Fundamentals of Finite Element Analysis

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What is Finite Element Analysis?

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The Finite Analysis (FEA)

The Finite Element Analysis (FEA) is a computerized method for predicting how a
real-world object will react to forces, vibration, heat, and etc.

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FEA in the product development design cycle

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Benefits of FEA

● Lower development costs

● Shortened design cycle

● Reduce the number of prototypes needed for physical testing

● A more robust and reliable finished product

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Adoption of FEA software

● Increasing computing capabilities (Cloud-based)

● Easier-to-use software

● Lower costs for software

● 3D Design and modeling

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Steps in the FEA Process

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Step 1: Create geometric model

Model with CAD software

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Step 2: Define the finite element model

Create mesh with FEA software

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Step 3: Define the operating environment

Apply materials, contacts, forces, constraints, etc

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Step 4: Compute the structural response

Visualize stress, deflection, etc.

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Step 5: Review and interpret the results

● Result precision
● Factor of safety for a design
● Distribution of stress
● Maximum stress/strain
● Maximum deflections

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Step 6: Re-design as necessary

Repeat the cycle until satisfied with the design

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How FEA works

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System of Linear Equations

● Partial differential equations describe

nature (continuous)

● In FEA, a continuous domain is

discretized using functions which Partial Differential Equations (PDEs)
give us a very good approximate
solution

● With the advent of computers, very

large linear systems of equations System of Linear
can be solved. Equations (Ax=b)

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Node

A node is a coordinate location in space where the Degrees of Freedom (DOFs) and
physical property (stress, strain, temperature, velocity, etc.) are defined.

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Element
An element is the basic building block of finite element analysis. It defines how
the Degrees of Freedom of one node relate to the next.

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Divide and Conquer!

● In FEA, a continuous domain is

discretized into simple geometric
shapes called elements.

● Nodes appear on the element boundaries

and fasten the elements together

Continuum : infinite number of degrees-of-freedom (DOF)

Discretized model : finite number of DOF

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FEM in 1D, 2D, and 3D
● 1D, 2D, and 3D FEM follow the same general principles

● Different element types

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1-Dimensional Elements

● Connect 2 nodes in a straight line

● The cross-sectional properties are defined

by the finite element properties

● Applicable for analyses where the

members are long, slender and have a
constant cross-section

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2-Dimensional Elements

● Structural element with one small

dimension and 2 larger dimensions

● Rule of thumb: the small dimension

should be at least 1/15 the size of the
larger dimensions

● Flat elements (plates)

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3-Dimensional Elements

● Contain all of the geometric definition in

the element geometry

● Volume elements

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Material Model
● Material properties define how a part or
structure will behave under a load
● Examples:
○ Steel
○ Aluminum
○ Copper
○ Iron
○ ABS
● More information on material properties: www.matweb.com

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Boundary Conditions - Constraints
● Constraints are displacement boundary conditions that restrict the displacement
of certain nodes in the mesh

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Boundary Conditions - Loads

● Loads are pressures or forces applied to the system on nodes, faces, or volumes

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Boundary Conditions - Contacts
● Contacts are used to establish the relationship between nodes in the mesh of parts
that are in contact with each other

Contact between the tire rim and frame

Contact between the tire and ground

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Solving
● The mathematical equations derived from the input criteria of model, materials,
constraints, loads, and contacts is solved with a computer or many computers
running in parallel

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Visualizing the results

● Stress
● Strain
● Displacement

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Are my results correct?

● Experience and engineering judgement are the most important factors for
creating the most accurate analysis.

● Engineering calculations should always be done to make sure they are correct

● Physical testing should be done to verify your model and the results

● Increase the deformation scale 100x, does the deformed shape look as expected?

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Common errors in FEA

● Modeling Error
○ We are not analyzing the physical model, but a simplified mathematical model
● Discretization Error
○ Errors that arise from the creation of the mesh
○ Infinite domain vs. finite domain

● Numerical Error
○ Introduced by the computer when it rounds or truncates numbers as it
assembles matrices and solved equations

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Responsibility of the user

● Smooth and colorful stress contours can be produced by any model, good and bad

● A responsible user must understand the nature of the problem and the inherent
assumptions before setting up the problem and analyzing the results

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Books & resources
● [Book] Introduction to the Finite Element Method – Niels Ottosen & Hans Petersson
● [Book] The Finite Element Method Set (Sixth Edition) – O.C. Zienkiewicz, R.L. Taylor and J.Z. Zhu
● [Book] A First Course in Finite Elements – Jacob Fish, Ted Belytschko
● [Book] Concepts and Applications of Finite Element Analysis – Robert D. Cook and David S. Malkus
● [Book] Finite Element Procedures – K.J. Bathe (MIT)
● [Video Lectures] Finite Element Procedures for Solids and Structures – K.J. Bathe (MIT)
● [PDF] Introduction to Finite Element Methods – University of Colorado at Boulder
● [PDF] Introduction to the Finite Element Method - G. P. Nikishkov

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FEA in SimScale:
Meshing
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3D meshes in SimScale

● SimScale supports tetrahedral volume elements

for FEA
4-node
○ Automatic meshing Tet Element
■ Mesh fineness setting from 1 (very coarse)
- 5 (very fine)
○ Manual meshing
■ User defines maximum and minimum 10-node
element edge lengths Tet Element

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3D meshes in SimScale

Defining element edge lengths for Manual Meshing

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3D meshes in SimScale

1st-Order 2nd-Order

● # of Nodes: 4 ● # of Nodes: 10
● Degrees of Freedom: UX, UY, ● Degrees of Freedom: UX, UY,
UZ UZ

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Creating a mesh
● Use a 1st order coarse mesh as starting point

○ Tetrahedral automatic mesh

○ Verify your simulation setup

○ Fast and easy to generate

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Performing a mesh convergence study
● Do a convergence study to obtain mesh-independent results

○ Create a mesh using the fewest, reasonable number of elements and analyze
the stress at a chosen point*.
○ Recreate the mesh with a denser element distribution, re-analyze it, and
compare the results to those of the previous mesh.
○ Keep increasing the mesh density and re-analyzing the model until the
results converge satisfactorily.

* Be sure to analyze the result field (stress or displacement) at the same point each time

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Performing a mesh convergence study

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Adding Local Refinement

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Adding Local Refinement

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1st- or 2nd-order mesh?
● Choosing a 1st-order mesh or 2nd-order mesh is problem dependent

● For problems involving contact, 1st-order elements perform much better than
2nd-order elements

● For problems involving bending,

2nd-order elements perform much
better than 1st-order elements.

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FEA in SimScale:
Analysis Types
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FEA Analysis Types in SimScale

● Linear Static Analysis

● Nonlinear Static Analysis
● Dynamic Analysis
■ Modal
■ Frequency
■ Harmonic Analysis

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Linear vs. Nonlinear

Linear Nonlinear
● The relationship between force and ● The relationship between force and
displacement is linear displacement is nonlinear
● Material behavior remains in the ● Material yields (plastic zone) or other
elastic zone material non-linearity
● Only valid for small deflections and ● Large deflections
rotations
● Examples: moving parts, non-metallic
materials such as composites or
rubber, impacts loads

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Static vs. Dynamic

Static Dynamic
● Static refers to a model which is ● Dynamic loads are applied as a
loaded slowly, thus inertial forces and function of time or frequency
damping are ignored
● Examples are shock, vibration, and
● Single time step - not a function of seismic loading where the load
time amplitudes vary significantly with
respect to time

● More complicated and more realistic

than static analysis

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Linear Static Analysis

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FEA in SimScale:
Linear Static Analysis
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What is Static Analysis?

● Static analysis is used to determine the displacements, stresses, strains, and

forces in structures or components caused by loads that do not induce
significant inertia and damping effects.

● Steady loading and response conditions are assumed

○ Externally applied forces and pressures
○ Steady-state inertial forces (such as gravity or
rotational velocity)
○ Imposed (non-zero) displacements

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Assumptions of Linear Static Analysis

Linear assumption
● Linear response of the system
● Small displacements, rotations etc.

Elasticity assumption
● Linear material behavior
● Removed loading → part returns to its initial shape

Static assumption
● Load can be applied in a single step

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Constraints on SimScale
Constraint Description

Fixed Support The fixed support boundary condition prescribes the value of zero displacement in all directions
(x,y,z)

Fixed Value Displacement The fixed value boundary condition type prescribes the value of the displacement on a certain
boundary of the domain. It is set in cartesian spatial dimensions. For every degree of freedom
(x,y,z) you may choose if it should be prescribed (fixed on a given value) or unconstrained (free to
move).

Symmetry The symmetry plane boundary condition is used to apply mirror-symmetry conditions on a structure.
The boundary condition can be applied to faces of a structure and no other user input is needed. If
a symmetry plane condition is applied to a face, the displacement of this face is locked in the
normal direction but free to slide in tangential directions.

Elastic Support Elastic support can be used to introduce virtual springs on selected face nodes, thus constraining
the body via springs. The user can manually define specific stiffness for the springs. There are two
spring stiffness criteria offered in SimScale: Isotropic spring stiffness and orthotropic spring stiffness

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Loads on SimScale
Load Description

Pressure With the pressure boundary condition type a distributed load is applied on a face or face set. As the pressure value is defined dependent on a unit surface area (force per
square length unit) the total load applied on the part depends on the total surface area of the faces. The load is directed normal to the assigned elements’ surfaces in the
initial (undeformed) configuration.

Force The force boundary condition applies a distributed force on the structure. It can be applied to faces or edges of a structure. It is applied as surface/line traction on each
element of the assigned topological entity and its value is proportional to each element’s area/length. The user has to define the force components in the global coordinate
system. Each force component can be applied as constant value, function or table. For function or table input the value can depend on time (or frequency respectively) or
spatial coordinates.

Nodal Load With the nodal load boundary condition type a vectorial force is applied on all nodes of a geometrical entity (node, edge or surface). Please take into consideration that in
case of nodal forces on an edge or a surface, the total force is applied equally on every node of the mesh lying on the chosen entity with its full magnitude.

Surface Load The surface load is used to apply a surface traction on faces of a structure. The user defines each traction component in global coordinate system with the unit of force per
area. It is a distributed load and the value for each surface element is proportional to its area. This load is equivalent to a force load if one applies a surface load which equals
the total force divided by the face area.

Volume Load The volume load is used to apply a volumetric force (force per volume) onto a structure. The user defines a volumetric force for each component in global coordinate system
with the unit of force per volume. It is a distributed load and the value for each solid element is proportional to its volume.

Centrifugal Force The Centrifugal force boundary condition is used to apply the forces that act on a structure when it rotates around a fixed axis. The axis itself has to be fixed, but the
rotational speed is allowed to vary with time (or frequency for a harmonic analysis). The user has to specify a volume on which the force acts as well as the rotational speed
(in radians per second) and the axis of rotation.

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Linear Contact on SimScale

Linear Contact Description

Bonded contact The bonded contact is a special type of contact which allows no relative
displacement between two connected solid bodies. This type of contact
constraint is used to glue together different solids of an assembly. The two
surfaces that are in contact are classified as master and slave. Every node
in the slave surface (slave nodes) is tied to a node in the master surface
(master node) by a constraint.

Sliding contact The sliding contact is a special type of contact which allows displacement
tangential to the contact surface but no relative movement along the normal
direction. This type of contact constraint is used to simulate small (linear)
sliding movement in the assembly

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 Available Static Solvers on SimScale
Analysis Type Static Analysis Static Analysis - Advanced
Solver Calculix Code_Aster
Reason to use •Faster Solver •Larger selection of boundary conditions
•Can handle contact between a single body •Larger selection of constraints
•Loads and constraints based on tables or functions
•Nonlinearity, geometric, material, time dependant
•Larger selection of results (solution fields) can be chosen
•Results can be calculated (plotted) based on points, edges, faces
or volumes

Reasons to Avoid •Limited to a fixed boundary condition •Cannot handle contact between a single body
•Loads are limited to nodal loads, pressure, torque (i.e. folded up sheet metal box)
•Hard to give material nonlinearity
•Results are only displacement, stress, strain
•Linear only

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Why Linear Static Analysis

Advantages
● Fast to perform
● Ideal starting point
● Less expertise necessary

Disadvantages
● No nonlinearity is taken into account
● Not fit for many real world problems

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Linear Static Analysis:
Stress analysis of a reclaimer arm
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Stress analysis of a reclaimer arm

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Stress analysis of a reclaimer arm

Material Properties (Mild Steel) fx

● Density = 7870 kg/m3
● Young’s Modulus = 205 GPa fz

● Poisson’s Ratio = 0.28

● Directional dependency =
isotropic
Z

Y
X

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Stress analysis of a reclaimer arm

Boundaries and Loading Conditions fx

● Force Load
○ fx = -3800000 N fz
○ fy = 0N
○ fz = -3800000 N

● Fixed faces at base

○ dx = 0
Z
○ dy = 0
○ dz = 0 Y
X

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Von Mises stress

● The von Mises stress is an equivalent stress derived from the 3 principal stresses.
It is generally used by design engineers to predict yielding of ductile materials.

3 principal stresses

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Von Mises stress

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Displacement

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