Introduction To Meshing
5 Introduction To Meshing
5.1 Types of Element
Elements
1-d 2-d 3-d other
Y Midsurface
X
Z
t
t2
t - thickness of plate
One of the dimension is two of the dimensions are All dimensions are Mass – Pt. element,
very large in comparison very large in comparison comparable concentrated mass at C.G.
to rest of the two to third one of the component
x ~y~ z
x >>> y, z x , z >>> y Spring –translational &
Element shape – tetra, rotational stiffness
Element shape – line. Element shape – quad, tri penta, hex, pyramid
Damper - damping
Additional data from user - Additional data from user Additional data from user coefficient
remaining two dimension - remaining dimension i.e. – nothing
i.e. Area of c/s thickness Gap – Gap distance,
Element type – solid stiffness, friction
Element type – rod, bar, Element type – thin shell,
beam, pipe, axi-symmetric plate, membrane, plane Practical applications- Rigid – RBE2, RBE3
shell etc stress, plane strain, , axi- Transmission casing,
symmetric solid etc engine block, crankshaft Weld
Practical applications- etc.
Long shafts, beams, pin Practical applications-
joint, connection elements Sheet metal parts,
etc. plastic components like
instrument panel etc.
5.2 How to decide element type?
Element type selection
Geometry size & shape Type of analysis Time available
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Practical Finite Element Analysis
Geometry size & shape
For analysis software needs all the three dimensions & it can not make calculations unless & until
geometry is defined completely (via meshing i.e. nodes and elements).
Geometry could be categorized as 1-d, 2-d or 3-d based on dominant dimensions as follows:
1-D element: Used for geometries having one of the dimension very large in comparison to rest of
the two.
5 X
10 Z
1000
x>>> y, z
1000>>> 5, 10
Shape of 1-d element is line. When the element is created by connecting two nodes, software comes
to know about only one out of 3 dimensions. Remaining two dimensions i.e. area of c/s must be
defined by the user as additional input data & assigned to respective elements
Practical Example: Long shaft, rod, beam, column, spot welding, bolted joints, pin joints, bearing
modeling etc.
2-D Element: Used when two of the dimensions of geometry are very large in comparison to third
one.
300
500 Y
500, 300 >> 10 mm Z
X, Y >>> Z X
2-d meshing is carried out on mid surface of the part. 2-d elements are planer elements just like
paper of this page. By creating 2-d element software comes to know 2 out of 3 required dimensions.
The third or remaining demission i.e. thickness should be provided by user as an additional input
data.
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Introduction To Meshing
Why 2-d meshing is carried out on mid surface?
Mathematically element thickness specified by user is assigned half on element top and half on
bottom side. Hence in order to represent the geometry appropriately via 2-d mesh its necessary to
extract mid surface & then mesh on the mid surface.
Midsurface
t2
t - thickness of plate
Practical Examples: All sheet metal parts, plastic components like instrument panels etc. In general
2-d meshing is used for parts having width / thickness ratio > 20.
Limitations of mid surface & 2-d meshing –
2-d meshing would lead to higher approximation if used for
- variable part thickness
- surfaces are not planner and have different features on two sides .
3-D Element: used when all the three dimension are comparable
100
200 Y
50
X~Y~Z Z
100 ~ 200 ~ 50 X
Practical Examples: Transmission casing, clutch housing, engine block, connecting rod, crank shaft
etc.
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Practical Finite Element Analysis
Based on type of analysis :
Crash and Non linear analysis – priority to mesh flow lines and brick elements over tetrahedron.
Mold flow analysis – 2-d triangular element are preferred.
Dynamic analysis – When the geometry is border case as per above classification of 2-d & 3-d
geometry, 2-d shell elements are preferred over 3-d. This is because shell elements being less stiff
captures mode shapes accurately & that to with lesser number of nodes & elements.
Delivery time:
When time is no constraint, appropriate selection of elements, mesh flow lines and good mesh
quality is recommended. Some times due to very tight deadline analyst is forced to submit report
quickly. For such situations
1) Automatic or batch meshing tools are used instead of time consuming but structured
& good quality providing methods.
2) For 3-d meshing tetras are preferred over hexas.
3) If assembly of several components is involved then only critical parts are meshed
appropriately. Other parts either coarse meshed or represented approximately via 1-d
beams, springs, concentrated mass etc.
Is it not possible to use 3-d elements for long slender beams (1-d geometry) or for sheet metal parts
(2-d geometry) and 2-d shell elements for representing big casting parts ?
The same geometry could be modeled using 1-d, 2-d and 3-d elements. What matters is number of
elements & nodes (dof ), accuracy of results & time consumed in the analysis.
For example consider cantilever beam, dimension 250 x 20 x 5 mm subjected to 35 N force
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Introduction To Meshing
1-d beam model
2-d shell model
3-d tetra model
nodes elements Stress Displacement
N/mm2 mm
Analytical -- -- 105 4.23
1-D 2 1 105 4.23
2-D 909 800 103 4.21
3-D 17,448 9,569 104 4.21
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Practical Finite Element Analysis
5.3 How to decide element length?
1) Based on previous experience for similar type of problem (successful correlation with
experimental results).
2) Type of analysis: Linear static analysis could be easily carried out that too quite fast
with high number of nodes and elements (less element length), but crash, non linear
, CFD or dynamic analysis consumes lot of time. Keeping control on number of nodes
and elements is necessary.
3) Hardware configuration and graphics card capacity of available computer.
Suppose a you are a part of newly formed CAE group (no clear guidelines or are available, also there
is no experienced person in the group):
In the first run accept default /logical mesh length with basic meshing thumb rules as discussed in
the book. Run the analysis, observe high stress region, remesh in localized areas of high stress (with
smaller element length) and solve again. Compare difference in original and new results. Continue
the process till convergence is achieved ( 5 to 10 % difference in strain energy / max. stress value).
5.4 How to start meshing
1) Spending sufficient time in studying the geometry
It’s a very common at least with new CAE engineers to start meshing on computer
immediately without properly studying the geometry & paying minute attentions to all the
requirements and instructions provided. Observing the geometry several times & thinking
from all the directions is strongly suggested. Mental visualization or planning before starting
the job is first step in right direction i.e. good meshing.
2) Time estimation for meshing:
Now a days trend is towards client / boss specifying time estimation for given job to
service provider / subordinate. Some times it is decided based on mutual understanding.
Time estimation is very relative & one can find lot of difference in estimation by different
engineers (as much as 2 to 3 times). Usually a less experience person will estimate more
time also if some one is handling a job for first time then also he will require more time. If
similar kind of jobs are given to same engineer again and again, meshing time would be
reduce drastically.
3) Geometry check:
Commonly geometry is imported in meshing software in *.igs format. What ever software
people might claim but the ground reality is “geometry cleanup is an integral part of
meshing”. CAE engineer should have at least basic knowledge of CAD. Before starting the
job geometry should be checked for following
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Introduction To Meshing
• Free edges
• Scar lines
• Duplicate surfaces
• Small fillets
• Small holes
• Beads
• Intersection of parts (for assembly)
If suppressing fillets, small holes, beads, generation of mid surfaces etc is required for meshing
then why not CAD data is provided like what is needed for CAE by the CAD engineers ?
Yes theoretically it would be an ideal situation but practically every one works with very tight
schedules & target dates. CAD data is generated keeping in mind final drawing to be released for
manufacturing. The same drawing / CAD model is provided simultaneously to tools and jig /fixture
manufactures, vendors, purchase engineers and CAE engineers.
- Simplifications required for FEA are understood better a CAE engineer rather than
CAD engineer. All Meshing softwares provides special tools for geometry cleanup
and simplifications which are usually much faster than CAD softwares. Many a times,
for complicated geometries surfacing operations fails in CAD softwares & it could be
easily handled by CAE engineer by avoiding the geometry and generation of mesh via
manual or special meshing operations.
4) Symmetry check :
• Complete part symmetry
Meshing only quarter of the plate & reflecting it twice will lead to complete plate mesh.
• Sub part symmetry , repetition of features & possibility of copy paste command
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Practical Finite Element Analysis
Meshing highlighted 22.5º portion and then reflection could lead to fast meshing as well same
structure of elements and nodes around critical areas (holes).
5 ) Selection of type of elements:
In real life rarely we use only single type of element, its usually combination of different
types of elements 1-d, 2-d, 3-d & others.
In above figure the handle of bucket modeled by beam (1-d) elements, bucket body via shell (2-d)
elements and connection between handle and bucket body through Rbe2 (rigid) elements.
6) Type of Meshing :
i. Geometry based – Mesh is associated to geometry. If geometry is modified
mesh will also get updated accordingly (automatically). Boundary conditions
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Introduction To Meshing
could be applied on geometry like surface or edge etc.
ii. FE based – Mesh is non associative. Boundary conditions to be applied on
elements & nodes only.
7) Joint modeling:
i. Special instructions for bolted joints (specific construction around holes)
ii. Spot & arc weld
iii. Contact or gap elements & requirement of same pattern on 2 matting
surfaces
8) Splitting the job -
Incase if time available is very less or if engineers in other group are sitting idle then the job
could be split among several engineers by providing common mesh on interfaces.
5.5 Meshing techniques
Manual (Special
Mapped command: Spline,
Automatic
(or Interactive) Ruled, Drag / extrude,
Spin / rotate,etc.)
≈ (intermediate i.e. less
Time required for meshing
↓ than auto but more ↑
geometry
than manual)
Geometry required X
No. of nodes and element
↑ ≈ ↓
generated
User friendliness ↑ ≈ ↓
User’s control over the
↓ ≈ ↑
mesh
Structured (flow of the
↓ ≈ ↑
mesh)
Experience or skill
↓ ≈ ↑
required
↑(specially for brick /
Patience ↓ ≈
hexa)
Batch meshing / Mesh adviser – Recently all the softwares have started providing special programs
for automatic geometry clean up and meshing with no or very little interaction from user. User has
to specify all the parameters like min. hole dia, min. fillet radius, avg. and minimum element length,
quality parameters etc. & software will run a program to produce best possible mesh by fulfilling
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Practical Finite Element Analysis
all or most of the specified instructions. Though these programs are still in initial stage & for many
applications output is not acceptable but research is in progress & its performance will surely improve
in coming years.
Batch meshing / Mesh adviser – Recently all the softwares have started providing special programs
for automatic geometry clean up and meshing with no or very little interaction from user. User has
to specify all the parameters like min. hole dia, min. fillet radius, avg. and minimum element length,
quality parameters etc. & software will run a program to produce best possible mesh by fulfilling
all or most of the specified instructions. Though these programs are still in initial stage & for many
applications output is not acceptable but research is in progress & its performance will surely improve
in coming years.
Automatic mesh Vs. Mapped / interactive / manual mesh
(For same element length & type)
Nodes = 1400, Elements = 1309
Nodes = 1073, Elements = 982
What is expected at professional level
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Introduction To Meshing
5.6 Meshing in Critical areas
Critical areas are high stress locations. Dense meshing & structured mesh (no trias / pentas) is
recommended in these regions. Areas away from critical are General areas. Geometry simplifications
& coarse mesh in general areas are recommended (to reduce total dofs and solution time).
How could I know which is the critical area before carrying out analysis ?
After going through previous analysis report of similar part (carried out by your colleague or senior in
the group) one can get fair idea about probable locations of high stress. But suppose there is no past
record & you are doing it for the first time, then just run the analysis with reasonable element length
and observe the results. Red color regions are critical & could be remeshed with lesser element
length.
Thumb rules for modeling holes & fillets:
Critical area General area
Minimum 12 elements around the hole
4 to 6 elements
Minimum 3 elements on fillet. Suppress small fillets, 1 element for large
fillets.
Mesh transition techniques & flow lines:
1 to 3 1 to 3
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Practical Finite Element Analysis
2 to 4 2 to 4
1 to 2 1 to 2 x 2
5.7 Mesh Display Options
1. Shell Mesh
A. Mixed mode: Geometry – line, Mesh - solid
This is the most common & preferred way of working. Some softwares like HyperMesh works faster &
consumes lesser graphics memory in this mode.
B. Line mode: Geometry & Mesh – both line
This mode is preferred for brick meshing, for internal mesh adjustment / modifications. Some software
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Introduction To Meshing
like Ideas work faster in this mode for 2-d as well 3-d applications.
C. Solid: Geometry & Mesh – both solid
This mode is not preferred for regular meshing but its very useful after completion of the job. It helps
in checking the mesh deviation from geometry & to find kinks or abrupt changes in the mesh.
2. Brick Mesh
a) Line mode options
First one is used for viewing internal details while second one could be used to check free faces
inside the mesh.
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Practical Finite Element Analysis
b) Solid mode
1. Solid 2. Shaded
c. Shrink
Solid view is commonly used during regular meshing. Shaded is used for checking kinks or deviation
of the mesh from geometry and Shrink mode for free faces and for missing or extra 1-d elements on
the edge of the element.
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