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Thursday, September 6, 2007
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Thursday, September 6, 2007
Finite Element Analysis: Pre-processing
The following four-article series was published in a newsletter of the American Society of Mechanical Engineers (ASME). It serves as an introduction to the recent analysis discipline known as the finite element method. The author is an engineering consultant and expert witness specializing in finite element analysis.
FINITE ELEMENT ANALYSIS: Pre-processing
by Steve Roensch, President, Roensch & Associates
Second in a four-part series
As discussed last month, finite element analysis is comprised of pre-processing, solution and post-processing phases. The goals of pre-processing are to develop an appropriate finite element mesh, assign suitable material properties, and apply boundary conditions in the form of restraints and loads.
The finite element mesh subdivides the geometry into elements, upon which are found nodes. The nodes, which are really just point locations in space, are generally located at the element corners and perhaps near each midside. For a two-dimensional (2D) analysis, or a three-dimensional (3D) thin shell analysis, the elements are essentially 2D, but may be "warped" slightly to conform to a 3D surface. An example is the thin shell linear quadrilateral; thin shell implies essentially classical shell theory, linear defines the interpolation of mathematical quantities across the element, and quadrilateral describes the geometry. For a 3D solid analysis, the elements have physical thickness in all three dimensions. Common examples include solid linear brick and solid parabolic tetrahedral elements. In addition, there are many special elements, such as axisymmetric elements for situations in which the geometry, material and boundary conditions are all symmetric about an axis.
The model's degrees of freedom (dof) are assigned at the nodes. Solid elements generally have three translational dof per node. Rotations are accomplished through translations of groups of nodes relative to other nodes. Thin shell elements, on the other hand, have six dof per node: three translations and three rotations. The addition of rotational dof allows for evaluation of quantities through the shell, such as bending stresses due to rotation of one node relative to another. Thus, for structures in which classical thin shell theory is a valid approximation, carrying extra dof at each node bypasses the necessity of modeling the physical thickness. The assignment of nodal dof also depends on the class of analysis. For a thermal analysis, for example, only one temperature dof exists at each node.
Developing the mesh is usually the most time-consuming task in FEA. In the past, node locations were keyed in manually to approximate the geometry. The more modern approach is to develop the mesh directly on the CAD geometry, which will be (1) wireframe, with points and curves representing edges, (2) surfaced, with surfaces defining boundaries, or (3) solid, defining where the material is. Solid geometry is preferred, but often a surfacing package can create a complex blend that a solids package will not handle. As far as geometric detail, an underlying rule of FEA is to "model what is there", and yet simplifying assumptions simply must be applied to avoid huge models. Analyst experience is of the essence.
The geometry is meshed with a mapping algorithm or an automatic free-meshing algorithm. The first maps a rectangular grid onto a geometric region, which must therefore have the correct number of sides. Mapped meshes can use the accurate and cheap solid linear brick 3D element, but can be very time-consuming, if not impossible, to apply to complex geometries. Free-meshing automatically subdivides meshing regions into elements, with the advantages of fast meshing, easy mesh-size transitioning (for a denser mesh in regions of large gradient), and adaptive capabilities. Disadvantages include generation of huge models, generation of distorted elements, and, in 3D, the use of the rather expensive solid parabolic tetrahedral element. It is always important to check elemental distortion prior to solution. A badly distorted element will cause a matrix singularity, killing the solution. A less distorted element may solve, but can deliver very poor answers. Acceptable levels of distortion are dependent upon the solver being used.
Material properties required vary with the type of solution. A linear statics analysis, for example, will require an elastic modulus, Poisson's ratio and perhaps a density for each material. Thermal properties are required for a thermal analysis. Examples of restraints are declaring a nodal translation or temperature. Loads include forces, pressures and heat flux. It is preferable to apply boundary conditions to the CAD geometry, with the FEA package transferring them to the underlying model, to allow for simpler application of adaptive and optimization algorithms. It is worth noting that the largest error in the entire process is often in the boundary conditions. Running multiple cases as a sensitivity analysis may be required.
Next month's article will discuss the solution phase of the finite element method.
copyright 2005 Roensch & Associates. All rights reserved.
Steve Roensch is a mechanical engineer with more than 20 years experience. He has served as an expert witness across many industries. Learn more about mechanical engineer expert witness services at www.FiniteElement.com.
Finite Element Analysis: Solution
The following four-article series was published in a newsletter of the American Society of Mechanical Engineers (ASME). It serves as an introduction to the recent analysis discipline known as the finite element method. The author is an engineering consultant and expert witness specializing in finite element analysis.
FINITE ELEMENT ANALYSIS: Solution
by Steve Roensch, President, Roensch & Associates
Third in a four-part series
While the pre-processing and post-processing phases of the finite element method are interactive and time-consuming for the analyst, the solution is often a batch process, and is demanding of computer resource. The governing equations are assembled into matrix form and are solved numerically. The assembly process depends not only on the type of analysis (e.g. static or dynamic), but also on the model's element types and properties, material properties and boundary conditions.
In the case of a linear static structural analysis, the assembled equation is of the form Kd = r, where K is the system stiffness matrix, d is the nodal degree of freedom (dof) displacement vector, and r is the applied nodal load vector. To appreciate this equation, one must begin with the underlying elasticity theory. The strain-displacement relation may be introduced into the stress-strain relation to express stress in terms of displacement. Under the assumption of compatibility, the differential equations of equilibrium in concert with the boundary conditions then determine a unique displacement field solution, which in turn determines the strain and stress fields. The chances of directly solving these equations are slim to none for anything but the most trivial geometries, hence the need for approximate numerical techniques presents itself.
A finite element mesh is actually a displacement-nodal displacement relation, which, through the element interpolation scheme, determines the displacement anywhere in an element given the values of its nodal dof. Introducing this relation into the strain-displacement relation, we may express strain in terms of the nodal displacement, element interpolation scheme and differential operator matrix. Recalling that the expression for the potential energy of an elastic body includes an integral for strain energy stored (dependent upon the strain field) and integrals for work done by external forces (dependent upon the displacement field), we can therefore express system potential energy in terms of nodal displacement.
Applying the principle of minimum potential energy, we may set the partial derivative of potential energy with respect to the nodal dof vector to zero, resulting in: a summation of element stiffness integrals, multiplied by the nodal displacement vector, equals a summation of load integrals. Each stiffness integral results in an element stiffness matrix, which sum to produce the system stiffness matrix, and the summation of load integrals yields the applied load vector, resulting in Kd = r. In practice, integration rules are applied to elements, loads appear in the r vector, and nodal dof boundary conditions may appear in the d vector or may be partitioned out of the equation.
Solution methods for finite element matrix equations are plentiful. In the case of the linear static Kd = r, inverting K is computationally expensive and numerically unstable. A better technique is Cholesky factorization, a form of Gauss elimination, and a minor variation on the "LDU" factorization theme. The K matrix may be efficiently factored into LDU, where L is lower triangular, D is diagonal, and U is upper triangular, resulting in LDUd = r. Since L and D are easily inverted, and U is upper triangular, d may be determined by back-substitution. Another popular approach is the wavefront method, which assembles and reduces the equations at the same time. Some of the best modern solution methods employ sparse matrix techniques. Because node-to-node stiffnesses are non-zero only for nearby node pairs, the stiffness matrix has a large number of zero entries. This can be exploited to reduce solution time and storage by a factor of 10 or more. Improved solution methods are continually being developed. The key point is that the analyst must understand the solution technique being applied.
Dynamic analysis for too many analysts means normal modes. Knowledge of the natural frequencies and mode shapes of a design may be enough in the case of a single-frequency vibration of an existing product or prototype, with FEA being used to investigate the effects of mass, stiffness and damping modifications. When investigating a future product, or an existing design with multiple modes excited, forced response modeling should be used to apply the expected transient or frequency environment to estimate the displacement and even dynamic stress at each time step.
This discussion has assumed h-code elements, for which the order of the interpolation polynomials is fixed. Another technique, p-code, increases the order iteratively until convergence, with error estimates available after one analysis. Finally, the boundary element method places elements only along the geometrical boundary. These techniques have limitations, but expect to see more of them in the near future.
Next month's article will discuss the post-processing phase of the finite element method.
copyright 2005 Roensch & Associates. All rights reserved.
Steve Roensch is a mechanical engineer with more than 20 years experience. He has served as an expert witness across many industries. Learn more about mechanical engineer expert witness services at www.FiniteElement.com.
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