MECH 4259: Computer Aided Engineering

Summer 2025

Ram Adhikari, Ph.D, [Link]

May 6, 2025

1
Today’s agenda
• Course syllabus review
• Preliminaries
• Introduction to Finite Element Method/Analysis
• A general workflow of FEA
• Stiffness method
• Example
• FEA problem: Axially loaded bent rod/symmetry

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Time and location

Lectures and Labs

Days Time Room

Lectures: Tuesday 9:00 am – 9:50am CEI1100

and Thursday

Labs: Friday Section 1: 8:30am -11:20am CE2105A/D

Section 2: 1:30pm -4:20pm

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Textbooks and resources

Lecture notes: Available in course website in Brightspace after the lecture

Primary textbook

• CATIA V5 FEA Tutorials, release 21 by Nader Zamani, SDC Publications,

ISBN-13: 978-1585037643. (Approx. price: $63.66)
• CATIA V5 Tutorials in Mechanism Design and Animation, Release 21 by
Nader Zamani and Jonathan Weaver, SDC Publications, ISBN-13: 978-
1585037629. (Approx. price: $141.59)

Additional textbooks
• Concepts and Applications of Finite Element Analysis by Robert D. Cook,
David S. Malkus, Michael E. Plesha, Robert J. Witt, 4th Edition Wiley
(Approx. price: $198.5)

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Course schedule

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Course schedule…contd.

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Learning outcomes

By the end of the course, you will be able to:

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Evaluation methods

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Add/drop dates/forms

• List of important Dates

[Link]

9
Office Hours

Ram Adhikari, PhD, [Link]

Office: Room CEI 2153
Office Hours: Tuesday and Thursday, 10:00AM – 11:00AM (in-
person) or by appointment
Contact via email: adhikari@[Link]

GA Information

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 MECH4259: Computer Aided Engineering

Lecture 1: Introduction to Finite Element

Analysis

Ram Adhikari, Ph.D, [Link]

May 6, 2025

11
Preliminaries

Computer Aided Engineering Tools

Computer-Aided Engineering (CAE) tools are software

applications that use computational techniques to
simulate, validate, analyze and optimize complex product
designs, processes, systems, and manufacturing.

Some Commercial CAE Tools (CAD/Multiphysics):

• ANSYS
• CATIA
• SOLIDWORKS
• Creo Parametric
• Altair HyperWorks
• MATLAB
• MSC Nastran
• Siemens NX
• DraftSight
13
Preliminaries…contd.
Uncertainties in Structural Design:

• Safety Factor: The uncertainties associated with the design

of a structure is addressed by a single factor of safety (=
ultimate strength/allowable stress).

• Load and Resistance Factor Design (LRFD): This method

considers both the uncertainties associated with the structure
and those associated with the load it is designed to support.
This allows the designer to distinguish between uncertainties
associated with the live load, 𝑃𝐿 (i.e., the active or time-
varying load to be supported by the structure) and the dead
load, 𝑃𝐷 (i.e., the self weight of the structure contributing to
the total load). This is expressed as:

where the coefficient 𝜙 is the resistance factor, which

accounts for the uncertainties associated with the
structure and will normally be less than 1. The coefficients
𝛾𝐷 and 𝛾𝐿 are the load factors.
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Preliminaries…contd.

• Analytical models: uniform/idealized stress field is assumed

An example of an idealized uniform An example of an idealized

stress distribution at the cross-section uniform shear stress at the cross-
of a beam element section of a beam element

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Preliminaries … contd.
Field Variables:

• Displacement (𝑢) Q
𝜕𝑢
• Strain (= )
𝜕𝑥
𝜕𝑢
• Stress (= 𝐸 )
𝜕𝑥

State of stress in an infinitesimal

differential element of a structure/solid
Stress-strain relationships:

Ductile material tested

specimens: (a) with
cross-section necking,
(b) ruptured. 16
Preliminaries … contd.

Failure/Yield Criteria for Ductile Materials

• According to the distortion energy theory, failure in ductile materials

occurs if the maximum equivalent stress or von Mises exceeds the
yield or failure strength.

• The state of stress at a point in a continuum body is described

by six stress components:

where 𝝈𝒆𝒒 is called effective or equivalent stress

or von Mises Stress. In terms of principal stresses,

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Preliminaries … contd.

Repeated Loadings - Fatigue:

• When loadings are repeated thousands

or millions of times, rupture can occur at
a stress much lower than the static
breaking strength; this phenomenon is
known as fatigue.

• A fatigue failure is of a brittle nature,

even for materials that are normally
ductile.

Fig. A typical S - N curve for steel

Fig. Fatigue crack in a steel girder of a Bridge

prior to repairs.
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Preliminaries…contd.
Units are important!
• Mars Climate Orbiter (MCO)
• was launched by NASA on December 11,
1998 to study Martian climate, weather and
surface changes and act as
communications relay back to Earth
• However, disintegrated during orbit insertion
on Sept 23, 1999; approach too close →
requirements not followed
• ‘Units’ confusion problem: Ground
Software produced output in non-SI units
(lbf-sec) instead of SI units: N.s
• Calculation of total momentum
produced by engine burns needed by
GNC
• Contract between NASA and Lockheed [Link]
Martin did specify SI-units fundamentals-of-systems-
engineering-fall-
o This requirement was flowed down to the Software 2015/7f2bc41156a04ecb94a6c04546f
Interface Specification (SIS), but not verified later
and not implemented in the Angular Momentum 122af_MIT16_842F15_Ses2_Req.pdf
Desaturation (AMD)
19
Introduction to Finite Element Analysis

Nanomechanics
Micromechanics Solids and structures
Fluids
Computational Mechanics Continuum mechanics Electromagnetics
Heat transfer
Systems Multiphysics

Field variables:
• Displacement
• Strain
• Stress

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Introduction to Finite Element Analysis

Application areas

• Mechanical/Aerospace/Civil/Autom
otive Engineering
• Structural/Stress Analysis
• Static/Dynamic
• Linear/Nonlinear
• Fluid Flow
• Heat Transfer
• Electromagnetic Fields
• Soil Mechanics
• Acoustics
• Biomechanics
The Boeing 747 aircraft, commercialized in
1969, was the first aircraft analyzed (Industry trend: new product/system
extensively using finite element methods design and development)
Source: [Link]
43e2-806d-1f3cec235960/[Link]

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Introduction to Finite Element Method

• Physical systems/phenomena are governed by partial differential equations

(PDEs) coupled with boundary conditions.

Real-life Physical Mathematical

system model model
Partial Differential Equations
• Structural (PDEs) + Boundary conditions
• Thermal (B.C.s)
• Fluids
• Electromagnetics P
• Acoustics
• Thermal-structural
Field variables:
• Thermal-acoustics- • displacement
structural • Stress
𝑃 𝑦
𝜎 = + 𝑀.
𝐴 𝐼

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Introduction to Finite Element Method

Mathematical models - governing equations (PDEs)

Physical Governing equations Finite element

phenomenon & BCs equations
Approx.
Solid Mechanics:
𝑑 𝑑𝑢
e.g. Axially loaded elastic bar: 𝐸𝐴 +𝑏 =0
𝑑𝑥 𝑑𝑥

Fluid Mechanics:
𝑑 𝐴𝐷2 𝑑𝑝 Static case:
e.g. Poiseuille flow in pipe: +𝑏 =0 + BCs
𝑑𝑥 32𝜇 𝑑𝑥
System of equations
Heat transfer: 𝐊 𝐮 = 𝐅
𝑑 𝑑𝑇
e.g. 1-D heat conduction: 𝐴𝑘 +𝑞 =0
𝑑𝑥 𝑑𝑥

Electromagnetics: Stiffness Nodal Force

e.g. 1-D conduction:
𝑑
𝐴𝜎
𝑑𝑉
+𝑞 =0 matrix vectors vectors
𝑑𝑥 𝑑𝑥

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Finite element method

• The Finite Element Method (FEM) is a numerical technique for finding

approximate solutions to governing equations (PDEs)

Element

An example of a discretized
geometry of a gear for FEA

Node

• Step 1: A continuous domain is decomposed into discrete, connected regions of

standard geometrical shapes (finite elements):
• Finite element: line (1-D), area (2-D), and volume (3-D)
• Node: connect the elements at the element boundaries
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Finite element method

Element types

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 Finite element method

• Step 2: An assumed displacement is introduced into each element to construct

the element stiffness matrix and load vector for the equilibrium equation at
the element level in terms of element nodal DOF.

The element stiffness matrices and load vectors are then assembled,
while the conditions of kinematic compatibility are enforced, for the
equilibrium equation at the global level, which can be solved to establish
the response of the complete domain to a particular set of boundary
conditions
Global equilibrium equation (linear elastic,
static structural system):

N = degree of freedom (DOF) 𝑲 𝒖 = {𝑭}

Global stiffness Nodal Force

matrix (N×N) Vector (N× 1) Vector (N×1)
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(unknowns)
Finite element method

Shape functions

• Step 3: The values of the field variables computed at the nodes are used
to approximate the values at non-nodal points (i.e. in the element interior)
by interpolation of the nodal values. For a three-node triangular element,
the field variable is described by the approximate relation:
𝜑2 y

x
𝜑3 𝜑1

• The nodal values are unknowns to be determined from the system of

equations above. The shape functions are most often polynomial forms
of the independent variables.

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A general workflow of FEA

Preprocessing
1. Define the geometric domain
2. Define the element type(s)
3. Define the material properties of the elements
4. Define the geometric properties of the elements (length, area,
volume)
5. Mesh the model
6. Specify the loading and boundary conditions
7. Final FE matrix (stiffness matrix and load vectors) is prepared
Solution
1. Compute the unknown values of the primary field variable(s)
2. Computed values are then used to compute additional, derived
variables, such as reaction forces, element stresses, and heat flow
Postprocessing
1. FEA software contains postprocessor for extracting and plotting
results or field variables from the FE solution

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CATIA FEA workflow

Geometry
Meshing

Solutions
Loads and boundary Postprocessing
conditions

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ANSYS Mechanical FEA workflow

• ANSYS Mechanical Workbench

environment

• Geometry, material, model, setup,

solution, and results in one
platform

• User-friendly GUI

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Responsibility of the FE analyst

• Even inept users can produce

FE results
• Understanding of the physical
nature of the problem is
critical
• responsibility of the results
produced is taken by the
analyst, not the software
vendor!

Fig: Lateral midpoint displacement versus time for a beam loaded by a

pressure pulse. The material is elastic-perfectly plastic. Plots were generated
by various users and various codes (Ref: D. Cook, textbook).
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Stiffness or displacement method
• Stiffness: resistance to unit deformation – property of a
system (embodies geometry and material information)

• Assuming “linear-elastic” response, displacement, u, is

directly proportional to the applied force, F

1-D single degree of freedom (SDOF) elastic spring

y
𝒌. 𝒖

F
Stiffness, k
Load
(kN/mm)
𝒌 (kN)

x
u, displacement (mm)
𝐅
𝒖 Equation of static equilibrium for SDOF system
F 𝑭 = 𝒌. 𝒖, where k is the “element stiffness” matrix
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Stiffness or displacement method

Element stiffness matrix of a 1-D elastic spring system

Element stiffness matrix

Element Stiffness Relation

2 – DOF system, 2x2 symmetric matrix 33
Stiffness or displacement method

Derivation of global stiffness matrix… contd.

𝑲 𝒖 = {𝑭}
global stiffness equation

Note the shared k1 and k2 at k22 because of the compatibility condition at u2.
Note: Global stiffness matrix is the sum of all the element stiffness matrices 34
Stiffness or displacement method

Example problem: Two bar elements of different cross-sections are

connected as shown in the Figure below. The beams are made up of structural
steel (E1 = 2 × 105 MPa) and copper alloy (E2 = 1.1 × 105 MPa) with cross-
section of 50mmx50mm (A1) and 30mmx30mm (A2) and a length of 200mm
(L1) and 150mm (L2), respectively. A force of magnitude 100 N is applied on
node 3. Determine the displacements u1 and u2 using the stiffness method.
Model each member as a 1-D beam element.

y F3
E1 A1 L1 E2 A2 L2

x 3
1 2
Steel Copper

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Stiffness or displacement method
Step 1. Consider the force equilibrium to determine the nodal
forces, including the one at node 2 (assumed frictionless pin):

F
E1 A1 L1 E2 A2 L2

1 2 3

-F F -F F
E1 A1 L1 E2 A2 L2

1 2.1 2.2 3
F1 = -100 N F2 = 0 N

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Stiffness or displacement method

Construct the element stiffness matrices and assemble to get the global
stiffness matrix
Step 2. Determine the element stiffnesses Step 3. Determine nodal displacements u:
k: 𝐸1 𝐴1 𝐸1 𝐴1
−
𝐿1 𝐿1 25 −25 0 0 −100
𝒌𝟏 = = 25 × 105 𝑁/𝑚𝑚 5
𝐸1 𝐴1 𝐸1 𝐴1 −25 31.6 −6.6 × 10 𝑢2 = 0
−
𝐿1 𝐿1 0 −6.6 6.6 𝑢3 100
𝐸2 𝐴2 𝐸2 𝐴2
−
𝐿2 𝐿2
𝒌𝟐 = = 6.6 × 105 𝑁/𝑚𝑚
𝐸2 𝐴2 𝐸2 𝐴2
−
𝐿2 𝐿2 𝑢2 = 4 × 10−5 𝑚𝑚

𝑢3 = 1.9 × 10−4 𝑚𝑚
𝐹𝑙 𝐸𝐴
Note: 𝑢 = 𝐴𝐸 or 𝐹 = 𝑢
𝑙

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 References

1. Finite Element Modeling for Stress Analysis by Cook, Robert D, Wiley

2. [Link]

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