ME 443/643 Design Techniques in Mechanical Engineering. Lecture 1: Introduction

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1 ME 443/643 Design Techniques in Mechanical Engineering Lecture 1: Introduction Instructor: Dr. Jagadeep Thota

2 Instructor Introduction Born in Bangalore, India. B.S. in Bangalore University, India. M.S. and Ph.D. in UNLV. Research specialization: Structural Mechanics, Finite Element Analysis, Composite Materials, and Optimization Working as Postdoctoral Researcher and UNLV. Author (co-author) of over 30 technical papers. Member of Tau Beta Pi, engineering honor society.

3 Students Introduction Name Standing (Junior/Senior/MS/PhD ) List atleast one of your favorite courses till now If you don t have a favorite course, you get to list one of your least liked course till now What do you know about Finite Element Analysis (FEA)? Any experience with FEA software?

4 Course Related Information

5 ME 443/643 Alternate course title, Applied Finite Element Analysis My office: SEB 2215 Office hours: Monday & Wednesday 1:00-5:00 pm Schedule beforehand (preferred) (mostly available any day) Phone: (office) (cell) (text friendly) Website: (Instructor) (Course) Pre-requisites: ME 220/240, ME 302 & ME 314

6 Books (Reference) Some parts of my notes are based from the below listed books. I would like to acknowledge the authors of the books: Moaveni S (3rd Edition) Finite element analysis: Theory and application with ANSYS. Reddy JN (3rd Edition) An introduction to the finite element method. Cook RD, Malkus DS, Plesha ME, Witt RJ (4rt Edition) Concepts and application of finite element analysis. Logan DL (5th Edition) A first course in the finite element method. MacDonald BJ (2nd Edition) Practical stress analysis with finite elements

7 Objectives Get introduced to a popular design technique known as Finite Element Method (FEM) Learn widely used Finite Element (FE) simulation software in academics and industry Altair HyperWorks and ANSYS Workbench Understand linear static FE analyses of structural and thermal systems Learn about different types of elements and problem specific boundary conditions Understand the assumptions used in setting up a FE analysis problem Learn the limitations of FE programs/methods Learn to analyze the simulated FE results Application of FE methods to real-life design problems Work on project(s) of realistic complexity to get a feel of the application of the FE software

8 Homework Policy Homework is due on the dates listed on the course Syllabus webpage. Solutions will be posted on the course website. Submit homework electronically Homework includes either: Solving a design problem analytically by applying the FE methods OR Simulating the design problem with the help of FE software taught in the class OR Combination of both analytical methods and simulation approach.

9 In-Class Assignments There will be quizzes through out the semester, which will be graded as part of the In-class assignments. The quizzes will mostly involve simple FE concepts covered in the previous classes. Some part of the In-class grade will also involve the student's diligence towards the subject, which shall be gauged by the Instructor. Extra-credit(s) will be given to students answering questions in the class.

10 Project There will be one project. Each student can pick a project topic of his/her choice. The project topic needs to be approved by me before the student can start working on it. Each student works on the project independently. The project will involve solving a design problem by either using Altair HyperWorks OR ANSYS Workbench. Based on the type of project there may or may not be any analytical calculations involved.

11 Class Grade Overall class grade is weighted as shown (subjective to change): Homework In-class Project 60% 10 % 30 % Approximate correlation between final percentage grade and final letter grade: > 89 % % % % < 50 % A A- to B B- to C D F

12 Extra Credit A total of 5% can be earned with extra credit activities. Join and participate in a national or international technical professional organization (1%) Become an officer, chairman, or representative of a local student organization (1%) Make a 5 minute presentation in class about an interesting /creative /new FE study/concept (1%) Volunteer to help with a department, college, or local technical event (1-2%)

13 Survey me the survey Attach your picture in the Course Semester Grade ME 220 Software Barely Familiar Mastering Basic Skills Mastering Advanced Skills ME 240 AutoCAD ME 302 Pro/E ME 314 SolidWorks ME 319 ME 440 Other CAD Software Mathcad Matlab Excell Other Programs FEA software

14 What does this class cover? The class is 30% theory, and the rest 70% simulating FE models using software. Theory: Direct Stiffness Method Spring, Truss (Bar) and Beam elements Heat Transfer (Conduction & Convection) for 1D [Maybe] Thermal Stress for 1D [Maybe] Simulation: 1D, 2D and 3D elements Linear solutions Heat Transfer Thermal Stress Modal Analysis

15 Syllabus Check the course website

16 Altair HyperWorks Software The class uses HyperWorks software predominantly The software is available in TBE B367 & A311 computer labs I can give out the software to interested students to install on their personal laptop or desktop I would highly recommend this to all the students The license for the software is $2500 Hence, make sure you do not pass on the software to non-me 443/643 individuals The license is valid for one year

17 ANSYS Worbench Software I will introduce ANSYS software later in the semester This software is also available in TBE B367 & A311 computer labs Unlike HyperWorks, I do not have access to give out ANSYS software to students If you are a Research Graduate student, you can ask the College of Engineering, thru your advisor, to install ANSYS on your university working computer Contact Ms. Kari Locke (Systems Admin.) OR Dr. Mohamed Trabia (Associate Dean)

18 Introduction

19 CAD/CAM/CAE? CAD: Computer Aided Design (Drafting) Involves designing/modeling a component with the aid of a computer software SolidWorks, Pro/E, AutoCAD, CAM: Computer Aided Manufacturing Involves controlling machine tools with the help of computer software Mastercam, CAMWorks, HyperMill,. CAE: Computer Aided Engineering Involves detailed analysis of engineering components with the aid computer software Finite Element Analysis (FEA) comes under this category ANSYS, Altair HyperWorks, Nastran, LS-DYNA, COMSOL,.

20 Finite Element Analysis (FEA) ME 443/643: Introduction Analysis of a problem by using finite element method is known as FEA Finite element method is a numerical method for solving problems of engineering and mathematical physics The problem can be structural analysis, heat transfer, fluid flow, mass transport, and electromagnetic potential For problems involving complicated geometries, loadings, and material properties, it is difficult or not possible to obtain analytical mathematical solutions Most of the methods require solving of differential equations, which is difficult or impossible for complicated problems Finite element method (FEM) helps to solve such complicated problems FEM involves solving a system of simultaneous algebraic equations irrespective of the complication of the problem

21 Application of FEA Simple structural analysis problem Apply basic material mechanics concepts Find out the required stresses and strains L P b h Apply Material Mechanics Stress = P / (b x h) Strain = ΔL / L Complicated structural analysis problem Can not apply basic material mechanics concepts Can be solved by FEM w P Cannot Apply Material Mechanics Need to Apply FEM Stress & Strain are obtained by solving a set of simultaneous algebraic equations and finding out the unknown displacements V

22 FEA Procedure Boundary condition Complicated structural analysis problem w P Enlarged view of the element Boundary condition Element P V Consider a small element of the structure Boundary condition Analyze this element and determine the necessary unknowns FEM divides the structure into such smaller elements (discretization) Solves the necessary unknowns for each element Combines the results from all the elements to give the solution for the overall complicated structure Dividing a body into an equivalent system of smaller bodies (finite elements) interconnected at points common to two or more elements and/or boundary lines and/or surfaces is called discretization.

23 FEA History 1943 Finite Element Analysis (FEA) first developed by R. Courant Used the Ritz method and variational calculus to obtain approximate solutions to vibration systems 1947 Prager and Synge also applied this method to analyze frames in BOEING structural dynamics group begins using the method for aircraft design 1960 The term Finite Element Method (FEM) is coined

24 FEA History 1965 NASA sponsors a project to develop a unified approach to computerized structural analysis NASTRAN (NASA Structural Analysis Program) is born 1970 FEA was limited to expensive mainframe computers generally owned by the aeronautics, automotive, defense, and nuclear industries ANSYS came into being 1985 Altair was established HyperMesh was introduced in 1990

25 Advantages of FEM Easily model complex shaped bodies Handle any general load conditions Model bodies composed of several different materials because the element equations are evaluated individually Handle unlimited numbers and kinds of boundary conditions Can vary size of the elements within a body Can alter the FE model relatively easily and cheaply Can include dynamic effects Handle non-linear behavior

26 FE Software Altair HyperWorks, ANSYS, Abaqus, NASTRAN, LS-DYNA, Pro/MECHANICA.. General capabilities of a FE software: Different element types available (beam, shell, solid..) Different analysis types available (static, nonlinear,..) General load types available (concentrated, thermal..) Automatic FE model creation (nodes, elements,.) Plotting contour results (deformation, stress, ) Option of selecting preferred output

27 Next Class Introduction of the FE software used in the course; Altair HyperWorks Go over the pre-processor HyperMesh Get a feel of the HyperMesh GUI (Graphical User Interface) Create simple geometries in HyperMesh

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