
 Fluid Dynamics
 Financial Analysis
FEM: Applications
Aerospace Engineering (AE)
FEM: Applications Civil Engineering (CE)
 FEM: Applications
Biomedical Engineering (BE)
Electrical Engineering (EE)

The Future – Virtual Engineering

FEM: The process
 Determine the displacement Co St
at the material interfaces
 Simplify by modeling the
F2 = 20kN F3 = 30kN
material as springs.
n1 n2 n3

k1 k2

F2 = 20kN F3 = 30kN
 FEM: The process n1 n2 n3
 Draw a FBD for each node, sum
the forces, and equate to zero k1 k2
ΣF = 0:
F2 = 20kN F3 = 30kN
n3 -k2(x3-x2)+F3 = 0
Spring force2 F3 k2*x2-k2*x3+F3 = 0
= k2(x3-x2)
-k2*x2+k2*x3 = F3

F2
n2
ΣF = 0:
Spring force1 Spring force2
= k1(x2-x1) = k2(x3-x2) -k1(x2-x1)+k2(x3-x2)+F2 = 0
-k1*x1+(k1+k2)*x2-k2*x3 = F2

ΣF = 0:
n1
R+k1(x2-x1)= 0
R Spring force1
= k1(x2-x1) k1*x1-k1*x2 = R
FEM: The process n1 n2 n3

k1 k2
 Re-write equations in
matrix form F2 = 20kN F3 = 30kN
k1*x1-k1*x2 = R (node 1)
-k1*x1+(k1+k2)*x2-k2*x3 = F2 (node 2)
-k2*x2+k2*x3 = F3 (node 3)

 k1 k1 0   x1   R 
 k1 k1  k2 k2    x2   F2 
    
 0 k2 k2   x3   F3 

Stiffness matrix [K] Displacement vector {δ} Load vector {F}

 FEM: The process n1 n2 n3

k1 k2
 Apply boundary
conditions and solve F2 = 20kN F3 = 30kN

 At left boundary  Plug in values and

 Zero displacement solve k1=40 MN/m
(x1=0) k2 = 60 MN/m
1
 Simplify matrix  x2   40  60 60   20 
equation  x3      
 x1   60 60   30 
 k1  k2 k2   x2   F2   x2  1.25
    x3     x3   
 k2 k2   x1   F3   x1  1.75 
FEM: The process
 The continuous model was cut into 2 smaller
elements
 An algebraic stiffness equation was developed
at each node
 The algebraic equations were assembled and
solved
 This process can be applied for complicated
system with the help of a finite element software
FEM: Element types
 Each of the elements have an
associated stiffness matrix
 1-dimensional  Different degrees of freedom
 Rod elements
(DOF) in each of the elements
 Beam elements
 Spring developed has 1 DOF
 Beam has 6 DOF
 2-dimensional
 Shell elements
 Linear, quadratic, and cubic
approximations for the
 3-dimensional displacement fields.
 Tetrahedral elements
 Hexahedral elements
 Special Elements
 Springs
 Dampers
 Contact elements
 Rigid elements
FEM: Materials
 Properties
 Modulus of elasticity (E)
 Poisson’s ratio ()
 Shear modulus (G)
 Density
 Damping
 Thermal expansion (α)
 Thermal conductivity
 Latent heat
 Specific heat
 Electrical conductivity
 Isotropic, orthotropic,
anisotropic
 Homogeneous, composite
 Elastic, plastic, viscoelastic
Strain (%)
 n1 n2 n3

FEM: Boundary Conditions k1 k2

(constraints and loads) F2 = 20kN F3 = 30kN

 Boundary conditions are used to mimic the surrounding

environment (what is not included in your model)
 Simple example: Cantilever beam
 Beam is bolted to a wall and displacements and rotations are hindered.
 More complex example: Tire of a car
 Is the bottom of the tire fixed to the ground?
 Is there friction involved?
 How is the force transferred into the tire?
 Are the transfer characteristics of the bearings considered?
 Are breaking loads considered?
 Interface between components?
 Garbage in – garbage out…
…but not in FEM
 Garbage in – beautiful, colorful, and believable…
…garbage out
FEM: Solution process
 Today’s computer speeds have made FEM computationally affordable. What
before may have required a couple of days to solve may now take only an hour.
 Inverse of the stiffness matrix

 k1 k1 0   x1   R 
 k1 k1  k2 k2    x2   F2 
    
 0 k2 k2   x3   F3 
 K*δ = F  δ = K-1*F
 Displacements  strains  stress
FEM: Analyzing results
 Interpreting results
 Consider the results wrong until you have convinced
your self differently.
 Sanity checks
 Does the shape of the deformation make sense? Pedestal
 Check boundary condition configurations assembly
 Are the deformation magnitudes reasonable?
 Check load magnitudes and unit consistency
 Is the quality of the stress fringes OK?
 Smoothness of unaveraged and noncontinuous results
 Review mesh density and quality of elements
 Are the results converging? Is a finer mesh needed?
 Verification of results
 Local unexpected results may be OK
 FBD, simplified analysis, relate to similar studies.
 Check reaction forces and moments
FEM: summary
 Use of FEM
 Predict failure
 Optimize design
 The process
 Elements and meshing
 Materials
 Boundary conditions and loads
 Solution process
 Analyzing results
ANSYS EXAMPLE:
 WORKSHOP
Summary
 Garbage in – garbage out!
 Even though you obtain pretty pictures.
 Anyone can run a FE analysis…
 Pay close attention to boundary conditions, degrees
of freedom, mesh quality and validity of results
 Applications
 Failure analysis, optimization, heat transfer, fluid flow,
electromagnetic analysis
 Inter-disciplinary problems.
 Last Comment

“ Finite Element Analysis makes a good engineer great”

and a bad engineer dangerous !”

Robert D. Cook,
Professor of Mechanical Engineering at University of Wisconsin, Madison

THANKS