MECH7002 Advanced Computer Aided Engineering

Week 1: Introduction
Mr Phan Nguyen and Prof Richard Yang
School of Engineering, Design and Built Environment
 CONTENTS
• Teaching Staff
• Introduction
– Review on Engineering Design Process
– CAE and FEA
– Unit Content and Learning Activities
– Assessments and Due Dates
• Mathematic Foundation of FEA
• Lecture and Tutorial Next Week
• Question Time

2
TEACHING STAFF

3
Subject Coordinator
• Prof Richard Yang
– Email: [email protected]
• Consultation Arrangement
– Every Tuesday from 12:00-1:00pm via ZOOM: https://uws.zoom.us/j/6820385252 or by appointment via
email.
Lecturer
• Mr Phan Nguyen
– Email: [email protected]
• Consultation Arrangement
– By appointment via email
Tutor and Lab Demonstrator
• Mr Dong An
– Email: [email protected]
• Consultation Arrangement
– By appointment via email

4
INTRODUCTION

5
REVIEW ON ENGINEERING DESIGN
PROCESS

6
Engineering Design Process

8
 Product Design and Development
• Design Concerns

9
 Evaluation Criteria
• Safety
• Performance
• Cost
• Ease of manufacture
• Ease of service or replacement of components
• Ease of operation https://www.alfaromeo.com.au/alfa-4c-spider.html

• Low noise and vibration; smooth operation

• Small size and low weight
• Use of readily available materials and purchased components
• Prudent use of both uniquely designed parts and commercially available
components
• Appearance that is attractive and appropriate to the application

10
CAE and Mechanical Engineering

11
CAE and FEA

12
• Computer-aided Engineering (CAE)
– Computer software in engineering
– Analyse the robustness and performance of components and assemblies
– Encompass simulation, validation and optimization of products and manufacturing tools
– Structural application of CAE takes the form of finite element analysis (FEA)

• FEA (Finite Element Analysis) = or  FEM (Finite Element Method)

– FEM – a mathematic way to obtain approximate numerical solutions of differential equations governing diverse
physical phenomena (Source: Finite Elements and Approximation by O. C. Zienkiewicz, K. Morgan, 2013)
– FEA - a computerised method for predicting how a product reacts to real-world forces, vibration, heat, fluid
flow, and other physical effects. (Source: www.autodesk.com/solutions/finite-element-analysis)

• Commercial FEA software as key tool of CAE

13
• The Future of Simulation-Driven Product Design and Development – ‘Desktop
Engineering’
– Computers increasingly take charge of product design and development and manufacturing processes.
– The ability to predict the product behaviour in the early design phase makes simulation an intuitive tool for
engineers during the development process.
– As product designs become more complex, the need for high-performance computing (HPC) becomes
essential.
– Simulation is an integral part of today’s product lifecycle management (PLM) systems, allowing collaboration
among analysts, engineers and designers, and fostering productivity by providing the right information to the
right user.
– Knowledge-based Engineering (KBE) plays a role in monitoring organisational performance. KBE and
systems engineering are expected to become more simulation-focused in the near future.

Source: http://www.deskeng.com/de/future-simulation-driven-product-
development
14
• Popular Applications of CAE across Automotive Design and Engineering Discipline:
– Applying suitable boundary conditions and loading cases to car body parts and identification of regions that need
a design modification.
– Conducting vibration analysis for auto parts like a purge chamber and suggesting design changes to reduce the
excessive stress concentration caused due to vibration if applicable.
– Aerodynamic analysis of a car design for higher fuel efficiency and better performance
– Auto part performance optimization using different computational methods and tools
– Reverse engineering automobile parts for identifying accurate dimensions and design, required for manufacturing
– Designing ergonomic interiors in an automobile for increased passenger comfort
– Analysing vehicle design for measuring carbon emissions, and suggesting design iterations to reduce the same.

15
• Practical Applications of Computer Aided Engineering (CAE)

– Reducing Aircraft Weight with Advanced Composite Materials

16
17
• Redefining Automotive Product Design
– Computer Expedited Design Process – Developing Well Engineered Automobiles
– Designing a Dream Vehicle for Every Consumer
– Reverse Engineering Using CAD/CAE – An Emerging Trend
– The Changing the Face of Automotive Engineering

18
– Design Elements that Contribute to the Aerodynamics of a Car Body

19
Role of FEA in Solving Engineering Problems

Physical problem

Mathematic model

Analytical Numerical
method method

Solution

20
• An example—uniaxial tensile test

F F

Analytical Analytical
method? method?
Yes. No.

F F
https://forcetechnology.com/en/services/tensile-testing

Physical problem Mathematic models

21
 FEA-driven product design and development procedure
Plan an initial FE
A problem must model
be solved
Pre Process
Anticipate physical
behaviour, Plan Plan a
Is FEA required? Y how FE results will revised
be validated FE model
N Solve

Analytical or
experimental N
solution Are results reasonable? Post Process
Are Error estimates small?
Y Does model revision do little to Software package
alter computer results?
Stop

22
 Intro to FEA Packages

Pre-Processor Solver Post-Processor

Dynaform or LS-Dyna PostGl or LSPREPOST
LSPREPOST
ANSYS/Workbench ANSYS ANSYS/Workbench
Abaqus/CAE Abaqus Abaqus/CAE or Viewer
Hypermesh (HM) Optistruct Hyperview
SolidWorks Simulation SolidWorks Simulation SolidWorks Simulation
Gambit/ANSYS WB ANSYS/Fluent ANSYS/Fluent
Patran/Marc/HM MSc.Marc Patran/ Marc
Patran/Nastran/HM Nastran Patran/Nastran /HM

23
• Intro to FEA Packages—SolidWorks Simulation
– SolidWorks Simulation, the former COSMOSWorks, is a design analysis tool
fully integrated with SolidWorks.
– It uses FEM to simulate the working conditions of designs and predict their
behaviours and performances.
– SolidWorks Simulation makes it possible for designers to quickly check the
integrity of their designs and search for the optimum solution.
– SolidWorks Simulation shortens time to market by saving time and effort in
searching for the optimum.

24
Flowchart of FEA using SolidWorks Simulation

SolidWorks—CAD
Preprocessing
Simulation—FE modelling

Processing/Simulation Simulation—FEA

Postprocessing Simulation—Visualisation

Comment:
• Actually these three steps of finite element analysis are the standard steps using by
engineers.

25
• SolidWorks Simulation

26
• FEA which can be conducted in SolidWorks Simulation
– Static
– Frequency
– Buckling
– Thermal
– Drop Test
– Fatigue
– Nonlinear
– Linear Dynamic
– Pressure Vessel Design

27
• Online resource on SolidWorks Simulation
– http://www.solidworks.com/sw/products/simulation/packages.htm
– Simulation Help Topics

28
• Intro to FEA Packages—ANSYS

ANSYS

COMMERCIAL PRODUCTS ACADEMIC PRODUCTS

ANSYS FLUENT
ANSYS ACADEMIC FLUENT ACADEMIC
COMMERCIAL COMMERCIAL
Significant technology Academic variants
Predominantly Commercial
bundles of ANSYS Inc. Fluent commercial
separate products products such as
products subject to products.
such as ANSYS FLUENT, POLYFLOW
academic terms of Some technology
Mechanical, CFX etc. etc.
use. bundling.

29
• ANSYS for Academics with size limits

Structural & Thermal

Direct Coupled Field

DesignSpace2

AUTODYN3
FLOTRAN
HF Emag
LF Emag

TAS2
CFX
Academic Teaching Advanced 256K 256K 512K 1024K 1024K ∞ 512K ∞
Academic Teaching Introductory 32K 32K 64K 512K 512K ∞ 512K ∞
Academic Teaching CFD 512K

Academic Teaching Mechanical 256K 256K ∞

Academic Teaching AUTODYN 50K

30
• Interface of ANSYS

31
• FEA which can be conducted in ANSYS Workbench

32
• Online Resources for ANSYS
– https://www.ansys.com/products/all-products
– http://ansys.com/academic

33
• Interface of ANSYS Mechanical APDL

34
• Interface between SolidWorks and ANSYS
– SolidWorks

– ANSYS

35
• Comments on FEA and CAE
– FEA is a very powerful tool in CAE, especially in the analysis of deformation
and failure of materials and structures.

– But remember that knowledge, ideas and skills are very important in the
application of FEA.

Knowledge needed:
• Engineering Mathematics, Solid Mechanics, Thermodynamics,
Fluid Mechanics and Finite Element Method
• Ideas and skills: Exercises

36
SUBJECT CONTENT AND LEARNING
ACTIVITIES

37
 Handbook Summary
• This subject describes the basics and fundamentals of computer aided engineering focusing on
the advanced topics of finite element methods, which is a powerful numerical tool for analysing a
wide range of engineering problems.

• The objective of this subject is to advance the students’ understanding on the finite element
method (FEM)-based computer aided engineering (CAE) and its applications in the fields of solid
mechanics, fluid mechanics, thermodynamics and heat transfer as well as product design and
development.

• The students’ research and presentation skills are achieved through conducting FEM-based CAE
projects.

38
 Subject Learning Outcomes (SLOs)
Apply the basic and fundamental principles of finite element method on solving typical engineering
1.
problems with aids from computer modelling and simulation;

Investigate and explain boundary conditions, mesh generation, error control and other practical
2.
considerations in finite element models for conducting finite element analyses for different types of
problems;

Implement finite element method into design process for optimal solution; and
3.
Apply commonly-used finite element programs to solve practical engineering problems in the following
4.
fields:
a) Solid mechanics
b) Fluid mechanics
c) Thermodynamics and heat transfer
d) Optimisation design
e) Product design and development

39
 Subject Content
• Review on fundamentals of finite element method
• 3-D finite element methods (solid, shell and plate elements)
• Boundary conditions, mesh generation, error control and other practical considerations
• Finite element analysis on Elasticity Problems (linear and nonlinear FEA)
• Finite element analysis on Heat Transfer Problems
• Finite element analysis on Fluid Mechanics Problems
• Computer aided engineering and product design and development
• FEA-based design optimisation

40
• Mode of Delivery
– 1 × 2-hour lecture per week (starting at Week 1): Online (Zoom ID: 298 862 4518; Password:
099243), attendance compulsory
– 1 × 1-hour tute per week (starting at Week 1): Face-to-Face, attendance compulsory
– 1 × 2-hour prac per week (starting at Week 1): Face-to-Face, attendance compulsory

• Assessments
Tutorial Assignments (3 tute sets, each 10%) 30%
Lab workbooks (4 sets, each 5%) 20%
CAE Project Report (Oral 5% and Report 30%) 35%
Quizzes (2 sets, 7.5% each) 15%

41
 ACAE Project
• Topic: CAE of a shredder The hopper of mini shredder
• Team forming: 3-4 students in a team
• Team Submission (35%):
• 15-min Oral Presentation & Project Slides (5%)
• Project Report each group (30%)

Mini shredder Mini Shredder with gear box

42
 ACAE Project (Cont’d)
ACAE Project Report should follow the format of a standard technical report (about 20-25 pages in main body)
• Introduction and Design Backgrounds
• Brief Literature Review
• Design Check and Analysis
– Design specification
– System Break-down Flowchart
– Bill of Materials (BOM)
– Computer Aided Design (CAD) Modelling
– Motion Analysis
• Finite Element Modelling and Simulations
– Defeaturing of CAD Model and FEA Selection
– FE Models, Boundary Conditions and Simulations
– Results and Discussion
• Design Innovation
• Summary

43
 CAE Project (Cont’d)
• Design Innovation

Resin Identification Codes

Waste bottle landfill © Corbisimages

Raw resin pellets – Left to right: acrylic, ABS and glass-fibre nylon © Ides.com
44
 Learning Activities
Weeks Lecture Tutorials Practicals Submissions
1 Intro to Computer Aided Engineering 1 1

2 Review on Fundamentals of Finite Element Analysis – I: 1-D FEA 2 2

3 Review on Fundamentals of Finite Element Analysis – II: 2-D FEA 3 3
4 3-D FEA – I: Solid Finite Elements 4 4 Tute Assign 1
5 3-D FEA – II: Plate Finite Elements 5 5 Lab Report 1

6 3-D FEA – III: Shell Finite Elements 6 6 Tute Assign 2

7 Practical Considerations of FEA 7 7 Mid-term Quiz 1; Lab Report 2

8 Intra-session break
9 Linear and nonlinear FEA for Solid Mechanics 8 8
10 FEA on Structural Dynamics and Vibrations 9 9 Lab Report 3
FEA on Heat Transfer
11 10 10 Tute Assign 3
FEA on Fluid Mechanics
12 11 11 Lab Report 4
CAE and Product Design and Development
13 12 12 Final-term Quiz 2

14 Group Oral Presentation of CAE Project 13 13 CAE Report and PPT Slides/Orals

45
• Textbook:
– Cook, R., Malkus, D., Plesha, M. and Witt, R., Concepts and applications of finite element analysis,
2002, John Wiley & Sons, ISBN 0-471-35605-03

• Recommended references:
– Moaveni, S., Finite Element Analysis Theory and Application with ANSYS, Pearson Education, 2007,
ISBN 9780131890800

– Chandrupatla, T. R. and Belegundu, A. D. Introduction to Finite Elements in Engineering, Pearson

Education, 2001, ISBN 0-13-061591-9

46
 CAE and FEA Software
• SolidWorks

47
 CAE and FEA Software (Cont’d)
• ANSYS

48
ASSESSMENTS AND DUE DATES

49
Tutorial Assignments:
• In-class submission during tutorial on Weeks 4, 6, and 11
Lab Workbooks:
• In-class submission during practical session on Weeks 5, 7, 10, and 12.
Quizzes:
• 1-hr closed or open book quiz
• In-class submission during lecture on Weeks 7 and 13.

ACAE Design Project Slides and Report:

• In-class submission during tutorial on Week 14.

50
• Instructions on all the assessments can be found in the Subject Outline on
vUWS site by clicking the link of Subject Information.
• Penalisation on late submission:
• A 10% per calendar day penalty is applied on late submissions.

Remember: to pass the unit you should achieve 50% at least with satisfying a threshold
of 50% in the ACAE Project.
51
• Use of Artificial Intelligence in Assessment Tasks:
• Tutorial Assessments and Lab Reports
• You will not be able to meet the learning outcomes related to [the development of writing skills/text
analysis/insert as appropriate to subject] by using generative artificial intelligence (AI) tools.
• CAE Project
• Use of generative artificial intelligence (AI) tools to brainstorm ideas, summarise reading material or to
edit your submission is permitted. The content of your final submission must be your original work. Be
aware that the output from generative AI tools may be incorrect, incomplete or biased.
• Working with another person or technology in order to gain an unfair advantage in assessment or improperly
obtaining answers from a third party including generative AI to questions in an examination or other form of
assessment may lead to sanctions under the Student Misconduct Rule. Use of generative AI tools may be
detected. More information is available on the Library web page.

52
MATHEMATIC FOUNDATION OF FEA

53
 Matrix
• Linear Algebra or Matrix Mathematics is the basis of finite element method
(FEM).
• What is a matrix?
– A matrix is a rectangular array of scalar quantities.
– The scalar quantities are the elements of the matrix.
– For instance, a matrix [A] composed of m rows and n columns:
jth column

 a11 a12 a1 j a1n 

a a22 a2 j a2 n 
 21 
 
 Amn = 
 ai1 ai 2 aij ain  ith row
  a ij
Order m  n  
 am1 am 2 amj amn  where, i= 1…m, j= 1…n

54
• Special matrices
– Square matrix (m = n)
– Row matrix or vector (m = 1)
– Column matrix or vector (n = 1)
– Diagonal matrix (aij = 0 but aii ≠ 0)
– Unity matrix (aij = 0 but aii =1)
– Symmetric matrix (aij = aji)
– Skew symmetric matrix (aij = - aji)
– Orthogonal matrix (A-1 = AT)

55
 Matrix Operations
– Addition
C mn =  Amn +  B mn  cij = aij + bij
– Multiplication by a scalar

 B mn = k  Amn  bij = kaij

– Multiplication by a matrix
n
C m p =  Amn  B n p  cij =  aik bkj
k =1
Premultiplier Postmultiplier
Conformable

56
• Multiplication of a vector by a matrix
n
cm1 =  Amn bn1  ci =  aik bk
k =1

 c1   a11 a12 a1 j a1n   b1 

c  a a22 a2 j a2 n  b 
 2  21   2
     
cm1 =    Amn =  bn1 =  
 ci   ai1 ai 2 aij ain   bi 
     
     
cn   am1 am 2 amj amn  bn 

57
• Transpose
 a11 a21 a j1 an1 
a a22 a j2 an 2 
 12
 
 B nm =  Amn
T
=   bij = a ji
 a1i a2 i a ji ani 
 
 
 a1m a2 m a jm anm 

( A B) =  B  A
T T T

58
 Example 1
• Example for basic matrix operations
0 5 0   4 6 −2  −1
 
 A = 8 3 7   B = 7 2 3  C =  2 
9 −2 9  1 3 −4  5
 

– Determine or demonstrate

• [A] + [B]; [A] – [B]; 3[A]; [A][B]; [A]{C}; [A]2; [I][A] = [A][I] = [A];

• [A] T; [B] T; ([A] + [B])T= [A]T + [B]T; ([A][B])T= [B]T[A]T

59
 Example 1
Question Solution
0 5 0   4 6 −2 0 + 4 5 + 6 0 − 2  4 11 −2 
Example for basic matrix operations  A + B = 8 3 7  + 7 2 3  = 8 + 7 3 + 2 7 + 3 = 15 5 10 
9 −2 9  1 3 −4  9 + 1 −2 + 3 9 − 4  10 1 5 

0 5 0   4 6 −2  −1
0 5 0   4 6 −2 0 − 4 5 − 6 0 + 2   −4 −1 2 
 A = 8 3 7   B = 7 2 3  C =  2   A − B = 8 3 7  − 7 2 3  = 8 − 7 3 − 2 7 − 3 =  1 1 4 
9 −2 9  1 3 −4  5
  9 −2 9  1 3 −4  9 − 1 −2 − 3 9 + 4   8 −5 13

Determine or demonstrate 0 5 0  0  3 5  3 0  3  0 15 0 
3 A = 3 8 3 7  = 8  3 3  3 7  3 =  24 9 21
[A] + [B]; [A] – [B]; 3[A]; [A][B]; [A]{C}; [A]2; [I][A] = [A][I] 9 −2 9  9  3 −2  3 9  3  27 −6 27 

−2 
= [A]; 0 5 0 4 6
 A B  = 8 3 7 7 2 3

9 −2 9   1 3 −4 
[A] T; [B] T; ([A] + [B])T= [A]T + [B]T; ([A][B])T= [B]T[A]T
0  4 + 5  7 + 0 1 0  6 + 5  2 + 0  3 −0  2 + 5  3 − 0  4 
= 8  4 + 3  7 + 7 1 8  6 + 3  2 + 7  3 −8  2 + 3  3 − 7  4 
 
9  4 − 2  7 + 9  1 9  6 − 2  2 + 9  3 −9  2 − 2  3 − 9  4 
 35 10 15 
=  252 75 −35
 
 31 77 −60
60
• Inversion (only for square matrix)
– Create a square cofactor matrix [C] and define the adjoint matrix as

 A  A =  A A = I 
−1 −1

adj  A
adj  A = C    A
T −1
=
A

( A B) =  B  A
−1 −1 −1

Notice:
• The inverse of [A] exists only and only if det [A] ≠ 0 !!!

61
• Linear algebraic equations:
– A linear system can be described by algebraic equations
 x1 
x 
 2
 k nn  xn1 =  f n1  
 xn1 =  
 xi 
 
 
 xn 
– Direct solving method using matrix inversion

x = k   f 
−1

62
• Vector and Tensor
– A vector is a quantity with a magnitude and a direction
 vx 
   
V = Vx i + V y j + Vz k  
V = Vx i + Vy j + Vz k V = v y 
v 
– Scalar magnitude  z

V = Vx2 + Vy2 + Vz2

– Directional cosines

A vector in a Cartesian coordinate system

63
• Dyadic product of two vectors

S = P Q

• e.g., 2nd - order tensor S

 P1   Q1   PQ1 1 PQ
1 2 1 3
PQ
     
P =  P2  Q = Q2   S =  P2Q1 P2Q2 P2Q3 
P  Q   P3Q1 P3Q3 
 3  3 P3Q2

64
• Tensor

– a linear mapping of a vector onto another vector

– represented by an ordered array of nine components
• In fact:
3

– 0th order tensor—Scalar C 31 =  A33 b31  ci =  aik bk

k =1

– 1st order tensor—Vector (Column matrix) Vector

Tensor
– 2nd order tensor (3 × 3 square matrix)
Vector

65
• Operations of 2nd order tensor

– Same as those for 3×3 order matrix

• Special types of tensors

– Unity tensor

– Symmetric tensor

– Skew tensor

– Orthogonal tensor

66
• The relationship among Matrix, Vector and Tensor

Matrix

3×1 Column Matrix 2nd order Tensor can be

presented by 3×3 matrix

Dyadic product of two vectors

Vector Tensor

Linear mapping of a vector onto another vector

67
• Stress and Strain Tensors
 11 
 
 22 
 33 
    = 11 22  21 
T
σ =  22 12 13
 11 12 13   12 
 13 
σ = 21 22 23   
 21 
 31 32 33   11 
 
 22 
 11 12 13   33 
 =   = 11  22  22 33 12 13 
T

ε =  21  22  23   12 
 13 
 
31 32 33    21 

2nd order Tensor can be Note that we rewrite the stress and strain tensors in
presented by 3×3 matrix column matrix (vector) form only for FE coding.

68
Next Week:
• Lecture & Tutorial:
• Review on Fundamentals of Finite Element Analysis – I: 1-D FEA
• Readings:
• Chapter 2 of Concepts and applications of finite element analysis

69
Questions?

Mr Phan Nguyen
Email: [email protected]

Prof Richard Yang

E-mail: [email protected]
70