Finite Element Analysis for Design Engineers

Description

Finite Element Analysis (FEA) has been widely implemented by the automotive industry as a productivity tool for design engineers to reduce both development time and cost. This essential work serves as a guide for FEA as a design tool and addresses the specific needs of design engineers to improve productivity. It provides a clear presentation that will help practitioners to avoid mistakes. Easy to use examples of FEA fundamentals are clearly presented that can be simply applied during the product development process. The FEA process is fully explored in this fundamental and practical approach that includes: Understanding FEA basics Commonly used modeling techniques Application of FEA in the design process Fundamental errors and their effect on the quality of results Hands-on simple and informative exercises This indispensable guide provides design engineers with proven methods to analyze their own work while it is still in the form of easily modifiable CAD models. Simple and informative exercises provide examples for improving the process to deliver quick turnaround times and prompt implementation. This is the latest version of Finite Element Analysis for Design Engineers. Front Cover Title Page Copyright Page Contents Preface CHAPTER 1 Introduction 1.1. What Is Finite Element Analysis? 1.2. What Is the Place of FEA among Other Tools of Computer-Aided Engineering? 1.3. Fields of Application of FEA and Mechanism Analysis 1.4. Fields of Application of FEA and CFD 1.5. What Is “FEA for Design Engineers”? 1.6. Note on Hands-On Exercises CHAPTER 2 From CAD Model to Results of FEA 2.1. Formulation of the Mathematical Model 2.2. Selecting the Numerical Method to Solve the Mathematical Model 2.2.1. Selected Numerical Methods in CAE 2.2.2. Reasons for the Dominance of FEM 2.3. FEA Model 2.3.1. Meshing 2.3.2. Formulation of FE Equations 2.3.3. Errors in FEA Results 2.4. Verification and Validation of FEA Results CHAPTER 3 Fundamental Concepts of FEA 3.1. Formulation of a Finite Element 3.1.1. Closer Look at Finite Element 3.1.2. Requirements to be Satisfied by Displacement Interpolation Function 3.1.3. Artificial Restraints 3.2. Choices of Discretization 3.3. Types of Finite Elements 3.3.1. Element Dimensionality 3.3.2. Element Shape 3.3.3. Element Order and Element Type 3.3.4. Summary of Commonly Used Elements 3.3.5. Element Modeling Capabilities CHAPTER 4 Controlling Discretization Errors 4.1. Presenting Stress Results 4.2. Types of Convergence Analysis 4.2.1. h Convergence by Global Mesh Refinement 4.2.2. h Convergence by Local Mesh Refinement 4.2.3. Adaptive h Convergence 4.2.4. p Convergence Process 4.2.5. Choice of Convergence Process 4.3. Discretization Error 4.3.1. Convergence Error 4.3.2. Solution Error 4.4. Problems with Convergence 4.4.1. Stress Singularity 4.4.2. Displacement Singularity 4.5. Hands-On Exercises 4.5.1. HOLLOW PLATE Description Objective Procedure 4.5.2. L BRACKET01 Description Objective Procedure 4.5.3. WEDGE Description Objective Procedure CHAPTER 5 Finite Element Mesh 5.1. Meshing Techniques 5.1.1. Manual Meshing 5.1.2. Semi-automatic Meshing 5.1.3. Automatic Meshing 5.2. Mesh Compatibility 5.2.1. Compatible Elements 5.2.2. Incompatible Elements 5.2.3. Forced Compatibility 5.3. Common Meshing Problems 5.3.1. Element Distortion 5.3.2. Mesh Adequacy 5.3.3. Element Mapping to Geometry 5.3.4. Incorrect Conversion to Shell Model 5.4. Hands-On Exercises 5.4.1. BRACKET01 Description Objective Procedure 5.4.2. CANTILEVER Description Objective Procedure CHAPTER 6 Modeling Process 6.1. Modeling Steps 6.1.1. Definition of the Objective of Analysis 6.1.2. Selection of the Units of Measurement 6.1.3. Geometry Preparation 6.1.4. Defining Material Properties 6.1.5. Defining Boundary Conditions 6.2. Selected Modeling Techniques 6.2.1. Mirror Symmetry and Anti-symmetry Boundary Conditions 6.2.2. Axial Symmetry 6.2.3. Cyclic Symmetry 6.2.4. Realignment of Degrees of Freedom 6.2.5. Using Point Restraints to Eliminate Rigid Body Motions 6.3. Hands-On Exercises 6.3.1. BRACKET02—Mirror Symmetry BC Description Objective Procedure 6.3.2. BRACKET02—Anti-symmetry BC Description Objective Procedure 6.3.3. BRACKET02—Mirror Symmetry and Anti-symmetry BC Description Objective Procedure 6.3.4. SHAFT01 Description Objective Procedure 6.3.5. PRESSURE TANK Description Objective Procedure 6.3.6. RING Description Objective Procedure 6.3.7. LINK01 Description Objective Procedure CHAPTER 7 Nonlinear Geometry Analysis 7.1. Classification of Different Types of Nonlinearities 7.2. Geometric Nonlinearity 7.3. Membrane Stress Stiffening 7.4. Contact 7.5. Hands-On Exercises 7.5.1. CANTILEVER BEAM Description Objective Procedure 7.5.2. SHAFT02 Description Objective Procedure 7.5.3. ROUND PLATE01 Description Objective Procedure 7.5.4. LINK02 Description Objective Procedure 7.5.5. SLIDING SUPPORT Description Objective Procedure 7.5.6. CLAMP01 Description Objective Procedure 7.5.7. CLAMP02 Description Objective Procedure CHAPTER 8 Nonlinear Material Analysis 8.1. Review of Nonlinear Material Models 8.2. Use of Nonlinear Material to Control Stress Singularity 8.3. Other Types of Nonlinearities 8.4. Hands-On Exercises 8.4.1. BRACKET NL Objective Procedure 8.4.2. L BRACKET02 Description Objective Procedure CHAPTER 9 Modal Analysis 9.1. Differences between Modal and Static Analysis 9.2. Interpretation of Displacement and Stress Results in Modal Analysis 9.3. Modal Analysis with Rigid Body Motions 9.4. Importance of Supports in Modal Analysis 9.5. Applications of Modal Analysis 9.5.1. Finding Modal Frequencies and Associated Shapes of Vibration 9.5.2. Locating “Weak Spots” in Structure 9.5.3. Modal Analysis Provides Input to Vibration Analysis 9.6. Pre-stress Modal Analysis 9.7. Symmetry and Anti-symmetry Boundary Conditions in Modal Analysis 9.8. Convergence of Modal Frequencies 9.9. Meshing Consideration for Modal Analysis 9.10. Hands-On Exercises 9.10.1. TUNING FORK Description Objective Procedure Comments 9.10.2. BOX Description Objective Procedure Comments 9.10.3. AIRPLANE Description Objective Procedure Comments 9.10.4. BALL Description Objective Procedure Comments 9.10.5. LINK03 Description Objective Procedure Comments 9.10.6. HELICOPTER BLADE Description Objective Procedure Comments 9.10.7. COLUMN Description Objective Procedure Comments 9.10.8. BRACKET03 Description Objective Procedure Comments CHAPTER 10 Buckling Analysis 10.1. Linear Buckling Analysis 10.2. Convergence of Results in Linear Buckling Analysis 10.3. Nonlinear Buckling Analysis 10.4. Controlling an Onset of Buckling in Nonlinear Buckling Analysis 10.5. Summary 10.6. Hands-On Exercises 10.6.1. NOTCHED COLUMN - Free End Description Objective Procedure Comments 10.6.2. NOTCHED COLUMN - Sliding End Procedure 10.6.3. ROUND PLATE02 Description Objective Procedure Comments 10.6.4. CURVED COLUMN Objective 10.6.5. STAND Description Objective Procedure Comments 10.6.6. CURVED SHEET Description Objective Procedure CHAPTER 11 Vibration Analysis 11.1. Modal Superposition Method 11.2. Time Response Analysis 11.3. Frequency Response Analysis 11.4. Nonlinear Vibration Analysis 11.5. Hands-On Exercises 11.5.1. HAMMER - Impulse Load Description Objective Procedure Comments 11.5.2. HAMMER - Beating Description Objective Procedure Comments 11.5.3. ELBOW PIPE Description Objective Procedure Comments 11.5.4. CENTRIFUGE Description Objective Procedure Comments 11.5.5. PLANK Description Objective Procedure Comments CHAPTER 12 Thermal Analysis 12.1. Heat Flow by Conduction 12.2. Heat Flow by Convection 12.3. Heat Transfer by Radiation 12.4. Modeling Considerations in Thermal Analysis 12.5. Challenges in Thermal Analysis 12.6. Hands-On Exercises 12.6.1. BRACKET04 Description Objective Procedure Comments 12.6.2. HEAT SINK Description Objective Procedure Comments 12.6.3. CHANNEL Description Objective Procedure Comments 12.6.4. SPACE HEATER Description Objective Procedure Comments CHAPTER 13 Implementation of Finite Element Analysis in the Design Process 13.1. Differences between CAD and FEA Geometry 13.1.1. Defeaturing 13.1.2. Idealization 13.1.3. Cleanup 13.2. Common Meshing Problems 13.3. Mesh Adequacy 13.4. Integration of CAD and FEA Programs 13.4.1. Stand-Alone FEA Programs 13.4.2. FEA Programs Integrated with CAD 13.4.3. Computer Aided Engineering (CAE) Programs 13.5. FEA Implementation 13.5.1. Positioning of CAD and FEA Activities 13.5.2. Personnel Training 13.5.3. FEA Program Selection 13.5.4. Hardware Selection 13.5.5. Building Confidence in FEA 13.5.6. Return on Investment 13.6. FEA Project 13.6.1. Before FEA Project Starts 13.6.2. Establish the Scope of Analysis 13.6.3. Create the Mathematical Model 13.6.4. Create the Finite Element Model and Solve It 13.6.5. Review the Results 13.6.6. Presentation of the Results 13.6.7. FEA Report 13.6.8. Project Documentation and Backups 13.6.9. Contracting Out FEA Services 13.6.10. Common Errors in Management of FEA Projects CHAPTER 14 Summary 14.1. FEA Quiz 14.2. Frequently Asked Questions CHAPTER 15 FEA Resources CHAPTER 16 Glossary CHAPTER 17 List of Exercises Index About the Author Back Cover