"8 Ways to Lose Money with Finite Element Analysis"

Engineering designers and company owners are hearing about the tremendous benefits of connecting Design and Product Testing through Finite Element Analysis (FEA). However, they frequently relegate computer simulation to the bottom of the To-Do list as something they will "worry about later." The School of Hard Knocks then delivers painful lessons, resulting in extensive investment loss.

The following list of critical mistakes will do as much to help dispel any false expectations you might have, as it will to help make your computer simulations cost effective.

1. Replacing product testing with FEA

An analyst needs to both calibrate AND verify the computer simulation against real-world experiments. The combination of simulation and physical testing returns the most bang for your buck and validates confidence in your computational predictions.

2. Buying the wrong software

Carefully consider all of your present and future simulation problems. Focus on the hard ones (nonlinear, implicit, etc.) Each software package best solves a particular class of nontrivial problems.

3. Tasking B.S.M.E. new hires with complex analysis jobs

Finite Element Analysis uses advanced computer software to solve discrete approximations of the weak solutions of nonlinear PDEs. A good user has an advanced understanding of the mechanics and composition of materials, mathematics, physics, and computer science.

4. Not paying enough attention to material properties

As an example, you can save solution time by modifying the material properties of an aircraft wing skin rather than modeling every underlying stringer. But, how DO you modify those properties? Only long experience simulating such problems can answer this question.

5. Using the wrong element type

In one program, you can choose from 16 different types of shell elements alone. Do you know which one best represents the physics of your problem? Simulation results WILL vary.

6. Having too much faith in the results of one simulation

Just because the program gives you 'an' answer does not mean it is 'the' answer. Confidence comes from methodically modifying the inputs, re-running the simulation, and comparing multiple results.

7. Failing to use accepted V&V procedures

Modern Verification and Validation standards are the primary means of assessing accuracy in computational simulations. If an inaccurate simulation can result in loss of life or other serious consequence, you need to be implementing the latest V&V procedures.

8. Underestimating the investment cost

Commercial FEA packages are expensive with non-trivial annual maintenance costs. The best pre- and post- processing software does NOT come bundled with these products. The hardware to run these codes wants lots of RAM, the fastest processors, and plenty of disk space. In addition, it is going to take time, months, for your new analyst to become familiar with new simulation tools.

This represents just a summary of some of the mistakes that people make when using computer simulations to predict behavior.

With consequences ranging from losing the money you invested to a loss of life lawsuit when your product fails, take the time to educate yourself on the proper methods of computer simulation. One good alternative is to develop a personal relationship with an independent consultant who can review or establish your simulation program and ensure your financial success.