1 case study 100lb cr01.sldprt fixed restraint. 2 but welds crack after one day of use (some 50 load...
DESCRIPTION
3 Stress results show no problem FOS=32000/2960=10.8 CASE STUDYTRANSCRIPT
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CASE STUDY
100lb
cr01.sldprt
Fixed restraint
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2
But welds crack after one day of use (some 50 load cycles)
Why?
RPN = R occurrence x R severity x R detection
CASE STUDY
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3Stress results show no problem
FOS=32000/2960=10.8
CASE STUDY
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4BLF =32 so buckling is not an issue
CASE STUDY
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Time
Load
100 lb
0.07s
Electric hoist
CASE STUDY
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6Electric hoist was applying a overload and it was exciting the first mode
CASE STUDY
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7Weld size calculations
One sided fillet weld 3/16”
One sided fillet weld 1/8”
Post modeled as surface
CASE STUDY
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8Weld size calculations
CASE STUDY
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2500N
30mmx30mm
30mmx30mm
Hinge
Hinge
Pin
case01.sldprt
CASE STUDY
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x =
d2y = 0.043mm
σ approx = 3MPa
CASE STUDY
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11Results of static analysis
Displacement results agree with hand calculations
case01.sldprt
CASE STUDY
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12Results of static analysis
Von Mises stress plot does not show any problem (yield strength 620MPa)
case01.sldprt
CASE STUDY
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… but hanger collapses during testing….
CASE STUDY
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14This is modeled by “stick” model This is the real geometry
CASE STUDY
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Results of static analysis
Von Mises still OK
CASE STUDY
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Results of buckling analysis
BLF = 0.87
CASE STUDY
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CASE STUDY 01 FIRST REDESIGN
Results of buckling analysis
BLF = 1.7
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CASE STUDY 01 SECOND REDESIGN
Results of buckling analysis
BLF = 4.4 much better
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CASE STUDY
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Verification
The process of determining that a model correctly represents the modeler’s
conceptual description of the model and the solution of the model
Validation
The process of determining the degree to which a model is correctly representing
reality from the perspective of the intended use of the model.
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REALITY
verification
validation
MATHEMATICAL MODEL
FEA
MODEL
RESULTS
Discretization error
Modeling error
Solution error
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Verification
The process of determining that a model correctly represents the modeler’s
conceptual description of the model and the solution of the model
Validation
The process of determining the degree to which a model is correctly representing
reality from the perspective of the intended use of the model.
REALITY
verification
validation
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Sinking of Sleipner A platformFailure occurred due to discretization error; model was not verified.http://www.ima.umn.edu/~arnold/disasters/sleipner.html
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Hartford Civic Centre Arena roof collapse.
Failure occurred due to modeling error; model was not validated.
http://www.eng.uab.edu/cee/faculty/ndelatte/case_studies_project/Hartford%20Civic%20Center/hartford.htm#Top
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In the case of hanger, mathematical model using 2D trusses was solved correctly, it passes verification.
However, it has incorrect geometry and it does not account for the predominant mode of failure: BUCKLING
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The finer is the mesh the better are your results
true ? false ?
Geometry should be represented as accurately as possible
true ? false ?
Solids give the best results because they accurately model the geometry
true ? false ?
High accuracy of FEA results from high processing accuracy of the computer
true ? false ?
If your FEA software reports no error, the solution will be correct
true ? false ?
You do not really need any error estimation, the FEA is always accurate enough
true ? false ?
Higher order elements will give you more accurate results
true ? false ?
First order tetrahedral solids are too stiff and should be avoided
true ? false ?
Use a coarse mesh first to find stress concentration, then refine it as needed
true ? false ?
If FEA results correlate well with (e.g.) strain-gauge readings, all FEA results are O.K.
true ? false ?
FEA QUIZ
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Always make the finest model possible
true ? false ?
Degenerated elements are O.K. as long as they are far away from stress concentrations
true ? false ?
If you want to know only displacements and do not care about stresses, then you can make a coarse model
true ? false ?
Modal analysis can use coarser mesh that stress analysis
true ? false ?
Finite Element Models offer a deceiving level of detail
true ? false ?
Model geometry is the most readily controlled, loads less so, restrains are the most difficult to control
true ? false ?
Test data always have error and may be inconsistent with FEA assumptions
true ? false ?
Incompetent analysis gives, at best , unreliable results, at worst is positively misleading
true ? false ?
Bad FEA gives you deceiving trust in the design
true ? false ?
FEA makes good engineer better and bad engineer dangerous
true ? false ?
FEA QUIZ
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# 1 FUNDAMENTALS OF FEA
1. State the objective of discretization of continuum
2. State major assumptions in the design of a finite element
3. How are FEA equations formulated ?
4. What is the primary unknown in FEA?
5. What is the nodal Degree of Freedom ( D.O.F.) ?
6. What is the relation between total number of D.O.F and total number of nodes in the FEA model ?
7. What is the price to pay for replacing continuum with a set of finite elements ?
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1. What is a shape function ?
2. What is the difference between h-element and p-element ?
3. Describe major types of finite elements
4. What are compatible elements ? Non-compatible elements ?
5. What is a distorted element ? What are types of element distortion ?
6. What is the difference between 1st and 2nd order element ?
7. How do elements "communicate" between each other ?
# 2 TYPES OF FINITE ELEMENTS
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# 3 ACCURACY OF FEA
1. List major steps in FEA and associated errors
2. Sort in the order of calculation: stress, strain, displacement
3. What is the accuracy of FEA results?
4. What are “artificial” restraints?
5. What is the objective of convergence analysis?
6. What are criteria of convergence analysis?
7. What is an h convergence, why is it called h-convergence?
8. What is the p-convergence, why is it called p-convergence?
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# 4 TYPES OF FEA ANALYSES, MODELING TECHNIQUES
1. What is calculated in modal analysis
2. What is calculated in linear buckling analysis
3. List some types of nonlinear behavior
4. What is the fundamental difference between linear and non-linear analysis?
5. Describe some techniques to reduce the size of finite element model
6. Describe some problems with CAD -FEA interfacing