Finite Element Simulation

Finite element simulation is at the core of what our FEA consultants do at our Singapore FEA consultancy offices in BroadTech Engineering.

It is Apparent that Top Performing FEA Services Vendor and Stress Analysis Services Companies are more empowered to make the right design decisions They have the Critical insight to make Engineering trade-off decisions to Satisfy goals for Built quality, while still Achieving cost targets 
FEA Services Companies can Review through enough Simulation iterations to Come to more innovative decisions. FEA Structural Engineering Consultants accomplish all of this while still maintaining efficiency.
Finite Element Simulation
Like Bigger corporations, SME and FEA Company alike, Encounters the Exact same business Growth drivers, such as Product Research & development time compression, Lowered product price expectations, overhead cost reductions, and Customer Ever Growing Requests for improvement products Built quality, Reliability, and longer Useful service life.
The research study also highlights the complexity of the Engineering Development Landscape in which Finite Element Analysts and Professional FEA Consulting Engineers Operate. FEA Piping Engineering Companies report using 3.6 different CAD tools on average, with 84% using two or more 3D CAD Softwares. Companies also work with 3.3 different Calculators for Finite Element Analysis (Ansys). This further aggravates the challenges associated with preparing models for Finite Element Modeling FEM Analysis.
Best Performing FEA Services Companies are more Probable to take advantage of multiple automation capabilities to Accelerate -up the Tiresome and repetitive tasks of preprocessing. They are twice as Probable to Totally automate assembly contact definition and four times more Probable to Intelligently automate geometry clean-up. 
They Are also 4.75 times as Probable to take Profit of customization for further Workflow automation. All of this Helps to save Precious Development time and reduces the workload Included with preprocessing. Top Performing Engineering Finite Element Simulation Companies and Finite Element Analysis Companies also take Profit from automated meshing, but more importantly, they still have the capacity to control and edit it for cases when the mesh is not sized properly Top Performing FEA Consulting Company are 69% more likely than Competitors to have the ability to Rapidly re-mesh with newly Added parameters. 
This Decreases the Hours needed by the Structural Engineering Consultants to evaluate Several iterations, making it Significantly Much Faster for the Top Performing Engineering Department to Invent and Advance.
Lastly, Top Performing Finite Element Analysis Companies are 4.2 times more Probable to use guided wizards to ensure best practices are followed. This guides the Workflow of defining the model properly and Allows avoid incorrect Conjectures.


Siemens PLM Software’s Solution

Solid Edge Simulation Analysis is a mid-range Front end FEA Structural simulation capability Seamlessly embedded Within Solid Edge CAD Software. This provides a very intuitive, easy-to-use FEA Design Optimization analysis environment that can Gain access to the Mainstream industry-standard NX Nastran FEA Simulation solver for Structural stress, normal modes, and buckling analyses, Offering Blazingly Quick and accurate FEA Structural Optimization Simulation results.
Femap FEA is also highly integrated with all Variants of Nastran, a leading FEA solver, and in particular NX Nastran. Femap Analysis Software offers a native Windows user GUI interface and file Format associativity with Solid Edge CAD, which further Improves general usability and productivity.
Both Solid Edge Software Simulation and Femap deliver pre-and post-processing capabilities that provide the Capability to update and improve product designs based on the FEA Finite Element Analysis results.

FEA Finite Element Simulation Software Module Advantages

Siemens PLM FEM Software has been helping large manufacturing Businesses as well as Finite Element Analysis Consulting Firms to be Commercially successful in the Mainstream automotive, Military, Aerospace Research and Development, Marine architect shipbuilding Design & Construction, Industrial electronics, and other Core industries for more than 35 years.
  1. Evaluate the dynamic performance of your physical FEA Engineering model when performing Structural Engineering Services
  2. Apply the FEA Software to Performing Practically Every Engineering applications, industries, and model sizes
  3. Save Valuable Project time and cost compared to physical build-test break cycles

Key FEA Finite Element Simulation Analysis features

  1. Comprehensive dynamic response Data Collection. Supports frequency, transient, complex eigenvalue, random response, shock spectrum, and other FEA Simulation service analysis
  2. Includes a Collection of eigenvalue Physics solvers such as Lanczos, Householder, Hessenberg, etc.
  3. FEA Structure Wind Load Simulation Software Supports numerous Forms of dynamic Force loading in Either time and frequency domain
  4. Quick frequency response solvers applicable to Huge FEA models Commonly used for Pipe Stress Engineering
“The analysis processes Offers in the FEA Analysis Software unprecedented fidelity with the FEA Simulation results, Enabling the Engineering design to pass the critical design review Stage with flying colors.

Understand the FEA Finite Element Simulation Process

When Targeting to improve the FEA Structural simulation Workflow in your Finite Element Consulting projects, there are Many distinct Stages involved. Conducting a Finite Element Analysis simulation Study involves :
  1. Preprocessing:

    The process of preparing a model for FEA Thermal Structural Analysis simulation and FEA Simulation Services. This includes defining the geometry, mesh, and boundary conditions. This step may involve simplifying the model. Models are often simplified by removing small features such as holes and Sharp edges that do not impact product performance but add to the calculation time of the analysis.
  1. Solver:

    After FEA Thermal Simulation preprocessing, the model 3D Geometry Information is ready for FEA Stress analysis. The solver performs Out the numerical computation based on modeling input Parameters and calculates Geometrical displacements, Loading forces, and Mechanical stresses Inside the model.
  1. Postprocessing:

    Once the FEA solver finishes its Computational Processing calculations, it is ready for post-processing. The FEA postprocessing involves Computing the FEA Simulation results pre-determined by the solver.


Featured Finite Element Simulation Case Studies

Finite Element Simulation

Finite Element (FE) Simulation of Chassis Main Frame

This finite element simulation project involves the structural analysis of an automotive Chassis mainframe
Tools & Methodology Used: Hypermesh and Optistruct
1. To analyze the stiffness of the latest Chrysler JL Frame
2. Displacement values are obtained from contour plot at local grid points.
3. Bending and torsional stiffness are calculated from the displacement values (k=uP) and concluded that the frame is successfully designed to meet the requirements.

Finite Element Simulation of Front Subframe

Geely KC2 Front Subframe Stiffness Analysis was done as part of our FEA consulting services
Tools & Methodology Used: Hypermesh and Optistruct was used during the Finite element analysis
1. To analyze the stiffness of the subframe of Geely KC2.
2. Displacement values are obtained from contour plot at local grid points.
3. Bending and torsional stiffness are calculated from the displacement values (k=uP) and concluded that the frame is successfully designed to meet the requirements.

Maximization of Dynamic Stiffness of Mounting Bracket of Engine

Tools & Methodology Used: Hypermesh and Nastran was used for the fatigue simulation
1.Improving the Frequency and dynamic stiffness of the Bracket reduces the engine transferring vibration.
2. In previous iteration Engin, RH mounting Bracket assembly has the frequency level of 450Hz.
Two ribs were added to the mounting plate and modal analysis carried with appropriate boundary conditions.
3. Dynamic stiffness is improved and the frequency level obtained is 570Hz.

Elastic and Elastic-Plastic Analysis of Thick Wall Pressure Vessel

Objective: To investigate the Von misses stresses, 1st yield, strain hardening and the plastic collapse of the thick-walled pressure vessel for purpose of carrying out a numerical optimization of the vessel design.
Methodology: Finite element analysis was carried out by our structural engineering consultants to investigate the behavior of the stress against time.
Outcome & Results: The first yield occurred in the inner knuckle and top crown of the vessel.
After yield point, if the load applied to the vessel increases (strain hardening), the material of the vessel will deform permanently.
From the structural analysis, the maximum stresses are concentrated at the top of the vessel representing the plastic collapse

Simulation of Pressure of Fluid through Orifice Plate

Objective: To investigate the nature of the flow which can be determined by the Reynolds number. At a low Reynolds number laminar flow is witnessed while at high Reynolds number turbulent flow is witnessed.
Tools & Methodology Used: FEA analysis was conducted for a different type of orifice plate. Circular, flat, forward and backward.
Outcome & Conclusion:
Circular orifice plate produced superior results due to the reduced amount of change in pressure. FEA analysis for venturi tube was also performed and the results were more promising due to smaller head losses compared to the orifice plate.

Design Optimization of Heavy Industrial Vehicle (Loader Bucket Assembly)

Tools & Methodology Used: The FE model was prepared for ABAQUS solver commonly used in stress engineering services companies.
2D and 3D elements were used to build the FE model according to the requirement defined for the required structural engineering services.
The FEM modeling used the bar elements to connect the bolt locations using the tool Hypermesh. A Modal Analysis and topology optimization were performed using the solver Optistruct in the FEA software.

Buckling of Tori-Spherical Domes (Thin Pressure Vessel)

1. Algor Fem Pro was used to conduct FEA finite element simulation on tori-spherical domes. The objective of the engineering simulation project was to investigate the effects of the thickness of the vessel against buckling and linear stress.
2. FEA analysis, Fatigue analysis, Fracture analysis, and Buckling analysis was performed for varying thickness to study the critical buckling pressure and yield pressure.
During the rendering of the failure analysis services, it was noted that with the increase in thickness of the pressure vessel the higher buckling loads it could withstand and a logarithmic relationship was observed. With the increase in thickness, a higher yield pressure was observed and the relationship was linear.

Finite Element Simulation of Thermal Stresses on Fin

Objective: The objective of the design optimization project was to investigate the effectiveness of the shape and number of fins (used in heat exchanger etc) subjected thermal stresses
Tools & Methodology Used:
FEA analysis was performed on a model without a fin and model with fin.  (Model 1: No fin, Model 2:1 Triangular fin, Model 3: 1 Rectangular fin, Model 4: 2 Triangular fins, Model 5: 2 Rectangular Fins). The effectiveness was calculated by comparing the max heat flux of model without fin vs models with fin (i.e max heat flux of model 3/max heat flux of model 1)
Outcome & Conclusion:
Fins are capable of transferring more heat outside than pipes without fins.
Enhanced heat transfer rates are increased by greater no of fins due to more surface area to the surrounding to compensate for higher resistance.
The model with the two parallel rectangular fins produced the best results. The FEA results were compared with the results from theoretical formulae to validate the results and calculate the error ineffectiveness.

Stress Analysis of Semi-Elliptic Edge Crack in a DNVX65 Steel Specimen

To investigate numerically the stress intensity factors of semi-elliptic edge crack in a DNVX65 steel specimen that has progressed beyond the width of the specimen under a four-point bending load, and to investigate via failure assessment diagram if the existing flaw is acceptable.
2. eXtended FEM enrichment was used in analyzing the crack propagation, to capture singularity of the crack tip.  Numerical modeling results were used to compare with benchmarks from BS7910 solutions.
R6-K solutions were supplemented on top of BS7910 considering the validity limits of its solutions.
Results for 4PB loads were also compared with past literature from Gross & Srawley’s beam bending analysis.
3. SIF distribution along the crack front showed consistency with the profile of the crack, with higher SIR at the extremities – kink points of the crack
Fatigue Analysis
Stress analysis simulation was conducted on engines stators and fan blades. Structural analysis report memos were produced to incorporate information on high-stress points.
As part of the analysis for a client project, fatigue crack growth (FCGR) was also analyzed.
Cyclic stress intensity factor range relating t the amount of crack propagation during every fatigue cycle was also part of the project.



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BroadTech Engineering is a Leading Engineering Simulation and Numerical Modelling Consultancy in Singapore.
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2. Simulation Consultants with Extensive Research & Professional Experience

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FEA Simulation of Disc Brake Assembly

Disc Brake Assembly
Tools & Methodology Used: Hypermesh and Nastran
  1. To carry out structural optimization and analysis for Automotive Disc Brake assembly.
  2. The stresses generated in the caliper components and contact (interface) pressure distributions at the rotor and piston-pad interface taking into consideration the dynamic condition of the assembly.
  3. It has been observed during the FEA simulation that higher pressure occurred on the leading side when the disc starts to slide, which again states that more wear appears on the leading side than the trailing side of the pad. So the study of dynamic pad pressure distribution helps in order to minimize and/or eliminate tapered wear in pads.


Optimization and FEA dynamic analysis for suspension brackets

1. FEA Simulation Objective:

Optimization and dynamic analysis for suspension brackets using Optistruct software.

2. FEA Simulation Methodology and Approach:

The objective of the topology optimization study was to minimize the compliance of the bracket and increase frequency based on 30% of its initial volume. Optimization in Optistruct, was followed by linear unit load static analysis. The design was proposed for the most efficient material layout based on design space.

Fatigue life analysis of plane problems in the presence of flaws.

1. FEA Simulation objective::

 The analysis of static and growing cracks becomes quite important for the health monitoring of the structures/ components under fatigue loading. In general, many components e.g. the engine of an aircraft, turbine blades, and rotating shafts subjected to cyclic loads may sometimes lead to fatigue failure. Thus, the design analysis of structures subjected to fatigue load needs to be performed accurately. Thus objective was to carry out the numerical simulations of fatigue crack growth in presence of multiple defects and investigate their effect on fatigue life.

2. FEA Simulation Methodology and Approach:

The eXtended Finite Element Method (XFEM) was employed to model the various discontinuities such as cracks, voids, and inclusions. Material behavior was modeled using Von-Mises failure criterion along with the Ramberg-Osgood equation. The J-integral for two fracture modes (mode-I and mode-II) was obtained by decomposing the displacement and stress fields into their symmetric and anti-symmetric parts, then individual stress intensity factors are extracted from J-integral. The plasticity-induced crack closure (PICC) phenomenon was modeled by fixing the nodal displacement of the crack faces and the developed finite element framework was applied to numerically simulate various crack growth problems.

3. Outcome & Conclusions:

The results obtained using linear elastic analyses were compared with elasto-plastic analyses for various edge crack configurations. On the basis of the present simulations, the following conclusions have been drawn:
  1. *In cyclic loading, the plastic strains developed near the crack tip during loading lead to the formation of the plastic wake behind the crack tip as the crack extends, which results in the development of compressive stresses at the crack tip.
  2. *The residual compressive stresses reduce the crack driving force for the next loading cycle as some portion of the applied tensile load was consumed to overcome the compressive stresses developed at the crack tip. These compressive stresses result in the improvement of fatigue life by reducing effective stress intensity factor. Thus, plasticity developed at the crack tip improves the fatigue life.
  3. *The fatigue life obtained by linear elastic analysis was found quite close to small strain plastic analysis. Hence, it can be stated that the linear elastic analysis is sufficient to perform fatigue crack growth simulations for small-scale yielding.
  4. *The presence of flaws significantly affects fatigue life.
  5. *The effect of holes is found most severe in comparison to other defects.


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Customers will be provided with fully tailored Finite Element Simulation reports which outline the Methodology, in-depth analysis, and recommendations. These insights allow our customers to optimize performance and make informed engineering decisions in a scientific, proven manner.
Discover what Finite Element Simulation can do for your company today by calling us today at +6594357865 for a no-obligation discussion of your needs.
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