FEA as an aid to Design Andrei Lozzi 2017

1. Too Much Information The FEA analysis of a typical part under load can
initially overburden us with information. We therefore need to analyse and
separate the various effects that loads have on components.

2. Multiple Load Paths FEA can help us separate the different paths that a
load can take from where it is applied to where it is resisted, and how the
load may be divided between paths. Furthermore which path can be more
effectively reinforced to reduce stress and or deflection.

3. Select cross sections. For loads that are predominantly tension,

compression, bending or torsion there are well known cross sections that
are well suited for each, possibly reducing sizes and mass.

3. Stress Concentration. Wherever there is a change of shape there will be

some sort of stress redistribution. There will be increase in stress at concave
corners and a reduction at convex corners. We can limit the concentration
using established design techniques, but never reduce it to zero.

1
A single load path from the point of application of a load,
to the point where reaction to that load takes place.

Point where the load is

applied to the component.
If at all possible, the most The ‘load’ may be some
effective load path is a combination of forces and
straight line from the load moments.
to the reaction.

The component is
presumed to be contained
within this envelope
Point or points where the
reaction to the load takes place

2
A sequence of load paths from the point of application of a load,
to the point where reaction to that load takes place.

Here the path is not the shortest, but

is made up of two indirect paths.

The stresses created within those

paths will be some complex
combination due to bending, shear,
torsion and other.

This may make arriving at an

effective overall shape of the
component somewhat difficult to
conceive.

3
 Multiple load paths from the point of application of a load, to the
reaction.

In general, the load will be shared

between the paths according to their
relative stiffness.

Reinforcing the less stiff path will have

a lesser outcome than augmenting
the more rigid one.

4
 A simple example of parallel load paths.
FT
Here for the spring at left, we can say because it
has fewer coils, of thicker wire and of smaller coil
diameter, will be stiffer than the one at right. Let
the relative stiffness be:
KL = 10 KR
If the applied force F causes an extension of Δ,
the force carried by the left and right springs are:
FR = Δ KR
FL = Δ KL = Δ 10 KR

Where FT = FL + FR = Δ 11 KR
The fraction of the force carried by either spring is
proportional to the relative stiffness of that
spring.
FL / FT = 10 / 11
FR / FT = 1/ 11

The applied external force is divided between the

two load paths in proportion to the ratio of their
FT stiffness to the total stiffness.

5
 A force F is shown applied to an edge
of the ‘angle’ L section at right, and
reproduced in plan view below F

l1 l2

l1

l2

The applied force is somehow divided between the

two legs of the L section - l1 & l2 .

What resistance does that force meet ? The aligned leg

- l1 has to bend about the neutral axis shown, it has a
relatively large second moment of area I1, hence it will
be stiff. Leg l2 has a small I2 hence will be relatively
flexible.
6
 An Example of reinforcing the less rigid load path on
l1 the stiffness and stress level of a part.
F
Here a web has been added to the more
flexible of the two legs of this ‘angle’
section. We compare here the stress and
deflection with a similar connection
l2 without the web as shown on slide 6.

Von Mises stress at the free edge

has increased from 65 to 70
N/mm^2.

Stress have been reduced from 87

to 73 N/mm^2 at the outer corner.

Max deflection has been reduced

from 0.494 to 0.447 mm

There are two loads paths for F to reach the

base plate, through l1, or through l1, l2 and
the web, to the plate. Obviously the second
path is the less stiff.
7
An Example of reinforcing the more rigid load path on
the stiffness and stress level of a part.

Here a web has been added to the more

rigid of the two legs of this ‘angle’ section.
As before we compare here the stress and
deflection with a similar connection
without a web as shown on slide 6.

Von Mises stress is reduced from 87

to 70 N/mm^2 at the outer corner.

Stress at the free edge has

decreased from 65 to 28 N/mm^2.

Max deflection has been reduced

from 0.494 to 0.307 mm.

8
We make the following observations:
Placing the webs in just about the least advantageous position reduce
deflection but by only 10%.
Placing similar sizes webs in a relatively advantageous position reduced
deflection by 40%.
Placing the hold-down bolt holes, close to the most heavily loaded welds,
reduces deflection by a further 10%.
Your challenge may be to add webs and holes to a point when there will
be diminishing return for the amount of work required. To decide what is
a better modification and what is not and when to stop, prepare a table of
design changes and outcomes.

9
 This is the applied force
Selecting shapes for a component This is the load path

Assuming that we have a single load

path through your part (slide 2).

you have to invent a shape for the

part, with a cross section that There is a
generates the least stresses, for the perpendicular
least amount of material. component of the
applied force that
This is the invention process that will cause a bending
will test your understanding and moment, which will
creativity, as a designer. reach a maximum
at the reaction end.
If we have two load paths as
represented on slide 3 & 4, the
vertical path would be subjected to
There is a larger
bending and compression while the
component that will cause
horizontal one predominantly to
a compressive - buckling
bending and torsion.
load, with the greatest
effect near the centre of
the part.
10
 Axial torque axial tension bending moment axial compression

These components
are shown as
elements of
approximately
equal cross-
sectional area.

Sections suitable for different loads

Tube of max practical bar or any section I beam tube or barrel

diameter of practical diameters
Relative merits of common sections, when used to carry bending
moments, torsion and other loads.

I beam U channel Box section

An I beam and a box section, made to the same cross-sectional area, can be
equally effective in bending. The box will also be better in torsion and in
compression than the I beam, but will close off a volume for most other purposes.

The channel section will be about 7% less effective than the I beam, in bending
about the axis shown, but may be easier to manufacture than the box section, and
can provide an open volume for other purposes. But it is relatively ineffective in
compression and torsion.
12
A real example – This ‘wheel upright’ is connected to the chassis by the 4 bolt holes at
top and the 2 at the bottom. The wheel is supported by 2 bearings in the centre. The
wheel transmits forces and moments through those bearings and a forces come from
the brake calliper. All these loads are then passed on to the chassis. The upright shown
here, is made in two halves in Al alloy, welded together at the mid-plane and is hollow,
about 1 -2 mm thick. 13
Stress and deflection is shown here. What would you do to principally reduce
deflection while actually trying to reduce mass ?

14
SOME HINTS - when working on the FEA design problems

Search for a reasonable solution:

Possibly less than 6 webs,
bolt holes closest to most heavily loaded weld ,or built into the web,
minimize or place no part into bending.

Some impractical solutions:

An infinity of webs will make a stiff joint but a very impractical one,
likewise an infinity of hold down bolt holes.

Put your best solution up front, otherwise we will not pick out what we think
to be the best and reward you for it. We have to presume that you could not tell
the difference.

Make table of attributes as you try different features or shapes, the differences
between good and bad may not be very large. After a 15% improvement may
be very significant

15
In general, to reduce stress concentration,
add material where the stress is high, and
remove material where the stress is low
– very simple, sometimes hard to see how
that can be done.

Examples of the means that may be used to

control stress concentration.

In (a) and (b) above the large fillet radii and

notches in the low stress areas, help to smooth
the force field (stress levels). Adding notched in
the high stress areas has the opposite effect.

At left the additional small holes before and after

the large one, helps to redistribute stress as if a
smoother elliptical hole were present.

16