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Why use FEA (Finite Element Analysis)? A Complete Guide


Most engineering design specialists are familiar with finite element analysis (FEA), a statistical procedure for estimating how an object will react to real-world forces, vibrations, and other physical impacts. FEA is an important part of the product development design cycle since it may help you save money on development while also producing a more durable and reliable end product.

Including FEA in your product development process will almost always result in shorter development timelines, lower development costs, and a more robust and reliable product… all of which is excellent for the bottom line.

You can test your design with FEA before venturing anywhere near a manufacturing facility. Do these components go together? What effect would subzero temperatures have on this component? What will happen if my design is subjected to a lot of vibration? Questions like these may be answered remotely, and your design can be changed and re-tested. In this manner, you may save money by just doing actual prototyping when you’re confident in your idea.

What is FEA (Finite Element Analysis)?

Finite Element Analysis (FEA) is a methodology for forecasting how a component or assembly will function over time. FEA allows you to anticipate potential design flaws, lowering the risk to your product, earnings, and bottom line.

You can use FEA to test the influence of various situations on your design (stress, vibration, buckling, fatigue, creep, heat, and so on). It’s a powerful simulation tool that’s utilized in conjunction with other simulation tools like CFD (computational fluid dynamics) and motion analysis. You may simulate the effects of real-world extremes on your design before you make a physical prototype by including FEA into your product development process. By reducing the number of actual prototypes needed, virtual prototyping saves you a lot of time and money.

Finite Element Analysis is now employed in almost every engineering discipline: the aerospace, automotive, biomedical, chemicals, electronics, energy, geotechnical, manufacturing, and plastics industries all use it.

Cosmos, SolidWorks Simulation, Femap, Nastran, Ansys, and Abaqus are some examples of popular FEA software.

FEA (Finite Element Analysis) Applications

The finite element (FEA) approach can be used to support a wide range of analyses. The following is a list of the most common types of FEA and their applications:

1. Linear and Non-Linear

There are two types of analyses: linear and non-linear. Non-linearity occurs when the ‘starting circumstances’ vary during an analysis.

Consider blowing up a balloon; the diameter of the balloon varies rapidly as it fills. The balloon material expands a lot, becoming thinner and stiffer as a result. As a result, the effort required to inflate the balloon fluctuates with time. A non-linear analysis can account for this, whereas a linear analysis can’t.

Linear analysis can be scaled immediately. If the load is doubled, the effects (stress, deflection, and so on) will also be doubled. The application of this knowledge can minimize the amount of FEA analyses required.

2. Static and Dynamic

Do the loads come on slowly or quickly? (Like snow on a roof or a phone that falls to the ground?) When stresses vary rapidly with respect to time, the structure’s mass and stiffness begin to influence the results. Using a cell phone as an example, the heavier the phone gets, the more structure is required to support it.

3. Comparative and Absolute

Is it necessary for the analysis to produce ‘correct’ results, or can a percentage change suffice? You may already have a successful product with ambiguous loading requirements that you’d like to modify. It could, for example, be a coil spring from a car suspension. Without knowing the stress that the spring is subjected to on the car, a comparative analysis may be used to determine whether design changes to the shape (for example) will improve or degrade the unit’s performance.


Benefits of FEA (Finite Element Analysis)

The benefits of the Finite Element Analysis Process are not limited to design efficiency and cost savings; FEA also solves the following questions:

  • What would it be worth to your company if you could foresee probable failures before releasing a product?
  • What impact will this have on the customer’s impression of your product?
  • What impact might fewer warranty claims have on your cash flow?
  • What if you could cut your prototype and testing expenditures in half or even a quarter? How much faster could you get your product to market?
  • What kind of financial impact would that have on you?
  • Would knowing if your structure or product can bear operating loads be useful to you? Will the distortion be permanent? Will buckling or vibrations be an issue in the future?
  • Is it possible to save money by reducing the amount of material used?

FEA is a crucial phase that you can simply incorporate into your development plan. It will save you time and money by revealing issues and discovering solutions during the design process of your product before any materials are ordered.

Advantages of FEA

  • Make sure your design is on track during the design process,
  • Verify calculations when manual calculations are too complicated,
  • Optimize stress, mass, heat, and other variables before the project’s production stage to achieve optimum results.
  • Obtain a better understanding of structural behavior and, as a result, eliminate uncertainty during the design phase.

Things to consider about FEA

  • Engineers use FEA to simulate how a product would respond in real-world settings to expected loading conditions.
  • If you’re creating a new product, think about how you can include FEA in the process.
  • Before prototyping, you can use FEA to test your design for stress, vibration, buckling, fatigue, and heat.
  • There are several different forms of FEA. Which type to employ is determined by the nature of your product, the materials used, how it will be created, and how it will be used.
  • If you’ve decided to have an FEA performed on your design, make sure you hire an experienced analyst and know exactly what you want to accomplish. It is necessary to have a goal.
  • Don’t be fooled by the nice pictures. Because FEA results are readily misconstrued, hand calculations and physical testing should be used to verify them.
  • Although the software has become more affordable, the competence necessary to do an accurate and trustworthy FEA has not changed.

INDOVANCE Inc provides Top-Notch structural stress analysis, piping stress analysis & FEA services, assuring structural and functional integrity for the safe and optimal design of systems. With Two decades of CAD & engineering experience enables us to help clients resolve their most challenging technical, design, and engineering problems and implement competitive and cost-effective solutions for optimizing the design of structures.

Our team of experienced FEA specialists and technically sound engineers use cutting-edge structural stress analysis software and tools to deliver an accurate and credible analysis of various components that may have an effect or impact on the efficiency, performance, and life cycle of the structure.

For more queries regarding any of the above-mentioned topics, feel free to connect with us on our website www.indovance.com , or contact us on +1-919-238-4044

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