Creating design models is a core part of the product development process and the first step in the simulation process. These models can be geometric forms representing actual design details, or simplified versions that retain the essential details required by the finite element analysis software. Besides being an essential component of finite element analysis – or computer simulation – 3D modeling geometry also links engineering simulation with design and manufacturing and thereby plays a critical role in Simulation Driven Product Development. Using the same file for design through manufacturing greatly reduces the likelihood of errors creeping into the product.
With electronic models, Gerber files and conductive trace files can be used to help build the analysis model. Conductive trace models are useful in estimating conductivity for the circuit card.
Finite element analysis is particularly useful for analyzing products that would take considerable time and expense to construct a prototype. The CAD model of the part or assembly can be subjected to a virtual “test” for heat transfer properties, thermal stress, impact behavior, power dissipation, aerodynamic loads, dynamic characteristics, etc. Virtually any physical condition that the product will experience in actual application can be simulated. For example, all new aircraft designs are first extensively computer modeled prior to building factory tooling or constructing a prototype. All or part of the aircraft CAD model is then subjected to FEA analysis. Complex models for sure, but much, much cheaper to do it this way than by relying on the older methods that relied on 2-dimmensional drawings, manual calculations and wind tunnel tests alone.
Norman T. Neher, P.E.
Analytical Engineering Services, Inc.
Elko New Market, MN
www.aesmn.org