Finite Element analysis

INTRODUCTION
Instructor:
Raja Farooq
MAIN REFERENCE
Finite Element Analysis: theory and application
with ANSYS, by Saeed Moaveni
Pearson Education (2008)
Department of Mechanical Engineering, FE&T, Bahauddin Zakariya University
 Finite Element analysis
 Objectives:
 Engineering Problems
 Numerical Methods
 A Brief History of the Finite Element Method and ANSYS
 Basic Steps in the Finite Element Method
 Direct Formulation
 Minimum Total Potential Energy Formulation
 Weighted Residual Formulations
 Verification of Results
 Understanding the Problem

Department of Mechanical Engineering, FE&T, Bahauddin Zakariya University

 Finite Element analysis
 The finite element method is a numerical procedure that can be used to
obtain solutions to a large class of engineering problems involving stress
analysis, heat transfer, electro-magnetism, and fluid flow.
 Finite Element Formulation includes:
 Direct Formulation
 The Minimum Potential Energy Theorem
 The Weighted Residual Methods

Department of Mechanical Engineering, FE&T, Bahauddin Zakariya University

 ENGINEERING PROBLEMS
 Engineering problems are mathematical models of physical situations.
 Mathematical models of many engineering problems are differential
equations with a set of corresponding boundary and/or initial conditions.
 The differential equations are derived by applying the fundamental laws
and principles of nature to a system or a con­trol volume.
 These governing equations represent balance of mass, force, or energy.
 When possible, the exact solution of these equations renders detailed
behavior of a system under a given set of conditions, as shown by some
examples in Table 1.1.

Department of Mechanical Engineering, FE&T, Bahauddin Zakariya University

 ENGINEERING PROBLEMS

Department of Mechanical Engineering, FE&T, Bahauddin Zakariya University

 ENGINEERING PROBLEMS
Table 1.1: Examples of governing differential equations, boundary conditions,
initial conditions, and exact solutions for some engineering problems.
Governing Equation,
Boundary Boundary Conditions, Solution
Problem Type
Conditions, or Initial or Initial Conditions
Conditions
A Beam Boundary Conditions: Deflection of the beam Y as the
at and function of distance X:
at
An Elastic
Initial Conditions: The position of the mass y as the
System Beam
At time and function of time:
Where,
at time

A fin Boundary Conditions: Temperature distribution along

at and the fin as the function of X:
at
Department of Mechanical Engineering, FE&T, Bahauddin Zakariya University
 ENGINEERING PROBLEMS
 The analytical solutions are composed of two parts:
 A homogenous part
 A par­ticular part
 In any given engineering problem, there are two sets of design
parameters that influence the way in which a system behaves.
 First, there are those parameters that provide information regarding
the natural behavior of a given system. These parameters include
material and geometric properties such as modulus of elasticity,
thermal conductivity, viscosity, and area, second moment of area.
 Table 1.2 summarizes the physical properties that define the natural
characteristics of various problems.

Department of Mechanical Engineering, FE&T, Bahauddin Zakariya University

 ENGINEERING PROBLEMS
Table 1.2: Physical properties characterizing various engineering systems.
Problem Type and Examples of Parameters That Characterize a System
Solid Mechanics Examples

Truss: Modulus of Beam: Modulus of

elasticity, E; cross- elasticity, E; second
sectional area, A. moment of area, I .

Shaft: Modulus of
Elastic Plate:
rigidity, G; polar
Modulus of
moment of inertia of
elasticity. E
the area, J.

Department of Mechanical Engineering, FE&T, Bahauddin Zakariya University

 ENGINEERING PROBLEMS
Table 1.2 continued: Physical properties characterizing various engineering systems.
Problem Type and Examples of Parameters That Characterize a System
Heat Transfer Examples

Wall: Thermal conductivity, K;

thickness, L; Area, A.

Fins: Thermal conductivity, K;

Cross-Sectional Area, A.

Department of Mechanical Engineering, FE&T, Bahauddin Zakariya University

 ENGINEERING PROBLEMS
Table 1.2 continued: Physical properties characterizing various engineering systems.
Problem Type and Examples of Parameters That Characterize a System
Fluid flow Examples

Pipe Networks: viscosity,μ: pipe

roughness, e; pipe diameter, D.

Concrete Dam: soil

permeability, k.

Department of Mechanical Engineering, FE&T, Bahauddin Zakariya University

 ENGINEERING PROBLEMS
Table 1.2 continued: Physical properties characterizing various engineering systems.
Problem Type and Examples of Parameters That Characterize a System
Electrical and Magnetism Problems

Electrical Networks:
Resistance, R

Magnetic field
of an electric motor:
Permeability, μ.

Department of Mechanical Engineering, FE&T, Bahauddin Zakariya University

 ENGINEERING PROBLEMS
 On the other hand, there are parameters that produce disturbances in a
system.
Table 1.3: Parameters causing disturbances in various engineering systems.
Examples of Parameters that Produce Disturbances
Problem Type
in a System
Solid Mechanics External forces and Moments; Support Excitation
Heat Transfer Temperature difference; Heat Input
Fluid Flow and Pipe
Pressure difference; Rate of flow
Networks
Electrical Network Voltage Difference

Department of Mechanical Engineering, FE&T, Bahauddin Zakariya University

 ENGINEERING PROBLEMS
 The system characteristics as shown in Table 1.2 dictate the natural
behavior of a system, and they always appear in the homogenous part of
the solution of a governing differential equation.
 In contrast, the parameters that cause the disturbances appear in the
particular solution. It is important to understand the role of these
parameters in finite element modeling in terms of their respective
appearances in stiffness or con­ductance matrices and load or forcing
matrices. The system characteristics will always show up in the stiffness
matrix, conductance matrix, or resistance matrix, whereas the
disturbance parameters will always appear in the load matrix.

Department of Mechanical Engineering, FE&T, Bahauddin Zakariya University

 Numerical Methods
 There are many practical engineering problems for which we cannot
obtain exact solu­tions. This inability to obtain an exact solution may be
attributed to either the complex nature of governing differential
equations or the difficulties that arise from dealing with the boundary
and initial conditions. To deal with such problems, we resort to
numerical approximations. In contrast to analytical solutions, which
show the exact behavior of a sys­tem at any point within the system,
numerical solutions approximate exact solutions only at discrete points,
called nodes. The first step of any numerical procedure is discretization.
This process divides the medium of interest into a number of small
subregions (elements) and nodes.

Department of Mechanical Engineering, FE&T, Bahauddin Zakariya University

 Numerical Methods
 There are two common classes of numerical methods:
 Finite difference methods
 Finite element methods
 With finite difference methods, the differential equations written for
each node, and the derivatives are replaced by difference equations.
 This approach results in a set of simultaneous linear equations. Although
finite difference methods are easy to understand and employ in simple
problems, they become difficult to apply to problems with complex
geometries or complex boundary conditions. This situation is also true
for problems with non-isotropic material properties.

Department of Mechanical Engineering, FE&T, Bahauddin Zakariya University

 Numerical Methods
 In contrast, the finite element method uses integral formulations rather
than dif­ference equations to create a system of algebraic equations.
Moreover, a continuous function is assumed to represent the
approximate solution for each element. The com­plete solution is then
generated by connecting or assembling the individual solutions,
Allowing for continuity at the inter-elemental boundaries.

Department of Mechanical Engineering, FE&T, Bahauddin Zakariya University

 Brief History, FEA and Ansys
 The finite element method is a numerical procedure that can be applied
to obtain so­lutions to a variety of problems in engineering. Steady,
transient, linear, or nonlinear problems in stress analysis, heat transfer,
fluid flow, and electromagnetism problems may be analyzed with finite
element methods. The origin of the modern finite element method may
be traced back to the early 1900s when some investigators
approximated and modeled elastic continua using discrete equivalent
elastic bars. However, Courant (1943) has been credited with being the
first person to develop the finite element method. In a paper published
in the early 1940s, Courant used piecewise polynomial interpolation
over triangular subregions to investigate torsion problems.

Department of Mechanical Engineering, FE&T, Bahauddin Zakariya University

 Brief History, FEA and Ansys
 The next significant step in the utilization of finite element methods was
taken by Boeing in the 1950s when Boeing, followed by others, used
triangular stress elements to model airplane wings. Yet, it was not until
1960 that Clough made the term finite el­ement popular. During the
1960s, investigators began to apply the finite element method to other
areas of engineering, such as heat transfer and seepage flow problems.
Zienkiewicz and Cheung (1967) wrote the first book entirely devoted to
the finite ele­ment method in 1967. In 1971, ANSYS was released for the
first time.

Department of Mechanical Engineering, FE&T, Bahauddin Zakariya University

 Brief History, FEA and Ansys
 ANSYS is a comprehensive general-purpose finite element computer
program that contains more than 100,000 lines of code. ANSYS is
capable of performing static, dynamic, heat transfer, fluid flow, and
electromagnetism analyses. ANSYS has been a leading FEA program for
well over 30 years. The current version of ANSYS has a com­pletely new
look, with multiple windows incorporating a graphical user interface (G
VI), pull-down menus, dialog boxes, and a tool bar. Today, you will find
ANSYS in use in many engineering fields , including aerospace,
automotive, electronics, and nuclear. In order to use ANSYS or any other
"canned" FEA computer program intelligently, it is imperative that one
first fully understands the underlying basic concepts and limitations of
the finite element methods.
Department of Mechanical Engineering, FE&T, Bahauddin Zakariya University
 Brief History, FEA and Ansys
 ANSYS is a very powerful and impressive engineering tool that may be
used to solve a variety of problems (see Table 1.4). However; a user
without a basic under­ standing of the finite element methods will find
himself or herself in the same predica­ment as a computer technician
with access to many impressive instruments and tools, but who cannot
fix a computer because he or she does not understand the inner
workings of a computer!

Department of Mechanical Engineering, FE&T, Bahauddin Zakariya University

 ENGINEERING PROBLEMS
Table 1.4: Examples of the capabilities of ANSYS

A V6 engine used in front-wheel-drive

automobiles was analyzed using ANSYS heat
transfer capabilities. The analyses were conducted
by Analysis & Design Appl. Co. Ltd. (ADAPCO) on
behalf of a major U.S. automobile manufacturer to
improve product performance. Controllers of
thermal stress in the engine block are shown in the
figure above.

Department of Mechanical Engineering, FE&T, Bahauddin Zakariya University

 ENGINEERING PROBLEMS
Table 1.4: Examples of the capabilities of ANSYS

Large deflection Capabilities of ANSYS were utilized by

engineers at Today's Kids, a toy manufacturer, to confirm
failure locations on the company's play slide, shown in
the figure above, when the slide is subjected to overload.
This nonlinear analysis capability is required to detect
these stresses because of the product's structural
behavior.

Department of Mechanical Engineering, FE&T, Bahauddin Zakariya University

 ENGINEERING PROBLEMS
Table 1.4: Examples of the capabilities of ANSYS

Electromagnetic capabilities of ANSYS, which

include the use of both vector and scalar potentials
interfaced through a specialized element, as well as
a three­ dimensional graphics representation of far-
field decay through infinite boundary elements, are
depicted in this analysis of a bath plate, shown in
the figure above. Iso-contours are used to depict
the intensity of the H-field.

Department of Mechanical Engineering, FE&T, Bahauddin Zakariya University

 ENGINEERING PROBLEMS
Table 1.4: Examples of the capabilities of ANSYS

Structural Analysis Engineering Corporation used ANSYS

to determine the natural frequency of a rotor in a disk-
brake assembly. In this analysis, 50 modes of vibration,
which are considered to contribute to brake squeal, were
found to exist in the light-truck brake rotor.

Department of Mechanical Engineering, FE&T, Bahauddin Zakariya University

 BASIC STEPS IN THE FINITE ELEMENT
 METHOD
The basic steps involved in any finite element analysis consist of the
following:
 Preprocessing Phase
 Create and discretize the solution domain into finite elements; that is,
subdivide the problem into nodes and elements.
 Assume a shape function to represent the physical behavior of an
element; that is, a continuous function is assumed to represent the
approximate behavior (solution) of an element.
 Develop equations for an element.
 Assemble the elements to present the entire problem. Construct the
global stiffness matrix.
 Apply boundary conditions, initial conditions, and loading.
Department of Mechanical Engineering, FE&T, Bahauddin Zakariya University
 BASIC STEPS IN THE FINITE ELEMENT
 Solution Phase METHOD
 Solve a set of linear or nonlinear algebraic equations simultaneously
to obtain nodal results, such as displacement values at different
nodes or temperature values at different nodes in a heat transfer
problem.
 Postprocessing Phase
 Obtain other important information. At this point, you may be
interested in values of principal stresses, heat fluxes, and so on.

Department of Mechanical Engineering, FE&T, Bahauddin Zakariya University

 BASIC STEPS IN THE FINITE ELEMENT
 METHOD
In general, there are several approaches to formulating finite element
prob­lems:
 Direct formulation,
 The minimum Total potential energy formulation, and
 Weighted residual formulation.
 Again, it is important to note that the basic steps involved in any finite
element analysis, regardless of how we generate the finite ele­ment
model, will be the same as those listed above.

Department of Mechanical Engineering, FE&T, Bahauddin Zakariya University

 Direct formulation
 Example 1.1:
 Consider a bar with a variable cross section
supporting a load P, as shown in Figure 1.1. The bar
is fixed at one end and carries the load P at the other
end. Let us designate the width of the bar at the top
by w1 at the bottom by w2, its thickness by t, and its
length by L. The bar's modulus of elasticity will be
denoted by E. We are interested in ap­proximating
how much the bar will deflect at various points
along its length when it is subjected to the load P.
We will neglect the weight of the bar in the
following analysis, assuming that the applied load is
considerably larger than the weight of the bar.

Department of Mechanical Engineering, FE&T, Bahauddin Zakariya University

 Direct formulation
 Example 1.1:
 Preprocessing Phase
 Discretize the solution domain into finite elements.

Department of Mechanical Engineering, FE&T, Bahauddin Zakariya University

 Direct formulation
 Example 1.1:
 In order to obtain numerical values of the nodal
displacements, let us assume that E = 10.4 * 10 6
(aluminum), w1 = 2 in, w2 = 1 in, t = 0.125 in, L = 10
in, and P = 1000 lb.

Department of Mechanical Engineering, FE&T, Bahauddin Zakariya University

 Direct formulation
 Example 1.1:
TABLE 1.5: Properties of the elements in Example 1.1

Average Cross- Length Modulus of Elasticity Element’s Stiffness

Elements Nodes
Sectional Area (in) (lb/in2) Coefficient (lb/in)

1 1 2 0.234375 2.5 10.4 X 106 975 X 103

2 2 3 0.203125 2.5 10.4 X 106 845 X 103

3 3 4 0.171875 2.5 10.4 X 106 715 X 103

4 4 5 0.140625 2.5 10.4 X 106 585 X 103

Department of Mechanical Engineering, FE&T, Bahauddin Zakariya University

 Direct formulation
 Example 1.1:
Node Displacement

u1 0

u2 0.001026

u3 0.002210

u4 0.003608

u5 0.005317

Department of Mechanical Engineering, FE&T, Bahauddin Zakariya University

 Direct formulation
 Example 1.2:
 A typical exterior frame wall (made up of2 X 4
studs) of a house contains the materi­als shown in
the table below. Let us assume an inside room
temperature of 70°F and an outside air temperature
of 20°F, with an exposed area of 150 ft 2. We are
interested in determining the temperature
distribution through the wall.

Department of Mechanical Engineering, FE&T, Bahauddin Zakariya University

 Direct formulation
 Example 1.2:

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 Direct formulation
 Example 1.3:
 Let us consider a shaft that is made of two parts, as shown in Figure. Part AB is
made of material with a shear modulus of elasticity of G AB = 3.9 * 106 lb/in2 and
has a diameter of 1.5 in. Segment BC is made of slightly different material with a
shear mod­ulus of elasticity of GBC = 4.0 * 106 lb/in2 and with a diameter of 1 in.
The shaft is fixed at both ends. A torque of 200 lb· ft is applied at D. Using three
elements, let us deter­mine the angle of twist at D and B, and the torsional
reactions at the boundaries.

Department of Mechanical Engineering, FE&T, Bahauddin Zakariya University

 Direct formulation
 Example 1.4:
 A steel plate is subjected to an axial load, as shown in Figure. Approximate the
deflections and average stresses along the plate. The plate is 1/16 in thick and
has a modulus of elasticity E = 29 * 106 1b/in2.

Department of Mechanical Engineering, FE&T, Bahauddin Zakariya University