FEA basics

Why FEA?

Finite Elements Analysis (FEA) is a method for solving complex mechanical problems using the power of modern computers. Choosing sound boundary conditions and loads, the engineer is actually able to simulate reality whatever the situation or complexity. The mechanical behavior of products and constructions can be analysed and optimised without the necessity of prototyping. Direct results are profits in the field of time and cost in the design phase. It also adds to the reliability of your product.

What is FEA?

The basic principle of the finite element method is the creation of a computer model which is built up from a finite number of elements. The elements all have an mathematical defined relationship between force and displacement. This relationship of each element can be used to estimate the stiffness distribution of the whole structure. By applying a matrix solution technique, the response of the entire structure to the prescribed loads and boundary conditions can be determined.

The most common FEA type is the linear elastic analysis. This assumes that the structure behaves elastically, the stresses are linearly proportional to stresses, the strains are small and the deformation has no effect on the behavior of the structure. Often this is a good approximation to how the structure behaves in reality, but in some cases these statements don’t fit the reality sufficiently. When this occurs the problem changes from a linear to a non-linear problem. Non-linearity can arise due to material behavior and/or geometric behavior. In practical terms a non-linear analysis is more time consuming and requires more input data.

Where is FEA?

Get an impression where FEA is applied.

Product optimization / development

Optimizing a product is about selecting the best option from a range of possible choices. How can you compare these options in an effective and quick way? How can you reach your goal to produce a product according to some optimal mix of criteria on cost, quality and timescale? With FEA it is possible to make predictions of structural response. Once the important features of a component have been established, fewer prototypes may need to be made. Although prototypes are still required, the reduction in the number of variants tested help to reduce the project costs and time span of the design process.

Qualification

Safety is an important requirement in industry. Not only is it essential to provide safe and reliable products, it can also be a selling point to be able to demonstrate a focus on safety. A key benefit of using FEA is that it can simulate events that may have severe effects on people and the environment if tested in real life. In some cases there is no alternative way to determine how a structure might behave under catastrophic loads by doing tests. Several examples can be found in the field of the offshore and earthquake analyses.

Failure analysis

The consequences of failure can diverge from mere irritation of the user to serious accidents. Therefore in many cases a prediction of possible failure mechanisms can be useful. FEA is used to simulate a variety of loading conditions to investigate the possible failure mode of a component, due to fatigue, creep, dynamic response and buckling.

Reverse engineering

After failure of a product in most cases it is advisable to determine the exact cause to make sure it won’t reoccur in the future. FEA is able to give you insight concerning the functionality of your product and can support you in finding the cause of the malfunction.