This paper on "Is the Honeymoon Finally Over? Observations on the State of Analysis in Product Design…" was presented at the NAFEMS World Congress on The Evolution of Product Simulation From Established Methods to Virtual Testing & Prototyping - 24-28 April 2001, The Grand Hotel, Lake Como, Italy.

Introduction to Paper

What is the purpose of Finite Element Analysis? In my opinion, it is a tool to enable engineering, or those engaged in engineering, to generate data that would be difficult, costly, or impossible to generate by other means. In product development (PD), this data must also provide more insight into performance so that better design decisions can be made in pursuit of better, faster, cheaper, and/or safer. If it doesn't provide that insight, one must question the validity of the technology for that particular application. As analysis is transitioning from the "exception" to the "rule" in many design environments, some study of its role and effectiveness is warranted. Are goals being set and met? Who is performing analysis? What types of problems are they solving? Are they building better, faster, cheaper, and/or safer products? How do they know if simulation has measurably impacted the design process? The answers to these questions are as fluid as the ever-changing analysis software market. Similarly, in different industries, the use and impact of analysis will and must vary. However, in all cases, the variables and questions must lead to improved product design.
It is fair to say that certain aspects of the use of these tools have improved dramatically. Few would argue that more reference material and access to qualified instructors has increased. The usability and speed of both hardware and software have made replacing testing and educated guessing with analysis an easy decision. One aspect that is critical to moving past the exploratory use of FEA and truly making the technology a driving factor in PD is the quality and integrity of the implementation. This paper will present an actual case study in the implementation of analysis in the PD process and then use that study to make some observations on the current state of design analysis. While some general recommendations will be made that can improve the overall quality of analysis usage, the paper will conclude with a set of questions. It is with the answers to these questions, on a case-by-case basis, that product development professionals can begin to blend their tools and talents into a harmonious, synergistic environment instead of a cacophony of powerful, yet unfocused, technologies.