How do you update and maintain your finite element stress analysis models?

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Finite element stress analysis (FESA) is a powerful tool for simulating the behavior of complex structures and materials under various loads and conditions. However, FESA models are not static and require regular updates and maintenance to ensure their accuracy, reliability, and efficiency. In this article, you will learn how to update and maintain your FESA models using some best practices and tips.

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Unnikrishnan S

Structural Analysis Engineer at Boeing | Aerospace Workflow/Process Automation Expert |
Richard Phillips

1 Review your model assumptions

Before you update your FESA model, you should review your model assumptions and make sure they are still valid and consistent with the design specifications, engineering standards, and physical phenomena. For example, you should check if your boundary conditions, material properties, load cases, and failure criteria are appropriate and realistic for your problem. You should also verify if your model assumptions are compatible with the software and solver you are using, and if they have any limitations or implications for your results.

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2 Update your geometry and mesh

One of the most common reasons to update your FESA model is to reflect the changes in the geometry of your structure or component due to design modifications, fabrication errors, or damage. You should update your geometry and mesh accordingly, using the latest CAD data or measurements, and applying the appropriate meshing techniques and quality criteria. You should also check for any errors or warnings in your geometry and mesh, such as gaps, overlaps, distortions, or singularities, and fix them before running your analysis.

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3 Validate and calibrate your model

Another important step in updating and maintaining your FESA model is to validate and calibrate your model against experimental data, analytical solutions, or other sources of verification. You should compare your model predictions with the available data and evaluate their agreement, accuracy, and sensitivity. You should also identify and quantify the sources of uncertainty and error in your model, such as simplifications, approximations, or discretizations, and adjust your model parameters or settings accordingly. You should document your validation and calibration process and results, and report any deviations or discrepancies.

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Unnikrishnan S

Structural Analysis Engineer at Boeing | Aerospace Workflow/Process Automation Expert |
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FEM=stress analysis powerhouse, but accuracy hinges on model upkeep. Keep yours sharp: Adapt to design changes (update geometry, material properties, loading). Maintain model health (refine mesh, review boundary conditions, select proper material model). Validate with data (analytical or test). Document for future (versions, assumptions, materials, results). Update software for efficiency. Validation: Check model behaves mathematically. Compare model predictions with physical tests. Refine Based on Validation Refine mesh in high-stress areas. Select a more complex material model if needed. Adjust boundary conditions to match tests. Validation: Update, re-run, and compare with new test data until model and experiment matches.

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4 Optimize your model performance

Updating and maintaining your FESA model also involves optimizing your model performance and reducing the computational time and resources required for your analysis. You should review your model settings and options, such as solver type, convergence criteria, output frequency, and parallel processing, and choose the ones that suit your problem and hardware. You should also consider using techniques such as submodeling, symmetry, adaptive mesh refinement, or model order reduction to simplify or refine your model as needed. You should test and compare different scenarios and configurations to find the optimal balance between accuracy and efficiency.

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5 Document and archive your model

The final step in updating and maintaining your FESA model is to document and archive your model for future reference, reuse, or revision. You should create a clear and comprehensive record of your model information, such as geometry, mesh, assumptions, parameters, settings, results, validation, calibration, optimization, and changes. You should also organize and store your model files and data in a secure and accessible location, using consistent and meaningful naming conventions and formats. You should follow the best practices and standards for data management and quality assurance in your field and organization.

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Richard Phillips
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Clear documentation of the design criteria is critical. Additionally which codes were used, how was the part was classified, and how the loads were developed need to be documented. A well documented model should allow a fellow engineer to recreate the model from scratch. Often times this means documenting more information than what is in the finite element analysis program.

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6 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 update and maintain your finite element stress analysis models?

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1 Review your model assumptions

2 Update your geometry and mesh

3 Validate and calibrate your model

4 Optimize your model performance

5 Document and archive your model

6 Here’s what else to consider

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