FEM-06. FINITE ELEMENT SIMULATION IN ENGINEERING

ICEMM – EXCELLENCE IN SIMULATION

The finite element method is a numerical technique that allows the approximate resolution of differential equations applied to complex problems in industry, mainly in the area of structural analysis and mechanics, although it is also applied in fluid analysis, acoustics, electromagnetism, …

Within the structural field, finite element simulation is applied to both simple problems such as linear static analysis, and much more complex problems involving complex material behaviour (plasticity, fracture, ductility, …), interactions (contacts), large displacements, linear or non-linear dynamic response, high speed impacts, … all applied to practically any industrial sector: space and aeronautics, naval, automotive, energy, equipment development, …

WHAT DO WE LOOK FOR WHEN WE CARRY OUT A FINITE ELEMENT SIMULATION?

The objectives of finite element simulations in structural and mechanical engineering are mainly defined by the requirements of the project. Some of the usual cases are:

  1. Static strength analysis: this case is probably the most widespread use, where we use Finite Element Simulations to obtain the values of displacements of the structure, and from them, obtain the values of stresses and strains in the structure for the loading conditions defined by the project or by the applicable regulations. This type of finite element models are usually linear models for simple behaviours or non-linear for more complex behaviours where we want to include plasticity, contact or other non-linearities. These FEM models are always built on the safety side, even if this implies certain deviations with respect to the real behaviour of the structure.
  2. Fatigue analysis: this type of problem can be tackled with two different approaches. A first approach, where we use a “coarse” Finite Element Model of the structure without much detail, but which correctly represents the force transmission and stiffness of the structure, and a second approach where we represent in detail the geometry of the area under study. The approach with the “coarse” model will allow us to obtain the far-field stresses, and by using stress concentration factors to obtain the maximum stresses (Peterson’s Stress Concentration Factors). The detailed model approach allows us to obtain the maximum stresses directly from the Finite Element Model. With these maximum stress values, we proceed to the fatigue analysis using the S-N or E-N curves as appropriate. There are circumstances, generally in multi-axial fatigue problems, where it is necessary to evaluate more complex fatigue criteria, requiring the use of specific tools such as fe-safe.
  3. Fracture analysis: this type of Finite Element Simulations is performed when the geometry or loads do not allow the structure to be analysed by traditional or analytical methods. The most common techniques are XFEM and VCCT.
  4. Calculation of vibrations or dynamic response: for this type of problem we carry out Finite Element Simulations using FEM models that accurately represent the stiffness and mass of the structure, which allows us to calculate the structure’s eigenfrequencies and vibration modes. This enables us to determine the dynamic response of the structure to dynamic stresses caused by engines, vehicles, earthquakes, wind, etc.
  5. Impact analysis: the resolution of high and medium speed impact problems requires resolution by finite element simulation techniques, and cannot be addressed by analytical techniques. These are complex and computationally demanding simulations involving contact phenomena, material damage, …
  6. Correlation of tests: in these cases, the finite element simulation aims to obtain a result as close as possible to the test. These are models with a very high degree of detail and complex behaviour in order to correctly represent the behaviour of the structure.
  7. Process simulation: to predict defects, residual stresses, and other problems in processes such as plastic injection moulding or metal stamping. These types of finite element models are very complex in terms of defining the material behaviour and modelling the manufacturing process.
  8. Simulation in biomechanics: biomechanical projects have two different objectives: on the one hand, to check that medical devices or prostheses withstand the loads of use, this case being similar to the static and fatigue tests indicated above, or to carry out the simulation by finite elements of the behaviour of living material, whether hard tissues such as bones or soft tissues such as organs or muscles. In the latter case, the use of a suitable constitutive model is essential to obtain correct results or results as close to reality as possible.
  9. Thermal analysis: the calculation of heat transfer problems using structural finite element codes presents an alternative to the use of complex CFD solvers. Its main application is when the heat transfer mechanism is mainly by conduction, and convective heat transfer is well defined and does not require the resolution of the fluid behaviour. It should be noted that heat transfer by radiation can also be evaluated using this technique. Generally, the thermal and mechanical problem is studied in a decoupled way, but there may be cases where it is necessary to couple them and solve both problems at the same time (for example, in the creep analysis of structures subjected to thermal treatments for the calculation of residual stresses).

ICEMM, A VALUE PROPOSAL

At ICEMM we have been carrying out finite element simulations for 20 years in different industrial sectors, mainly in:

  • Aeronautics – Primary structure in metallic and composite materials – Linear and non-linear static, dynamic, fatigue and fracture or damage tolerance analyses
  • Railway – Dynamic and fatigue analysis of on-board equipment – Calculation of railway wheelsets (European and American standards, AAR)
  • Naval – Static and fatigue analysis – Crash analysis according to MIL-STD-810 and MIL-DTL-901E (experts in crash test simulation with lightweight, medium weight and DSSM)
  • Wind – Static and Fatigue Analysis
  • Solar – Static analysisSolar – Static analysis
  • Biomechanics – Simulation in dentistry – Implant dentistry – Bone behaviour
  • Automotive – Static analysis
  • Civil engineering – Static, fatigue and dynamic analysis
  • Hydraulic Structures – Static, Fatigue and Dynamic Analyses

Our approach is focused on the customer and the specific needs of the project or development, where we apply our experience and technical capabilities to help deliver a safer, top quality product with the help of finite element simulation.

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