FE Analysis Steps

Typical within lly the code

Finite Element Modeling and Mesh Quality Checks Lecture - 2

CE 264 Non-linear Finite Element Modeling and Simulation

Development of a model (Geometry discretization) Formulation of the governing equations Discretization o t e equat o s sc et at o of the equations Solution of the equations Interpretation of the results

Engineer is responsible

CE 264, Lecture 2

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Mesh Descriptions

Finite Element Modeling Process

Lagrangian Mesh

Nodes are coincident with the material points

Obtain CAD data (catia, unigraphics etc.,) for each part Clean up geometry and prepare for meshing Determine connections between adjacent parts and setup same mesh pattern along flanges Create the FE mesh and check model quality

Original

Deformed

Eulerian Mesh

10 15 mm element size is recommended for modeling main structural areas 20 25 mm element size is recommended for modeling nonstructural areas

Avoid fast transitions from small elements to large elements

Original

Deformed

Assemble the meshed parts to define a complete finite element model Check model for free nodes, free edges, undesired mesh overlap between parts, etc.
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CE 264, Lecture 2

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CE 264, Lecture 2

Modeling Guidelines General

Modeling Guidelines General

The element mesh should be orthogonal to the centerline of the part The element mesh should be on the mid-plane of the cross section of the component thickness

Element mesh is to be orthogonal to the centerline of the part

The mid-plane is established by offsetting the geometry by 1/2 of the gage thickness in the direction that the material is shown in the cross section of the drawing

No component thickness penetration or part intersection is allowed Element size should be uniform whenever possible Maintain a smooth transition from Coarse to Fine Mesh

Transition Mesh

CE 264, Lecture 2

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CE 264, Lecture 2

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Modeling Guidelines Flanges

Modeling Guidelines Flanges

Flanges of Crash models are to be modeled with three (3) elements across the flange Two (2) elements can be used if the flange width is less th 15 mm l than

Bend radii less than 8mm are to be modeled as a sharp corner angle Bend Radii greater than 8mm are to have a minimum of 2 elements 1 node, following the geometry elements, node

CE 264, Lecture 2

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CE 264, Lecture 2

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Modeling Guidelines Beads and Ribs

Modeling Guidelines Holes

Heights less than 3mm ignore and mesh as flat Heights between 3-5mm increase the height to 5mm Heights greater than 5mm mesh as 3 equal length sides on the geometry

Holes

d < 10 mm

Holes with a diameter less than 10 mm are ignored Holes with a diameter greater than 10 mm are to h be included When meshing around holes, a minimum of 6 elements is required

d > 10 mm

CE 264, Lecture 2

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CE 264, Lecture 2

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Modeling Guidelines Notches

Modeling Guidelines Transitions

Notches greater than 20 mm

l < 20 mm

Mesh Transition

Keep notch and split element to a minimum of 2 across the width eliminate and replace with 2 triangular elements l < 6 mm eliminate and replace with 2 g (larger triangular elements ( g than 6 mm)

Notches less than 20 mm

Use triangular elements to transition Check aspect ratio of triangular elements

Notches less than 6 mm

Triangular elements are stiffer than quad elements, particularly for coarse mesh

Mesh Transition

Use Co option in LS-DYNA (*CONTROL_SHELL, full sorting) ti ) Triangular elements. should be less than 10% of total elements

CE 264, Lecture 2

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CE 264, Lecture 2

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Modeling Guidelines Transitions

2-D and 3-D Elements

Modeling Guidelines Special Shapes

2-D and 3-D Elements

Special Mesh Shape

It is possible to use quad elements for triangular meshes

Triangular Mesh 1-2 Transition

CE 264, Lecture 2

1-3 Transition Trapezoidal Mesh

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Modeling Guidelines Special Shapes

2-D and 3-D Elements

Modeling Guidelines General

2D and 3-D Elements

When modeling a sectional structure component

Use a minimum of 3 rows of elements to get a good in-plane bending b di Use a minimum of 5 elements for a buckle

NOT DESIRABLE
CE 264, Lecture 2

DESIRABLE

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CE 264, Lecture 2

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Modeling Guidelines Solids

3-D Elements

Element Quality Check

Warpage

Solid Element Selection

Regular shaped 8-node brick is recommended (hexa) Avoid 4, 5 and 7 node solid elements

Amount by which an element or element face (solid elements) deviates from being planar Should be less than 150 Ratio of the longest edge of an element to its shortest edge Should be less than 5:1 Should be less than 600 Measure of the deviation of an element from an ideally shaped element Ranges from 0 to 1.0, where 1.0 represents a perfectly shaped element Should be greater than 0.6
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Aspect Ratio

Skew

Jacobian

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CE 264, Lecture 2

Element Quality Check - Warpage

Element Quality Check - Skew

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Final Quality Checks Shells

Final Quality Checks Solids

CE 264, Lecture 2

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CE 264, Lecture 2

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Final Quality Checks

Homework

Align element NORMALS for each component in 1 direction BOUNDARY CHECK

SHELL ELEMENTS: No SPLITS or CRACKS allowed in the mesh SOLID ELEMENTS: No interior SPLITS or CRACKS allowed in the mesh

Check for and eliminate DUPLICATE ELEMENTS Check for and eliminate FREE 1-D ELEMENTS Check for and eliminate RIGID DEPENDENCIES and RIGID LOOPS or CIRCULAR DEPENDENCIES
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http://crash.ncac.gwu.edu/pradeep/ Select CE-264 Download Homework No 1 (HM file) No. Mesh file using Hypermesh Use element size of 10 mm Check Mesh Quality Homework due Feb 24, 2009 E-mail E mail Hypermesh ( hm) file and Mesh Quality Form (.hm) to pradeep@ncac.gwu.edu.

CE 264, Lecture 2

CE 264, Lecture 2

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