FINITE ELEMENT ANALYSIS

FINITE ELEMENT ANALYSIS

Introduction
 What is FEA?
• FEA is a mathematical solution to
engineering problems where a physical
model is divided into discrete components.
• FEA models are defined by nodes and
elements (commonly called a mesh).
 What is FEA?
• Basic engineering equations, such as
Hooke’s law, are solved at the nodes and
elements.
• A matrix equation, including terms from
each element, is solved.
 What is FEA?
• Predicts changes within the element (for
example, deformation and stress).
• The results are plotted on the model
using colors to show the lowest and
highest values.
 Why Use FEA?
• Provides a non-destructive means of
testing products.
• Faster prototyping for “what if” scenarios.
• Design optimization.
• Speed up time to market by shortening
the design cycle.
 Best Practices
• FEA requires engineering judgment. In
the best case, you should know the
approximate answer before you begin.
• Proper selection of elements, materials,
loads, constraints, and analysis
parameters comes from experience.
 Best Practices
• Understand that the computer model
never exactly matches reality (it’s only
an approximation).
• The surest route to failure in FEA is to
underestimate the complexity of the
technology.
 FEA in Different Industries
• The link below may be used to access
examples of various types of FEA models
from different industries:

Algor® Simulation Software in Action

Finite Element Analysis in Practice

FEA Overview and

Examples using
Autodesk® Algor®
Simulation
 The Basic Steps of FEA
Build/Mesh a Model

Define FEA Model –

Element and Analysis Details

Define Loads and Constraints

Analyze Model (Solve)

Review Results and Create

Presentations
Example Using Algor® Simulation
Create the Mesh within the FEA Editor
Environment

Set up Analysis Type, Element Type/Data,

Materials, and Analysis Parameters within
the FEA Editor Environment

Apply Loads and Constraints within the

FEA Editor Environment

Analyze the Model (Solve)

Review Results within the Results

Environment and Create an HTML Report
within the Report Environment
Algor® Simulation User Interface
• A. Title bar
• B. Menu
bar
• C. Toolbars
• D. Tree
view
• E.
ViewCube &
View Controls
• F. Display
Area
• G. Miniaxis
& Scale
Ruler
 Create Mesh

• Open and mesh models from • Generate 2-D and 3-D

CAD solid modelers or meshes from sketches.
universal files. • Add lines to existing
meshes.
Assign FEA Parameters

• Assign element types and parameters.

• Assign material properties.
• Apply loads and constraints.
• Assign analysis parameters.
• Analyze the model.
 Review Results

• Results Environment
– Review the model setup.
– Review the analysis results.
– Create images or animations of results.
 Present Results

• Report Environment
– Generate a report of the analysis for presentation
purposes.
– Add images or animations.
– View summary and log files from the analysis.
Finite Element Analysis in Practice

Introductory
Example
 Opening the Model
• Select “File: Open...”
• Change the file type to
“STEP (*.ste, *.stp, *.step)”
• Select “MotorMount.stp”
• Choose model’s existing
units when prompted.
(Note: The CAD model’s length
unit is inches. STEP files may
be rescaled on import if
desired.)
• Choose “Linear: Static
Stress with Linear Material
Models” when prompted.
 Creating a Mesh
• Go to the model mesh
settings dialog (“Mesh:
Model Mesh Settings…”).
• Move the Mesh Size slider to
75% of the default mesh
size.
• Create a mesh by pressing
the “Mesh model” button.
• As desired, choose “Yes” or
“No” when asked if you wish
to view the meshing results.
 Applying the Materials
• Select the Material headings
in the model tree view for all
three parts by clicking on
the first one and holding
down the <Ctrl> key while
clicking on the second and
third ones.
• Right-click on any of the
selected headings and
choose “Modify:
Materials...”.
• Select “Steel (ASTM-A36)”,
which is near the bottom of
the listed materials in the
“Steel” folder, and click the
“OK” button.
 Applying the Loads
• Rotate the view as required to
see the top surfaces of the
brackets.
• Use the surface selection
option.
• Select the two top surfaces of
the brackets.
• After the surfaces are
selected, right-click and select
“Add: Surface Forces...”
• Specify a magnitude of 75 lbf
(this is the force per surface).
Keep the default “Normal”
direction.
 Applying the Constraints
• Rotate the model as required
to see the surfaces of both
holes running through the
shaft.
• Select the inside surfaces of
both holes. (Note: There are
two surfaces per hole.)
• After the surfaces are
selected, right-click and
select “Add: Surface
Boundary Conditions...”.
• Press the “Fixed” button and
then the “OK” button.
 Reviewing the Results

• Run the analysis by

selecting “Analysis:
Perform Analysis...”.
• Once the analysis is
complete, the von Mises
stress results will appear.
 Creating a Report
• Select the “Report” tab at the bottom of the screen or go to the “Tools:
Report” menu command.
• Select the “HTML
Report” heading.
• Right-click and select
the “Configure Report”
command.
• The configure report
screen may be used to
reorder the contents of
the report and to
customize user-defined
content. (Image shown
with optional Autodesk®
logo activated.
 Additional Examples

Refer to the “Tutorials” command

within the software’s “Help” menu for
additional analysis examples.
Finite Element Analysis in Practice

FEA Concepts
 What is a DOF?
• The unknowns in a finite element
problem are referred to as degrees of
freedom (DOF).
• Degrees of freedom vary by element
and analysis type.

DOF Type Action Application

Displacement Force Structural
Temperature Heat Flow Rate Thermal
Velocity Fluid Flow Rate Fluid
Voltage Electromotive Force (EMF) Electrostatic
 What is a DOF?
Uy

Rot y

Node Rot x
Ux

Rot z
Uz
 Node
• A node is a coordinate location in space
where the DOF are defined. The DOF of this
point represent the possible response at
this point due to the loading of the
structure.
 Element
• An element is a mathematical relation that
defines how the DOF of a node relate to the
next. These elements can be lines (beams),
areas (2-D or 3-D plates) or solids (bricks
and tetrahedra).
 Nodes and Elements
• A node has a given set of DOF, which
characterizes the response. For structural
analyses, these DOF include translations and
rotations in the three global directions.
• The type of element being used will also
characterize which type of DOF a node will have.
• Some analysis types have only one DOF at a
node. An example is the temperature in a heat
transfer analysis. Heat flow rates are calculated
from the nodal temperatures and the material
thermal conductivity (no flow DOF).
 Element Connectivity
(Conventional Bonding)
• Elements can only transfer loads to one
another via common nodes.

No Communication Communication
Between the Elements Between the Elements
 Element Connectivity
(“Smart Bonding”)
With "Smart Bonding" it is possible to connect
adjacent parts to each other without having to
match the meshes (i.e., common nodes at part
boundaries are no longer mandatory). This feature
is available for both CAD and hand-built models
and is applicable to the following analysis types:
 
• Static Stress with Linear Material Models
• Natural Frequency (Modal)
• Transient Stress (Direct Integration)
 Element Connectivity
(“Smart Bonding” – continued)
Smart bonding is disabled by default for new models and
for legacy models. The option may be changed within the
"Contact" tab of the Analysis Parameters dialog. Note that
where nodal coordinates do not fall within the default or
user-specified tolerance for matching, the nodes will be
bonded by means of multipoint constraint equations
(MPCs). This is indicated below by the white nodes…
 Stress and Strain Review
• The basic stress and strain equations:
 Stress
• Basic equations do not require the use of a
computer to solve.
• Computer-based analysis is needed when
complexity is added as follows:
– Geometric complexity makes the elasticity
equation difficult or impossible to solve.
– Variations in material properties exist throughout
the part.
– Multiple load cases and complex or combined
loading exists.
– Dynamics are of interest.
 General Case
• The DOF components of each element
combine to form a matrix equation:

[K] {d} = {A}

– [K] = element stiffness components

– {d} = DOF results (unknown)
– {A} = action value (e.g., force, temperature)
 Structural FEA Equation
• To determine the displacement of a simple linear
spring under load, the relevant equation is:

{f} = [K] {d}

Known Unknown

where {f} = force vector

[K] = stiffness matrix
{d} = displacement vector
 FEA Equation Solution

• This can be solved with matrix algebra by

rearranging the equation as follows:

-1
{d} = [K] {f}
 Calculation of s and e
• Strains are computed based on the
classical differential equations previously
discussed.
• Stress can then be obtained from the
strains using Hooke’s law (F = kx).
 Dynamic Equation
• For a more complex analysis, more terms
are needed. This is true in a dynamic
analysis, which is defined by the following
equation:
{f} = [K] {d} + [c] {v} + [m] {a}
where... {f} = force vector
[K] = stiffness matrix
{d} = displacement vector
[c] = damping matrix
{v} = velocity vector
[m] = mass matrix
{a} = acceleration vector
 Other Applications
• FEA can be applied to a wide variety of
applications such as:
– Dynamics
– Nonlinear Materials
– Heat Transfer
– Fluid Flow
– Electrostatics
Exercise A – FEA Example by Hand

• Draw trusses in the Node

2
Node
3

XY plane
• No TZ DOF (2-D)
• F = 10,000 lb L

• A = 2 in2
Node Node
• E = 30 x 10 psi
6 1 4

y L
• L = 120 in F
• = 45° x
Element Stiffness Matrix Formulation
(General Case)
Node
2

D1x D1y D2x D2y

 c2 cs  c 2  cs  D1x
 2  Li
A i E i  cs s 2
 cs  s  D1y
k Element i 
L i  c 2  cs c 2 cs  D 2 x
 2 
  cs  s
2
cs s  D 2 y i

where... Node
1

c  cos( i ), s  sin(  i ), D  displaceme nt y

(All Z-translation is constrained and, therefore, not x

considered for this example.)
 Element 1
Node
2

D1x D1y D2x D2y L

0 0 0 0  D1x
2   30 x10   0
6  D
k1 
 1 0 1  1y = 90º
120 0 0 0 0  D2x Node
  1

0 1 0 1  D2y F

x
 Element 2
D1x D1y D3x D3y
½ ½  ½  ½  D1x

k2 
30x10  2 
6 ½ ½  ½  ½ D
 1y Node

120 2  ½  ½ ½ ½  D3x 3

 
 ½  ½ ½ ½  D3 y

y
= 45º
Node
1
x
F
 Element 3
Node Node
1
= 0º 4

L
F
y

D1x D1y D4x D4y

x
 1 0 1 0  D1x
2  30 x106   0
 D
k3 
 0 0 0  1y
120  1 0 1 0  D4x
 
0 0 0 0  D4y
 Global Stiffness Matrix Assembly
D1x D1y D2x D2y D 3x D3y D4x D4y
 2 2 2 2 
0  1 0 0 000 000 0 0 0 0 0  0 1 0  0  0 D1x
 4 4 4 4 
 2 2 2 2 
0  0 1 0 000 1  0  0 0 0 0 0 000 0  0  0 D1y
 4 4 4 4 
 
 000 000 000 000 000 000 000 0  0  0 D 2 x
 
 
   
2  30x106  0  0  0 1  0  0 000 0  0 1 000 000 000 0  0  0 D 2 y
K 
120  
0  2  0 0
2
0 000 000 0
2
0 0
2
0 000 0  0  0 D 3 x
 4 4 4 4 
 
0  2  0 0
2
0 000 000 0
2
0 0
2
0 000 0  0  0 D 3 y
 4 4 4 4 
 
 
 0  0 1 000 000 000 000 000 0  0 1 0  0  0 D 4 x
 
 
 000 000 000 000 000 000 000 0  0  0 D 4 y

Each entry in the global stiffness matrix is the sum of the cell values for the
three individual element matrices (in order of ascending element number).
 Global Stiffness Matrix

 1.354 0.354 0 0  0.354  0.354  1 0

 0.354 1.354 0  1  0.354  0.354 0 0

 0 0 0 0 0 0 0 0
 
 0 1 0 1 0 0 0 0
K  (500,000)
 0.354  0.354 0 0 0.354 0.354 0 0
 
 0.354  0.354 0 0 0.354 0.354 0 0
 1 0 0 0 0 0 1 0
 
 0 0 0 0 0 0 0 0

Struck out values are where there is no DOF, due to nodal constraints.
This simplifies the solution to a 2x2 matrix for this example.
Force and Displacement Vectors

 F1x  0   D1x 
F  10,000  D 
 1y   1y 
 F2 x  D 2 x  0
   
 F  D  0
F
2y
D  2y 
 F3x   D3x  0
   
 F3 y   D3y  0
 F4 x  D  0
   4x 
 F4 y  D 4 x  0
Displacement and Stress Results

1  3,964.5 psi
D1x  0.00414214 in
 2  1,464.6 psi
D1y  0.0158579 in
3  1,035.3 psi

Displacements are found by solving the equation… {F} [K]-1 = {D}

This is simply Hooke’s law, in matrix notation, with the terms arranged
as required.

Once displacements are known, element strains can be determined.

Finally, the stress can be determined via the equation…
Algor® Simulation Model
 Algor® Simulation Results

1  3,964 psi
D1x  0.00414 in
 2  1,464 psi
D1y  0.0159 in
3  1,036 psi
Finite Element Analysis in Practice

Analysis
Options
 Choosing an Analysis Type
• The first decision in the FEA process is to
decide what type of analysis you need to
run.
• The analysis type will dictate what type of
results you will obtain.
• For example, if you need the displacement
of your part, then you will need to run a
structural analysis.
 Analysis Options
• Linear • Electrostatic
– Linear static – Current and voltage
– Linear dynamics (incl. eight – Field strength and voltage
analysis types + DDAM)
• Nonlinear • Mass Transfer
– Nonlinear static – Transient mass transfer
– MES • Multiphysics
– Modal w/ nonlinear materials
– Riks (post buckling & collapse) – Steady coupled fluid flow and
thermal
• Thermal
– Steady-state heat transfer – Transient coupled fluid flow
and thermal
– Transient heat transfer
• Fluid Flow
– Steady fluid flow
– Unsteady fluid flow
– Flow through porous media
– Open channel flow
 Structural
• Linear static
– Small changes in stiffness.
– No changes in loading direction.
– Material remains in the linear elastic range.
– Small deformation and strain.
 Structural (continued)
• Linear dynamics
– Natural frequency (modal)
– Natural frequency (modal) with load stiffening
– Response spectrum
– Random vibration
– Frequency response
– Transient stress (direct integration)
– Transient stress (modal superposition)
– Critical buckling load
– Dynamic Design Analysis Method (DDAM)
 Structural (continued)
• Nonlinear/MES
– Linear and nonlinear material models.
– Large deformation and strain.
– Failure due to:
• Material yielding.
• Local and structural buckling.

– Permanent deformation – residual stress.

– Large-scale motion.
 Structural (continued)
• Nonlinear/MES
– Surface-to-surface contact
– Impact
– Creep
 Thermal
• Steady-state heat transfer
– Steady-state conditions
• Transient heat transfer
– Time-varying conditions
 Fluid Flow
• Steady fluid flow
• Unsteady fluid flow
• Flow through porous media
• Open channel flow
 Electrostatic
• Electrostatic current and voltage
• Electrostatic field strength and voltage
 Mass Transfer
• Transient mass transfer
– Mass transfer refers to mass in transit due to
gradients in the concentration of species within a
mixture, and the transfer is due to random
molecular motion. A typical application example is
chemical species migrating through a membrane.
Finite Element Analysis in Practice

Element
Options
 Choosing an Element Type
• Selecting the type of element will depend on
the following:
– Analysis type selected.
– How you create your mesh.
– Assumptions you can make about geometric
properties.
 Element Categories
• Line Elements: A line connecting 2 nodes (representing
beams, trusses, springs, actuators, pipes, and so on).
• Area (2-D) Elements: YZ-planar elements that are each
triangular or quadrilateral (3 or 4 lines enclosing an area).
These elements can represent thin parts, cross-sections of
a specified thickness, or radial cross-sections of
axisymmetric parts.
• Area (3-D Planar) Elements: Planar or nearly planar
elements in 3-D space. Each must be triangular or
quadrilateral and represents a thin part with a specified
thickness. The plane of the element is at the midplane of
the part it represents.
• 3-D Solid Elements: Must be enclosed volumes with 4, 5,
or 6 triangular and/or quadrilateral faces and with 4, 5, 6, or
8 corner nodes.
Finite Element Analysis in Practice

Meshing and
Modeling
 Proper Modeling Techniques
• For any region (3, 4, 5, 6 or 8-nodes), to be a
valid element, it:
– Must consist of either three or four undivided line
segments (forming triangular or quadrilateral
faces). If an element edge consists of multiple
line segments, the region is invalid.
– Must not have curved or arched sides. The
exception to this is second order elements, where
midside nodes are located on the original surface
for curved, CAD-based geometry.
 Proper Modeling Techniques
(continued)
• Certain shapes can create elements which
are not recommended for FEA analysis. The
following regions will be eliminated,
requiring adjustment of the geometry or
meshing parameters:
o Regions with any collinear or concave sides.
o Regions with excessive curvature relative to the
element size (causing non-flat, excessively
warped element faces).
Proper Modeling Techniques
(continued)

Valid and Invalid Regions

 Meshing Guidelines
• Meshing can be completed either by using
automatic mesh engines, semiautomatic
structured meshing tools, or by creating a
mesh completely “by hand”.
• Automatic mesh generation is usually
completed on CAD solid models or within
outline sketches (for 2D models).
• Semiautomatic meshing tools and “hand”
meshing techniques are generally used for
simple models where a structured mesh is
desirable.
 Structured Meshing Tools
• Regions can be meshed based on user-
specified coordinates and edge divisions
using the following commands:
– “Mesh: Structured Mesh: 3 Point Triangular…”
– “Mesh: Structured Mesh: 4 Point Rectangular…”
– “Mesh: Structured Mesh: 8 Point 3-D…”
• Meshes can be generated from bounding
edges represented by construction lines
and arcs using the following commands:
– “Mesh: Structured Mesh: Divide 1 Object…”
– “Mesh: Structured Mesh: Between 2 Objects…”
– “Mesh: Structured Mesh: 4 Object 3-D…”
 “Hand” Meshing
• There are two types of “hand” meshing—
building from scratch and building from a
sketch or wireframe.
• Building from scratch:
– Draw the elements by hand one at a time, line-by-
line, to create a structured mesh.
• Building from a sketch or wireframe:
– Build a 2-D sketch or 3-D wireframe of the model
using construction objects and apply a watertight
surface mesh using the 2-D mesh engine and/or
structured meshing tools. Use an automatic solid
mesh engine to generate internal elements for
3-D parts, or extrude planar meshes into solids.
 Extruding Lines and Planar Meshes
• Selected lines or 1 object meshes may be
extruded into surfaces. Planar meshes (hand
drawn or from structured meshing tools) may
be extruded into solids. Use one of the
following three commands with the “Copy”
and “Join” options enabled to do so:
– Move or Copy…
– Rotate or Copy…
– Scale or Copy…
(These three operations may be combined to
simultaneously move, rotate, and scale the selected
lines or mesh into a surface or solid structure.)
Finite Element Analysis in Practice

Loads and
Constraints
Introduction to Loads & Constraints
• You will have to decide what type of loads
and constraints will properly define the
engineering criteria for the model.
• In FEA, there are different types of loads
and constraints for each analysis type.
• Applying the proper loads and constraints
is one of the most important factors in
getting the correct answer.
• Always double-check your model.
Introduction to Loads & Constraints
(continued)
• There are multiple ways to apply different
loads and constraints to a model:
– Nodal Loads and Constraints
– Edge Loads and Constraints
– Surface Loads and Constraints
– Element Loads (this includes part-based or global
loads). An example is gravity or acceleration.
Other examples are axial preloads, end releases,
and neutral axis offsets applied to beam elements.
 Structural Nodal Loads
• Displacements
• Forces
• Lumped Masses
• Moments
• Temperatures (thermal stress)
• Voltages (piezoelectric materials)
 Structural Nodal Constraints
• Boundary Conditions: Prevent specified
DOF from undergoing translation or rotation
in a specified direction.
• Boundary Elements: Act like a spring with a
specified stiffness along a specified
direction.
 Structural Nodal Constraints
(continued)

• Using Boundary Conditions to Model

Symmetry
– Along the line or plane of symmetry, boundary
conditions must be applied to represent the
symmetrical part, as follows:
• Out-of-plane displacement = 0
• Two in-plane rotations = 0
Structural Nodal Constraints
(continued)
P P
P

Line of
Symmetry

Plane of
Symmetry
 Structural Nodal Constraints
(continued)
• Using Boundary Conditions to Model
Antisymmetry (where the part is
symmetrical but the loads act in opposite
directions)
– Along the line or plane of antisymmetry, boundary
conditions must be applied to represent the part, as
follows:
• Out-of-plane rotation = 0
• Two in-plane displacements = 0
Structural Nodal Constraints
(continued)
P P P

Line of
Antisymmetry

Plane of
Antisymmetry
 Boundary Conditions
• Proper boundary conditions are necessary
for an accurate analysis.
• The global stiffness of the system must be
modeled correctly for any local behavior to
be captured correctly.
Boundary Conditions (continued)
• Two of the most unwanted FEA effects to
watch out for are:
– Overstiffening
– Understiffening
• Unlike the real-world equivalent, constraints
in FEA are perfect.
 Linear Surface Loads
• Uniform or Hydrostatic Pressure and
Traction
– Applied to the faces of plate, composite, brick,
shell, and nonlinear membrane elements.
– Applied to the edges of 2-D elements (though
selected as surfaces because the edges represent
surfaces).
• Surface Force
– Can specify magnitude and direction of a force that
will be evenly distributed over a given surface.
Linear Surface Loads (continued)
• Variable Pressure or Traction
– Define a function of the position (i.e., the X-, Y-
and/or Z-coordinates along the surface) that
controls the varying magnitude of the load acting
on the surface.
 Surface and Edge Constraints

Note: The same boundary constraints,

including symmetry/antisymmetry,
described previously under
“Structural Nodal Constraints” are
also available and applicable to
surfaces and edges.
 Linear Element Loads
• Gravity/Acceleration
– Can specify gravitational or general acceleration
value and direction. You must have a mass
density defined for each part.
• Centrifugal Loads
– Specify center of rotation, angular velocity and
angular acceleration values.
• Distributed Loads
– Specify the magnitude and direction at each end of
beam elements.
Finite Element Analysis in Practice

Truss Elements
 Truss Elements
• Truss elements are two-node
members, which allow arbitrary
orientation in the X, Y, Z system.
• The truss transmits axial force
only and, in general, is a three
DOF element (i.e., three global
translation components at each
end of the member). Trusses are
used to model structures such as
towers, bridges, and building
framework (skeletons).
 Truss Elements (continued)
• Guidelines for using truss elements:
– The length of the element is much greater than
the width or depth (approximately 8-10 times or
more).
– The connections to the rest of the model are as
ball joints that do not transfer moments.
– The external forces are applied only at joints.
Exercise B – Truss Frame Model
• Objective: Construct and analyze a frame of truss
elements loaded with 2 nodal forces.
• Geometry: Cross-sectional area = 1 in2.

• Material: Aluminum (6061-T6).

• Loads: Nodal forces as shown in
the image to the right.
• Constraints:
– Fully fixed at Point A.
– Ty and Tz constrained at Point G.
– The rest of the model will have Tz
constrained.
Finite Element Analysis in Practice

Beam Elements
 Beam Elements
• Beam elements are slender
structural members that offer
resistance to axial forces, bending,
and torsion under applied loads.
• Beams are found in building
frames, transmission towers, and
bridges.
• A beam differs from a truss in that
a beam resists moments (twisting
and bending) at the connections.
 Beam Elements (continued)
• In addition to the two nodes defining the
location and length of the element, beams
use a third node (auxiliary vertex) to define
the orientation of the cross-section. The
location of the auxiliary vertex is controlled
by the surface number of the beam element
lines or may be manually specified at a
custom coordinate location for selected lines.
• Cross-sectional properties are defined for
bending about both the strong and weak axes
and for torsional resistance.
 Beam Elements (continued)

NOTE: For details concerning beam element

orientation, access the “Contents” tab of
the Help files, go to “Autodesk Algor
Simulation: Setting Up and Performing
the Analysis: Setting Up Part 1: Linear:
Element Types and Parameters: Beam
Elements.” Scroll down the resultant page,
and click on the “Beam Element
Orientation” heading.
 Beam Elements (continued)
• Guidelines for using beam elements:
– The length of the element is much greater than the width or
depth.
– The cross-section of the element is constant. (Note: A variable
cross-section wizard is available for approximating tapered
beam spans via a series of multiple elements, each having a
constant cross-section that differs from the adjacent beam
elements.)
– The element is able to transfer moments, though end releases
are available to simulate pinned or slotted connections.
– The element is able to handle a load distributed along its length.
Exercise C – Support Beam Under Gravity
• Objective: Determine the
maximum deflection of the
beam due to its own weight.
• Geometry: W10 x 100
cross-section.
• Material: Steel (AISI 4130).
• Loads: Gravity in the -Y
direction.
• Constraints:
– Far end has constraints against all DOF except Rz.
– Near end has constraints against all DOF except Tx and Rz.
Finite Element Analysis in Practice

2-D
Elements
 2-D Elements
• Two-dimensional elements, with
three or four corner nodes, that are
formulated in the Y-Z plane. They
are used to model any part or
assembly that can be accurately
represented using a 2-D outline or
cross-section and for which 2-D
loading and constraint assumptions
are valid (examples to follow).
 2-D Elements (continued)
• 2-D Geometry Types
– Axisymmetric: For parts that are represented by
cross-sections revolved about an axis (such as a
bearing, shaft seal, or hydraulic cylinder).
– Plane strain: A cross-section of an object of
semi-infinite length, having no deflection normal to
the cross-section (such as a large dam).
– Plane stress: Objects of finite thickness with no
stress normal to the cross-section (such as a
plate under in-plane loads).
 2-D Elements (continued)

• Within the FEA Editor environment, create

wireframe sketches for each part.
• Use the 2-D mesh engine to generate the
2-D elements within the sketch outlines.
Exercise D - Axisymmetric Thick-walled Cylinder

• Objective: Determine the

hoop stress at the inner
radius of the cylinder from
the applied pressure load.
• Material: Steel (AISI 4130).
• Loads: Uniform internal
pressure of 10,000 psi.
• Constraints: The bottom
surface will have Tz
constrainted.
Finite Element Analysis in Practice

Plate/Shell
Elements
 Plate/Shell Elements
• Plate/shell elements have three or
four corner nodes are planar (or
nearly planar), and are formulated in
3-D space. These elements are used
to model and analyze thin objects
such as pressure vessels and
automotive body parts.
• A numerical thickness is assigned to
the elements but the model geometry
itself has no thickness.
• Stresses are assumed to vary
linearly through the thickness.
 Plate/Shell Elements (continued)
• Guidelines for using plate/shell elements:
– The thickness is small in relation to the length and
width (about 1/10).
– Good for small displacements and rotations.
– Elements remain planar (i.e., no warpage).
– No rotation about the direction normal to the
element.
 Membrane Elements
• Planar (or nearly planar) elements,
with three or four corner nodes,
formulated in three-dimensional
space.
• Used to model "fabric-like" objects
such as tents or cots, or structures
such as the roof of a sports
stadium.
• Represent thin solids of a specified
thickness that exhibit no stress
normal to the thickness.
 Composite Elements
• There are two types of composite
elements—thin and thick. Thick
composites have a core layer that is
typically much thicker than the other
laminae.
• Each element can have multiple
laminae, each with different material
properties and fiber orientations.
• Multiple failure criteria are available.
• As with plates and membranes, the
thickness, in this case for each lamina,
is defined numerically (not graphically).
Exercise E - Plate Under Uniform Pressure
• Objective: Determine the maximum stress in the
plate from the applied pressure load. Use the
4 Point structured meshing tool to make the plate.
• Geometry: The plate is 10” x 5” x 0.25”.
• Material: Steel (AISI 4130).
• Loads: Uniform pressure
of 50 psi.
• Constraints:
– The two long edges will have
Ty and Tz constraints.
– One short edge will have Tx
and Tz constraints.
Finite Element Analysis in Practice

Brick Elements
 Brick Elements
• Brick elements are four-,
five-, six- or eight-node
elements formulated in
three-dimensional space.
• Brick elements should be
used for solids with irregular
shapes and when the stress
through the thickness of a
part is important.
Exercise F – Cantilever Beam Model
• Objective: Using brick
elements, determine the
maximum bending stress
in the beam from the
applied load.
• Material: Steel (4130).
• Loads: 10,000 pounds distributed
across the free end.
• Constraints:
– The center horizontal row of nodes (running in the Y-direction)
at the fixed end will be fully constrained.
– The remaining nodes at the fixed end will have only the Tx
constraint applied.
Finite Element Analysis in Practice

Comparing
Element
Types
 Exercise G - Comparing Element Types
• Elements:
– 2-D: Apply a 100 psi pressure to the
top edge.
– Beam: Convert the 100 psi load over
the 0.25” width to a 25 lb/in distributed
load.
• Objective: Analyze a beam
– Plate: Model the 10” x 0.5” dimensions
model using different element with a thickness of 0.25”. Apply nodal
types and compare the results. forces equivalent to the pressure load.
• Material: Steel (AISI 4130). The forces at the end nodes should be
half the magnitude of the forces at the
• Loads: 100 psi in the -Z interior nodes.
direction on the top of the beam.
– Plate: Model the 10” x 0.25” dimensions
• Constraints: Fixed at the left with a thickness of 0.5”. Apply a 100 psi
end and simply supported at the pressure load in the –Z direction to the
right. surface of the plate elements.
– Brick: Apply a 100 psi pressure to the
top surface.
 Comparison of Results
Displacement X-Reaction Shear y * y * yz
Element Type Magnitude Moment * Force * Max. at mid-span Max.
(inch) (in-lb) (lb) (psi) (psi) (psi)
2-D 0.01751 ** ** 28,349 14, 976 1,625
First Plate Model
0.01751 ** ** 28,349 14,976 1,625
(0.25" Thick)
Beam 0.01761 311.9 156.2 29,933 15,024 **
Second Plate Model
0.01722 313.5 *** ** 30,413 14,929 **** **
(0.5" Thick)
Brick 0.01741 ** ** 29,331 14,912 **** 1,814
Values above are magnitudes. Actual results may be positive or negative.
Notes: * For the beam element part, the “Local 3 Moment” corresponds to the X-Reaction
Moment; the "Local 2 Force" corresponds to the Shear Force; and the "Bending Stress in
Local 3 Direction" corresponds to the bending stress ( y).
** This result type is not calculated for this element type.
*** The X-Reaction moment for the 0.5” thick plate is the sum the reactions for all fixed
nodes.
**** This stress was determined at the node in the middle of the 0.25” thickness.
Finite Element Analysis in Practice

Mesh
Convergence
 Mesh Convergence
• For mesh convergence testing, it is
suggested that you run at least three
analyses at different mesh sizes:
– Coarse
– Fine
– Somewhere in between coarse and fine
 Mesh Convergence (continued)
• Usually, you will not see much change in
the direct equation solutions (such as
displacements) for the differing mesh sizes.
• You will see the numerical method answers
(such as stresses) converge to an answer
as the mesh gets finer.
 Exercise H – Mesh Convergence
• Objective: To perform a 2-D analysis using plane
stress elements, utilizing different mesh density
settings of 200, 400, 800, 1600, 3200, and 6400.
Use an angle setting of 30 degrees for all cases.
Compare the y values.
• Geometry: Thickness = 1.0”.
• Material: Stainless steel (AISI
302) cold-rolled.
• Loads: 1000 psi on one edge
as shown in the image.
• Constraints: Fixed at opposite
end as shown in the image.
 y max

Mesh Convergence Example

Mesh Reference
y max (psi) % difference
Density (psi)
200 3,460.5 3,560 -2.80
400 3,448.1 3,560 -3.14
800 3,494.6 3,560 -1.84
1,600 3,544.3 3,560 -0.44
3,200 3,552.9 3,560 -0.20
6,400 3,563.4 3,560 +0.10
 Mesh Study Wizard
• Automates the process of checking multiple
mesh sizes to achieve good convergence of the
stress results.
• May be performed only for CAD-based models
and for the analysis type "Static Stress with
Linear Material Models.“
• To access this feature, go to the command "Mesh
Study Wizard," found in the Start menu within the
folder "All Programs: Autodesk: Autodesk Algor
Simulation: Tools."
For more information regarding how to set up and run a mesh
study, go to the "Contents" tab of the help files, accessible from
the “Help” pull-down menu in the user interface. Then, go to
“Autodesk Algor Simulation: Meshing Overview: Mesh Overview:
Meshing CAD Solid Models: Performing a Mesh Study."
Finite Element Analysis in Practice

Meshing CAD
Solid Models
 Meshing CAD Models
• Build a solid model in any CAD solid
modeler.
• Using direct CAD/CAE data exchange or a
universal file (IGES, STEP, ACIS), open the
model in Autodesk® Algor® Simulation.
• Create a mesh on the model.
 Mesh Refinement
• To optimize solution time, it is useful to
create a fine mesh in areas where the
results are critical and a coarser mesh in
areas where the results will not be as high
or as important.
• You can add refinement points to achieve
localized refinement.
 Exercise I - Bracket Model
• Objective: Determine the
maximum stress in the bracket
from a load applied at the hole.
• Material: Steel (ASTM - A514).
• Loads: 40 pounds in the -Y
direction at the hole.
• Constraints: The back surface
(-X end of bracket) is fully
constrained.
 Midplane Meshing

Refer to the software’s “Help: Tutorials” menu

command. The “Computer Case CAD Model”
tutorial listed under “Meshing and Modeling
Tutorials” demonstrates midplane meshing.
 Assembly Meshing
• When working with multiple parts in an
assembly, it is critical that the meshes
match between the parts if they are to
interact with each other (via conventional
bonded, welded, surface, or edge contact).
• If the parts that come together should be
free to slide along each other or separate
but not penetrate each other, then surface
or edge contact should be used to produce
the desired interaction.
 Assembly Meshing (continued)

• Alternately, the optional feature, “Smart

Bonding” may be enabled (as previously
discussed under the “Element Connectivity”
topic). When enabled, meshes that are not
perfectly matched will be connected
automatically using multipoint constraint
equations (MPCs) between the mismatched
nodes. The Smart Bonding settings are
found within the “Contact” tab of the
Analysis Parameters dialog.
Exercise J – Hanger Assembly Model
• Objective: Determine the maximum
stress in the hanger assembly from a
load applied at the center of the shaft.
• Mesh the model at 90% of the
default mesh size.
• Material: Brackets: Iron, Fe
Shaft: Steel (4130)
• Loads: 100 pounds in the -Y direction.
Distribute over a full ring on nodes at
the center of the shaft.
• Constraints: The bottom surfaces of
both brackets are fully constrained.
Finite Element Analysis in Practice

Combining
Element Types
 Combining Element Types
• Any combination of element types is
possible in an assembly.
• Nodes must be matched where the parts
meet in order for loads to be transferred.
• The available DOF of the element types that
are connected must be considered to avoid
unstable geometry.
Combining Element Types (continued)
• Non-brick elements may be created using
the plate/shell or midplane mesh settings;
by using structured meshing tools; via tools
such as “Create bolt,” “Create Joint” and
“Create Remote Load” (all of which
generate line elements); or they may be
manually drawn.
Refer to the software’s “Help: Tutorials” menu
command. The “Crank CAD Model” tutorial
listed under “Meshing and Modeling Tutorials”
demonstrates the combination of brick and
beam elements.
Finite Element Analysis in Practice

Contact
 Contact
• Select pairs of parts or surfaces in the FEA
Editor environment and specify edge or
surface contact.
• The nodes on the surfaces will be able to
move apart from each other with no
restrictions.
• The nodes will translate loads when they
move together.
• An iterative solution method is used to
determine which nodes are in contact.
 Contact (continued)
• Contact is not considered during the first
iteration. Therefore, it may be necessary to
apply weak elastic boundary elements to
ensure stability.
• When specifying linear contact, only the
first load case is considered. Any other
load case(s) defined within the Analysis
Parameters dialog will be ignored.
Exercise K – Linear Contact Model
• Objective: Determine the stress in the assembly
for a maximum load of 1,000 pounds applied
to the bottom of the latch. Use a mesh
size of 0.15” (absolute).
• Material: Latch: Iron, Fe
Handle: Brass, Red
Housing & Base Plate:
Steel (ASTM - A36)
• Constraints:
– Four bolt holes are fully constrained.
– Weak (100 lb./in.) “rigid” boundary elements in the X, Y, and Z
directions at the back face (+Y end) of the latch.
• Load: 1,000 pounds will be applied in the Z direction at the
underside of the latch extension.
• Default contact should be Bonded. Surface contact should be
defined between the latch and the housing, and between the
latch and the base plate.
Finite Element Analysis in Practice

Solving
Options
 Introduction to Solvers
• There are many different ways to solve the
matrices that were discussed earlier.
• As computers get faster, new technologies
are used that create faster processing of the
equations.
• You should usually accept the default
settings, which are optimized for the fastest
processing.
 Solver Options
• Sparse
– Solves only non-zero equations
• Skyline
– Variable bandwidth
• Banded
– Fixed bandwidth
• Iterative
– Requires a tolerance and initial conditions
Finite Element Analysis in Practice

Results
Evaluation
 Result Options
• The types of results depend on the type of
analysis that is performed.
• For example, a structural analysis will give
you displacement and stress results while a
thermal analysis will give you temperature
and heat flux results.
 How Results are Calculated
• The results are either calculated directly
through linear equations or calculated
through numerical integration methods.
• For example, displacements are calculated
directly from Hooke’s law, but strains are
calculated through numerical methods.
 How to Justify Your Results
• The best method for justification is to run
the model with different mesh sizes.
• Remember, you are approximating an area
or volume with the elements.
• The better the quality of the elements, the
better the results.
• Usually a fine mesh will give more accurate
answers than a coarse mesh.
• Verify that reaction forces are as expected.
 Structural Results
• Displacement (unit: length)
• Stress (units: force / length2)
• Strain (units: dimensionless, length/length)
• Reaction Forces (internal nodal forces)
Note: Equivalent forces applied to elements to produce expansion
or contraction associated with thermal effects will be included in this
result.

• Residual Forces (support reactions)

Finite Element Analysis in Practice

Presentation of
Results
 Presentation Guidelines
• Use colors that will stand out from each
other.
• Make presentations that everyone can
understand.
• Remember that many people looking at
engineering reports are not engineers.
• Have a standard report template.
• Include 3-D representations with charts and
graphs.
 Presentation Options
• Contour images
• Animations
• Time-dependent plots
• Report generation
Contour Images
Animations
Time-Dependent Plots
Report Generation
Finite Element Analysis in Practice

Other Analysis
Types
Other Analysis Types

Thermal
Analyses
 Thermal Analyses
The following two types of thermal analysis
are available:

• Steady-State Heat Transfer

• Transient Heat Transfer
 Thermal Elements
• Thermal elements are geometrically
identical to the corresponding structural
elements. The available types are:
– Rod (this is a line element)
– 2-D
– Plate
– Brick
 Thermal Nodal Loads
• Initial Temperature
– Specify the temperature of a node(s) at the
beginning of the analysis (transient analysis).
• Applied Temperature
– Specify a temperature at which a node(s) will be
held during the analysis. A stiffness value specifies
the amount of thermal energy (heat source or heat
sink) available for maintaining the temperature.
 Thermal Surface Loads
• Convection
– Assign a convection coefficient and the ambient
temperature.
• Radiation
– Assign the radiation function and the ambient
temperature.
• Heat Flux
– Assign the amount of heat added or removed per
unit area.
 Thermal Element Loads
• Heat Generation
– Enter the amount of volumetric heat generated in a
given part.
 Body-to-Body Radiation
• Define the surfaces that will exchange heat
through radiation and assign emissivity
values.
• Define body-to-body radiation enclosures
(i.e., groups of surfaces that will radiate
to/from each other).
• The processor will automatically calculate
the view factors between elements.
 Thermal Contact
• Used to simulate imperfect thermal conduction
between two parts or the resistance of a
substance that is not modeled (such as epoxy)
between two parts.
• Define contact pairs in the FEA Editor
environment.
• Define the resistance value between the
surfaces.
• Applicable to 3D CAD, hand-built, and 2-D
models.
 Thermal Results
• Temperature
• Heat flux (energy / time / length2)
• Heat rate of face (energy / time)
 Exercise L - Thermal Model
• Objective: Analyze
the thermal effects of
a material containing
hot and cold water
passages. Use a mesh
size of 80% of default.
• Material: Steel (ASTM - A514)
• Loads:
– Largest Hole: Convection coefficient = 1.4
in lbs
in 2 sec F
Ambient temperature= 65°F

– Second Largest Hole: Convection coefficient = 2.8 in lbs

in 2 sec F
Ambient temperature = 180°F
Other Analysis Types

Electrostatic
Analyses
 Electrostatic Analyses
The following two types of electrostatic
analysis are available:

• Electrostatic Field Strength and Voltage

• Electrostatic Current and Coltage
 Electrostatic Elements
• Electrostatic 2-D and brick elements are
geometrically identical to the analogous
structural elements.
 Electrostatic Nodal Loads
• Applied Voltages
– Specify a certain voltage at which a node(s) will
be held, due to a voltage source.
• Temperatures
– Specify the temperature of a node(s) to influence
the electrostatic results when temperature-
dependent material properties are being used.
 Electrostatic Results
• Voltage (Volts or mV)
• Current (Amps or mA / length2)
• Current Rate of Face (Amps or mA)
• Electric field (voltage/length)
• Displacement field (force/voltage * length)
• Electrostatic force
• Electrostatic charge (current * time)
 Electrostatic Analysis Exercise

Refer to the software’s “Help: Tutorials” menu

command. Follow the “Radial Comb Motor
Electrostatic Analysis” tutorial listed under
“Analyzing and Evaluating Results Tutorials”
for further information on performing an
electrostatic analysis.
Other Analysis Types

Fluid Flow
Analyses
 Fluid Flow Analyses
The following four types of fluid flow analysis
are available:

• Steady Fluid Flow

• Unsteady Fluid Flow
• Flow Through Porous Media
• Open Channel Flow
 Fluid Flow Elements
• The fluid flow 2-D and brick elements are
geometrically identical to the analogous
structural elements.
 Fluid Flow Loads
• Prescribed Velocity
– Can be used to specify an inlet velocity or zero
velocity along a wall.
• Surface Prescribed Inlet/Outlet
• Fan Curves
– Can be used to model flow generated by intake,
exhaust or internal fans.
• Rotating Frames of Reference
– Can be used to model flow in rotating machinery.
• Gravity
 Fluid Flow Loads (continued)
• Pressure/Traction
– Applied normal to the edge of 2-D elements (selected
as surfaces since the edges represent surfaces).
– Applied normal to the face of 3-D elements.
– Applied in a specified vector direction to the edge
surface of 2-D elements or the face of 3-D elements.
• Buoyancy Force
– Apply thermal results from a steady-state heat
transfer analysis to a steady fluid flow analysis.
• Surface Prescribed Turbulence Condition
• Surface Prescribed Wall Roughness
 Fluid Flow Results
• Velocity (length/time)
• Pressure (force/length2)
• Stress tensors (force/length2)
• Reaction forces
 Fluid Flow Analysis

Refer to the software’s “Help: Tutorials” menu

command. Follow the “Ball Valve Fluid Flow
Analysis” tutorial listed under “Analyzing and
Evaluating Results Tutorials” for further
information on performing a fluid flow analysis.
Other Analysis Types

Mechanical
Event
Simulation
(MES)
Mechanical Event Simulation (MES)
MES overcomes many limitations of static stress
analysis by accounting for…
• Geometric nonlinearity (large deformations that change
the load and/or constraint positions and directions)
• Acceleration/inertia
• Damping
• Motion-enabled contact or impact (that is, surface-to-
surface contact that changes over time due to motion or
component deformation)
• Nonlinear material behavior (such as plastic deformation
due to exceeding the material yield strength).
Mechanical Event Simulation (MES)
(continued)
Other MES characteristics:

• Loads and results are time-dependent, providing

many instantaneous results “snapshots” over a
user-defined period of time.
• Load curves are used to define how the given
loads vary over time.
• Multiple results time steps are provided for post-
processing.
• Results may be graphed versus time. The integral
and first or second derivative of the results may
also be graphed.
Comparison of Linear Static Stress and MES
Previously, we introduced the following governing
equation for static stress analysis:

{f} = [K] {d}

Where: {f} = force vector, [K] = stiffness matrix, {d} = displacement vector

For MES, additional terms are included, resulting

in the following equation:
 f    K  d   cd   [m]{d}
Where: [c] = damping matrix, [m] = mass matrix,
d  = velocity vector (first derivative of displacement),
d = acceleration vector (second derivative of displacement)
 MES – Shell Elements
• MES shell elements are similar to
linear plate elements. They are
triangular or quadrilateral, are
planar (or nearly planar), and have
three or four corner nodes.
• There are several available
formulations (consult the Help files
for more information).
• Composites are a subset of shell
elements in MES, rather than a
separate element type.
 MES – Kinematic Elements
• Kinematic elements can be either 2-D or
3-D elements.
• Kinematic elements do not experience strains
and do not report stresses. Otherwise, these
elements behave just like flexible brick
elements.
• They have an advantage over conventional
brick elements because of their small
contribution to the size of the global stiffness
matrix. This results in faster run times.
 MES – Contact Elements
• Contact elements can have
different stiffness values in
compression and tension.
• These elements can also have a
breaking stress at which point
the stiffness will be zero.
• These elements can be used to
simulate cables.
 MES – Coupling Elements
• Coupling elements aid in the
simulation of parts that "couple"
at a known length.
• This coupling is modeled by
introducing a stiffness when it
reaches this length. This
stiffness is calculated using the
modulus of elasticity, a coupling
area, and the length of the
element.
 MES – Dashpot Elements
• Dashpot elements can be used
to apply local damping to a
model.
• You can specify a damping
coefficient that will control how
much these elements affect
motion.
 MES – Actuator Elements
• Actuator elements are line
elements whose lengths can
change over time.
• They are used to simulate
defined movement of a part
(such as hydraulic cylinders or
solenoids).
 MES – Slider Elements
• A slider element consists of two
collinear lines connected at one
node.
• The node in the middle will be
allowed to move along the line
defined by the other two points,
letting the node “slide” such as
if it were in a guide or slot.
 MES – Pulley Elements
• Pulley elements consist
of three nodes: driver,
pivot, and slack.
• As the driver node
moves toward or away
from the pivot, the slack
node will move in the
opposite direction by a
set relationship.
 MES – Pipe Elements
• Pipe elements allow you to
model piping systems under
internal pressure loads.
• The pipe elements can be either
straight sections or bends.
 MES – Hydrodynamic Elements
• Hydrodynamic elements
can be either 2-D or 3-D
elements.
• These elements allow for
the simulation of the
interaction of fluids with
solids without considering
the details of the flow.
 MES – Impact Planes
• Specify a wall, floor, or ceiling parallel to the
global X, Y and Z axes.
• Objects will not be able to pass through this
plane.
MES – Surface-to-Surface Contact
• Specify two or more surfaces that may come
into contact during the event duration.
• Can include static and dynamic friction effects.
• A “slide, no bounce” option is available to
prevent objects from separating once they’ve
come into contact.
• Consult the Help files for more information
concerning the various surface contact options
and parameters.
Mechanical Event Simulation Example

For an introductory level mechanical event

simulation (MES) example, refer to the
software’s “Help: Tutorials” menu command.
Follow the “Piston Mechanical Event
Simulation” tutorial listed under “Analyzing
and Evaluating Results Tutorials.”
Also, refer to “Example M” (next slide) for a
more complex and challenging MES example
involving surface number reassignment and
surface-to-surface contact.
 Exercise M – MES, Geneva Mechanism

• Center of Joint 1 (0, 0, -0.125) & Joint 2 (1.414214, 0, -0.125): Fixed except for Rz
• Center of Joint 3 (0, 0, 0.875) & Joint 4 (1.414214, 0, 0.875): Tx, Ty, Rx & Ry
constrained
Slide 1 of 4
 Exercise M (continued)
1. Before meshing, set the default contact = “Free/No Contact” and define a surface
contact pair between Part 1 and Part 2, which will prevent mesh matching
between the parts (this is desirable for MES contact surfaces).
2. Mesh the model at an absolute mesh size of 0.0625” (1/16th of an inch).
3. Modify line attributes to consolidate the contact surfaces. Use surface 100 for
the 1st contact pair, 101 for the 2nd, and 102 for the 3rd – include chamfers. For the
drive wheel, surfaces 100 and 101 will each encompass about one-third of the
perimeter of the wheel’s C-shaped cylindrical contact surface.
4. From the “General Surface-to-Surface Contact” screen, redefine the first pair to
be Part 1/Surface 100 to Part 2/Surface 100. Create two more pair—Part 1/
Surface 101 to Part 2/Surface 101 and Part 1/Surface 102 to Part 2/Surface 102.
Set the contact element “Updating” to “Automatic.” Set the contact parameters
for all three pair as follows…
• Contact problem type = “High Speed Contact (Impact)”
• Contact type = “Surface to Surface”
• User specified contact stiffness = 1000 lbf/in
• User specified contact tolerance = 0.0011” (eliminates the effects of 0.001” part clearances
and prevents chatter, resulting in a quicker and more stable solution).

Slide 2 of 4
 Exercise M (continued)
5. Create four universal joints, one at each end face of the four stub shafts,
entering the specified vertex coordinates from the preceding diagram.
6. In the element definition screen for parts 1 and 2, set the analysis type to
“Large Displacement.” Set the material for the drive wheel to “Brass, Red” and
for the driven wheel to “Plastic – Nylon Type 6/6.” For all four joints… Change
the element type to “Pipe” – In the element definition screen, set the OD to
0.1” and the wall thickness to 0.03” – The material is to be custom defined,
E=100e6; all other values remain at zero.
7. Apply the nodal boundary conditions and loads specified on the preceding
diagram to the center points of the four joints. For Joint 4’s lumped mass,
specify a uniform mass of 0.00088 lbf·s2/in and a mass moment of inertia in the
Z-direction of 0.00135 lbf·s2·in. These values simulate a steel disk 1/8” thick
with a diameter of 3.5”.
Use load curve 1 for the prescribed displacement (rotation) and load
curve 2 for the nodal moment. Load curve 1 ramps linearly from 0 to 1 in
1 second. Load curve 2 is constant at 1. Set a death time of 1 second in the
active range data dialog for the prescribed displacement.

Slide 3 of 4
 Exercise M (continued)
8. In the analysis parameters screen, set the event duration to 1 second and
the capture rate to 90. This will produce a time step for every two degrees
of drive wheel rotation.
9. Under the equilibrium tab of the advanced analysis parameters, uncheck the
“Automatic” box for the displacement tolerance and set the value to 0.02.
10. Run the Analysis and review the results. Generate a von Mises stress
animation and a plot of displacement magnitude vs. time for two
nodes – one on the drive wheel’s indexing pin and one on the perimeter of
the driven wheel.
***
NOTE: Depending upon the computer hardware, this analysis may take several
hours to run. You may wish to allow several steps to converge, stop the
analysis, and then load the already completed model from the provided
archive file, “Exercise M\Results Archive\Exercise M.ach”.

Slide 4 of 4
Finite Element Analysis in Practice

Combining
Analysis Types
(Multiphysics)
 Multiphysics
• A multiphysics analysis combines the effects of
multiple analysis types.
• The initial analysis is performed.
• Another analysis is set up using the results from
the initial analysis as the loading in the
subsequent analysis.
• For some analyses, iterations are required to
reach a converged solution.
• Steady or unsteady coupled fluid flow and
thermal analyses solve for fluid and thermal
results simultaneously.
Examples of Combining Analysis Types
• Apply temperature results from a heat transfer
analysis to a stress analysis to analyze thermal
stress.
• Apply boundary forces from a fluid flow analysis to
a stress analysis (fluid/structural interaction).
• Apply velocity results from a fluid flow analysis to a
heat transfer analysis to analyze the effect of forced
convection on the temperature distribution (where
the temperature does not significantly influence the flow
pattern).
• Apply temperature results from a heat transfer
analysis to a fluid flow analysis to drive natural
convection (where the flow does not significantly
influence the temperature distribution).
Examples of Combining Analysis Types
(continued)
• Apply current results from an electrostatic
analysis to a heat transfer analysis to analyze
Joule heating.
• Apply electrostatic attraction/repulsion forces
from an electrostatic analysis to a stress
analysis to determine displacements and
stresses (commonly used in the analysis of
micro electromechanical systems – MEMS).
 Multiphysics Example:
Analysis of Stresses due to
Electrostatic Forces
Refer to the software’s “Help: Tutorials” menu
command. Follow the “Radial Comb Motor
Static Stress Analysis” tutorial listed under
“Analyzing and Evaluating Results Tutorials”
for further information on performing a
multiphysics analysis of structural stress and
displacement due to electrostatic forces.
Finite Element Analysis in Practice

Material
Models
Background on Material Models
• Material models are subsets of the element
types.
• These models allow you to make decisions
on what type of material properties will be
used for each part in the model.
• For example, if a part will see the plastic
region of a stress versus strain curve, you
should select one of the von Mises material
models for an elastic/plastic analysis.
 Isotropic
• This is the standard material model. The
material properties are independent of
direction.
 Orthotropic
• This material model can have different
properties in the three orthogonal
directions.
• The required properties are identical to the
isotropic material model. However, you
enter separate values for the three
directions.
 Temperature-Dependent
• For some elements, the properties for both
isotropic and orthotropic materials can be
defined on a temperature-dependent basis.
• The values are linearly interpolated between
the specified temperature points.
 Elastic-Plastic (von Mises)
• von Mises: This material models is based on a bilinear
simplification of the stress-strain curve. The modulus
for the elastic region, the yield point, and the modulus
for the plastic region must be defined. If the material
library includes the elastic modulus, yield point,
ultimate strength, and elongation; the program will
automatically calculate the plastic modulus for you.
• von Mises Curve: This material model uses either an
approximated stress-strain curve or actual stress-strain
data. As above, if the material library includes the
elastic modulus, yield point, ultimate strength, and
elongation; the approximated stress-strain curve will be
generated automatically. Alternately, you may define a
table of true stress-strain data (either within the material
library manager or the material application screen).
 Elastic-Plastic (von Mises)
(continued)
• Isotropic hardening and kinematic hardening
variants of the von Mises material models are
available.
– Use the “von Mises with Isotropic Hardening” model for
non-reversing load conditions.
– The “von Mises with Kinematic Hardening” model is
recommended for greater accuracy when reversing
strain cycles will occur.
Hyperelastic and Foam Material Models
• The following rubber-like (hyperelastic)
material models are available:
– Mooney-Rivlin – Yeoh
– Arruda-Boyce – Neo-Hookean
– Ogden – Van der Waals
• The following foam-like material models are
available:
– Blatz-Ko
– Hyperfoam (accounts for compressibility)
 Drucker-Prager
• This material model is used to model rock
and concrete.
 Viscoelastic and Viscoplastic
• These material models are used to account
for rate-dependent material behavior due to
dissipative losses from viscous effects.
The viscoelastic material models are
variants of the previously listed
hyperelastic material models.
• A material model that can be used to model
thermal creep is also available (“Thermal
Creep Viscoelastic”).
Thermoelastic and Thermoplastic
• These material models are used for thermal
stress analyses. The Thermoplastic model
is used when stresses beyond the yield
point occur.
 Piezoelectric
• This material model is for parts that
experience stress due to a voltage
distribution.
 Curve
• This material model allows you to input a
bulk modulus versus strain curve to control
the behavior of the part.
 Reinforced Concrete
• This material model allows different tensile
and compressive behaviors. It can simulate
cracking and crushing failure of concrete
under relatively monotonic loading. A
maximum of three independent directions
of rebar are allowed for the concrete
material. The rebar locations (in height or
depth) are not considered; they are treated
as "smeared" throughout the part.
Exercise N - Nonlinear Material Model
• Objective: Analyze a cantilever beam
using beam elements and an elastic
material model. Determine if yielding
occurs. If it does, reanalyze the beam
using a plastic material model.
• Geometry: The beam is 10’ long
and is 5” x 5” square.
• Material: Steel (ASTM - A36)
• Loads: 56,000 pounds in the
Load curve:
-Y direction at the free end.
• Constraints: The fixed end is fully Time
Multiplier
constrained. (s)
0 0
• Duration: 10 seconds.
10 1
• Capture rate: 2 steps per second.