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Mechanical

Modified on

16 Sep 2024 04:43 pm

Basics of FEA using SolidWorks: For Beginners

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Skill-Lync

As a Mechanical Engineer, you might be required to design and conceptualize several products. How do you ensure that these products are efficient and perform optimally? This is where FEA comes in. 

Finite Element Analysis (FEA) is a powerful computational tool that has revolutionized the way engineers design and analyze products. It's a numerical method used to solve complex engineering problems by breaking down a large problem into smaller, simpler ones known as finite elements. 

In this blog, we'll explore how to perform various types of FEA analyses based on the problem at hand, all using SolidWorks Simulation software. Let's dive into the basics, types of analyses, and why FEA is crucial in engineering. 


Methods to solve engineering problems 

When we want to solve any engineering problem, there are three common methods: 

1. Analytical method: 

It involves using mathematical formulas, either derived or pre-existing, to solve a problem. For example, if you drop a ball from a 100m building, you can use Newton's equations of motion to calculate how long it will take to hit the ground. This method works well as long as the problem can be accurately represented by the formula. 


2. Experimental method:  

The experimental approach involves performing a physical experiment to find the solution. Continuing with the ball example, you would drop the ball from 100m and use a stopwatch to record the time it takes to hit the ground. While this method can yield accurate results, it’s not always practical for every engineering problem. 

3. Numerical method: 

Numerical methods use mathematical tools to approximate solutions. Imagine you want to find the circumference of a circle but don’t know the formula. You could place sticks along the circumference, measure one, and multiply it by the number of sticks to get an approximate value. Similarly, you can approximate the area under a curve by dividing it into rectangles and summing their areas. Numerical methods are valuable when an exact solution is difficult to obtain. 


4. FEA method:  

FEA is a numerical method that provides an approximate solution to complex engineering problems by dividing a large system into smaller, simpler parts called elements. These elements are connected at points called nodes. The smaller and more numerous the elements, the more accurate the solution. FEA is particularly useful for complex problems where analytical or experimental methods fall short. 

The Cantilever Beam example 

A cantilever beam is one where one side is attached to a wall or object and the other is suspended in air. The objective is to study what would happen if external forces were applied to the free end, and how much the beam would be displaced from its original position. 

If we were to solve this the analytical way, we can apply a differential equation that exists: 


Now let’s try solving this using FEA method. We would need to split the beam into tow equal elements.  

We solve for this displacement using the formula  

F = [K] [x] 

Where F = forces, K = stiffness of the beam, x = displacement 

We use matrix calculations to calculate this. 

This may seem very complex to look at. However, these computations are taken care of by software tools, where we just need to input the initial conditions and values. 


Real-world applications of FEA 

Let’s say there is a car that collides with a wall at a certain speed. We need to find out the degree of intrusion into the passenger compartment and the potential damage, so that we can optimise the design of a car to minimise damage to the greatest extent. 

One could consider solving these problems analytically. However, with increasing complexity of the problem, it can be difficult to find the right analytical solution. This is where FEA software comes in. 


Stress-Strain Plot 

Let us now look at a topic called Stress-Stain Plot. These graphs are material-specific, plotted through experimental methods. These graphs help us understand how the material behaves when different kinds of external forces are applied on it. Hence, we can understand how much load can be applied on a certain structure. 


Following are the key points in the stress-strain graph: 

  • Proportional Limit (Point A): Stress and strain are proportional up to this point. 
  • Elastic Limit (Point B): Beyond this point, plastic deformation begins, and the material won’t return to its original shape. 
  • Ultimate Tensile Strength (Point C): The maximum stress the material can withstand before starting to break. 
  • Fracture Point (Point D): Where the material finally snaps. 
  • The FEA Process: Pre-processing, Processing, and Post-processing 


The FEA Process: Pre-processing, Processing, and Post-processing 

Let's start by diving into the FEA process itself. This is where the magic happens in engineering simulations! FEA analysis can be broken into three main steps: 

1. Pre-processing: 

Start with a CAD model of the product. Import the model into FEA software, check for issues, and discretize (mesh) the model into elements. Define simulation conditions, including material properties, loads, and constraints. 

2. Processing: 

This step involves running the simulation in the software, where all the mathematical calculations are performed in the background. 

3. Post-processing: 

Finally, visualise and interpret the results. Based on the simulation data, you can verify your hypothesis, select the best design, or recommend changes. 


Mesh Refinement: H-Refinement vs. P-Refinement 

Meshing is a crucial step for accurate simulations. It divides your model into small, manageable elements, which makes it easier to analyse how each part reacts under stress or pressure. But not all meshes are created equal! Sometimes, to get more accurate results, you need to refine your mesh by making those elements even smaller or more detailed—kind of like using a finer brush to paint a more detailed picture. 

There are two main types of meshing: 

  • H-Refinement: Increases the number of elements by reducing their size. 
  • P-Refinement: Increases the number of nodes within the existing elements, enhancing the accuracy of the shape functions used in the simulation.


Types of FEA Analyses in SolidWorks 

Now let us explore the different types of analyses you can perform. Each one is tailored to a specific need, making SolidWorks a versatile tool for engineers. 

  1. Static Analysis: For models subjected to constant loads that don’t vary over time. 
  2. Fatigue Analysis: For components subjected to repeated loads, predicting the lifespan before failure. 
  3. Frequency Analysis: To find the natural frequencies of a model, crucial in vibration-related problems. 
  4. Buckling Analysis: For predicting when a structure will fail due to compressive loads. 
  5. Drop Test: To assess the impact on a component if dropped from a certain height. 


In this blog, we’ve covered the basics of FEA, including the traditional methods of solving engineering problems, the FEA process, and the various types of analyses available in SolidWorks. As we proceed, we'll delve deeper into each of these topics and explore how to effectively use FEA in real-world engineering scenarios.  

Would you like to have a more interactive demonstration of the above concepts? 

Skill-Lync has released a FREE comprehensive course covering FEA with SolidWorks in detail! Check it out here.

Right from the user interface's fundamentals, menus and options, this course covers most aspects of the tool from a practical perspective. It even includes a certificate to add to your resume after completion! 

Check out our hands-on course today and add SolidWorks to your list of skills!  

Let’s get #IndustryReady together, one skill at a time! 

Start Course Now.


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