3-Step Finite Element Analysis with 3D Scanning for Accurate Engineering

October 14, 2024

Modern engineering issues are becoming more complicated, and Finite Element Analysis (FEA) is a cost-effective, reliable service to mitigate these problems. It allows precise simulations that predict how components and systems will perform under various conditions. Incorporating advanced technologies and software ensures analyses are detailed, accurate, and aligned with real-world applications. This article delves into the FEA process and highlights the crucial role of advanced tools and expertise in delivering superior results.

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Step 1: Preprocessing – Creating a Detailed Digital Model

Preprocessing is the first and most critical step in the FEA process. It involves converting a physical component or system into a highly detailed digital model for analysis. Here’s how it is performed:

Geometry Acquisition: The accuracy of FEA depends significantly on the precision of the digital model. Industrial CT scanners capture the complete geometry of components, including external and internal structures. These scanners produce high-resolution 3D images accurately representing every component aspect, including complex features like microporosity and lattice structures.

‍Zeiss CT Scanners: Nel PreTech’s industrial CT scanning services can penetrate dense materials. This capability allows us to reveal intricate internal features that traditional, light-based scanning methods cannot capture. The detailed imaging forms the foundation for creating a voxel-based model, crucial for developing a high-fidelity finite element mesh.

Mesh Generation: After capturing the geometry, the next step is to generate a finite element mesh. In traditional FEA, a geometry-conforming mesh is essential. It ensures the mesh accurately represents the physical component’s shape, particularly at critical points like edges, corners, and interfaces. This mesh divides the component into small, discrete elements for individual analysis.

‍VGStudio MAX Software: This advanced software can refine the mesh to ensure it conforms precisely to the captured geometry. VGStudio MAX also simulates stress concentration around micro defects, enhancing the accuracy of FEA results. ‍
Handling Complex Structures Without a Geometry-Conforming Mesh: VGStudio MAX can handle components with intricate internal geometries, like foams or lattice structures. When creating a traditional conforming mesh is impractical or impossible, VGStudio MAX uses voxel-based approaches or other advanced methods. This process yields accurate results, even when the mesh does not strictly conform to the geometry.

Material Properties Assignment: Once the mesh is in place, material properties are assigned to each element. This step is critical because the material properties influence the component’s behavior under different conditions. The data from CT scans provides invaluable insights into the material’s internal structure, including variations in density and composition.

‍Material Analysis: The integration of material properties with CT scan data allows the simulation of components made from mono- and multi-materials with linear-elastic properties. This capability is particularly beneficial for analyzing complex, biomechanical structures or components with microporosity, where accurate material characterization is essential.

Boundary Conditions and Loading: The final step in preprocessing involves defining the boundary conditions and loading scenarios. Boundary conditions specify how the component is constrained while loading scenarios describe the forces, pressures, or torques acting on the component.

‍Advanced Simulation Setup: VGStudio MAX enables the simulation of static mechanical loading by applying directed force, torque, or pressure to the component. The software also allows the comparison of simulation results of the actual part against the original CAD model. This comparison highlights discontinuities, shape deviations, and stress distribution under load, ensuring that simulations reflect real-world conditions as accurately as possible.

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Step 2: Solving – Analyzing the Model

Once preprocessing is complete, the FEA software begins solving the equations for each element within the mesh. This step involves using high-performance computing systems to handle the complex calculations required to simulate the component’s behavior under defined conditions. The solver calculates factors such as stress, strain, deformation, thermal gradients, fluid flow, or vibrations, depending on the type of analysis being performed.

Step 3: Postprocessing – Interpreting the Results

Postprocessing is where the results of the FEA are visualized and interpreted. The data generated during the solving stage is translated into 3D visualizations, graphs, and charts. These tools provide a clear understanding of how the component behaves under the applied conditions. Key insights might include areas of high stress, potential failure points, temperature distributions, or flow patterns.

- Data Interpretation: Engineers analyze the results to identify critical data points, potential issues, or areas where the component performance may be impacted. Insights and data are used to make informed decisions.

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Applications of FEA

FEA is widely used across various industries, including aerospace, automotive, medical devices, high-performance sports, civil engineering, and biomedical engineering. It helps in:

Structural Analysis: Predicting how structures will respond to loads, stresses, and deformations.

Thermal Analysis: Understanding heat distribution and thermal stresses in components.

Fluid Dynamics: Simulating the behavior of fluids within systems, which is crucial for optimizing designs.

Vibration Analysis: Assessing the impact of vibrations on mechanical systems to ensure durability and performance.

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The Role of Industrial CT Scanning and VGStudio MAX in FEA

Integrating industrial CT scanning technology and software into the Finite Element Analysis (FEA) process provides the capabilities to deliver precise, reliable, and actionable results. Below is an overview of how these technologies contribute to FEA services:

Industrial CT Scanning Technology:

High-Resolution Imaging: CT scanners provide high-resolution 3D imaging that captures every detail of a component, including minute internal features like microporosity and lattice structures. This level of detail is essential for creating accurate digital models used in FEA, ensuring that simulations reflect the real-world behavior of the components.

Non-Destructive Testing: One of the key advantages of industrial CT technology is its non-destructive nature. Components can be scanned without altering or damaging them. This allows for repeat analysis and validation without compromising the part's integrity, which is particularly valuable for quality control and failure analysis in critical industries such as aerospace and automotive.

Versatility and Flexibility: The Zeiss Metrotom series is an example of versatile technology that can accommodate components of various sizes and complexities. Whether dealing with small, intricate parts or larger assemblies, these scanners consistently deliver high-quality results that form the foundation of FEA processes.

VGStudio MAX Software:

Advanced Material Analysis: VGStudio MAX can perform detailed material analysis directly on the CT scan data. It can assess material properties, detect defects, and analyze the impact of these factors on the component’s performance. The software’s ability to simulate stress concentration around micro defects is particularly valuable for ensuring the smallest imperfections are accounted for in FEA models.

Precision in Complex Structures: The software excels in handling highly complex structures, such as foams, lattice structures, and components with microporosity. VGStudio MAX can build simulation models without needing a geometry-conforming mesh, streamlining the process while maintaining accuracy. This capability is crucial for industries where components often feature intricate internal geometries that standard software might struggle to handle.

Comparison with CAD Models: VGStudio MAX enables direct comparison between the actual scanned part and its CAD model. This feature is essential for identifying deviations and discontinuities, allowing adjustments to simulations accordingly. By comparing the two models, it can detect areas where stress concentrations might occur due to manufacturing deviations, leading to more robust and reliable designs.

Stress and Displacement Analysis: The software provides sophisticated tools for stress and displacement analysis, allowing visualization of local maxima of Von Mises stress, maximum shear stress, and principal stresses. It can also identify connected areas where these stress components exceed specific thresholds, providing critical insights into potential failure points.

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What to Look for in Advanced FEA Services?

Advanced Tools and Technology: Seek service providers offering precise and data-driven Finite Element Analysis (FEA) services. Expertise is rooted in combining advanced technology, like industrial CT scanners and VGStudio MAX software, with a rigorous approach to delivering comprehensive data.

High-Performance Computing (HPC): To handle the computational demands of advanced FEA, they must utilize high-performance computing systems. These systems process large datasets quickly and efficiently, delivering results faster without compromising accuracy. Whether running simulations of complex assemblies or analyzing the effects of multiple variables, HPC infrastructure ensures they can meet the most demanding requirements.

Expertise and Experience: Look for seasoned engineers who have honed their skills across various industries. From aerospace to automotive, they should understand unique challenges each sector faces and tailor FEA services to meet those specific needs. Extensive experience means they can tackle the most complex engineering problems, delivering solutions that drive success.

Customized Solutions: Your project is unique. The service provider should take a tailored approach to FEA, working closely with you to understand your specific challenges and objectives. Whether you’re looking to optimize a new design, validate a prototype, or investigate a failure, they can provide customized solutions that address your needs. They should also offer flexible engagement models, allowing you to access their expertise as needed, from one-time projects to long-term partnerships.

Quality and Reliability: Your analysis should be conducted with the highest level of accuracy, backed by rigorous quality control processes. Accreditation to ISO 17025 is important. It will give you confidence that the results are reliable and traceable.

Client-Centric Approach: A client-centric approach means they are willing to work collaboratively throughout the entire process, from initial consultation to final delivery. They should be committed to understanding your goals, providing clear communication, and delivering results that exceed your expectations. Your success should be their priority.

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That’s a Wrap!

Finite Element Analysis (FEA) is an invaluable tool for engineers across various industries. Whether you're looking to optimize a design, validate a prototype, or solve a complex engineering challenge, FEA can help. Contact us today to learn more about FEA services and how they can benefit your projects.