A04 - Introduction to the Finite Element Method 1 Introduction to the Finite Element Method Background Material AERO 306 notes and Introduction to Aerospace Structural Analysis, Allen and Haisler http://ceaspub.eas.asu.edu/structures/FiniteElementAnalysis.htm http://www.myb2o.net/myb2ous/Analysis/Features/10547.htm http://www.myb2o.net/myb2ous/Analysis/Tools/Process/10407.htm http://larcpubs.larc.nasa.gov/randt/1993/RandT/SectionG/G11.html Assumptions It is assumed that you are familiar with basic FEM theory (AERO 306) and with applications to truss or beam elements and structures, and: know FEM theory based on an energy or variational formulation, know what a stiffness matrix is, know how to assemble element stiffness and force matrices into global (structural) stiffness and force matrices, know how to solve the resulting equilibrium equations [ K ]{q} {Q} for displacements, and know how to determine resulting strains and stresses. A04 - Introduction to the Finite Element Method 2 Structures are often analyzed using complex finite element analysis methods. These tools have evolved over the past decades (since early 1960's) to be the basis of most structural design tasks. A candidate structure is analyzed subject to the predicted loads and the finite element program predicts deflections, stresses, strains, and even buckling of the many elements. The designed can then resize components to reduce weight or prevent failure. In recent years, structural optimization has been combined with finite element analysis to determine component gauges that may minimize weight subject to a number of constraints. Such tools are becoming very useful and there are many examples of substantial weight reduction using these methods. Surprisingly, however, it appears that modern methods do not do a better job of predicting failure of the resulting designs, as shown by the figure below, constructed from recent Air Force data. The data compares static test failures of wing, fuselage, vertical tail, horizontal tail, landing gear and other components for New Aircraft (designed with finite element methods) and Older aircraft (designed without FEM). A04 - Introduction to the Finite Element Method 3 Moral of the story as presented by the chart above? Don't believe that just because you are using modern, sophisticated finite element tools that the analysis will in some way be better or safer. It still takes engineering judgment, know-how and experience. A04 - Introduction to the Finite Element Method Aircraft have many main structural components in the wings, fuselage, tail section, landing gear, etc. as shown below: 4 A04 - Introduction to the Finite Element Method Structural members shown above may be variously modeled as beams, thin plates, membranes, shells, etc. In some cases, it may be necessary to perform a full 3-D stress analysis (an elasticity type analysis as opposed to an approximate one like plate theory). 5 A04 - Introduction to the Finite Element Method 6 The webs in wing ribs and floor beams, and wing and fuselage skins are typically thin members that might be considered as being in a state of plane stress. Plane stress describes a three-dimensional geometry wherein the non-zero stresses all occur in a single plane. For a thin plate, web or skin lying in the x-y plane, the only non-zero stress components are xx , yy , xy . A04 - Introduction to the Finite Element Method 7 We now consider the development of a plane stress finite element. Suppose we have a geometry like that shown below where the thickness is small compared to the other two dimensions: The only major stress components are xx , yy , xy . Consider another example of a thin bracket in tension and the corresponding finite element mesh. The boundary at the hole is welded and therefore fixed. A static tensile load of 5,500 lbs is applied to one end. The dimensions are 25" x 10" x 0.5" thick. A04 - Introduction to the Finite Element Method t = 0.5 in. Bracket Geometry & FEM Mesh, Loading and BC 8 A04 - Introduction to the Finite Element Method 9 Notice that the geometry has been divided up into a number of rectangular regions (elements) - these are called Quad elements. We could also use triangular elements. We will demonstrate the development of the stiffness matrix and load vector for a triangular element as shown below. We assume that plane stress occurs in the x-y plane and define displacement components u ( x, y ) and v( x, y ) . We define nodal displacements at the three corners as: Node 1: u1 and v1 Node 2: u2 and v2 Node 3: u3 and v3 10 A04 - Introduction to the Finite Element Method The process of developing the equilibrium equations for a given element requires that we utilize an energy or variational principle; for example, the principle of minimum potential energy given by: (U V ) 0 (1.1) where U is the internal strain energy and V is the external potential energy. For a plane stress state, the internal (potential) energy is given by U 12 { }T { }dV (1.2) xx xx { } yy and { } yy xy xy (1.3) V where 11 A04 - Introduction to the Finite Element Method Assuming a linear elastic material, the constitutive equation may be written as (1.4) { } [ D]{ } where [D] for plane stress is given by: 0 1 E [ D] 1 0 1 2 0 0 (1 ) / 2 Note that [D] is symmetric. (1.5) The infinitesimal strains are given: xx u , x yy v , y xy u v y x where u ( x, y ) and v( x, y ) are the displacement fields. (1.6) 12 A04 - Introduction to the Finite Element Method Substituting (1.4) into (1.2) gives the strain energy as U 12 { }T [ D]{ }dV V (1.7) where use has been made of the symmetry of [D]. Note that if we substitute (1.6) into (1.7), U is now in terms of the displacement fields u ( x, y ) and v( x, y ) . The external potential V can be evaluated once the external tractions and body forces are specified. In general, V will have the form of V pxu p y v)ds ( Fxu Fy v )dV (1.8) S V where px and p y are boundary tractions, S is the element boundary surface, Fx and Fy are body forces. Note that V is in terms of displacements u ( x, y ) and v( x, y ) . A04 - Introduction to the Finite Element Method 13 We now have U and V in terms of u ( x, y ) and v( x, y ) ; and the equilibrium equations for are an element are defined by the energy principle (U V ) 0 (1.1). However, we can't apply (1.1) just yet. Why? Because u ( x, y ) and v( x, y ) must be in terms of discrete variables (nodal displacements) but u ( x, y ) and v( x, y ) are continuous functions. Constant Strain Triangle For any element, the displacement components u ( x, y ) and v( x, y ) are unknown. Following a Rayleigh-Ritz type solution, we assume a solution for each. The simplest assumption that can be made in this case is to assume that the displacement varies linearly over the element. Hence, we assume: u ( x, y ) 1 2 x 3 y v( x, y ) 1 2 x 3 y where the ' s and 's are constants. These constants can be related to nodal displacements for the triangular element: (1.9) A04 - Introduction to the Finite Element Method 14 Assume the corners of the triangle (nodes) are numbered CCW, and have coordinates ( x1, y1 ) , etc. as shown. At each node (i=1,2,3), assume the nodal displacements are given by (ui , vi ) . We can now write 6 "boundary conditions" as follows: For u(x,y): At node 1: u1 u ( x1, y1 ) 1 2 x1 3 y1 At node 2: u2 u ( x2 , y2 ) 1 2 x2 3 y2 At node 3: u3 u ( x3 , y3 ) 1 2 x3 3 y3 (1.10) 15 A04 - Introduction to the Finite Element Method For v(x,y): At node 1: v1 v( x1, y1 ) 1 2 x1 3 y1 At node 2: v2 v( x2 , y2 ) 1 2 x2 3 y2 At node 3: v3 v( x3 , y3 ) 1 2 x3 3 y3 (1.11) We can now solve for the constants in terms of nodal displacements. Eqs. (1.10) can be written in matrix form as 1 x1 1 x 2 1 x3 Solution is: y1 1 u1 y2 2 u2 y3 3 u3 1 (a1u1 a2u2 a3u3 ) /(2 A) 2 (b1u1 b2u2 b3u3 ) /(2 A) 3 (c1u1 c2u2 c3u3 ) /(2 A) (1.12) (1.13) 16 A04 - Introduction to the Finite Element Method where a1 x2 y3 x3 y2 , a2 x3 y1 x1 y3 , a3 x1 y2 x2 y1 b1 y2 y3 , b2 y3 y1 , b3 y1 y2 c1 x3 x2 , c 2 x1 x3 , c3 x2 x1 (1.14) and 1 x1 2 A 1 x2 1 x3 y1 y2 2(area of triangle) y3 Substituting (1.13) into (1.9) and rearranging, u(x,y) can be written 1 u ( x, y ) [(a1 b1x c1 y )u1 (a2 b2 x c2 y )u2 2A ( a3 b3 x c3 y )u3 ] (1.15) Note that the a's, b's and c's are constants and depend only upon the nodal coordinates (x,y) of the 3 corner nodes. 17 A04 - Introduction to the Finite Element Method Defining the coefficients of ui as Ni , equation (1.15) becomes: 3 u ( x, y ) Ni ui (1.16) 1 N i ( x, y ) (ai bi x ci y ) 2A (1.17) i 1 where A similar result is obtained for v(x,y): 3 v( x, y ) Ni vi (1.18) i 1 The quantities Ni ( x, y ) are called shape functions. Note that the same shape functions apply for both u ( x, y ) and v( x, y ) . We can now obtain the strains by substituting displacement functions (1.16) and (1.18) into strain expressions (1.6) to obtain: A04 - Introduction to the Finite Element Method xx 3 b u 3 Ni ui i ui x i 1 x i 1 2 A yy 3 ci v 3 Ni vi vi y i 1 y i 1 2 A xy 3 3 3 Ni ci bi u v 3 Ni ui vi ui vi y x i 1 y i 1 x i 1 2 A i 1 2 A 18 (1.19) The last 3 equations for strains can be put into matrix notation as: u1 v 1 b 0 b 0 b 0 2 3 xx 1 1 u2 (1.20) 0 c1 0 c2 0 c3 yy 2 A c b c b c b v2 1 1 2 2 3 3 u xy 3 v3 A04 - Introduction to the Finite Element Method Or, more compactly as (for any element "e"): { e } [ Be ]{qe } 19 (1.21) b1 0 b2 0 b3 0 1 e where (1.22) [B ] 0 c1 0 c2 0 c3 2A c1 b1 c2 b2 c3 b3 u1 v 1 u2 e and (1.23) {q } v2 u3 v3 Since the terms in [ B e ] are constant for an element, the strains { e } are constant within an element; hence the name "constant strain triangle" or CST. 20 A04 - Introduction to the Finite Element Method We can now evaluate the internal strain energy U. Substituting (1.21) into (1.7) gives: Ue e T e T e e e 1 { q } [ B ] [ D ][ B ]{ q }dV 2 V = 12 {q e }T [ B e ]T [ D e ][ B e ]dV {q e } V (1.24) The quantity in parentheses can be identified as the element stiffness matrix [ k e ] and (1.24) can be written as: U e 12 {q e }T [k e ]{q e } (1.25) where the element stiffness matrix [ k e ] is defined by: [k e ] [ Be ]T [ De ][ Be ]dV V (1.26) 21 A04 - Introduction to the Finite Element Method e If the element has a constant thickness t , then dV=tdA. Assuming that E is constant over the element and noting that the terms in B are constants, then [k e ] t e Ae [ B e ]T [ D e ][ B e ] (1.27) Note that the element stiffness matrix [ k e ] is a 6x6 matrix, i.e., we have a 6 degree-of-freedom (dof) element. Note that the general form for the strain energy (1.25) can be written in index notation also: 6 6 U 12 {q } [k ]{q } 12 kije qie q ej e e T e e (1.28) i 1 j 1 Because [ D e ] is symmetric, the stiffness matrix [ k e ] defined by either (1.26) or (1.27) is a symmetric matrix (always the case). 22 A04 - Introduction to the Finite Element Method The stiffness matrix for the CST defined by (1.27) can be written in sub-matrix notation as: k11 k12 [k e ] k21 k22 (6 x 6) k31 k32 k13 k23 k33 (1.29) where each of the kij is a (2x2) sub-matrix defined by (bi b j D11 ci c j D33 ) (bi c j D12 ci b j D33 ) [kij ] 41A (1.30) (ci b j D21 bi c j D33 ) (ci c j D22 bi b j D33 ) (2 x 2) where the Dij are material properties ( E , ) defined by (1.5) and the bi and ci are geometry parameters (x-y coordinates of nodes) defined by (1.14). A04 - Introduction to the Finite Element Method To define the external potential energy V, we have to define the external load. Suppose we have a uniform traction (pressure) p applied on the element edge defined by nodes 1 and 2. The external potential then becomes: L V [u ( s) p cos v( s) p sin ]tds e 0 Note that p cos is the component of p in the x direction. Displacements u and v on boundary 1-2 must be written as functions of position s on the boundary: u12 ( s ) (1 s / L)u1 ( s / L)u2 v12 ( s) (1 s / L)v1 ( s / L)v2 23 24 A04 - Introduction to the Finite Element Method Substituting u(s) and v(s) into V, and integrating over the boundary, gives: V 12 ptL cos u1 12 ptL sin v1 12 ptL cos u2 12 ptL sin v2 The last result can be written in matrix notation as 6 V e {q e }T {F e } Fie qie (1.31) 1 pt e L cos 2 1 pt e L sin 2 1 pt e L cos e {F } 2 1 pt e L sin 2 0 0 (1.32) i 1 where 25 A04 - Introduction to the Finite Element Method The matrix {F} represents the equivalent generalized nodal force vector due to pressure load on boundary 1-2, i.e., we have replaced the pressure p on boundary 1-2 by the nodal forces {F} at nodes 1 and 2. = Note that the total force due to p on boundary 1-2 is (ptL) and divides equally between nodes 1 and 2. 26 A04 - Introduction to the Finite Element Method Another set of forces exists on the boundary of any element. These are due to surrounding elements that apply forces due to contact with the element in question, i.e., surrounding elements are being deformed and hence they try to deform the element in question and thereby put forces on this element. Additionally, where a node is at a support or "fixed," there will be a reaction force on the element node. Call these reaction forces {S }. S4 2 S3 S2 S6 1 S1 S5 3 Si reactions from adjacent elements The ext. pot. energy due to reactions is V e {qe }T {S e } (1.33) 27 A04 - Introduction to the Finite Element Method We can determine the equations of equilibrium for the element. Using (1.1) and noting that U e and V e are functions of nodal displacements qie , i 1,...,6 , we have 6 (U e V e ) i 1 qie (U e V e ) 0 qie (1.34) Since qi 0 , then (U e V e ) qie 0 for i 1, 2,...,6 (1.35) Substituting U (1.28) and V [(1.31) and (1.33)] into (1.35) gives the equilibrium equation for any element. [k e ]{qe } {F e } {S e } Note that [ K e ] is (6x6) and {F e } & {S e } are (6x1) matrices. (1.36) 28 A04 - Introduction to the Finite Element Method Equations (1.34)-(1.36) provide the equilibrium equation for a single element. Suppose we look at a collection of elements (i.e., a complete structure). Then the total energy of the structure is given by the sum of internal and potential energy of all the elements ( N el ): N el N el U str U e e1 e1 6 6 e e e 1 {q } [ k ]{q } 1 kij qi q j (1.37) 2 2 e1 i 1 j 1 e T e e N el N el and N el N el e1 e1 N el 6 Vstr V e {q e }T {F e } {q e }T {S e } e1 i 1 e e Fi qi e1 e e Si qi e1 i 1 N el 6 The principle of minimum potential energy for the structure requires that (1.38) 29 A04 - Introduction to the Finite Element Method M (U str Vstr ) 0 (U str Vstr ) qi i 1 qi (1.39) where {q} contains the M degrees of freedom for the structure (NOT dof for each element). For qi 0 , the last equation requires that (U str Vstr ) (1.40) 0 for i 1, 2,..., M qi Substituting U str (1.37) and Vstr (1.38) into (1.40) gives N el e1 1 {q e }T [ k e ]{q e } 2 {q } {S } 0 {q } {F } N el e T e 1 qi e N el e 1 e T e for i 1, 2,..., M (1.41) Problem: The energy terms for each element are in terms of the element dof, but in order to obtain the equations of equilibrium for 30 A04 - Introduction to the Finite Element Method the structure (above equation), we have to take the partial derivatives with respect to the global structural dof. In order to complete the above, the element degrees of freedom {q e } must be written in terms of the M global structural degrees of freedom {q}. For any element, we can write a transformation between element local and global dof (called the local-global transformation): {q e } [T e ] {q} (6 x1) y (1.42) (6 xM ) ( Mx1) The transformation will be nothing more then 1's and 0's. As an example, suppose we have the following element and structural node numbering: q2 q6 q8 q4 1 2 3 4 1 q1 2 q3 3 q5 4 q7 q10 1 5 9 5 2 6 6 7 10 8 p 5 q9 6 7 8 q18 3 7 11 q24 q17 q23 4 8 12 9 x 10 11 12 y 9 x 10 11 12 31 A04 - Introduction to the Finite Element Method Consider element 7. Suppose we place element node 1 at global node 6. q12 q14 q2e q6e q11 7 e q1e q13 3 q 6 5 1 7 7 q22 q4e q21 q3e 11 2 Element nodes and local dofs Structural nodes and global dofs We see that for element 7, there is a correspondence between the 6 element local dofs at element nodes 1, 2 and 3, and the 6 structural global dofs at nodes 6, 11and 7. We see that local (element) node 1 corresponds to global node 6, local (element) node 2 corresponds to global node 11, and local node 3 corresponds to global node 7. We can write this local to global transformation {qe } [T e ]{q} as: A04 - Introduction to the Finite Element Method 32 q1,2 q 1 2 3 4 8 9 10 11 12 3,4 q5,6 q7,8 1 0 [0] [0] [0] [0] [0] [0] [0] [0] [0] [0] [0] 0 1 e 7 q1,2 q9,10 7 q11,12 1 0 [0] [0] [0] [0] [0] q3,4 [0] [0] [0] [0] [0] [0] q 0 1 13,14 7 q15,16 q5,6 1 0 [0] [0] [0] [0] [0] [0] [0] [0] 0 1 [0] [0] [0] q 17,18 q19,20 q 21,22 q23,24 global node # 5 6 7 Each [0] is a (2x2). The above says that for element 7, local (element) node 1 corresponds to global node 6, i.e., local dofs 1,2 correspond to global dofs 11,12; local node 2 corresponds to global node 11, i.e., local dofs 3,4 correspond to global dofs 21,22, etc. 33 A04 - Introduction to the Finite Element Method Now transform U e and V e from local to global dof by substituting (1.42) into (1.37) and (1.38) to obtain U e 12 {q e }T [k e ]{q e } 12 {q}T [T e ]T [ k e ][T e ]{q} 12 {q}T [ K ge ]{q} V {q} [T ] {F } {q} [T ] {S } {q} e T e T e T e T e T {Fge } {q}T {S ge } (1.43) Now we can define the following element matrices in global dof (instead of local element dof): [ K ge ] [T e ]T [k e ] [T e ] ( MxM ) ( Mx 6) (6 x 6) (6 xM ) {Fge } [T e ]T {F e } ( Mx1) (1.44) ( Mx 6) (6 x1) {S ge } [T e ]T {S e } To see what an element stiffness and force matrix written in global dof looks like, consider element 7 again. We obtain for [ K g7 ] and {Fg7 }: 6 A04 - Introduction to the Finite Element Method 7 6 k11 7 11 k21 7 7 k31 Element 7 Each block is a (2x2) sub-matrix 1 2 3 4 5 1 2 3 4 5 [ K g7 ] 6 7 8 9 10 11 12 6 7 11 7 k12 7 k22 7 k32 7 7 k13 7 k23 7 k33 F17 7 F2 7 F3 34 8 9 10 11 12 7 7 k13 k11 7 k12 7 7 k31 k33 7 k32 7 7 k23 k21 7 k22 {Fg7 } F37 35 A04 - Introduction to the Finite Element Method Now the internal and external potential energy is given by N el N el N el M M e T e e 1 1 U str U 2 {q} [k g ]{q} 2 k gij qi q j (1.45) e1 e1 e1 i 1 j 1 N el N el e1 e1 N el M N el Vstr V e {q}T {Fge } {q}T {S ge } e1 i 1 Fgie qi e1 N el M e S gi qi e1 i 1 (1.46) Now we can substitute (1.45) and (1.46) into (1.40) to obtain: N el e1 {q} 1 {q}T [ k e ]{q} g 2 N el e1 qi T {Fge } {q} N el e1 T {S ge } 0 for i 1, 2,..., M (1.47) 36 A04 - Introduction to the Finite Element Method which gives a system of M equations in terms of the structural displacements: N el e1 N el N el [k ge ]{q} {Fge } {S ge } {0} e1 (1.48) e1 or N el N el Nel e e e [ k ] { q } { F } { S g g g} e1 e1 e1 (1.49) When all the element contributions have been summed, we simply write (1.50) [ K ]{q} {Q} {S} Note that when the element stiffness and force matrices are written in terms of structural displacements (using local to global transformation), they become additive [see eq. (1.49)]; i.e., to get the structural stiffness matrix [K], we sum the contributions for all elements. 37 A04 - Introduction to the Finite Element Method Assemblage of Elements A single element by itself is useless. We must determine the equilibrium equations for an assemblage of elements that comprise the entire structures. Consider the following structure (only a few elements are taken to simplify the discussion) with a uniformly pressure p on the right boundary and fixed on the left boundary (assume a constant thickness t). 1 We number the structural nodes from 1 to 12 as shown. We also number the elements from 1 to 12 as shown (in any order). 5 y 2 1 4 9 x 2 3 6 3 5 8 10 6 7 7 4 9 12 11 For each global node of the structure, we can specify the (x,y) coordinates: xi , yi , i=1, 2, …, 12. 10 8 11 12 p A04 - Introduction to the Finite Element Method 38 q6 q8 q4 Each node of the structure will q2 q3 q5 1 q1 2 3 4 q7 have two degrees of freedom q10 (dof). We label these 5 q9 6 7 8 structural (global) degrees of q18 q24 q17 q23 freedom in order as shown to y 9 the right. Note that the 10 11 12 x structural nodal displacements are written without the superscript "e." The nodal displacement vector is written as {q} and is (24x1) for this problem. We note that the left side is fixed (nodes 1, 5 and 9). Hence, displacement boundary conditions will require that q1 q2 q9 q10 q17 q18 0 . Note: we do not have to number the dof consistently and in sequence with the structural nodes. However, this makes the bookkeeping much, much simpler! For each element, we can construct a table called the element connectivity that specifies which structural (global) nodes are A04 - Introduction to the Finite Element Method 39 connected by an element. Hence, for the problem above, we have the following element connectivity table: Element No. Element Node 1 Element Node 2 Element Node 3 1 1 5 2 2 5 6 2 3 5 10 6 4 5 9 10 5 2 6 3 6 6 7 3 7 6 11 7 8 6 10 11 9 3 7 4 10 7 8 4 11 7 12 8 12 7 11 12 Note that for the CST, element nodes MUST be given as CCW. Element node 1 can be attached with any global node of the element. A04 - Introduction to the Finite Element Method 40 Note that if we are careful in numbering the nodes and choosing the element connectivity in a "systematic" manner, there will be a pattern to the element connectivity table (see above). An automatic mesh generator, like the one in FEMAP, tries to follow this pattern. Note that the global node numbers for the structure are somewhat arbitrary, i.e., we could number them in any order. However, it will turn out that there are optimum ways to number nodes (for a given structure and mesh) in order to reduce the bandwidth of the structural stiffness matrix [K] - this saves time solving the equations. For the mesh above, it would be optimum to number downward and left-to-right, as opposed to left-to-right and downward. We'll discuss that later. Likewise, the element numbering is arbitrary, but again there may be optimum approaches. An automatic mesh generator tries to do the numbering in an optimum fashion. 41 A04 - Introduction to the Finite Element Method Note that for this structure, we have 12 global nodes. There are 2 degrees of freedom (dof) at each node (u and v). Hence, the structure has 24 dof and the structural stiffness matrix [K] will be (24x24). The structural equilibrium equations can be written as: [ K ] {q} {Q} {S} (24 x 24) (24 x1) (1.51) (24 x1) where [K]=structural stiffness matrix, {Q}=structural forces matrix (due to applied tractions and body forces) {S}=structure reaction forces due to boundary conditions Lets see how each element contributes to global matrices. Take element 1 to start with. Note that we can use sub-matrix notation to divide the element matrices as following. Use a superscript of 1 on the k terms to indicate element 1. 42 A04 - Introduction to the Finite Element Method 1 1 k11 k12 (2 x 2) 1 1 1 [k ] k21 k22 (6 x 6) 1 1 k k 32 31 1 k13 1 k23 , 1 k33 F11 (2 x1) 1 1 {F } F2 1 F3 We now look at element 1 and note that element node numbers 1, 2, 3 correspond to global node numbers 1, 5, 2 (from the drawing of the mesh, or from the element connectivity table). We can indicate this information on the stiffness and force matrices as follows: 1 5 1 1 k11 k 12 1 (2 x 2) 1 1 1 [k ] 5 k21 k22 (6 x 6) 1 1 k k 32 2 31 2 1 k13 1 k23 , 1 k33 F11 1 (2 x1) 1 {F 1} 5 F2 (6 x1) 1 2 F3 43 A04 - Introduction to the Finite Element Method Hence, we see that element 1 contributes stiffness and forces to global nodes 1, 5 and 2. Placing these contributions into the global stiffness matrix gives: Element 1 only K 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 {q} Q 1 1 k13 k11 1 k12 q1,2 F11 1 1 k31 k33 1 k32 q3,4 F31 1 k22 q5,6 q7,8 q9,10 F21 1 1 k23 k21 = q23,24 ** remember, each block is a (2x2) sub-matrix 6 A04 - Introduction to the Finite Element Method 7 6 k11 7 k 11 21 7 7 k31 Now take element 7. Element 7 only K 1 1 2 3 4 5 6 7 8 9 10 11 12 2 3 4 5 6 7 8 11 7 k12 7 k22 7 k32 7 7 k13 7 k23 7 k33 9 10 11 12 F17 7 F 2 7 F 3 {q} Q q1,2 q3,4 q5,6 q7,8 q9,10 = q23,24 ** remember, each block is a (2x2) sub-matrix 44 A04 - Introduction to the Finite Element Method 45 Note that the distributed pressure load p is applied only to the right boundary of elements 10 and 11. Hence {F} for all elements except 10 and 11 will be zero. For elements 10 and 11, we will have 0 0 0 7 7 0 1 ptL 1 ptL 48 812 2 2 10 11 {F } 8 {F } 12 0 0 1 ptL48 1 ptL812 2 4 2 8 0 0 where L48 is the length between global nodes 4 and 8, etc. If we assemble all element stiffness matrices [k] and forces matrices {F} to the global equilibrium equations, we have the following result: A04 - Introduction to the Finite Element Method 46 Structural Equations of Equilibrium K 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 {q} Q q1,2 X X X q3,4 X X X X X q5,6 X X X X X q7,8 X X X X X q9,10 X X X X X X X X X X X X X = X X X X X X X X X X X X X X X X X X X X X X X X X q23,24 X X X X X X means that one or more elements have contributed here ** remember, each block is a (2x2) sub-matrix Note that [K] is symmetric; also it is banded (semi-bandwidth=12). 47 A04 - Introduction to the Finite Element Method In the previous page, each X 1 2 3 means that one or more elements 3 3 1 3 31 1 5 have contributed to that (2x2) sub-matrix. For example, we note 5 2 1 2 2 2 1 6 2 7 1 1 3 36 1 7 that node 2 will have stiffness from elements 1, 2 and 5. Hence, 22 8 2 2 4 3 3 the 2,2 position of the global 9 10 11 stiffness matrix will be equal to (note: you have to refer to the element connectivity to see which element node for each element corresponds to global node 2): 1 2 5 [ K 22 ] [k33 ] [k33 ] [k11 ] each sub-matrix is (2x2) The global node 2-6 coupling term [ K 26 ] will have contributions from elements 2 and 5 since only these elements share the 2 5 boundary between nodes 2 and 6: [ K 26 ] [k32 ] [k12 ]. Global node 6 will have stiffness contributions from elements 2, 3, 2 3 5 6 7 8 5, 6, 7, and 8: [ K66 ] [k22 ] [k33 ] [k22 ] [k11 ] [k11 ] [k11 ]. 48 A04 - Introduction to the Finite Element Method Question? What happened to the reactions {S} for each element? Why don't they show up in the structural stiffness matrix? Simple. It is equilibrium. Recall that when we make a free-body, in this case take a single finite element as the free-body, we will have equal and opposite reactions where the cut is made though the body. Consider elements 1 and 2 below: S41 2 1 1 2 3 S21 S31 S 42 S11 S61 1 S51 S62 3 2 2 S52 S32 S22 S12 1 At the boundary between elements 1 and 2, the reactions are equal and opposite. Hence, we add them up we have: S11 S32 0 , S21 S42 0, S51 S52 0, and S61 S62 0 . Hence, all the reactions 49 A04 - Introduction to the Finite Element Method between elements sum to zero and do not have to be put into the structural equilibrium equations. OK, but what about the boundary where there are supports? What happens to the reactions there? For example, the cantilever plate example above: 1 2 3 4 1 They don't disappear and should 5 2 be included in the structural 3 4 stiffness matrix. y 9 We know that there will be x unknown reactions at global nodes 1, 5 and 9. We could call R2 1 R1 these reactions R1, R2 , R9 , R10 , R10 1 5 R9 2 R17 and R18 (consistent with R18 3 global displacements). So we 4 y have the free body of the 9 R17 structure: x 6 5 8 6 7 9 7 12 10 8 11 10 11 12 2 3 4 6 5 8 10 6 7 7 9 12 11 10 8 11 12 p p 50 A04 - Introduction to the Finite Element Method Structural Equations of Equilibrium with Support Reactions K 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X 8 9 10 11 12 X X X X X X X X X X X X X X X X X X X X X {q} q1,2 Q R1,2 q3,4 q5,6 q7,8 q9,10 X R9,10 = X R17,18 q23,24 X means that one or more elements have contributed here ** remember, each block is a (2x2) sub-matrix X A04 - Introduction to the Finite Element Method 51 OK, now one last step. We have to apply displacement boundary conditions. The structure is fixed at nodes 1, 5 and 9; thus, q1 q2 q9 q10 q17 q18 0 . The easiest way to apply boundary conditions to any system of equations is as follows: 1. Zero out the row and column on the left side matrix (the [K] matrix) corresponding to each B.C., and zero out the row of the right side (the {Q} matrix) corresponding to each B.C. 2. Place a 1 on the diagonal of the left side matrix (the [K] matrix) corresponding to each B.C. You will notice that every dof that has a B.C. also corresponds to a dof where a support reaction (R) occurs. Applying B.C. as described above will thus eliminate the reactions from the equilibrium equations. A theoretical reason why we don’t have to worry about reactions in structural equations of equilibrium? Because these support reactions R do no work (displacement is zero at support) and hence do not affect equilibrium of the structure!!! 52 A04 - Introduction to the Finite Element Method Structural Equations of Equilibrium with B.C. Applied K 1 2 3 4 5 6 7 8 9 10 11 12 1 2 1 1 0 0 0 0 0 0 0 0 0 0 0 0 3 4 X X X X X X X 0 0 0 0 X X X X X 5 0 0 0 0 0 0 0 0 1 1 0 0 0 0 0 0 0 0 0 0 0 0 6 7 8 9 10 11 12 0 0 0 0 X X X X X X X X X X X X Q q1,2 0 0 q3,4 X X X X X 0 0 0 0 {q} 0 0 0 0 q5,6 q7,8 q9,10 X X X X X 1 1 0 0 0 0 X 0 0 = X 0 0 0 0 X X X X X X X 0 0 q23,24 X means that one or more elements have contributed here ** remember, each block is a (2x2) sub-matrix X 53 A04 - Introduction to the Finite Element Method The structural equations with B.C. may now be solved for the unknown displacements. Note that when we solve the system of equations, the solution will give q1 q2 q9 q10 q17 q18 0 , i.e, the 1st equation simply says (1)q1 0, etc. Element Strains and Stresses Now we are ready to solve for the element strains and stresses. For each element, we can substitute the 6 global displacements corresponding to that element into (1.21): { e } [ B e ]{q e } (3 x1) e=1, 2, …, no. of elements (3 x 6) (6 x1) The stresses for each element can then be obtained by substituting the strains for that element into (1.4): { e } [ De ]{ e } (3 x1) (3 x3) (3 x1) e=1, 2, …, no. of elements A04 - Introduction to the Finite Element Method 54 Evaluation of stress results based on stress components in the Cartesian coordinates directions ( xx , yy , xy , etc.) leaves something to be desired. Why? Stresses in these directions may not necessarily represent the largest stresses and we need these in order to consider yielding or failure. You already know that you can calculate principal stresses and maximum shear stress using stress transformation equations or Mohr's Circle. Hence, stress results (stress components) are often represented in two additional ways: Principal stresses and maximum shear stress, and von Mises stress. Principal stresses can, as noted above, be obtained by either stress transformation equations or through the use of Mohr's Circle. An alternate approach to define principal stresses is to write: 55 A04 - Introduction to the Finite Element Method xx p xy xy yx yy p yz zx zy zz p 0 (1.52) Expansion of the determinant provides a cubic equation that can be solved for the three principal stresses p . Comparing principal stresses to a tensile yield stress provides some measure of evaluation; however, one has to keep in mind that comparing the principal stress (obtained from a three-dimensional stress state) to a yield stress obtained from a uniaxial tension test is risky at best. The von Mises stress provides a means to extrapolate uniaxial tensile test data (for yield stress) to a three-dimensional stress state. In effect, the von Mises stress provides an "equivalent" uniaxial stress approximation to the three-dimensional stress state in a body through the following equation: 56 A04 - Introduction to the Finite Element Method VM 1 22 ( xx yy ) ( yy zz ) ( zz xx ) 12 (1.53) 6 xy 6 yz 6 zx 2 2 or VM 1 2 1 22 ( p1 p 2 )2 ( p 2 p 3 ) 2 ( p 3 p1 ) (1.54) where ( p1, p 2 , p3 ) are the principal stresses. Given the stress components ( xx , yy , xy , etc.) or principal stresses, one can compute the von Mises stress. This representation has been used quite successfully to model the onset of yielding in ductile metals and collaborates well with experiment. It is widely used in industry. For a material to remain elastic, VM y (for no yielding) A04 - Introduction to the Finite Element Method 57 Equation (1.54) forms an ellipsoid in 3-D (ellipse in 2-D) when the stresses are plotted in principal stress space. As long as the stress state represented by the principal stresses is inside the ellipse (the yield surface), the material is elastic. A04 - Introduction to the Finite Element Method 58 Element Libraries (or, choose the right element for a structural component and loading, in order to maximize potential for correct results with the least amount of computation) Many, many finite elements have been developed for use in modern FEM software. Choosing the correct element for a particular structural is paramount. For example, if a structural member behaves like a beam in bending, we should choose a beam element to model it, if a structural member behaves like a thin plate in plane stress, we should choose an appropriate element to model it, if a structural member looks like a shell of revolution, we should use a thin shell of revolution element, if a structural member will experience a three-dimensional stress state, we have to choose an element that models that behavior, etc. 59 A04 - Introduction to the Finite Element Method Here are some examples of the types of elements available: Truss element (2-D and 3-D) Beam bending element (2-D and 3-D; straight and curved) dof at each node Membrane element (no bending; flat and curved) Triangular, Quad (both straight and curved sides) A04 - Introduction to the Finite Element Method 60 Planes Stress and Plane Strain elements Triangular and Quadrilateral shapes (both straight and curved sides). Plane stress requires that the only non-zero stresses occur in the plane of the element (however, strain does occur normal to plane). Generally applicable to thin geometries. Two displacement dof per node (NO rotational dof). Plane strain requires that the only non-zero strains occur in the plane of the element (strain is zero normal to plane, but stress is not zero). Long constrained geometries (for example, a long pipe, a dam). Elements with curved boundaries will always have 3 or more nodes per edge. A04 - Introduction to the Finite Element Method Plate and shell bending elements (bending and in-plane stresses; flat and curved elements) Triangular, Quad (both straight and curved sides) Plate and shell bending elements are characterized as being thin compared to other dimensions, and having no stress normal to the plate (similar to plane stress). 61 A04 - Introduction to the Finite Element Method 62 Plate and shell bending elements will have in-plane and normal displacements ( u, v, w) and rotations ( x , y ) about the two axes in the plane of the plate/shell. No stiffness about the normal axes. A04 - Introduction to the Finite Element Method 63 Axisymmetric shell bending element (for shell of revolution) The shell of revolution can be described geometrically by a curved (or straight) line that is revolved about the axis of symmetry. Top two figures are examples of thin shells of revolution. Degrees of freedom and stress state for a shell of revolution are similar to plate and shell bending elements, i.e., displacements parallel and perpendicular to the shell surface, and rotations about the two axes that lie in the plane of the shell. No stress normal to surface. Lower figure (multicell tube) is NOT a shell of revolution, but would require plate or shell elements. A04 - Introduction to the Finite Element Method 64 Axisymmetric body of revolution element (3-D stress analysis) Body is solid and axisymmetric about some axis of revolution. Stress state is fully three-dimensional (includes all stress components). Note that the element forms a triangular-shaped ring, i.e., the element itself is a body of revolution. A04 - Introduction to the Finite Element Method 65 General solid element (for full 3-D stress analysis) Tetrahedron, Brick shapes (both straight and curved sides) Stress state is fully three-dimensional (includes all stress components). Three-dimensional solid elements have 3 displacements per node (NO rotational dofs). Elements with curved boundaries will always have 3 or more nodes per edge. A04 - Introduction to the Finite Element Method 66 Mesh Generation, Pre and Post-processing, Solvers In order to generate the structural stiffness matrix, we must specify the nodal coordinates (x,y,z) of each global node and element connectivity for each element. For a large problem with complex geometry, this is a monumental task if done by hand. Mesh generators are software tools that automate this process. Mesh Generation and Preprocessing In general, mesh generation starts by specifying the coordinates of a few key locations that will sufficiently define the outer boundary t = 0.5 in. A04 - Introduction to the Finite Element Method 67 of a structural component and other distinguishing features such as holes, fillets, etc. Consider the bracket shown above. We could first define the corners of a 10" x 25" rectangle. To specify the rounded edges on the right boundary, we could specify that a 4" radius fillet is to be placed at each right corner. Finally, to specify the location of the hole, we would define a 2" radius circle whose center is located 5" from the right boundary. To specify the mesh (how many elements are to be used), we would specify so many elements in the x direction and so many elements in the y direction. Since the structure is 2-D and in plane stress, we would specify the type of element (triangular, quad, etc.) to be used in defining the mesh. A04 - Introduction to the Finite Element Method 68 The mesh generator would then automatically determine the coordinates of all global nodes and determine the element connectivity for all elements. As a part of the mesh generation, we would also specify the thickness to be used for each element. Generally, the mesh generator would allow for a linear thickness variation within the region being meshed. For a variable thickness case, one would have to specify the thickness at several key locations and mesh generator would determine the thickness for all elements in the region. Also, the material properties would be specified for each element in the region. Most mesh generators only provide for one material set to be used within a region (i.e., same material for all elements). Next, the mesh generator (also called the preprocessor, because it processes all the required input) would require the type of loading A04 - Introduction to the Finite Element Method 69 that is applied to elements or element boundaries (point forces, body forces, surface tractions). For a thermal stress analysis, the preprocessor would also require information on thermal loading. For a dynamic (transient) analysis, we would have to specify mass properties for each element and the time history of the loading. Lastly, the displacement boundary conditions must be specified. Given all this information, the mesh generator/preprocessor will have generated a model something like that shown below: A04 - Introduction to the Finite Element Method 70 With this information, the preprocessor would create a data set (an output file) in a format suitable to be read and processed by the finite element analysis program (also called the solver). Solver Once the solver has created the structural stiffness and force matrices, solved for global nodal displacements, and solved for stresses and strains (plus a few other things appropriate to each element type), it generates an output file and we are now ready to examine and interpret the results. Post-processing Clearly, for a complicated structure with many nodes and elements, the examination and evaluation of all results is an enormous task because of the shear volume of data (displacements, strains, stresses, etc). The post-processor now takes over. Its purpose is to provide output such as the deformed geometry, contour plots of principal stress components, contour plots of von A04 - Introduction to the Finite Element Method 71 Mises stress, contour plots of strain components, etc. (what ever you decide is important). What, and how, the postprocessor can display information depends on the type of elements being used. Below are outputs of the deformed geometry and vonMises stress. A04 - Introduction to the Finite Element Method 72 Often the pre and post-processor are combined into one software package (like FEMAP or PATRAN). Most preprocessor programs will create output files in formats acceptable to various solvers A04 - Introduction to the Finite Element Method 73 (like CAEFEM, NASTRAN, ANSYS, ABACUS, etc.). Likewise, most postprocessor programs will accept the output file of most solvers and display a variety of data results generated by the solver. Last Thoughts on Mesh Generators, Pre/Post-Processors & Solvers They will do a lot the tedious work for you. They are not a substitute for good engineering know-how, judgement and experience. In the end, YOU are responsible for the model you have generated for the structure, and for the correct interpretation and usage of the analysis results. They aid you in the design process; but in the end, YOU are the designer.
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