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.
Author(s): Paul M. Kurowski
Edition: 3
Publisher: SAE International
Year: 2022
Language: English
Pages: 286
City: Warrendale
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
