What's your approach to solving complex geometries and boundary conditions in finite element analysis?

1 Meshing methods

One of the first steps in FEA is to create a mesh, which is a discretization of the geometry into smaller elements that can be solved by the FEA software. The quality and size of the mesh affect the accuracy and speed of the analysis. There are different meshing methods available, such as structured, unstructured, or hybrid meshes, and each has its advantages and disadvantages. For example, structured meshes are more efficient and consistent, but they may not fit complex geometries well. Unstructured meshes are more flexible and can adapt to complex shapes, but they may introduce errors and inconsistencies. Hybrid meshes combine both methods and can offer a balance between accuracy and efficiency.

2 Boundary conditions

Another important step in FEA is to apply boundary conditions, which are the constraints and loads that act on the structure. Boundary conditions determine how the structure responds to the external forces and deformations. There are different types of boundary conditions, such as fixed, free, or prescribed displacements, forces, pressures, or temperatures. Choosing the right boundary conditions is crucial for obtaining realistic and meaningful results. Some tips to choose boundary conditions are to consider the physical situation, the symmetry or asymmetry of the structure, the degrees of freedom, and the sensitivity analysis.

3 Mesh refinement

One of the ways to improve the accuracy and reliability of FEA results is to perform mesh refinement, which is the process of increasing the number of elements or reducing the element size in the mesh. Mesh refinement can help to capture the stress concentrations, singularities, or gradients in the structure. However, mesh refinement also increases the computational cost and time of the analysis. Therefore, it is important to perform mesh refinement strategically and selectively, rather than uniformly. Some techniques to perform mesh refinement are to use adaptive meshing, which adjusts the mesh according to the error estimates, or to use local mesh refinement, which focuses on the regions of interest or critical areas.

4 Validation and verification

Another way to improve the confidence and credibility of FEA results is to perform validation and verification, which are the processes of checking the accuracy and correctness of the FEA model and results. Validation is the comparison of the FEA results with experimental data or analytical solutions, while verification is the assessment of the FEA model and methods against the mathematical and physical principles. Validation and verification can help to identify and correct the sources of error, uncertainty, or discrepancy in the FEA process. Some methods to perform validation and verification are to use benchmark problems, sensitivity analysis, convergence analysis, or error estimation.

5 Software tools

One of the factors that influence the quality and efficiency of FEA is the choice of software tools. There are many FEA software packages available, such as ANSYS, Abaqus, SolidWorks, or COMSOL, and each has its features, capabilities, and limitations. Depending on the type, complexity, and purpose of the FEA problem, some software tools may be more suitable or convenient than others. Some criteria to choose software tools are to consider the user interface, the meshing options, the solver algorithms, the post-processing functions, and the compatibility with other software or data formats.

6 Best practices

Finally, to achieve successful and satisfactory FEA results, it is advisable to follow some best practices and guidelines that can help to avoid common mistakes and pitfalls. Some of the best practices are to use a systematic and logical approach, to document and justify the assumptions and decisions, to simplify the model and problem as much as possible, to use appropriate units and dimensions, to test and debug the model and results, and to review and interpret the results critically and objectively.

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?