National Level Work shop on

“How to become FEA Design Engineer”

Organized by

Department of Aeronautical Engineering

Excel Group institutions
 Engineering Analysis

1. Analytical method
2. Experimental method
3. Numerical Method [FEM]
 FEA method
Step 1: Take any physical problem
Step 2 : Create the model and assign
material properties
Step 3: Divide the problem in to small
parts[ Create node and element called
meshing
Step 4: Apply the loading and boundary
conditions
Step 5 : Select type of analysis & solve
the equations
Step 6 : Calculate results
Types of elements
1. One dimensional elements
[bar,rod,link,beam,pipe]Line

2. Two dimensional elements

[ plane stress,plane strain,
Axisymmetric]Traingle, Quad

3. Three dimensional element

[ tetrahendran, brick]

4. Shell element { thickness}

(2) Analysis procedures of linear static structural analysis

A. Build up geometric model

a. 1D problem
line
b. 2D problem
surface
c. 3D problem
solid
B. Construct the finite element model
a. Discretize and select the element types
(a) element type
1D line element
2D element
3D brick element
(b) total number of element (mesh)
1D:
2D:
3D:
•Abaqus: Franco-American software from SIMULIA, owned by
Dassault Systemes.
•ADINA: finite element software for structural, fluid, heat transfer,
electromagnetic, and multiphysics problems, including fluid
structure interaction and thermo-mechanical coupling
•ALGOR: American software from Autodesk.
(Renamed to Simulation Multiphysics.)
• Altair HyperWorks: A full CAE pre-processing and post-processing suite.
•ANSA: An advanced CAE pre-processing software for complete model
build up.
•ANSYS: American software CosmosWorks Deform Marc Femap,
Siemens PLM Software
•LS-DYNA, LSTC - Livermore Software Technology Corporation
•Nastran/ patran : American software, from MSC Software
•NEi Nastran, NEi Software: General purpose Finite Element Analysis
 Types of Engineering problem
1. Structural Analysis [FEM]

a. Static [linear, non linear ] Stress, Strain ,deflection

b. Dynamic [ Transient ,Modal, Harmonic, Spectrum,

Fatigue, Impact] [linear, non linear ]

2. Thermal or heat transfer Analysis [FEM] Steady state ,

Transient

3. Fluid Analysis [CFD] internal, External

4. Coupled Analysis[ combination] [FEM,CFD]

 Structural Load
•Point load or Force [N]
• UDL ,UVL [Pressure load [Kg/mm2 or N/mm2]]
•Gravity load
•Angular Velocity ,Angular Acceleration
•Torque

Thermal Load
•Conduction Temperature
•Convection Temperature , Heat Transfer Coeff
•Radiation
•Heat Generation
•Heat Flow
 Skills expected in Industry from FEA Design
Engineer
•Knowledge in Strength of Materials, Heat Transfer, Thermodynamics
•Knowledge in Materials, Composite Materials
•Knowledge in Loading and Boundary Conditions
•Knowledge In linear ,non linear, impact, dynamic ,modal, spectrum,
harmonic ,fatigue ,creep, fracture ,Buckling analysis, etc
•Knowledge in Aircraft components , Automobile components,
Machine ,heavy Structures
 MODELLING OF JOINTS

turbine blade

nodes at
turbine disc interface

(a) (b)
Similar for plate connected to 3D solid

Mesh for plate

Mesh for Solid

 Simple convergence checks
In a test problem with a known exact solution, it is
straightforward to assess convergence of an FEA.

With a first coarse mesh and a second refined mesh,

direct comparison with the exact result for the stress of
interest reveals whether the error is reducing with mesh
refinement; that is, whether the FEA is converging.

Then comparison of the result for this stress from the

refined mesh reveals whether the error is sufficiently low; that
is, whether the FEA has converged.
Coarse Mesh And Mesh
 INDUSTRIES USING FEA SOFTWARES
Automotive &transportation
industry OEM &suppliers
Renault: Nissan Chennai
MAHENDRA AND
MAHENDRA (chennai)
Tata motors : pune
General motors : bangalore
Volkswagen:pune
Maruti Suzuki : Gurgoan,delhi
Volvo:bangalore
Caterpillar:chennai
Chrylsler:chennai
Faurecia:pune
Johnson controls: pune
Lera corporation: pune
Arvin meritor: bangalore
Bosch:bangalore
Aerospace &Defense
industry
Moog controls: bangalore
Eaton corporation, pune
Rockwell Collins: hyderabad
Goodrich : bangalore
Safran bangalore
Assystem : bangalore
Hyde: bangalore
Atkins: bangalore
Thales: delhi
Rolls Royce: bangalore
Altran : bangalore
Mahendra aerospace:
bangalore
HAL: bangalore
TATA power : bangalore
Energy ,Construction and
heavy engineering
industry
ABB: bangalore
L&T COIMBATORE
BOMBARDIER: BORODA
Alstom: culcutta
TRF : Jamshedpur
Komatasu : Bangalore
Vestas, Chennai
Gamesha pondicheerry
LM windpower
Acciona ,Bangalore
ITER,ahmedabad
Thermax, pune
Babcock,Chennai
Suzlon,pune
Valeo:chennai BE aerospace, hyderaBAD John deere,pune

Tata Autocomp: pune Tata ADVANCE , BANGALORE Terex ,HOSURE CHENNAI

FORCE MORTORS: pune PRATT AND WHITNETY Altas copco, pune
Magna steyr:pune BEML AEROSPACE ,bangalore Terax hosure,Chennai
Asia motor works Tata andvanced materila Escort klass,delhi
(mumbai)
Ashok Leyland ,chennai L&T AEROSPACE Sandvik,Bangalore
Bajaj auto,pune TANEJA AEROSPACE AVIATION ENERCON Mumbai
LIMITED

timken Dynamatic-Oldland Aerospace Alfa laval,pune

Hero Honda,DELHI capgemini Walchandnagar ind pune

MERCENDAZE BENZ, general electric aviation RRB Energy Chennai
BANGALORE

Daimler truck, chennai quest global ONGC., delhi/ ge energy

bangalore
 Fuselage Analysis

Static Analysis, optimization ,vibration modes, fatigue analysis

FLUTTER
Aircraft Main Landing gear analysis
Rotor blade analysis
Heat transfer mother board
Processor cooling
Electrical motor stator vibration
Vibration amplitude of motor
Friction
 Boundary condition for gas force

Web shapes of crankshaft

Rolling Element Bearing Stiffness Matrix
Determination

Radial Ball
Bearing Cylindrical

Bearing Contact Grid

Vibration loading is commonly encountered during the service life of
electronic products. However, compared to thermal cycling durability,
vibration durability is more complex and has been less investigated. In
surface mount technology, solder joints are the primary mechanical,
thermal and electrical interconnects between the component and the
PWB. So the reliability of solder joints is very crucial for most electronic
assemblies.
 Structural analysis is probably the most common
application of the finite element method as it implies bridges and
buildings, naval, aeronautical, and mechanical structures such as
ship hulls, aircraft bodies, and machine housings, as well as
mechanical components such as pistons, machine parts, and tools.
1.Static Analysis
Used to determine displacements, stresses, etc. under static
loading conditions.
Nonlinearities can include plasticity, stress stiffening, large
deflection, large strain, hyper elasticity, contact surfaces, and
creep.
2. Transient Dynamic Analysis
(sometimes called time-history analysis) is a technique
used to determine the dynamic response of a structure under the
action of any general time-dependent loads. You can use this type
of analysis to determine the time-varying displacements, strains,
stresses, and forces in a structure as it responds to any combination
of static, transient, and harmonic loads. The time scale of the
loading is such that the inertia or damping effects are considered to
be important
3. Buckling Analysis
Used to calculate the buckling loads and determine the
buckling mode shape. Both linear (eigenvalue) buckling and nonlinear
buckling analyses are possible. In addition to the above analysis types,
several special-purpose features are available such as Fracture mechanics,
Composite material analysis, Fatigue, and both p-Method and Beam
analyses.

Vibration Analysis
1. Free vibration [initial load]
2. Forced Vibration [continuous load]
 Modal Analysis
You use modal analysis to determine the vibration
characteristics (natural frequencies and mode shapes) of a structure or a
machine component while it is being designed. It also can be a starting
point for another, more detailed, dynamic analysis, such as a transient
dynamic analysis, a harmonic response analysis, or a spectrum analysis
Harmonic Analysis
Any sustained cyclic load will produce a sustained cyclic
response (a harmonic response) in a structural system. Harmonic
response analysis gives you the ability to predict the sustained dynamic
behavior of your structures, thus enabling you to verify whether or not
your designs will successfully overcome resonance, fatigue, and other
harmful effects of forced vibrations.
Gas Turbines for Aircraft and Power Generation , Steam Turbines
Wind Turbine Water Turbines Turbo pumps
Internal Combustion engines Electric motors and generators
Gas and fluid pumps
Disc drives
 A spectrum analysis is one in which the results of a
modal analysis are used with a known spectrum to calculate
displacements and stresses in the model. It is mainly used in
place of a time-history analysis to determine the response of
structures to random or time-dependent loading conditions
such as earthquakes, wind loads, ocean wave loads, jet engine
thrust, rocket motor vibrations, and so on.

A response spectrum represents the response of single-

DOF systems to a time-history loading function. It is a graph
of response versus frequency, where the response might be
displacement, velocity, acceleration, or force. Two types of
response spectrum analysis are possible: single-point response
spectrum and multi-point response spectrum.
Nonlinear structural behavior arises from a number of causes, which can be grouped
into three principal categories:
Changing Status (Including Contact)
Many common structural features exhibit nonlinear behavior that is status-
dependent. For example, a tension-only cable is either slack or taut; a roller support
is either in contact or not in contact. Status changes might be directly related to load
(as in the case of the cable), or they might be determined by some external cause.
Situations in which contact occurs are common to many different nonlinear
applications. Contact forms a distinctive and important subset to the category of
changing-status nonlinearities.
Geometric Nonlinearities
If a structure experiences large deformations, its changing geometric
configuration can cause the structure to respond nonlinearly. An example would be
the fishing rod shown in Figure. Geometric nonlinearity is characterized by "large"
displacements and/or rotations.
 Material Nonlinearities

Nonlinear stress-strain relationships are a common cause

of nonlinear structural behavior. Many factors can influence
a material's stress-strain properties, including load history
(as in elasto-plastic response), environmental conditions
(such as temperature), and the amount of time that a load is
applied (as in creep response)
 Contact problems are highly nonlinear and require significant computer
resources to solve. It is important that you understand the physics of the
problem and take the time to set up your model to run as efficiently as
possible. Contact problems present two significant difficulties. First, you
generally do not know the regions of contact until you've run the problem.
Depending on the loads, material, boundary conditions, and other factors,
surfaces can come into and go out of contact with each other in a largely
unpredictable and abrupt manner. Second, most contact problems need to
account for friction. There are several friction laws and models to choose
from, and all are nonlinear. Frictional response can be chaotic, making
solution convergence difficult.
 Fracture Mechanics
Cracks and flaws occur in many structures and components,
sometimes leading to disastrous results. The engineering field of fracture
mechanics was established to develop a basic understanding of such crack
propagation problems. Fracture mechanics deals with the study of how a
crack or flaw in a structure propagates under applied loads. It involves
correlating analytical predictions of crack propagation and failure with
experimental results. The analytical predictions are made by calculating
fracture parameters such as stress intensity factors in the crack region, which
you can use to estimate crack growth rate. Typically, the crack length
increases with each application of some cyclic load, such as cabin
pressurization-depressurization in an airplane. Further, environmental
conditions such as temperature or extensive exposure to irradiation can affect
the fracture propensity of a given material.
Some typical fracture parameters of interest are:
Stress intensity factors (KI, KII, KIII) associated with the three basic modes of
fracture J-integral, which may be defined as a path-independent line integral
that measures the strength of the singular stresses and strains near a crack tip
Energy release rate (G), which represents the amount of work associated with
a crack opening or closure
 Composites Analysis
Composite materials have been used in structures for a
long time. In recent times composite parts have been used
extensively in aircraft structures, automobiles, sporting goods,
and many consumer products. Composite materials are those
containing more than one bonded material, each with
different structural properties. The main advantage of
composite materials is the potential for a high ratio of
stiffness to weight. Composites used for typical engineering
applications are advanced fiber or laminated composites, such
as fiberglass, glass epoxy, graphite epoxy, and boron epoxy.
 Definition of Fatigue
Fatigue is the phenomenon in which a
repetitively loaded structure fractures at a
load level less than its ultimate static
strength. For instance, a steel bar might
successfully resist a single static
application of a 300 kN tensile load, but
might fail after 1,000,000 repetitions of a
200 kN load. The main factors that
contribute to fatigue failures include:
Number of load cycles experienced
Range of stress experienced in each load
cycle
Mean stress experienced in each load
cycle
Presence of local stress concentrations
 Impact is a high force or shock applied over a short
time period when two or more bodies collide. Such a
force or acceleration usually has a greater effect than a
lower force applied over a proportionally longer time
period of time. The effect depends critically on the
relative velocity of the bodies to one another.
 Thermal /Heat Transfer Analysis

To calculate temperature distribution, heat flow, thermal stress

in the objects which subject to heat load

Types of mode
Conduction
Convection
Radiation

Inputs: Temperature , heat flow, heat generation.

Output: Temperature distribution ,heat flux, heat flow, thermal
stress[from coupled analysis]
Applications: Engine, clutch, brake, heat exchanger, boiler,
nuclear reactor, machining processs.
 Coupled Fields Analysis
A coupled-field analysis is an analysis that takes into account
the interaction (coupling) between two or more disciplines
(fields) of engineering.
A piezoelectric analysis, for example, handles the interaction
between the structural and electric fields:it solves for the
voltage distribution due to applied displacements, or vice
versa.
Other examples of coupled-field analysis are thermal-stress
analysis, thermal-electric analysis, and fluid-structure
analysis.
Some of the applications in which coupled-field analysis may
be required are pressure vessels (thermal-stress analysis),
fluid flow constrictions (fluid-structure analysis),induction
heating (magnetic-thermal analysis),ultrasonic transducers
(piezoelectric analysis),magnetic forming (magneto-structural
analysis), and micro electro mechanical systems (MEMS).
Anti-roll bar that is one of the basic parts of a suspension
system used to reduce the roll tendency of the vehicle body.
Composite material testing
 Buckling Analysis
Composite laminated plates when loaded in compression are subjected
to a type of behavior known as buckling as long as the load on the plate is
relatively small, then any increase in the load results only in an axial
shortening of the plate.
However once a certain critical load is reach, the plate suddenly bows out
sideways. This bending gives rise to large deformations, which cause the plate
collapse. The load at which buckling occurs is thus a design criterion for
compression plate. Plates with circular
and other holes are extensively used as
structural members in aircraft design.
The buckling behavior of such plate has
always received much concentration by
investigators.
 HARMONIC ANALYSIS:

This analysis gives the ability to predict the

sustained dynamic behaviour of structures, thus it enabling to
verify the designs will successfully overcome resonance,
fatigue and other harmful effects of forced vibrations.
Harmonic response analysis is a technique used to determine
the steady state response of a linear structure to loads that
vary sinesoidally with time.