FEA Background
Finite Element Analysis (FEA) is a technique used in structural engineering analysis to simulate the functionality of various designs. A FEA software package is utilized to build a model and then solve calculus and linear algebra equations in order to output results. Preprocessing is the first step involved in creating a finite element model. A map of discrete nodes is created throughout the model. The nodes serve as the points at which stress, strain, displacement and temperature are calculated. Elements are created connecting the nodes. The nodes and elements combined are referred to as the model's mesh. The proper material properties and boundary conditions are then defined. After preprocessing the model, load cases are defined based on the functionality of the design. The software package then solves partial differential equations and integral equations and outputs the results of the load cases. Various types of analysis can be performed using FEA, such as but not limited to: structural, thermal and vibration. Linear and non-linear analysis can be performed using this method.
FEA reduces the number of iterations of prototypes for a new design and reduces the engineering time necessary to generate an optimal design. A trade study is performed by examining design factors such as the strength, weight, cost, and manufacturability of the part. Many design iterations are analyzed using FEA, and the resulting effects on the design factors are examined before a prototype is built. A finite element model can be manipulated much easier than an actual prototype. For example, an engineer can change the thickness of a feature and determine the effect on the stress of the part under its maximum potential load without manufacturing a new prototype. The optimization can be done iteratively or through optimization functions that are typically included with FEA packages.