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The Finite Element Analysis (FEA) is a technique to study a model and its behavior towards simulated physical phenomena like vibrations, temperature, pressure, stress, etc.
Engineers and designers use the Finite Element Method (FEM) to reduce physical prototypes and save time and cost on experiments while building optimized products.
With FEA, complex numerical problems are solved using computing software that helps designers study a design or its parts for performance, lifespan, and areas of optimization.
Engineers and designers use FEA in the design and construction phase in automobile, construction, aerospace, buildings, etc, to assess structures, parts, or components. They build Finite Element Models (FEM) using suitable software and simulation to make predictions and draw conclusions.
To make the best use of this technique, engineers must learn to use the FEA technique properly. Use these pointers to ensure good results from FEA.
George Feuchsal, an IBM programmer and instructor, coined this term to briefly emphasize that computing software produces an output only as good as the input.
In FEA, the input data and the problem must be critically framed to achieve the solution being looked for. Thus, when the input problems are not precise or accurate, the output might not be the expected solution, and in rare cases, it may be inaccurate.
Interpreting the answer is an essential skill in FEA. But feeding accurate data and formulating the problem correctly is equally important.
FEA involves multiphysics. FEM is used to study how objects behave under real-world stresses like heat transfer analysis, fluid flow analysis, and electrostatic analysis.
These effects can happen in unison or independently. Therefore, FEA analysts and engineers must understand the different factors that affect an object’s performance and reproduce them into computer simulations for analysis.
Failure to understand the science and nature of the stress and their interactions with the object may lead to inaccurate solutions.
Using Finite Element Models, large-scale motion simulation can be used to study objects. There are three standard methods used in FEA Motion Simulation:
Engineers use a kinematics program to get a rough estimate of the stress loads and use this data for FEA analysis. This helps to calculate stresses faster than through manual rigid body programs, but it cannot be used to analyze flexible parts or objects.
This method simulates a model’s precise motion using several short intervals. For a given time interval, solutions can be found by “marching” along in time and using predictions from the previous step.
The object’s motion cycle is simulated using larger time steps for relative inactivities like constant acceleration or deceleration. The timestep is automatically reduced to assess critical activity like contact between objects or surfaces, impact, etc. Through this, motion, deformations, and stresses can be studied and calculated more accurately at every point in time.
Based on the type of FEA analysis, the modeling method is chosen to ensure the model responds appropriately to the characteristics of the operating environment.
The CAD solid model is exported to a neutral format like IGES, ACIS, or Parasolid and then is imported and processed in the FEA System. Sometimes, certain CAD geometry data is lost when the model is translated and the problems are simplified before analysis.
The CAD universal file format method requires an engineer to export the CAD solid model to a neutral file format, such as IGES, ACIS, or Parasolid, and then import the neutral file into the FEA system for setup and analysis.
Although this method usually enables engineers to take full advantage of an FEA program, it can also result in the loss of CAD geometry data as the model is translated. So it’s not an ideal method since it sometimes involves using a simplified version of the problem.
Analyzing features are built into the CAD Solid Modeller by the FEA vendor. Hence, no translation is required with this method. Therefore, this is easier and more accessible for most engineers.
Though this method takes up less computing space, the drawback is that engineers must be well versed with multiple software. In addition, FEA vendors must also customize the software based on the user’s requirements, which can make this method slightly expensive and labor-intensive.
FEA Analysis and CAD Modelling can be done on different computers with no translation required. As FEA runs on a separate application, enabling more complete packages.
Although, the engineer must be skilled in FEA and CAD Softwares to use this method.
Before interpretation, the results obtained must be verified and validated using experts or other supported databases.
After verification, the results must be interpreted to understand what the numbers and simulation signify.
With linear static stress analysis, the available contours must be studied, and the values must be compared with the yield stress of the respective materials.
With motion analysis, the results will be easier to interpret and sometimes even appear as models will wear or tear over time, flex, bend or break with impact.
With sophisticated tools like FEA and CAD, it gets more challenging as the complexity of the problem progresses. However, FEM analysis is exceptionally vital in the design and construction phase of any product. Tiny niches and details significantly alter the outcomes.
FEA consultants or validation service providers can help make this process easier. With FEA validation and verification, Mechartes has built exceptional designs and constructions with the help of a highly skilled engineering team, consultants, and analysts.
Learn more about their case studies and services here.
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