In thermo mechanical members and structures, finite-element analysis (FEA) is
typically invoked to compute displacement and temperature fields from known
applied loads and heat fluxes. FEA has emerged in recent years as an essential
resource for mechanical and structural designers. Its use is often mandated by
standards such as the ASME Pressure Vessel Code, by insurance requirements, and
even by law. Its acceptance has benefited from rapid progress in related computer
hardware and software, especially computer-aided design (CAD) systems.
Today, a number of highly developed, user-friendly finite-element codes are
available commercially.
In FEA practice, a design file developed using CAD is often imported into finite
element codes, from which point little or no additional effort is required to develop
the finite-element model and perform sophisticated thermo mechanical analysis
and simulation. CAD integrated with an analysis tool, such as FEA, is an example
of computer-aided engineering (CAE). CAE is a powerful resource with the
potential of identifying design problems much more efficiently and rapidly than by
trial and error.
A major FEM application is the determination of stresses and temperatures in a
component or member in locations where failure is thought most likely. If the
stresses or temperatures exceed allowable or safe values, the product can be
redesigned and then reanalyzed. Analysis can be diagnostic, supporting
interpretation of product-failure data. Analysis also can be used to assess
performance, for example, by determining whether the design-stiffness coefficient
for a rubber spring is attained.
OVERVIEW OF THE FINITE-ELEMENT METHOD
Consider a thermo elastic body with force and heat applied to its exterior boundary.
The finite-element method serves to determine the displacement vector u(X,t) and
the temperature T( X,t ) as functions of the un deformed position X and time t .
The process of creating a finite-element model to support the design of a
mechanical system can be viewed as having (at least) eight steps:
1. The body is first discretized, i.e., it is modeled as a mesh of finite elements
connected at nodes.
2. Within each element, interpolation models are introduced to provide
approximate expressions for the unknowns, typically u(X,t) and T(X,t), in terms of
their nodal values, which now become the unknowns in the finite-element model.
3. The strain-displacement relation and its thermal analog are applied to the
approximations for u and T to furnish approximations for the (Lagrangian) strain
and the thermal gradient.
4. The stress-strain relation and its thermal analog (Fouriers Law) are applied to
obtain approximations to stress S and heat flux q in terms of the nodal values of u
and T.
5. Equilibrium principles in variation form are applied using the various
approximations within each element, leading to element equilibrium equations.
6. The element equilibrium equations are assembled to provide a global
equilibrium Equation
7. Prescribed kinematic and temperature conditions on the boundaries (constraints)
are applied to the global equilibrium equations, thereby reducing the number of
degrees of freedom and eliminating rigid-body modes.
8. The resulting global equilibrium equations are then solved using computer
algorithms.
The output is post processed. Initially, the output should be compared to data or
benchmarks, or otherwise validated, to establish that the model correctly represents
the underlying mechanical system. If not satisfied, the analyst can revise the finiteelement model and repeat the computations. When the model is validated, post
processing, with heavy reliance on graphics, then serves to interpret the results, for
example, determining whether the underlying design is satisfactory. If problems
with the design are identified, the analyst can then choose to revise the design. The
revised design is modeled, and the process of validation and interpretation is
repeated.
MESH DEVELOPMENT
Finite-element simulation has classically been viewed as having three stages:
preprocessing, analysis, and post processing. The input file developed at the
preprocessing stage consists of several elements:
1. Control information (type of analysis, etc.)
2. Material properties (e.g., elastic modulus)
3. Mesh (element types, nodal coordinates, connectivities)
4. Applied force and heat flux data
5. Supports and constraints (e.g., prescribed displacements)
6. Initial conditions (dynamic problems)
In problems without severe stress concentrations, much of the mesh data can be
developed conveniently using automatic-mesh generation. With the input file
developed, the analysis processor is activated and raw output files are generated.
The postprocessor module typically contains (interfaces to) graphical utilities, thus
facilitating display of output in the form chosen by the analyst, for example,
contours of the Von Mises stress. Two problems arise at this stage: Validation and
interpretation.
The analyst can use benchmark solutions, special cases, or experimental data to
validate the analysis. With validation, the analyst gains confidence in, for example,
the mesh. He or she still may face problems of interpretation, particularly if the
output is voluminous. Fortunately, current graphical-display systems make
interpretation easier and more reliable, such as by displaying high stress regions in
vivid colors. Postprocessors often allow the analyst to zoom in on regions of
high interest, for example, where rubber is highly confined. More recent methods
based on virtual-reality technology enable the analyst to fly through and otherwise
become immersed in the model.
The goal of mesh design is to select the number and location of finite-element
nodes and element types so that the associated analyses are sufficiently accurate.
Several methods include automatic-mesh generation with adaptive capabilities,
which serve to produce and iteratively refine the mesh based on a user-selected
error tolerance. Even so, satisfactory meshes are not necessarily obtained, so that
model editing by the analyst may be necessary. Several practical rules are as
follows:
1. Nodes should be located where concentrated loads and heat fluxes are applied.
2. Nodes should be located where displacements and temperatures are constrained
or prescribed in a concentrated manner, for example, where pins prevent
movement.
3. Nodes should be located where concentrated springs and masses and their
thermal analogs are present.
4. Nodes should be located along lines and surface patches, over which pressures,
shear stresses, compliant foundations, distributed heat fluxes, and surface
convection are applied.
5. Nodes should be located at boundary points where the applied tractions and heat
fluxes experience discontinuities.
6. Nodes should be located along lines of symmetry.
7. Nodes should be located along interfaces between different materials or
components.
8. Element-aspect ratios (ratio of largest to smallest element dimensions) should be
no greater than, for example, five.
9. Symmetric configurations should have symmetric meshes.
10. The density of elements should be greater in domains with higher gradients.
11. Interior angles in elements should not be excessively acute or obtuse, for
example, less than 45or greater than 135.
12. Element-density variations should be gradual rather than abrupt.
13. Meshes should be uniform in subdomains with low gradients.
14. Element orientations should be staggered to prevent bias.
In modeling a configuration, a good practice is initially to develop the mesh locally
in domains expected to have high gradients, and thereafter to develop the mesh in
the intervening low-gradient domains, thereby reconciling the high-gradient
domains.
There are two classes of errors in finite-element analysis:
Modeling error ensues from inaccuracies in such input data as the material
properties, boundary conditions, and initial values. In addition, there often are
compromises in the mesh, for example, modeling sharp corners as rounded.
Numerical error is primarily due to truncation and round-off. As a practical matter,
error in a finite-element simulation is often assessed by comparing solutions from
two meshes, the second of which is a refinement of the first.
The sensitivity of finite-element computations to error is to some extent
controllable. If the condition number of the stiffness matrix (the ratio of the
maximum to the minimum eigen value) is modest, sensitivity is reduced. Typically,
the condition number increases rapidly as the number of nodes in a system grows.
In addition, highly irregular meshes tend to produce high-condition numbers.
Models mixing soft components, for example, rubber, with stiff components, such
as steel plates, are also likely to have high-condition numbers. Where possible, the
model should be designed to reduce the condition number.
1.1 Starting up ANSYS:
To start ANSYS in Windows environment simply follow the path:
Start Menu >Programs >ANSYS 7.1 >ANSYS Classic
The first window you may see is the main window as shown in Figure 1.
Figure 1: ANSYS main Window
1.2 ANSYS Interface
There are two methods to use ANSYS; Graphical Interface and Command File
Coding. The graphical user interface or GUI follows the conventions of Windows
based programs. This method is probably the best approach for new users. The
command approach is used by professional users. It has the advantage that an
entire analysis can be described in a small text file, typically in less than 50 lines of
commands. This approach enables easy model modifications and minimal file
space requirements. In this lab manual we mainly use the GUI. However, in some
cases both the GUI and command code are used to show that how command code
could be easy to use.
1.3 ANSYS Files
When run even a simple program by ANSYS, a large number of files are created.
Each file has specific purposes. The most important files are described briefly as
follows:
[Link]: Database file (binary). This file stores the geometry, boundary conditions
and any solutions.
[Link]: Backup of the database file (binary).
[Link]: Error file (text). Listing of all error and warning messages.
[Link]: Output of all ANSYS operations (text). This is what normally scrolls in
the output window during an ANSYS session.
[Link]: Logfile or listing of ANSYS commands (text). Listing of all equivalent
ANSYS command line commands used during the current session.
Note that if you started ANSYS without specifying a jobname, the name of all the
files created will be FILE.*. If you specified a jobname, then all files will be saved
by the jobname.
When you are using the GUI, then you only require to save the .db file. This file
stores the geometry, boundary conditions and any solutions. When you start
ANSYS you only need to Resume from and call your saved [Link]
1.4 Plotting of Figures
To Plot your created model or output results such as deformed shape, you may
follow the following path.
Utility menu bar>PlotCtrls>Hard Copy>Graphics window>Monochrome>Reverse
Video>Landscape>Save to>choose a name>OK.
