Finite Element Analysis in Mechanical Engineering

ME489:
Finite Element Analysis in Mechanical Design

Sec 01
11:00 -11:50 am
Room: 63-022

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Finite Element Analysis in Mechanical Engineering
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25 August 2024
Lecture 1
 Who am I ….

Finite Element Analysis in Mechanical Engineering

ABUL FAZAL M. ARIF, Ph.D., P.Eng., FASME
Professor, Mechanical Engineering
King Fahd University of Petroleum & Minerals
Room 201-2, Building 63, KFUPM Campus | DHAHRAN | Saudi Arabia
Tel: 860-5543 Email: abulfazal.arif@kfupm.edu.sa

EDUCATION
1991Ph.D. Mechanical Engineering, University of Minnesota, Minneapolis, MN, USA.
1988M.S. Mechanical Engineering, University of Minnesota, Minneapolis, MN, USA.
1985B.E. Mechanical Engineering, NED University of Eng. & Tech., Karachi, Pakistan.

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Finite Element Analysis in Mechanical Engineering
https://darajati.kfupm.edu.sa/
Class Attendance

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 Finite Element Analysis in Mechanical Engineering
A FRIENDLY CONVERSATION

■ Help me develop and deliver this course.

■ Develop courses in collaboration with students.
■ Accessibility to me.
■ You are welcome to provide comments and feedback regarding
the course, lectures, tutorial, etc.

ME489 Course Syllabus

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 Finite Element Analysis in Mechanical Engineering
Review Few Concepts

▪ STRUCTURE
▪ DEFORMABLE BODY
▪ DEFORMATION
▪ STRAIN
▪ STRESS
▪ STRUCTURAL ANALYSIS
▪ LOAD

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Finite Element Analysis in Mechanical Engineering
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Thank You
Finite Element Analysis in Mechanical Engineering
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27 August 2024
Lecture 2
 Finite Element Analysis in Mechanical Engineering
Topic 1: Introduction to FEA

1-1 Finite Element Method: Background

1-2 Finite Element Method: Applications
1-3 Finite Element types and Basic Steps
1-4 Sources of Error and Responsibility of Users

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Finite Element Analysis in Mechanical Engineering
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1.1 Finite Element Method:
Background
 Finite Element Analysis in Mechanical Engineering
DESIGN PROCESS

Identify the need and constraints.

Research the problem.

Develop possible solutions.

Select a promising solution.

Build a model (MODELLING)

Test and evaluate (ANALYSIS)

Redesign as needed.

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 Finite Element Analysis in Mechanical Engineering
Experimental Vs Mathematical Model
MODEL
A model may help to explain a system and to study the effects of
different components, and to make predictions about behavior.

MATHEMATICAL EXPERIMENTAL
▪ The governing equations of a mathematical A prototype is an early sample,
model describe how the values of the model, or release of a product built
unknown variables (i.e. the dependent to test a concept or process.
variables) change when one or more of the Expensive and time consuming.
known (i.e. independent) variables change.

▪ Based on solution type

➢ Analytical ➔ exact solution
➢ Numerical ➔ approximate solution Discussion item:
✓ Finite element, Importance of modelling for structural
✓ finite difference, analysis.
Stress ➔ Factor of safety  Strength
✓ boundary element
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 Finite Element Analysis in Mechanical Engineering
■ Complexities in the geometry, properties and in the boundary conditions
that are seen in most real-world problems usually means that an exact
solution cannot be obtained or obtained in a reasonable amount of time.

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 Finite Element Analysis in Mechanical Engineering
Finite Element Method

■ Current product design cycle times imply that engineers must obtain
design solutions in a ‘short’ amount of time.

■ They are content to obtain approximate solutions that can be readily

obtained in a reasonable time frame, and with reasonable effort. The
FEM is one such approximate solution technique.

■ The FEM is a numerical procedure for obtaining

approximate solutions to many of the problems encountered
in engineering analysis.

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 Finite Element Analysis in Mechanical Engineering
…. Finite Element Method

■ Basic concept: building a

complicated object with “Element Si”
simple blocks, or, dividing a 
complicated object into small
and manageable pieces.

■ Examples:
Area of one triangle: Si = 12 R 2 sin  i
● Lego (kids’ play)
N
● Buildings Area of the circle: S N = S
i =1
i = 12 R 2 N sin( 2N ) ⎯→ R 2
⎯
● Approximation of Nthe
S
area of a circleN = 
i =1
S i = 1
2 R 2
N sin( 2
N ) ⎯
⎯→ R 2
as N⎯ ⎯→ 
where N = total number of triangles ( elements)
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 Finite Element

Finite Element Analysis in Mechanical Engineering

Types
▪ Finite Element: Elements of
finite (measurable) size of a
body preserving original
properties.
▪ The finite element method
(FEM) is a numerical method for
solving problems of engineering
and mathematical physics.
▪ Studying or analyzing a
phenomenon with FEM is often
referred to as finite element
analysis (FEA).
▪ FE modelling and simulation.

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 Finite Element Analysis in Mechanical Engineering
Top-Down: Steps in FEM

8 7
discretize interpolate 5 6
object 4 u 3
1 2
nodal mesh
+ + interpolate values between nodes
global model local model

Bottom-Up: Steps in FEM

8 7
5 6
u
4 3
1 2
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Finite Element Analysis in Mechanical Engineering
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Thank You
Finite Element Analysis in Mechanical Engineering
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29 August 2024
Lecture 3
 Finite Element Analysis in Mechanical Engineering
Brief History

■ Basic concepts of FEM have evolved over a period of 150 or more

years.

■ The term finite element (FE) was first coined by Clough in 1960.

■ The first book on the FEM by Zienkiewicz and Chung in 1967.

■ The FEM is one of the most important developments in computational

methods to occur. In just a few decades, the method has evolved from
one with applications in structural engineering to a widely utilized
and richly varied computational approach for many scientific and
technological areas.

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 Finite Element Analysis in Mechanical Engineering
Advantages of the Finite Element Method

■ Physically meaningful to engineers and resemble actual structure.

■ Can readily handle complex problems
● Geometry
● Material behavior (nonhomogeneous, non-isotropic (orthotropic,
plasticity, creep, temperature dependent properties)
● Loading (point loads, pressure, thermal, inertial forces)
● Boundary/Support conditions
■ Complex analysis types (static, dynamic, heat transfer, fluids, vibration)
● special effects: large displacements/rotations/strain, contact.
■ Corrective measures can be taken before any hardware is built → reduce
the number of physical prototypes and experiments and optimize components in
their design phase to develop better products, faster.
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 Finite Element Analysis in Mechanical Engineering
Disadvantages of the Finite Element Method

■ Experience and judgment are needed for finite element model.

■ A specific numerical result is obtained for a specific problem.

■ Numerical problems (computers only carry a finite number of significant digits. → round off
and error accumulation.

■ Susceptible to user-introduced modeling errors → Poor choice of element types, distorted

elements, geometry not adequately modeled.

■ Certain effects not automatically included (Material nonlinearities, Buckling, Large

deflections and rotations)

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Finite Element Analysis in Mechanical Engineering
https://darajati.kfupm.edu.sa/
Class Attendance

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Finite Element Analysis in Mechanical Engineering
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1.2 Applications of FEA
 Finite Element Analysis in Mechanical Engineering
Common Fields of Application

■ . Mechanical Engineering · Aerospace Engineering

■ · Civil Engineering · Automobile Engineering
■ · Electrical Engineering · Chemical Engineering
■ · Geomechanics · Biomechanics

■ · …..

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 Finite Element Analysis in Mechanical Engineering
Applications - Structural problems.

■ Stress analysis, including truss and frame analysis

(such as pedestrian walk bridges, high rise
building frames, and windmill towers), and stress
concentration problems, typically associated with
holes, fillets, or other changes in geometry in a https://www.google.ca/url?sa=i&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwi
IsMyeyqjkAhUI16wKHdnOCFAQMwhRKA8wDw&url=https%3A%2F%2Femafd.com%2F&
psig=AOvVaw3BaLpmmjg5UG14E54AxjBO&ust=1567185276352360&ictx=3&uact=3

body (such as automotive parts, pressures vessels,

medical devices, aircraft, and sports equipment).
■ Buckling, such as in columns, frames, and vessels
■ Vibration analysis, such as in vibratory
equipment
■ Impact problems, including crash analysis of
https://www.google.ca/url?sa=i&source=images&cd=&cad=rja&uact=8&ved=0ahU

vehicles, projectile impact, and bodies falling and KEwiIsMyeyqjkAhUI16wKHdnOCFAQMwhwKCEwIQ&url=https%3A%2F%2Fwww.an

sys.com%2Fproducts%2Fstructures&psig=AOvVaw3BaLpmmjg5UG14E54AxjBO&us
t=1567185276352360&ictx=3&uact=3

impacting objects
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 Finite Element Analysis in Mechanical Engineering
Applications - Non-structural problems

■ Heat transfer, such as in electronic devices emitting heat as in a personal

computer microprocessor chip, engines, and cooling fins in radiators

■ Fluid flow, including seepage through porous media (such as water

seeping through earthen dams), cooling ponds, and in air ventilation
systems as used in sports arenas, etc., air flow around racing cars,
yachting boats, and surfboards, etc.

■ Distribution of electric or magnetic potential, such as in antennas and

transistors

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 Finite Element Analysis in Mechanical Engineering
Multi-Physics Applications

A. Structural
A1 Stress analysis
A2 Buckling
A3 Vibration analysis and others
B. Non-Structural
B1 Heat transfer
B2 Fluid flow
B3 Distribution of electric or magnetic potential
B4 Lubrication and others
Examples of Multi-Physics Applications:
− Thermal analysis: A + B1
− Convective flow: B1 + B2
− Manufacturing Processes: A+B1+B2
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 Finite Element Analysis in Mechanical Engineering
Results from various Types of FEM Analysis

■ Static analysis ■ Heat transfer analysis

● Deflection ● Temperature
● Stresses and Strains ● Heat fluxes
● Forces ● Thermal gradients
● Energies ● Heat flow from convection faces
■ Dynamic analysis ■ Fluid analysis
− Frequencies − Pressures
− Deflection (mode shape) − Gas temperatures
− Stresses and Strains − Convection coefficients
− Forces − Velocities
− Energies
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 Finite Element Analysis in Mechanical Engineering
Example FEM Application Areas

■ Automotive industry ■ Aerospace industry

● Static analyses ● Static analyses

● Modal analyses ● Modal analyses

● Transient dynamics ● Aerodynamics

● Heat transfer ● Transient dynamics

● Mechanisms ● Heat transfer

● Fracture mechanics ● Fracture mechanics

● Metal forming ● Creep and plasticity analyses

● Crashworthiness ● Composite materials

● Aeroelasticity
● Metal forming
● Crashworthiness

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Finite Element Analysis in Mechanical Engineering
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Basic
1.3 Finite Element Types and
Steps
 Finite Element Analysis in Mechanical Engineering
Basic Steps

■ Basic steps involved in any finite element analysis:

PRE-PROCESSING
(Build FE Model)

PROCESSING
(Assemble & Solve)

POST-PROCESSING
(Sort & See Results)

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 Finite Element Analysis in Mechanical Engineering
…. Basic Steps

■ Preprocessing Phase (Build FE model, Loads and constraints)

● Discretize and Select Element Type
● Select a Displacement Function
● Define Strain/Displacement and Stress/Strain Relationships
● Derive Element Stiffness Matrix & Eqs.
● Assemble Equations and Introduce B.C.’s

■ Solution Phase: ( Assemble and solve the system of equations)

● Solve for the Unknown Degrees of Freedom

■ Postprocessing Phase: (sort and display the results. )

● Solve for Element Stresses and Strains
● Interpret the Results
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 Finite Element Analysis in Mechanical Engineering
Line Elements

© 2002 Brooks/Cole Publishing / Thomson Learning

Stress Analysis of 2D Elastic Beam

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Finite Element Analysis in Mechanical Engineering
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Plane (Area) Elements
 7 mm side R = 1.25 cm

Finite Element Analysis in Mechanical Engineering

88 N / cm

1.5 cm

Stress
Analysis 1 cm 3 cm 1 cm
9 mm side

of Bicycle Fixed all around

Wrench Bicycle Wrench

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Finite Element Analysis in Mechanical Engineering
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Solid (Volume) Elements

Crane Cable
 Finite Element Analysis in Mechanical Engineering
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Open-Ended Cylinder With Internal Pressure
Finite Element Analysis in Mechanical Engineering
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Extrusion Die
Finite Element Analysis in Mechanical Engineering
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Lathe Cutter
 Finite Element Analysis in Mechanical Engineering
1.4 Sources of Error and
Responsibility of Users.

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Finite Element Analysis in Mechanical Engineering
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FEA: Modeling, Errors, and Accuracy.
 Finite Element Analysis in Mechanical Engineering
Sources of error
■ Modelling error: We do not analyze the actual physical problem; rather, we
analyze a mathematical model based on the idealization of the problem.
For example, in elementary beam theory we represent a beam by a line (its
axis) and typically ignore deformations associated with transverse shear.
This is an excellent approximation for slender beams but not for very short
beams.
■ Discretization error: The physical structure and the mathematical model
each have infinitely number of d.o.f., while the FE model has a finite
number of d.o.f.
● How many elements are enough? Mesh convergence through a
sequence of solutions.
■ Numerical error: the computer introduces numerical error by rounding or
truncating numbers as it builds matrices and solves equations.
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 Finite Element Analysis in Mechanical Engineering
Responsibility of Users

■ FE computer programs have become widely available, easier to use, and

can display results with attractive graphics. Any model, good or bad, can
produce colorful stress contours.
● Even an inept user can produce some kind of answer.

● Even a poor mesh, inappropriate element types, incorrect loads, or

improper supports may produce results that appear reasonable on
casual inspection.
■ A responsible user must understand the physical nature of the problem and
the behavior of finite elements well enough to prepare a suitable model and
evaluate the quality of the results.
● Competence in using FE for stress analysis does not imply competence
in using FE for (say) magnetic field problems.
● The engineer who uses the software, not the software vendor, takes
responsibility for results produced.
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 Finite Element Analysis in Mechanical Engineering
■ Lateral midpoint displacement versus time for a beam loaded by a pressure
pulse. The material is elastic-perfectly plastic. Plots were generated by
various users and various codes.
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Finite Element Analysis in Mechanical Engineering
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Thank You