Computer Aided Design (CAD)

Is based on parametric models

Copyright 2010

J. E. Akin

Rice University, MEMS Dept.

Computer Aided Design (CAD)

Creates parametric solid models for: 1. Automatic multi-view drawings with di ith dimensions i 2. Manufacturing control with Geometric dimensioning & tolerances (GD&T)

Copyright 2010

J. E. Akin

Rice University, MEMS Dept.

Computer Aided Design (CAD)

Creates parametric solid models for: 3. 3 Rapid prototypes via 3D printing (wax (wax, plastic, metals, casting sand) 4. 4 Computer Numerical Controlled (CNC) machining from an initial solid block

Copyright 2010

J. E. Akin

Rice University, MEMS Dept.

Computer Aided Design (CAD)

Creates parametric solid model data for: 5. 5 Mass property calculations (surface area, area volume, centroid, moment of inertia) 6. 6 Product Data Management (PDM)

Copyright 2010

J. E. Akin

Rice University, MEMS Dept.

Computer Aided Design (CAD)

Creates parametric solid model data to feed analysis systems such as automatic mesh y y generators, finite element analysis (FEA), finite volume analysis ( y (FVA), finite ), difference methods (FDM), mechanism motion and kinetics studies, etc. ,

Copyright 2010

J. E. Akin

Rice University, MEMS Dept.

CAD and Finite Element Analysis

Most ME CAD applications require a FEA in one or more areas:
Stress Analysis Thermal Analysis Vibrations or Structural Dynamics Computational Fluid Dynamics (CFD) Electromagnetic Analysis ...
J. E. Akin Rice University, MEMS Dept.

Copyright 2010

FEA Data Reliability

Geometry: generally most accurate Material: accurate if standardized Mesh: requires engineering judgement Loads: less accurate, require assumptions , q p Restraints: least accurate, drastically effects results; several reasonable restraint cases should be studied
J. E. Akin Rice University, MEMS Dept.

Copyright 2010

Primary FEA Assumptions

Model geometry Material Properties
Elastic modulus, Thermal Conductivity, etc.

M h( ) Mesh(s)
Element type and size, size transition rates

Source (Load) Cases

Types of loads, Factors of safety, Coord. Sys.

Boundary conditions (Fixtures)

Coordinate system(s)
Copyright 2010 J. E. Akin Rice University, MEMS Dept.

General Approach for FEA

Select verification tools to check the study
analytic, experimental, other FEA method, etc.

Understand the primary variables (PV) in the differential equation Understand boundary conditions (BC) Essential, or Dirichlet BC on PV in the original
differential equation at a boundary (EBC) N t l or N Natural, Neumann BC i l in lower space b boundary d differential equation (NBC)

One or the other applied at a boundary point

Copyright 2010 J. E. Akin Rice University, MEMS Dept.

General Approach for FEA, 2

Understand secondary variables (SV) obtained from the gradient of the primary g p y variables and usually combined with the p p material properties
Statics: strains, stresses, failure criterion Thermal: temperature gradient, heat flux

Copyright 2010

J. E. Akin

Rice University, MEMS Dept.

General Approach for FEA, 3

Understand boundary conditions (BC)
Essential, or Dirichlet BC (on PV)
Statics: displacement and/or (maybe) rotation Thermal: temperature

Natural, or Neumann BC (on SV)

Statics: zero surface traction vector Thermal: zero normal heat flux

One or the other at a boundary point.

Copyright 2010 J. E. Akin Rice University, MEMS Dept.

FEA Accuracy
PV are most accurate at the mesh nodes. SV are least accurate at the mesh nodes. nodes
SV are most accurate at the Gauss integration points SV can be post-processed for accurate nodal va ues (and error estimates) values (a d e o est ates)

Copyright 2010

J. E. Akin

Rice University, MEMS Dept.

General Approach for FE, 1 FE

Select verification tools to check the study
analytic, experimental, other fea method, etc.

Select element type(s) and degree

2-D, 3-D solid, axisymmetric solid, thick surface, thin surface, thick curve, thin curve, etc.

U d t d primary variables (PV) Understand i i bl

Stress Analysis: displacements & (maybe) rotations Thermal Analysis: temperature Fluid Flow: velocity & pressure

Copyright 2010

J. E. Akin

Rice University, MEMS Dept.

General Approach for FE, 4

Understand reactions needed to maintain the Essential BC
Statics:
Force at given displacement g p Moment at given rotation (if active)

Thermal:
Heat flux at given temperature

Copyright 2002

J. E. Akin

Rice University, MEMS Dept.

General Approach for FE, 5

1. Estimate the solution results and gradients p (1 ) 2. Select an acceptable error ( %) 3. Mesh the model pp y 4. Load the model and apply essential BC 5. Solve the model (PV), then post-process (SV) 6. Estimate the error levels
A. Unacceptable error: Adapt mesh, go to 3 B. Acceptable error: Validate the analysis p y
Copyright 2002 J. E. Akin Rice University, MEMS Dept.

FE Mesh (FEM)
Crude meshes that look like a part are ok look like for images and mass properties but not for FE analysis. y Local error is proportional to product of the local mesh size (h) and the gradient of the ( ) g secondary variables. PV piecewise continuous polynomials of degree p, and SV are discontinuous polynomials of degree (p-1).
Copyright 2002 J. E. Akin Rice University, MEMS Dept.

FEA Stress Models

3-D Solid, PV: 3 displacements (no rotations), SV: SV 6 stresses (3 normal & 3 shear stresses) l h ) 2-D Approximations
Plane Stress (zz = 0) PV: 2 displacements, SV: 3 stresses Plane Strain ( zz = 0) PV: 2 displacements, SV: 3 stresses (and zz from Poissons ratio) Axisymmetric (/ = 0) PV: 2 displacements, SV: 4 stresses
Copyright 2002 J. E. Akin Rice University, MEMS Dept.

FEA Stress Models, 2 ,

2-D Approximations 2D
Thick Shells, PV: 3 displacements (no rotations), SV: 5 ( 6) stresses ), (or ) Thin Shells, PV: 3 displacements and 3 rotations, SV: 5 stresses (each at top, middle, ( p and bottom surfaces) Plate bending PV: normal displacement, inplane rotation vector, SV: 3 stresses (each at top, middle, and bottom surfaces)
Copyright 2002 J. E. Akin Rice University, MEMS Dept.

FEA Stress Models, 3

1-D Approximations pp
Bars (Trusses), PV: 3 displacements (1 local axial displacement), SV: 1 axial stress Torsion member, PV: 3 rotations (1 local axial rotation), SV: 1 torsional stress B Beams (Frames), PV: 3 displacements, 3 (F ) PV di l t rotations, SV: axial, bending, & shear stress
Thick beam, thin beam, curved beam Pipe element, pipe elbow, pipe tee

Copyright 2002

J. E. Akin

Rice University, MEMS Dept.

Local Error
The error at a (non-singular) point is the product of the element size, h the d f h l i h, h gradient of the secondary variables, and a constant d dependent on the d d h domain i shape and boundary conditions.
Large gradient points need small h Small gradient points can have large h

Plan local mesh size with engineering judgement of estimated gradients.

Copyright 2002 J. E. Akin Rice University, MEMS Dept.

Error Estimators
Global and element error estimates are often available from mathematical norms of the secondary variables. The energy norm is the most common. It is proven to be asymptotically exact for elliptical problems. Typically we want less than 1 % error.
Copyright 2002 J. E. Akin Rice University, MEMS Dept.

Error Estimates
Quite good for elliptic problems (thermal, elasticity, ideal flow), Navier-Stokes, etc. y, ), , Can predict the new mesh size needed to reach the required accuracy. accuracy Can predict needed polynomial degree. R Require second post-processing pass for i d i f localized (element level) gradient smoothing.
Copyright 2002 J. E. Akin Rice University, MEMS Dept.

Primary FEA Matrix Costs y

Assume sparse banded linear algebra system of E equations with a half-bandwidth of B equations, B. Full system if B = E.
Storage required S = B * E (Mb) required, Solution Cost, C B * E2 (time) H lf symmetry: B B/2 E E/2 S S/4 Half t B/2, E/2, S/4, C C/8 Quarter symmetry: B B/4 E E/4 S S/16 B/4, E/4, S/16, C C/64 Eighth symmetry Cyclic symmetry, ... symmetry, symmetry
Copyright 2002 J. E. Akin Rice University, MEMS Dept.

Symmetry and Anti-symmetry y y y y

Use symmetry states for the maximum accuracy at the least cost in stress and t e a p ob e s. thermal problems. Cut the object with symmetry planes (or surfaces) and apply new boundary conditions (EBC or NBC) to account for the removed material material.

Copyright 2002

J. E. Akin

Rice University, MEMS Dept.

Symmetry (Anti-symmetry)
Requires symmetry of the geometry and material properties. p p Requires symmetry (anti-symmetry) of the source terms. terms Requires symmetry (anti-symmetry) of the essential boundary conditions. conditions

Copyright 2002

J. E. Akin

Rice University, MEMS Dept.

Structural Model
Symmetry
Zero displacement normal to surface Zero rotation vector tangent to surface

Anti-symmetry
Zero displacement vector tangent to surface Z Zero rotation normal to surface t ti lt f

Copyright 2002

J. E. Akin

Rice University, MEMS Dept.

Thermal Model
Symmetry
Zero gradient normal to surface (insulated surface, zero heat flux)

Anti-symmetry Anti symmetry

Average temperature on surface known

Copyright 2002

J. E. Akin

Rice University, MEMS Dept.

Local Singularities
All elliptical problems have local radial gradient singularities near re-entrant corners in the domain. domain p
Radius, r Strength, p = /C Re-entrant, C u/r as r 0
Copyright 2002 J. E. Akin Rice University, MEMS Dept.

u = r f() u/r = r (p-1) f()

Corner: p = 2/3, weak Crack: p = 1/2 strong 1/2,

Stress Analysis Verification, 1

Prepare initial estimates of deflections, reactions and stresses. Eyeball check the deflected shape and p p the principal stress vectors. Eyeball check the contour lines for wiggles. wiggles (OK in low stress regions.) regions )

Copyright 2002

J. E. Akin

Rice University, MEMS Dept.

Stress A l i V ifi ti St Analysis Verification, 2

The stresses often depend only on the shape of the part and are independent of the material properties. You must also verify the displacements y p which almost always depend on the p p material properties.

Copyright 2002

J. E. Akin

Rice University, MEMS Dept.

Stress Analysis Verification, 3

The reaction resultant forces and/or moments are equal and opposite to the q pp actual applied loading. For pressures or tractions remember to compare their integral (resultant) to the solution reactions. Reactions can be obtained at elements too.
Copyright 2002 J. E. Akin Rice University, MEMS Dept.

Stress Analysis Verification, 4

Compare displacements, reactions and stresses to initial estimates. Investigate any differences. Check maximum error estimates, if , available in the code.

Copyright 2002

J. E. Akin

Rice University, MEMS Dept.

Thermal Analysis Verification 1 Verification,

Prepare initial estimates of the temperatures, reaction flux, and heat flux vectors. vectors Eyeball check the temperature contours and the heat flux vectors. vectors Temperature contours should be perpendicular to an insulated boundary. di l i l db d

Copyright 2002

J. E. Akin

Rice University, MEMS Dept.

Thermal Analysis Verification, 2

The temperatures often depend only on the shape of the part. Verify the heat flux magnitudes which y p almost always depend on the material properties.

Copyright 2002

J. E. Akin

Rice University, MEMS Dept.

Thermal Analysis Verification 3 Verification,

The reaction resultant nodal heat fluxes are equal and opposite to the applied heat fluxes. q pp pp For distributed heat fluxes remember to compare their integral (resultant) to the solution reactions. Reactions can be obtained at elements too too.

Copyright 2002

J. E. Akin

Rice University, MEMS Dept.

Thermal Analysis Verification, 4

Compare temperatures, reactions and heat flux vectors to initial estimates. Investigate any differences. Check maximum error estimates, if , available in the code.

Copyright 2002

J. E. Akin

Rice University, MEMS Dept.