How do you choose between FEA and CFD for your CAD/CAM projects?

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If you use CAD/CAM software for designing and manufacturing products, you may need to perform some type of analysis to test and optimize your designs. Two common methods of analysis are finite element analysis (FEA) and computational fluid dynamics (CFD). But how do you choose between them for your CAD/CAM projects? In this article, we will explain the differences, advantages, and disadvantages of FEA and CFD, and give you some tips on how to select the best method for your needs.

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Ahmed Abdelnaser

1 What is FEA?

FEA is a numerical technique that divides a complex solid or structure into smaller, simpler elements. Then, it applies equations and boundary conditions to each element to calculate the stresses, strains, displacements, and other physical quantities. FEA can help you evaluate the strength, stiffness, deformation, vibration, and failure modes of your designs under various loads and scenarios.

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Ahmed Abdelnaser
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FEA is the evolution of this century as it gives us the opportunity to make virtual prototypes that save money and time. being good in FEA is the tool that never die

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Ricardo Camargo

Engenheiro de Desenvolvimento de Produto | Gest?o de Projetos | Projetista de Produtos e Pe?as Plásticas | Projetista de Moldes Plásticos | Black Belt Lean Six Sigma
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FEA (Finite Element Analysis) is a powerful tool that helps engineers in the project development. In other words, it allows the engineers to analyze the behavior one part (or a group of parts), without the necessity of making physical prototypes. With this tool, is possible to analyze stress regions, displacements, deformations, and another conditions, that can help engineers to make better parts, reducing time and money in the development phase.

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2 What is CFD?

CFD is a numerical technique that solves the equations of fluid flow and heat transfer for a fluid domain. It can simulate how fluids behave and interact with solid surfaces, such as pressure, velocity, temperature, turbulence, and drag. CFD can help you analyze the aerodynamics, thermodynamics, fluid-structure interaction, and combustion of your designs involving gases or liquids.

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3 When to use FEA?

Finite Element Analysis (FEA) is a useful tool for CAD/CAM projects that involve solid or structural mechanics, such as metal parts, composite materials, mechanical assemblies, and civil engineering structures. It can help you optimize the shape, size, material, and configuration of your designs to achieve the desired performance and reliability. As an example, FEA can be used for stress analysis of a car chassis, modal analysis of a guitar string, fatigue analysis of a turbine blade, and buckling analysis of a column.

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Ricardo Camargo

Engenheiro de Desenvolvimento de Produto | Gest?o de Projetos | Projetista de Produtos e Pe?as Plásticas | Projetista de Moldes Plásticos | Black Belt Lean Six Sigma
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In my opinion, the most common application of FEA tool, is to support engineers to make decisions, especially, in the project development phase. When this tool works integrated with the CAD software, the project improvement process can be more optimized, since all the tools (CAD and FEA) are in the same ambient. Once this tool allows the virtual mechanical behavior analysis of one part individually (or a group of parts) no physical prototypes are necessary (or the amount of prototypes can be drastically reduced). With on click, the material can be changed, or the geometry can be modified, and one new analysis can be run, saving time and money with new physical prototypes.

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4 When to use CFD?

CFD is an ideal tool for CAD/CAM projects that involve fluid mechanics, such as airfoils, ducts, valves, pumps, and heat exchangers. It can help you optimize the flow characteristics, heat transfer, and efficiency of your designs to reduce drag, noise, and energy consumption. For instance, CFD can be used to analyze the aerodynamics of a wing, the flow of a pipe, the heat transfer of a radiator, and the combustion of an engine.

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5 How to choose between FEA and CFD?

There is no one-size-fits-all answer to this question, as it depends on the nature and objectives of your CAD/CAM project. Generally, if your design is mainly solid or structural, FEA should be used to evaluate its mechanical behavior and response. On the other hand, CFD should be employed if your design is mainly fluid or thermal, in order to evaluate its fluid dynamics and heat transfer. If your design involves both solid and fluid components, then both FEA and CFD should be used, or a hybrid method that combines them. If you are not sure which method is more appropriate, start with a simpler or more familiar method and compare the results with experimental data or other sources of validation.

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Ahmed Abdelnaser
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It's totally different concept as FEA works with solid bodies and CFD works with fluids. but in real life, we need to use both together in some projects.

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6 What are the benefits and challenges of FEA and CFD?

FEA and CFD both offer benefits and present challenges when used for CAD/CAM projects. Benefits include improved design quality, accuracy, and efficiency with less need for physical testing, prototyping, and trial-and-error. Additionally, they can help explore different design options, scenarios, and parameters while visualizing the results in various formats and perspectives. Challenges include the need for a lot of computational resources, time, and expertise to perform correctly and reliably. They also require careful selection and validation of models, assumptions, inputs, outputs, and errors - which can lead to inaccuracy or lack of realism in capturing the complexities of the real world.

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Ricardo Camargo

Engenheiro de Desenvolvimento de Produto | Gest?o de Projetos | Projetista de Produtos e Pe?as Plásticas | Projetista de Moldes Plásticos | Black Belt Lean Six Sigma
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I would like to make some “alerts” about FEA: 1- Is so important to input reliable material data, because with poor material data, you will obtain a simulation result with different behavior of the real world; 2- The mesh quality is another important item, that needs special care and attention in the simulation steps; 3- Understanding the expected physical / mechanical behavior is important to check if the simulation results are not showing different behaviors from the real world.

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7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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How do you choose between FEA and CFD for your CAD/CAM projects?

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1 What is FEA?

2 What is CFD?

3 When to use FEA?

4 When to use CFD?

5 How to choose between FEA and CFD?

6 What are the benefits and challenges of FEA and CFD?

7 Here’s what else to consider

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