Introducing Tips In Machinery Designing
There is no doubt that finite-element analysis is getting a bigger role in development projects. One of the many strong reasons is that it helps reduce expensiveprototype testing.
Despite FEA’s reputation for accurately pinpointing weak spots in designs, a few faulty assumptions and organizational flaws may render analysis work unusable. For instance, some companies treat FEA as an extension to CAD packages. In fact, it requires specialized training all its own.
What could possibly go wrong?
Similarities between CAD and FEA are superficial, and limited at best to geometry. Proficiency in CAD does not assure expertise in FEA, and someone skilled in running an FEA program is not necessarily a good analyst. CAD operators running FE programs often strive for the most accurate representation of geometry because geometry is the prime focus of drafting. Meshing, element type, loads, supports, error estimation, and result analysis get less attention.
Unfortunately, FEA is not that easy. Geometric accuracy and impressive color plots never guarantee of better results in case of FEA, CFD or any other virtual analysis. Following are the key factors which should be avoided to get the results more practical and accurate.
Assigning FEA to engineers lacking product experience….
For producing meaningful result in FEA, the analyst must know the principles behind the finite element method. Practical experience ensures more precise result for the analyst. Experience led them to simulate the physics behind the problem nicely. He or she must understand the product as well as its intended work environment. This knowledge is critical for the analyst in creating the FE model, simulate the proper working condition, applying loads and constraints (Boundary conditions), analyzing the result and conveying the results to the designers or customers.
Assigning FEA operations to recent graduates produces other problems. Newcomers may not be comfortable interacting with others and withdraw into an isolated world of computer simulations. This situation does not contribute to the learning process that young engineers need nor does it serve the best interests of the engineering department.
More dependency over the training programs….
Aiming Badly….
Main objective of the FEA should be very clear before starting the simulation. Poorly defined FEA objectives lead to wasted effort. Mostly, the analyst receives a project requirement by saying or conveying only “Perform FEA on the engine block”. Goals should cover why the analysis is needed, the expectations, and how results will be used. The perform-FEA syndrome often stems from bureaucratic misunderstanding rather than engineering need for the results.
Lack of well-maintained project repository
Proper documentation of any project not only assures the availability of the same whenever required but also helps creating asset for the organization. Results always should be confirmed through testing. Where there are discrepancies, an appendix to the project report should address the problem. Users need to verify results with experiments until they get confidence in the method.
Self-explanatory report having all required information is the absolute need of any organization to go forward. A good report together with backup, provides sufficient detail for rerunning the analysis without any additional instructions. Though it is complex and time consuming process, it is very useful for the future course of action when the design modification is required.
What FEA reports and backups should do
Restart the work.
Provide a basis for executing a modified analyses.
Provide a basis for training personnel.
Establish in-house expertise in FEA
Provide legal documents when liability is involved
Bad company policy
Looking for the instant specialist is also a bad policy. Some job ads explicitly ask for experience with particular software, again indicating a superficial, CAD-like approach to FEA. Understanding the FE method is more important than specific software commands which are easily learned.
How to be a smart FEA shopper?
Following points should be considered while selecting the software for your personal or organizational need.
Select software first, then a hardware platform.
Ask for references and check them yourself.
Insist on a free trial period with full support.
Do not trust canned demos, they highlight best features and hide problems.
Ask the vendor to prepare a problem from your files.
Ask for training along with the software.
Train managers on capabilities of FEA and CAE.
How to find the specialist FE Analyst or FE Service provider for your product design need?
Following points should be considered while collaborating for the design specialist cum FE expert.
Select a service provider based on their overall experience for the field as well as tool.
Ask for references and check them yourself.
Ask for a proof of business performance and company history.
Work with the service provider on a pilot project, if possible.
Ask for the training of your current staff for the future requirement, if your outsourcing is one time requirement.
