Chapter 2 FEM: Digital Engineering

Page 1 | Prof. Dr.Ing. Th.
Binder | Status March 2014

Digital Engineering
Chapter 2 FEM
Page 2 | Prof. Dr.Ing. Th. Binder | Status March 2014
Property describing CA systems:
FE systems (FEM)
Multibody systems (MKS)
Flow simulation (CFD)
Animation and visualisation (VR)
.
The FEM principle

Basic idea of the FE method:
Already in the antiquity, one could determine the circle constant by geometric approximation
of the area of the circle by means of inscribed triangles, finite elements, very accurately.
The FEM principle

Basic idea of the FE method:
Idea: To very accurately determine the behaviour of any body by approximation of regular
bodies (finite elements). In doing so the transition conditions between the elements and
between several bodies are to be defined such that the sum of all finite elements portrays the
overall system. Each body can thereby be approximated "as accurately as desired"
For the solution of the problem, an
appropriate mathematical model will be
selected, which is described by ordinary or
partial differential equations.
The equations can be linear or non-linear, by
means of this, stationary and transient
processes and/or systems are representable.
The FEM principle

FE model:
Real body is idealised in the model:
The FEM principle

FE modelling:
Description of the real body as a
discrete or continuous model
The FEM principle

Element selection:
Picture source: Bathe 2002
line
elements
surface
elements
volume
elements
The FEM principle

Element selection:
Bridge girders
Roof constructions
Frameworks utility poles
Cable way supports
Chassis
Ship hulls
Aerofoils
Turbine blades
Thin-walled housing
Thick-walled housing
Girders
Boilers
Walls
Prostheses (hips)
Tools (drills)
The FEM principle

The rod the simplest finite element
In the following, these prerequisites always apply:
linear material behaviour
small deformation
(equilibrium on undeformed body)
Otherwise the 2nd order theory applies!
"arbitrary body" "arbitrary body as spring"
The FEM principle

Hookes law
Spring constant k
s
This context applies in equal manner to a
fixed rod
The FEM principle

Cross-section A, E-modulus E
Load by means of force or deformation
unambiguous context between force and
deformation:
the linear FEM is nothing but the Hooke's
law!
l
l
E
A
F A
= = o results in:
The FEM principle

Cross-section A,
Elasticity modulus E
u
1
and u
2
are the displacements of the rod ends: It applies that:
Deformation l = u
2
u
1
Equilibrium of forces on the element: F
1
+ F
2
= 0, i.e. F = -F
1
= F
2
from F = kl it follows that:

Element stiffness relationship: in matrix notation:

"Basic FEM equation!"
F: Vector of the nodal forces
K: Element stiffness matrix
u: Vector of the nodal displacements
l l A +
l
2
u
1
u
2 1
u l u l l + = + A +
now the fixation is replaced by a force!
F
1
F
2

1
2
The FEM principle

Length l = 1000 mm
Cross-section A = 100 mm
2
E-modulus E = 200000 MPa
F = 1 kN

Solved with the FE method: Solved with classic mechanics:
l
l
E
A
F A
=
mm
A E
l F
u u l
I II
05 , 0
100 200000
1000 1000
) ( =
= = A
N F F F F
I II I x
1000 0 = + = =
The FEM principle

Length l = 1000 mm
Cross-section A = 100 mm
2
, E-modulus E = 200000 MPa
F
1
= -1 kN F
2
= 1 kN
Units: N and mm!

Solving the equation (multiplying the matrix, etc.) delivers.
0 + 0 = 0, i.e. mathematically correct but worthless!

Why? Statically indeterminate!
l
E A
k

=
1
2
The FEM principle

Approximation character of the FEM
One-dimensional example: Framework rod with variable cross-section
Beam with variable cross-section should be discretized by means of a 1-D rod element!
F
l u
x
A1 A2
Real body
Rod element
F
l u
x
One-dimensional example: Framework rod with constant cross-section
Strain is constant along the overall length, i.e. for every point the strain can be specified
dependent upon x.
F
l u
x
A1 A2
local tension can be specified exactly:
Cross-section dependent upon x:
Strain:
results in:
Framework rod with variable cross-section
} }
= = dx x
E
dx x x u ) (
1
) ( ) ( o c
|
|
.
|
\
|
+
+
=
l A x A A
A A x lA
A A E
Fl
x u
1 1 2
1 2 1
1 2
) (
ln
) (
) (
Analytical solution with number values
A
1
= 40 mm
2
; A
2
= 100 mm
2
; l = 1 m;
F = 10 kN; E = 200000 MPa;
FEM: Solution with linear
approach
deformations between the nodes are approximated by means of a displacement approach, the
simplest is a linear approach:
Analytical solution: FEM approximation solution:
Note:
tensions are wrongly
calculated in the linear
approach!
Discretisation with an element
F
1000
A1 A2
Stiffness matrix and forces equilibrium of a rod element:

i.e. one must work here with the mean cross-section area

here:
For comparison, the analytical solution:
Discretisation with two elements
F
500
A1 A2
500
Element 1 Element 2
Linear approach with two elements
linear displacement, tension
constant within an element!
==> fine discretization necessary
Gaussian idea: quadratic displacement approach
Express displacements by means of the three nodal displacements u
1
, u
2
, u
3
and determine the
parameters a
0
, a
1
, a
2
there from:

Calculate the tensions using the material law!
Quadratic approach:
u(x) = a
0
+ a
1
x + a
2
x
2
1 2 3
Mean nodes
F
III II I
III II I
III II I III II I
I
u x
l l
u x
l l
u x
l l
x u
dx
d
x
u x
l
x
l
u x
l
x
l
u x
l
x
l
x u
l
u
l
u
l
u
a
l
u
l
u
l
u
a u a
|
.
|
\
|
+
|
.
|
\
|
+
|
.
|
\
|
+ = =
|
.
|
\
|
+
|
.
|
\
|
+
|
.
|
\
|
+ =
= =
2 2 2
2
2
2
2
2
2
2 2 2 2 1 0
4 1 8 4 4 3
) ( ) (
;
2 1 4 4 2 3
1 ) (
;
2 4 2
;
4 3
;
c
Quadratic displacement approach
Stiffness matrix in quadratic displacement approach:
Quadratic approach:
u(x) = a
0
+ a
1
x + a
2
x
2
1 2 3
Mean nodes
2
1 2
:
6
11
3
7
2
3
8
6 3
1
2
3
8
3
8
3
16
3
2
3
8
6 3
1
3
2
3
8
2 3
7
A
A A
mit

=
(
(
(
(
(
(
+
o
o o
o
o o o
o
o
o
F
Quadratic displacement approach
2
1 2
3
2
1
1
3
2
1
:
6
11
3
7
2
3
8
6 3
1
2
3
8
3
8
3
16
3
2
3
8
6 3
1
3
2
3
8
2 3
7
A
A A
mit
u
u
u
l
A E
F
F
F
=
|
|
|
.
|
\
|
(
(
(
(
(
(
=
|
|
|
.
|
\
|
o
o o
o
o o o
o
o
o
Solving the FEM basic equation:
results in:
mm u 459 , 0
2
=
mm u 756 , 0
3
=
MPa 216
1
= o
Quadratic displacement approach with
two elements
Trial function Elements
Tension [MPa]
Position
0 1/4 1/2 3/4 l l
analytical - 250 182 143 118 100
linear 1 143 143 143 143 143
2 182 182 182/118 118 118
quadratic 1 217 185 152 120 87.0
2 237 186 135/140 119 97.9
FEM: quadratic displacement
approach
Resume
Deformation is more exact than tensions
Nodal displacements are too small ==> FE model stiffer than in reality
Tensions in element middle more exact than at the boundary
Approach always from the bottom
Deformations always an order higher than tensions = ( = du/dx)
More elements increase accuracy
Displacement approach of higher order improves the result
Finite-elements work procedure

FEM procedure:
FEM applications:

FEM programme:
Trend for the FE programme with special application modules and integrated pre- and
postprocessor

Fig. Conversion of the problem definition in the FEM analysis
Spec. CAE software:
Ansa
Hypermesh
Patran
Medina


Geometry definition
Fig. Model simplification on the basis of a perforated disk
Objective:
Reduction of computer time
Simplification of network fineness
Reduction file size
Boundary conditions
Fig. boundary conditions on a screw wrench
3 Types of boundary conditions:
Loads

Fig. Determining the equivalent nodal forces for a constant compressive load for linear
displacement approaches and different networks
Fig: stepwise refinement of the real load application over a distributed surface load
Loads

Model refinement:
Increase of the quality of results by increasing the number of elements or degrees of trial
function

Stress singularities
at the load introduction point
Networking

Fig. Partial modelling technology (submodelling), global modelling and partial modelling
Using sub models:
Networking

5.2 Finite elements application examples

Examples:
Examples: Topology optimisation for appropriate casting construction
5.2 Finite elements application examples

Problematic nature of result analysis

Lacking physical basis skill of the calculation engineer
Lacking design experience of the calculation engineer
Lacking basic knowledge of the calculation engineer in the FEM theory
Missing or incorrect characteristic values and data
Deadline pressure, hasty interpretation
Lacking practice in handling the FEM results/software
Incorrect estimation (overestimation) of the efficiency of the FEM software
Rough calculation, measurement adjustment
Error causes in the FEM analysis:
Fig. Occurring errors in the FEM
Application error of the FE method:

Model quality in the FE
system
Problematic nature of result analysis

Chapter 2 FEM: Digital Engineering

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Page 1 | Prof. Dr.Ing. Th.

Binder | Status March 2014

The FEM principle

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