How do you perform finite element analysis (FEA) in CAD?

Short Answer:

Finite Element Analysis (FEA) in CAD is done by breaking a 3D model into small parts called elements and then checking how it reacts to forces, pressure, heat, or other physical conditions. CAD software with FEA tools allows engineers to simulate real-world conditions before making the part.

To perform FEA, you import or create a CAD model, apply material properties, add loads and boundary conditions, then mesh the model into elements and run the simulation. This helps predict stress, deformation, and safety of the design without making a physical prototype.

Detailed Explanation:

Performing finite element analysis in CAD

Finite Element Analysis (FEA) is a powerful simulation technique used in CAD to evaluate how a design will perform under different physical conditions. It helps engineers analyze stress, strain, displacement, temperature, and other results before manufacturing the part. By using FEA in CAD software, you can save time, reduce cost, and improve product reliability.

FEA works by dividing a solid model into a mesh of small elements. Then, mathematical equations are solved for each element to predict the behavior of the entire model under the given conditions.

Steps to perform FEA in CAD

Most CAD software like SolidWorks, Fusion 360, ANSYS, CATIA, or Autodesk Inventor have built-in FEA tools or support FEA through plugins. The steps below describe the general process:

  1. Prepare the CAD model
  • Start with a complete and clean 3D model of the part or assembly.
  • Remove unnecessary details (like small holes or fillets) that do not affect the analysis.
  • Ensure the model is watertight (no open edges) for correct meshing.
  1. Assign material properties
  • Select the material from the library or define a custom material.
  • The software needs properties like:
    • Young’s Modulus
    • Poisson’s Ratio
    • Density
    • Yield Strength
    • Thermal Conductivity (for thermal analysis)
  1. Apply boundary conditions
  • Fix certain areas of the model using fixtures or constraints (e.g., fixed supports, rollers).
  • Define loads, such as:
    • Force
    • Pressure
    • Torque
    • Gravity
    • Temperature
  • Boundary conditions tell the software how the part is held and how loads are applied.
  1. Generate the mesh
  • The software divides the model into many small finite elements (usually triangles or tetrahedrons).
  • This process is called meshing.
  • A finer mesh gives more accurate results but takes more computing time.
  • Mesh quality affects simulation reliability, so check for distorted or overly large elements.
  1. Run the simulation
  • After meshing and applying all settings, run the FEA solver.
  • The solver calculates results based on the physical and mathematical model.
  • Results may take seconds to hours depending on model size and complexity.
  1. Analyze the results
  • The software shows results using color-coded plots.
  • Key results include:
    • Von Mises stress
    • Displacement
    • Factor of safety (FOS)
    • Strain distribution
  • Use graphs, probes, and animations to better understand the results.
  1. Modify the design if needed
  • If the stress exceeds the material’s strength or the displacement is too high, change the design.
  • You can:
    • Increase thickness
    • Change shape
    • Use a stronger material
    • Add fillets or ribs for support
  • Re-run the simulation after changes to check improvements.

Benefits of using FEA in CAD

  • Reduces physical prototyping
    Saves time and cost by testing virtually.
  • Improves safety and reliability
    Ensures the part will not fail under real conditions.
  • Enhances design quality
    Allows optimization of weight, shape, and material.
  • Increases design confidence
    Helps engineers make informed decisions.
  • Supports innovation
    You can test bold ideas without the risk of failure.
Conclusion:

Performing Finite Element Analysis (FEA) in CAD involves preparing a clean model, assigning materials, applying loads and supports, meshing the geometry, and analyzing simulation results. This process helps engineers predict how a part will behave under real-world conditions. FEA is a vital tool for improving product performance, ensuring safety, and reducing design errors before manufacturing begins.