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WHY FEA Projects?

Use of Cutting Edge Technology

It Has Been observed that the majority of the Engineering students are still doing final year academic projects exactly those projects which were being done a years ago. This fact tells a lot about the current state of our education and our inability to motivate the students to adopt those technologies that are being used extensively by the industry to improve existing products & develop new ones......
The engineering students, who opt for & complete their FEA projects, score the highest marks for their projects and preferred over others in the job market. This is due to the fact that the industry understands & appreciates the depth of understanding on the part of the engineering students which goes into completing their FEA projects.
A lot of weightage is being given during the job interviews to the FEA project done by the students. This is because good knowledge about the engineering subjects like Machine Design, Theory of Machines, Strength of Materials, Thermodynamics etc. is a pre-requisite for doing FEA projects.

FEA - Industry Scenario

The advantages of FEA are numerous and important. Once a detailed CAD model has been developed, FEA can analyse the design in detail, saving time and money by reducing the number of prototypes required. An existing product which is experiencing a field problem, or is simply being improved, can be analysed to speed an engineering change and reduce its cost.

Some benefits of FEA Analysis

  • Accuracy, timeliness that exceed your expectations
  • Reduction in field failures
  • Faster time-to-market your product
  • Increased productivity
  • Overall cost reduction
  • Elimination of design iteration by incorporating FEA in the earlier stages
  • Increased reliability and efficiency.........

What is FEA?

Finite element analysis consists of a computer material or design that is analysed and stressed for achieving specific results. It is also used in new product design and for refining existing products. A company is able to correctly verify a proposed design and is able to accommodate client specifications prior to the actual manufacturing or construction. A product can also be made to qualify for same service condition by modifying its structure. If a design meets structural failure, the finite element analysis can determine design modifications needed for meeting the new condition.

Generally two types of modeling are used in the industry, the 2D modeling and 3D modeling. Though the 2D model helps the model to be run on a relatively normal computer, it gives results which are less accurate. The use of 3D models gives more accurate results, but cannot be run on all computers. In both the modeling schemes the programmers are able to insert numerous functions and algorithms which make the system to behave linearly or non-linearly. The non-linear systems can test the materials up to the fracture stages and account for plastic deformation. The linear systems are less complex and do not take into account the plastic formation.

The working of Finite Element Analysis

The finite system analysis uses a complex system of points called nodes. These nodes make a grid which is called a mesh. The mesh is programmed to contain the material and other structural properties associated with it and define how the structure will react to the loading conditions provided. Nodes are then assigned at various densities though out the material. The assigning of the nodes also depends on the anticipated stress level at a given area. Higher node density is provided at the points which have large amount of stress. The point of interest consists of the fracture points of previously tested material, corners, fillers, complex detail and the high stress area. The mesh also acts like a spider web, extending a mesh element to each of the adjacent nodes. The material properties of the objects are carried by this web of vectors.

For minimization and maximization purposes, a wide range of objective functions are present:

  • Mass, temperature, volume.
  • Stress strain, strain energy.
  • Acceleration, velocity, displacement and force. 
  • User defined synthetic.

The various loading conditions applied to a system are:

  • Point pressure by thermal gravity as well as centrifugal static loads.
  • Thermal loads from the solution of heat transfer analysis.
  • Enforced displacements. 
  • Convection and heat flux.
  • Pressure and gravity dynamic loads.
  • The element library of the finite element analysis is constructed over time, and some examples are rod elements, beam,elements, shear panel, spring elements,               rigid elements, mass elements, viscous damping elements etc.
  • Some finite element analysis programs also use capability to use multiple materials within their structure. Some examples are isotropic, orthotropic and general             anisotropic materials.

Finite Elements Analysis- Brief History

Finite element analysis was developed by R. Courant in the year 1943, by utilizing the Ritz method of numerical analysis and by minimizing the variation calculus for obtaining approximate solutions for vibrations systems. Later, a paper published in the year 1956 by M.J Turner, H.C. Martin and .W. Clough established a somewhat broader definition of numerical analysis. This paper was based on stiffness and deflection of complex structures.
In the early decade of 1970, the FEA was limited to expensive mainframe computers which were generally used by automotive, aeronautics, defence and nuclear industries. Now, with the most of computers on rapid decline along with increase in their computational power, the finite element analysis has gained an incredible position. The present day supercomputers can now produce more accurate results for all kinds of parameters. 

PROJECT Domains

Linear Static Stress Analysis:

  • Factor of Safety Calculation
  • Part & Assembly Stress Analysis
  • Deflection Calculations
  • Correlation to Measurements of Deflections and Strains
  • Contact Stress Computation
  • Super-position of Thermal Stresses
  • Stiffness Calculations to achieve stated Targets
 

Frequency & Buckling Analysis:

 
  • Computation of Frequencies & Mode Shapes
  • Modal Assurance Criteria (MAC)
  • Correlation to Measured data
  • Buckling Calculations for axially loaded members
  • Critical Speed Calculations
  • Campbell Diagram for Rotor-dynamics
  • Point Mobility Analysis
 

Dynamic Analysis:

 
  • Frequency Response Analysis
  • Seismic Analysis Response Calculations
  • Harmonic Analysis
  • Random Vibration Calculations
  • Dynamic Stress Computations
  • Power Train Vibration Analysis
  • Shock Calculations per NAVSEA, DDAM, MIL STD
 

Non-Linear Analysis:

 
  • Material Non-linear Analysis
  • Geometric Non-linear Analysis
  • FEA of Rubber & Elastomers
  • Non-linear Dynamic Analysis
  • Time Domain Response Analysis
  • Impact Analysis
  • Thermo-mechanical Analysis involving large displacements
  • Elasto-plastic Deformation Analysis
 

Analysis of Composites:

 
  • Frequency Response Analysis
  • Seismic Analysis Response Calculations
  • Harmonic Analysis
  • Random Vibration Calculations
  • Dynamic Stress Computations
  • Power Train Vibration Analysis
  • Shock Calculations per NAVSEA, DDAM, MIL STD
 

Thermal Analysis:

 
  • Thermal Stress Analysis of parts and assemblies
  • Transient Thermal Analysis
  • Thermo-mechanical Analysis
  • Coupled Thermo-fluid analysis
  • Natural and Forced Convection Analysis
  • Non-Linear Thermal analysis of curing processes
  • Creep Analysis
 

Fatigue Analysis:

 
  • Remaining Life Analysis ( RLA )
  • Durability Analysis
  • Failure Prediction Analysis
  • High Cycle Fatigue Calculations
  • Correlation to Real-world situations
  • Comparison of Alternate materials for extended life and warranty
  • Life extension analysis
 

CFD Fluid Flow Analysis:

 
  • Pressure Drop Calculations
  • Conjugate Heat Transfer Analysis
  • Electronic Cooling Analysis
  • Thermal Efficiency Calculations
  • Fluid Flow simulation in Devices such as pumps, valves, ducts, piping networks, fans, diffusers, cyclones, blowers, heat exchangers
  • Design optimization based on performance prediction
 

ASME Stress Analysis:

 
  • Stress Analysis per ASME Codes
  • Nozzle stress analysis
  • Stress Intensity Calculations
  • Shell & Full Scale 3D Stress Analysis of Pressure Vessels among others
 

Design Optimization:

 
  • Optimization of CAD Geometries
  • Weight Reduction Analysis
  • Value Addition & Value Engineering Analysis
  • Sensitivity Based Optimization
  • Optimization of design variables based on performance targets