Finite Element Analysis

A 3D CAD model, or virtual prototype, is first constructed then, using FEA software, simulated loads and performance conditions (i.e. forces, pressures, temperatures, voltages etc.) can be applied to the model to imitate the conditions in which the component is expected to function in its real environment.

Finite Element Analysis can provide the engineer with deep insights into the behavior of the component or assembly being designed. Design revisions, to improve or refine the part, can be undertaken at the design stage in CAD, dramatically reducing the need for, physical prototype testing. These analyses provide detailed quantitative reports of internal stresses, heat flow, temperature changes, strains etc.

Most manufacturing companies still make physical prototypes and test them to destruction to establish ultimate limits. Whereas this process will continue to be used, costs can be dramatically reduced by undertaking “virtual prototyping” using Finite Element Analysis. A series of design studies for a particular component can be generated, analysed, and only the final design iteration sent for physical prototyping and testing.

Typically, with a hand calculated analysis, an engineer will adopt a conservative approach to the design of a component. This may result in a part which is over engineered, and therefore excessively heavy and unnecessarily expensive in both materials and manufacturing costs. An FEA avoids these errors by optimising the design function.