ibex 2002 - session 602slide 1 ibex 2002 - session 602 finite element analysis paul h. miller, d....
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IBEX 2002 - SESSION 602
Slide 1
IBEX 2002 - Session 602Finite Element Analysis
Paul H. Miller, D. Engr.
Assistant Professor of Naval Architecture
United States Naval Academy
IBEX 2002 - SESSION 602
Slide 2
Presentation Overview• What is FEA and what will it do for
us • What FEA will not do for us• Limitations of FEA• Working with Finite Element
Analysts• Case Studies
IBEX 2002 - SESSION 602
Slide 3
Getting started with a simple exampleA new mast step for an old wooden sailboat
t=0.5”
• Designer: L. Francis Herreshoff, 1955
• Built: 1962 Lunenberg, N.S.
• Original Mast Step was Red Oak (not designed that way)
• It broke at a bad moment!
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Slide 4
The Mast StepAs it’s thickness is about the same dimension
as its width, we must use solid elements.
• Loads – 7000 lb down
• Geometry – 24”x4”x4”
• Material – Black Locust
• Boundry Conditions – supported by 3 oak floors
The grain is longitudinal
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Slide 5
t=0.5”
• The actual boundary conditions with the three floors.
Black Locust mast step
White Oak floors
Floor grain is vertical Forward
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Slide 6
Deformation (300x)
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Slide 7
Displacement
Maximum displacement is 0.0084”
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Slide 8
Stress with vertical grain floors
Max Stress = -1889 psi
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Slide 9
Stress with transverse grain floors
Max Stress = -2706 psi43% higher!
But floor loads are more even
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Slide 10
Rolling Shear Stress
Maximum shear stress is 559 psi
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Slide 11
Mast Step Analysis Results• The analysis took 5 hours• The predicted weight was 7.5 pounds• The minimum factor of safety for
bending was 10.2• The minimum factor of safety for
shear was 4.4• The recommended minimum FOS is 4• Therefore LFH over-designed it by
3/8”!• I built it to LFH’s drawing…
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Slide 12
What is Finite Element Analysis?In the real world of structural response…
• Deform – strain (in/in)– If the strains are always
proportional to the load it is “linear deformation”
– If not, then “non-linear”
• Have internal stress (psi)• Are made of materials
– Which could be linear or non-linear themselves
• Discrete Forces• Pressures• Vibrations (or
fatigue)• Accelerations
– Gravity– Dynamics
• Temperature• Moisture
Objects with loads on them: Loads include:
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Slide 13
In the world of mathematics…• FEA divides the object up into multiple
small parts (up to 100K+!)• Each part is represented by stiffness
constants (like springs, f=k·x• All the parts are combined
mathematically (by matrix algebra) into a global structure
• The solution is found from equilibrium (ΣF=0, ΣM=0)
RDK Stiffness matrix
Displacements and Rotations (DOFs)
Loads
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Slide 14
Solving the basic equation for the unknown degrees of freedom…
1. Finding the final displacement gives us the elongation
2. Elongation gives us the strain3. Strain and area gives us the stress4. Stress and failure criteria give us
the Factors of Safety!
KRD 11
OK, Ready for the quiz?!
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Slide 15
Physical modeling of structures
• An FEA model is made of simple structural “elements” connected at “nodes”
• The basic building blocks (elements) are:– Beams (1 primary dimension)– Plates/shells (2 primary dimensions)– Solids (3 primary dimensions)
“Primary” means “much bigger than the other dimensions”
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Slide 16
Just To Avoid Confusion!An element with 2 Primary Dimensions, a shell element, has a length and a width, but is thin compared to the other two dimensions.
It can be either used in either 2-D analysis (x and y axes) or in 3-D analysis (x, y and z axes).
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Slide 17
Common Structural Element Types
• Solid• Shell• Beam• Cable• Truss• Radiation
• Mass• Gap• Immersed
pipe• Buoy• Magnetic• Fluid/heat
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Slide 18
FEA can handle almost any structure
• It’s greatest power (and cost) is with complex structures.
• The structure needs to be envisioned in terms of element types which are available, and suitable.
• The structure is then represented with many (often thousands) of these elements.
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Slide 19
Example of Beam/Cable/Truss Elements:What they are
•
•
2 nodes,Each node has up to 6 degrees of freedom, giving 12 per element
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Slide 20
Example of Beam Elements: A Mast tube is shells, spreaders are beams, rigging is cables
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Slide 21
Example of Shell Elements: What they are
4 nodes,Each node has up to 6 degrees of freedom, giving 24 DOF per element
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Slide 22
Example of Shell Elements: A 77-foot Hull
Note the beam elements
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Slide 23
Example of Solid Elements: What they are
8 nodes,Each node has up to 3 degrees of freedom(translation only), giving 24 DOF
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Slide 24
Example of Solid Elements:The Mast Step (again)
Solids are sometimes called “brick elements”
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Slide 25
What FEA does beautifully!
• Handles complex geometry. (Indeterminate structures)
• Isotropic materials (materials with consistent properties in all directions)
• Static and simple dynamic problems• Examples
– A steel keel, a bronze rudder shaft– Metal hulls (tanker fatigue)
• Accuracy is within 0-5%!
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What FEA does “OK”…
• Complex materials– Composites– Wood
• Non-linear static deformation (x5)
• Buckling of isotropic materials (x2)
• Increased uncertainty– From 1-5%
potential error– To 3-30% error– HIGHER MIN
FOS!
• Increased manhours required to prepare model
This means: Examples:
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Slide 27
Example: A Composite Sailboat
• Model took 127 manhours to build
• Predicted deformations within 4% for static loads
• Static strains within 6%
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Slide 28
Composite Sailboat• Fatigue-influenced dynamic strains were
predicted within 14% when compared to strain gages and coupons.
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Slide 29
Non-linear deformationHigh Aspect Ratio Rudder
• 8 foot span/16 lb• 20” of tip
deflection• High membrane
stresses reduce predicted deflection and stress
• 5% error in deflection
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Slide 30
Tsai- Wu Factors of Safety
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Slide 31
Non-linear Mast Deformation
• Small dinghy mast
• Used to size spreaders, wire and pretension
• Input was gust spectrum
• 8% error in deformation
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Slide 32
What FEA does not do well
• Dynamic impact (slamming loads)• Joints ( composites or metal )• Buckling of “real world”
composites.• Misc details unaccounted for in
element formulations.• Error can be 30-300%!
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Slide 33
Dynamic Analysis• FEA has great strengths in dynamic
analysis for certain types of problems.
• Standard FEA doesn’t handle slamming impacts well.
• One of the major difficulties are in the definition of the loads.
• The other is in the speed of the transient nature of the load.
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Slide 34
Joint Analysis with FEA
• FEA is good for extracting loads at joints.
• FEA is weak in micro analyzing joint designs
• This is primarily due to difficulty with material properties and failure mechanisms.
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Slide 35
Joint Design with FEA(some variation with programs)
1. Normal FEA solution assumes joint is perfect2. Either a) list nodal forces
b) use nodal stresses and area3. Determine stress concentration factors for
specific joint geometry4. Calculate joint loads by spreadsheet (isotropic
or wood) or5. Use laminate analysis program and
spreadsheet (for composites)
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Slide 36
Not all aspects of structres can be accounted for in FEA models
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Slide 37
Failure mode prediction is only as good as it’s modeling.
This means realistic material testing to support the FEA.
“Special” failure mode analysis (post-processing) using spreadsheets or macros
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Slide 38
Limitations of FEA= High Error Possibility!
• Uncertain loads– Slamming– Impact– Transient– Unanalyzed loads!
• IACC cockpit example
• Uncertain materials– Testing– QA/QC from builder
• Model Errors– Mesh density– Linear or non-
linear analysis– Wrong elements– Boundary
conditions– Results analysis
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Slide 39
A Multiple Issue Problem!• Loads, materials and boundary conditions• FEA assumes “continuum mechanics”
Eventually we got the deflections to match within 10%,But the strength was under predicted by 110%.
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Slide 40
Working with a Consultant - and getting good value from it -
an overview
• Choosing a consultant• What you’ll be asked to supply• Getting what you expect• Several projects outlined
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Slide 41
Choosing a ConsultantQuestions to Ask
• Analyst versus engineer or designer– Their experience/education– Your relationship (micromanagement?)
• Experience with similar projects– Loads– Materials (isotropic or orthotropic?)
• Track record of success and failure• Rates and availability (current
range is $25-275/hour)
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Slide 42
Information You’ll Be Asked To Supply:
• Geometry• Loads (are they biased or real?) SES• Material types and properties
(guess or test?)
• Goals • Deliverables
• Any guesses increase the error and may make using FEA uneconomical!
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Slide 43
Deliverables:• Do you expect guidence in making
decisions?• Do you want a specifc question
answered or do you want design work?
• Do you expect formal documentation?– If so, then in what form?– Report, e-mail, spreadsheet, tables,
drawings (dxf, dwg, igs, etc)
• Do you want nice color stress plots?
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Slide 44
Extra hints to make your life easier
• Be specific on the design criteria– Stiffness, deflection, strength, FOS
• Be flexible on the geometry• Don’t be stuck on a particular
design (just because it worked in the past doesn’t mean it is the best)
• Keep the design simple!• Communicate!
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Slide 45
Another Case Study
• A 77-foot performance cruiser
• Designed by Carl Schumacher
• Under Construction in Seattle
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Slide 46
Project Overview
• Began in January 2000• Structures to meet ABS and
realistic loads if not specified• Multiple materials intended• Goal is “ULDB” cruiser
– Light but strong with a deep bulb keel
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FEA work• Designer subcontracted out structural
FEA design• Designer provided dxf files for all
geometries (hull, appendages)• FEA consultants optimized and
specified construction• Designer did hull structure drawings• Consultants did keel structure drawings
and interfaced with keel and hull manufacturer to ease construction
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Slide 48
Design Limit Load Cases
• Upwind in heavy air, wave height equal to freeboard, wave length equal to boat length
• Slamming• Grounding• Lifting
Each load case drove the design of different parts of the boat.
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Slide 49
Upwind in 30 knots on port tack
Rig loads supplied by mast maker
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Slide 50
Displacements (25x)
Maximum displacement = 3.32”Max rotation 0.5 degrees
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Factors of SafetyTsai-Wu or Max Stress or Hashin
Minimum “real” FOS = 2.25
Not “real”!
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Slide 52
Interior
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Slide 53
Interior FOS
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Slide 54
Project Summary (to date)
• Smooth transition of files (AutoCad, GenericCad, Excel, Word)
• Communication is 50% phone, 45% email, 5% meetings
• FEA has been approximately 300 hours and is 95% complete
• A third of that was redesign due to the owner’s wishes
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Slide 55
Final Thoughts• Good FEA programs used in the
marine industry include:– COSMOS– Ansys– Algor– Abaqus
• Costs range from $400-30,000• Free demo’s available on the web• Short courses are also available• Be realistic about your needs…• Do you need this tool?