Practical Introduction to Finite Element Analysis (FEA)

Ensure your organization is getting maximum benefit from using FEA.

FEA is a powerful technique, able to produce solutions to challenging structural analysis problems. The technology and computational efficiency of the method, together with the rapid increases in computer processing power means that today the scope and size of simulations far exceeds the capabilities of even a few years ago.

However for those engineers embarking on FEA, or companies adopting the technique to improve designs or achieve certification of new products, there is a steep learning curve to overcome.

There are a bewildering array of element types, solution types, meshing methods and pre-post processing options that have to be faced. This is before we get down to the engineering physics behind the problem, with associated classic traps and errors. What is needed is guidance via a thorough but practical assessment of the method and how to use it in the real world.

Students are shown the background to the FEA methodology, via simple real examples with a minimum of theory. The strength and weaknesses of the various FEA techniques are shown and discussed. Practical considerations of loadings, boundary conditions and structural details are shown by numerous examples.

The assessment, validation and interpretation of FEA results are vital for delivering safe, effective products. A process is shown which provides confidence in the results and aims to provide conservative, reliable and qualified results. The attendees join in the activity of building this process themselves and come away with an embryo Procedural Check List

The course offers excellent guidance on how to assess and plan the task of carrying out a structural analysis using FEA. A clear understanding of the objectives of each analysis is vital and a road map for achieving this is presented. A review of the tradeoff between available resource and analysis methodology is given.

Course Program

Background to FEA

• Origins of FEA, leading to today’s process
• Emphasis on limitations of a displacement solution
• The route from CAD to Mesh to Solver to Results
• A simple case study – a plate with a hole
• The Analysis Input file
• Simple Element stiffness matrices
• Grid Points , Degrees Of Freedom (DOFs)

Overview of Element Types

• 1d elements
• 2d elements
• 3d elements
• Solid 3D elements: Hex versus Tets, the trade off
• Types of meshing and meshing issues
• I-beam example spanning element types

Making healthy models

• Mis-matched DOF’S and other issues
• Element distortions – effect on accuracy
• Convergence checking
• Solver and Preprocessor checking
• Post processor checking and the dangers of smoothing
• Stress concentrations and stress singularities
• Window cutout example
• Building an Analysis Process ‘Cheat Sheet’ Part 1

Constraints

• Constraint methods
• Real world boundary conditions
• Poisons effect
• Minimum support 321 method
• Case Study – bracket analysis
• Linear Contact methods – new technology to supplement constraints

Loading Types

• Distributed load, Point Loading
• Real world loading versus FEA
• Bearing load methods
• Nonlinear implications
• Centrifugal and Inertial Loading
• Unit load cases for better understanding
• Case Study – tanker body under cornering and accident loading

Multi Point Constraints (MPCs)

• What are they and why use them?
• Different terminologies and usage
• Soft and rigid load and constraint distribution

Making Life simpler

• Symmetry
• Anti-symmetry and Axi-symmetry
• Sector Symmetry
• Plane Stress
• Plane strain
• Comparing 1d, 2d, 3d modeling case study of a pressure vessel

Understanding the objective of the analysis

• Clear view of scope of problem – how do we tackle it
• Resource and timescale factors
• FEA Analysis objectives – reservoir case study
• Class exercise develop an analysis strategy

Looking at CAD geometry

• Why not use 20 million elements
• Trade offs
• De-featuring
• The reality of CAD models
• Manual methods of meshing
• Building an Analysis Process ‘Cheat Sheet’ Part 2

Engineering Assessment

• Anticipate the load paths
• Free body Diagrams
• Force Balance
• Review of Stress and Load fundamentals
• Revisiting the I-Beam, comparing theory with FEA

Checking the answers

• Ways of checking the results
• What type of stress do I use?
• Review of fundamentals
• Post Processing and More Checking
• Other Checks
• Class Exercise – review an FE report

Other Topics

• Buckling
• Introduction to Non-linear Analysis
• Introduction to Dynamics and Normal Modes Analysis
• Introduction to Composite Analysis

Conclusions

• Review of the Class exercise – developed Analysis Process ‘Cheat Sheet’
• Debrief

All NAFEMS training courses are entirely code independent, meaning they are suitable for users of any software package.

Courses are available to both members and non-members of NAFEMS, although member organisations will enjoy a significant discount on all fees.

NAFEMS course tutors enjoy a world-class reputation in the engineering analysis community, and with decades of experience between them, will deliver tangible benefits to you, your analysis team, and your wider organisation.

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PSE Competencies addressed by this training course

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