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SIMULATION
CAD has been utilized to create simulations of real-world objects, analyze their strength, and predict
performance through finite element analysis. As a result, CAD has become a crucial tool and catalyst for
research in computational, graphic, and differential geometry.
Finite element analysis serves as a tool to forecast the behavior of engineering components, enabling
maintenance to be scheduled before failure occurs (Nyemba, 2022).
Finite Element Analysis (Siemens, 2023 & PTC Education, 2024)
Finite Element Analysis (FEA)
► The mathematical simulation of a physical structure when internal and external forces are applied to it.
FEA is a crucial tool in engineering design, as it simulates the behavior of a design under real-world conditions,
enabling entire designs to be constructed, refined, and optimized, allowing potential issues to be identified
and addressed prior to committing significant time and resources to fabrication. This reduces the time-to-
market and the costs incurred in rework.
General Applications of FEA
▪ Structural Design - Stress analysis in beams, bridges, and mechanical components.
▪ Thermal Engineering - Heat distribution in systems like engines or electronics.
▪ Aerospace and Automotive Engineering - Stress testing of parts under extreme conditions and under
the influence of fluid dynamics.
▪ Medical and Biomechanics - Modeling of human joints, implants, and prosthetics.
▪ Electromagnetic Design - Simulation of electrical circuits and antennas.
▪ Topology Optimization - Identifying optimal material distribution within a design space to meet
performance goals, such as weight reduction or strength improvement.
Structural Analysis Fundamentals
Initial Requirements
Fixtures (Boundary Conditions) and Loads
Fixtures define how the model is constrained (e.g., fixed, free, or moving surfaces) and how forces, pressures,
or thermal conditions are applied to the system. These conditions are critical in determining the response of
the system being analyzed.
• Simulation Fixtures – a part in an assembly that is fixed or grounded in place to help simulate how the
entire assembly behaves under specific conditions.
▪ It ensures that the assembly is properly constrained, preventing unwanted motion during
simulation and helping to accurately assess the performance of the design. It is recommended
that only one part is fixed or grounded unless the design requires more than one fixture. It is best
practice to choose a part that does not have to move in terms of its function.
• Simulation Connections – refer to the relationships between parts (assembly relationships) in an
assembly that define how they interact with each other during a simulation.
▪ These connections can be controlled and visualized to specify which regions of the parts are
constrained or allowed to move, ensuring accurate simulation of forces, motions, and interactions
between components.
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• Loads – are forces or moments applied to components in an assembly during a simulation to simulate
real-world conditions and evaluate the behavior of the parts under stress, pressure, or other physical
effects.
▪ Force Load - A direct push or pull applied to a component, such as the weight of an object pressing
down on a beam.
▪ Moment Load - A rotational force applied around an axis, such as the torque applied to a shaft.
▪ Bearing Load - A load applied to a bearing, typically due to rotational forces, like the weight of a
rotating wheel on its axle.
▪ Pressure Load - A uniform force distributed over an area, such as the pressure exerted by fluid on
the walls of a pipe.
▪ Acceleration Load - A load that simulates the effect of acceleration, such as the force exerted on
a component when a vehicle speeds up or slows down.
Materials
In structural analysis simulations (e.g., Solid Edge, ANSYS, Abaqus, SimScale), assigning accurate material
properties is crucial for reliable results. Each non-fixed component in the simulation must have materials with
specific physical properties, as these directly influence stress, strain, and deformation predictions. Fixed parts
or parts that will not be simulated do not need to have any materials associated with them.
Required Material Properties
• Density – determines mass-related effects, such as gravitational forces.
• Poisson's Ratio – describes the material's deformation response in perpendicular directions when
stretched or compressed.
• Young's Modulus – indicates the material's stiffness, which is critical for calculating elastic
deformation.
• Tensile Yield Strength – defines the stress level at which a material begins to deform plastically.
Assigning Materials
► Standard Material Libraries - Use available libraries from the simulation platform, ensuring the chosen
material has all the necessary properties. Some materials, like wood, silicone, or rubber, might lack
essential properties for simulations.
► Custom Materials - When custom materials are added, all property fields must be complete; any
default to zero will trigger errors in simulation calculations.
Structural Analysis
In simulation software for structural analysis, various result options and visualization tools help interpret the
stress, strain, and deformation in a model. Each tool or result offers specific insights into how the assembly or
component responds under applied loads.
• Von Mises Stress - This measures the combined stress within the material to predict when it might
begin to yield or permanently deform under complex loading conditions. This stress measurement
helps to ensure a design won’t fail under anticipated loading. By default, it’s measured in MPa
(megapascals).
▪ Example: Imagine bending a metal rod. Von Mises stress calculates the combined stress from all
directions to predict if the rod will bend permanently or stay intact.
• Signed von Mises Stress - Like von Mises stress, this measurement includes a sign that shows whether
stress is in tension (stretching) or compression (squeezing). It combines stresses from all directions,
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and if the total is negative, a minus sign is added. This distinction helps assess the type of load the
material is experiencing.
▪ Example: Think of a rubber band stretched or compressed. Signed von Mises stress indicates
whether the band is stretched (tension) or squished (compression) based on the direction of
forces.
• Safety Factor - The safety factor is a ratio that compares the material’s yield strength to the von Mises
stress. It indicates how much stronger the material is than the applied stresses. A higher safety factor
suggests a design is more robust, while a lower factor might mean the design is closer to yielding or
failing.
▪ Example: Imagine a chair that can hold up to 300 pounds, but most people using it weigh 150
pounds. The safety factor is like a "safety cushion" that ensures the chair won’t break even if
someone a bit heavier sits on it.
• Max Principal Stress - This shows the maximum normal stress acting within the component. It reveals
where the most significant single-directional stress occurs, which helps identify potential failure points
in the design. Like von Mises stress, it’s also measured in MPa.
▪ Example: Picture a large glass windowpane. Max principal stress helps find the spots with the most
pressure, like where the pane is screwed in, to prevent cracks.
• Displacement - This shows how much each part of the assembly or component moves under the
applied load. It indicates areas of higher flexibility or potential misalignment and is measured in units
like millimeters. Take note that the deformation may be exaggerated in the simulation, but the values
may be minuscule and cannot be seen by the naked eye, as the displacement can be in micrometers
or nanometers.
▪ Example: Imagine a bookshelf sagging under heavy books. Displacement measures how much the
shelf bends to help decide if it needs reinforcement.
Common Structural Analysis Visualization Tools
• Deformation - This tool visually displays how parts of the assembly or component are displaced due
to the applied loads. The displacement’s direction and scale can be observed. The original shape is
outlined in a wireframe, displaying how much a design has deformed. Note that the deformations are
exaggerated for better visuals.
• Animate - Animation displays the simulated deformation as a moving sequence. The initial position is
shown while the animated movement represents the deformation over time, providing a clearer view
of how the structure behaves dynamically under load.
• Deformation Scale - This adjusts the visual extent of deformation in the display. By scaling the
deformation up or down, small or large displacements can be better observed. This setting affects
only the visual display and not the actual measured deformation.
• Color Scale - The color scale is a gradient legend that corresponds to the intensity of results, like stress
or displacement, on the model.
Modal Analysis
Modal analysis is a method used in engineering to understand how a structure or object responds to
vibrations.
When a structure vibrates, it does so at specific frequencies called natural frequencies and in specific patterns
called mode shapes. By examining these responses, engineers can assess whether a design is stable and will
not resonate or fail under expected vibrations.
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The modal analysis provides essential information for improving structural reliability, especially in designs that
may encounter varying vibrations, such as buildings, machinery, vehicles, and electronics. This insight guides
engineers to reinforce areas, adjust materials, or change the structure’s shape to avoid resonance -related
damage.
Main Components of Modal Analysis
• Natural Frequencies – Every object has unique frequencies at which it prefers to vibrate. These are called
natural frequencies. When vibrations in the environment match these frequencies, the object can enter
into resonance, where the vibrations amplify, potentially causing damage.
▪ Understanding an object’s natural frequencies helps engineers avoid situations where resonance
could occur.
• Mode Shapes – For each natural frequency, an object vibrates in a specific pattern called a mode shape.
Mode shapes show how different parts of the structure move or deform relative to each other at that
particular frequency.
▪ Visualizing these shapes lets engineers identify which areas are under stress and may need additional
reinforcement.
• Rigid-Body Modes – If a structure is free to move without constraints, it can translate or rotate as a whole
without deforming. These movements are called rigid-body modes.
▪ Identifying these modes confirms that a structure has free movement in certain directions and helps
engineers understand its degrees of freedom before fixing or anchoring it.
Common Modal Analysis Visualization Tools
• Mode Visualization - Engineers can visualize each mode shape, observing how the structure deforms at
each natural frequency. This helps pinpoint weak spots and improve structural rigidity.
• Deformation Scaling and Animation - By scaling the deformation or animating the mode shape, engineers
can see exaggerated movements that make the mode shapes more understandable. This can highlight
potential failure points in real-world conditions.
• Frequency Selection - Selecting specific modes from the frequency range allows engineers to focus on the
most critical frequencies, especially lower ones that are typically easier to excite and, thus, more likely to
cause resonance.
REFERENCES:
Nyemba, W. R. (2022). Computer-Aided Design Engineering Design and Modeling using AutoCAD. CRC Press.
Onshape. (2024). Introduction to Onshape Simulation. PTC Education. Retrieved from
[Link]
Siemens. (2023). Solid Edge Simulation Finite Element Analysis. Siemens. Retrieved from [Link]
US/doc/246738425/[Link]/aboutsesim1a.
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