RENSSELAER POLYTECHNIC INSTITUTE Application of the Finite Element Method to Deflection in a Cantilever Beam MANE 4240 – Introduction to Finite Elements José DeFaria 5/14/2015 DeFaria 2 Abstract A cantilever beam was modeled as a 1D, 2D, and 3D model in Abaqus using various element types to determine its deflection. A mesh refinement study was conducted and the results compared to the exact values to compare and contrast the accuracy of the various element types. Overall, it was determined that quadratic elements are more accurate than linear elements, and traditional integration elements are more accurate than reduced integration elements. Despite these generalized findings, the most accurate element type at convergence was a linear, reduced integration element in 2D. DeFaria 3 Table of Contents Abstract ..................................................................................................................................................... 2 Table of Contents ...................................................................................................................................... 3 Introduction .............................................................................................................................................. 4 Finite Element Theory -- The Importance of Basis Functions .................................................................. 5 Abaqus Element Types .............................................................................................................................. 6 Model Construction .................................................................................................................................. 7 1D .......................................................................................................................................................... 7 2D .......................................................................................................................................................... 7 3D .......................................................................................................................................................... 8 Results ....................................................................................................................................................... 9 1D .......................................................................................................................................................... 9 2D ........................................................................................................................................................ 10 3D ........................................................................................................................................................ 11 1D, 2D, 3D Comparison ....................................................................................................................... 12 Conclusion ............................................................................................................................................... 13 References .............................................................................................................................................. 14 Appendix – Result Tables ........................................................................................................................ 15 1D ........................................................................................................................................................ 15 2D ........................................................................................................................................................ 15 3D ........................................................................................................................................................ 16 DeFaria 4 Introduction Finite element analysis is a method of numerical analysis to approximate solutions to problems which would be difficult to obtain using traditional analysis methods. Although variational calculus has existed for centuries, the concept of using finite elements to solve difficult problems has taken new meaning in the era of computers. As computational strength increases, the effective cost of finite element analysis decreases. This has increased the adoption of finite element analysis throughout industry as a method to determine acceptability of a design. Although finite element analysis is widely used, one must remember it is a method of approximation. Different methods and inputs will affect the accuracy of the approximation. This study will examine one of the classic problems in engineering: the cantilever beam. The cantilever beam is a well-defined problem with specific formulas to determine its deflection based on the length and section of the beam and the magnitude and location of the load. Because the cantilever beam is well-defined, the exact value of its deflection can be determined and compared to the analysis results. Analysis will be conducted on a 1D, 2D, and 3D model of the cantilever beam, using different mesh sizes and element types to determine the relationship between element type/geometry and accuracy. In a cantilever beam with a concentrated load at the free end, the maximum deflection occurs at the free end. The maximum deflection is found by: πΏ= ππ 3 3πΈπΌ For the purposes of this study, a cantilever beam 12 inches in length, 2 inches wide, and 1 inch tall (I=0.166667 in4), will be considered to be constructed of steel (E=30,000,000 psi, v=0.3). A load of 500 lbs will be applied to the free end. Using these values, the exact solution of the maximum deflection is: πΏ= (500 πππ )(12 ππ)3 ππ 3 = = 0.0576 ππ 3πΈπΌ 3(30,000,000 ππ π)(0.166667 ππ4 ) DeFaria 5 Finite Element Theory -- The Importance of Basis Functions The success of finite element analysis depends heavily on the selection of a test function. This test function is determined by the collection of the finite element basis functions. This study uses two different orders of elements: first-order elements (P1 or linear) and second-order elements (P2 or quadratic). The graphs of sample linear and quadratic basis functions are presented below for an interval divided into two elements. Linear Basis Function Quadratic Basis Function In the linear example above, the interval is divided into two elements. Each element has one node at each end for a total of three nodes. Each node has its own basis functions, which are assembled into the global basis function for each element. The global basis functions for both elements are plotted above. In the quadratic basis function above, the interval is also divided into two elements, but each element has a node in the center of the element in addition to the nodes at each end. This results in a total of five nodes. Each node has its own basis functions, which are assembled into the global basis function for each element. The global basis functions for both elements are plotted above. The quadratic basis functions are much more detailed since they are of second-order and they introduce additional nodes; therefore, quadratic elements are expected to be more accurate than linear elements. DeFaria 6 Abaqus Element Types Although it is unknown what particular test functions the Abaqus software uses, the concepts presented above are the same. Elements can be linear or quadratic. Quadratic elements introduce additional nodes compared to linear elements. This can be observed for 1D, 2D, and 3D elements below. Linear 1D 2 nodes 2D 4 nodes 3D 8 nodes Quadratic 3 nodes 8 nodes 20 nodes In addition to the element types above, Abaqus also offers a “reduced integration” option which is on by default in 2D and 3D analysis. When this method is off, the software uses Simpson’s rule, a method of numerical analysis of definite integrals where the interval is broken into fixed intervals for evaluation. When the reduced integration option is turned on, a different method called Gaussian Quadrature is used. This does not use fixed intervals and can often reach the same approximation as Simpson’s rule with less coordinates and therefore is less computationally expensive. This reduced integration method can be prone to “hourglassing” in certain applications. Geometry Element Type 1D B21 B22 S4 S4R S8R C3D8 C3D8R C3D20 C3D20R 2D 3D Order Linear Quadratic Linear Linear Quadratic Linear Linear Quadratic Quadratic Description # of Nodes 2 3 4 4 8 8 8 20 20 Integration Reduced Reduced Reduced Reduced DeFaria 7 Model Construction 1D The 1D model was created by creating a wire part twelve inches long. The steel material properties were defined in the property module and the cross-section was defined in the create profile tab. In the load module, the left end of the beam was considered fixed (encastre) and a 500 pound load was placed on the right end. The beam was meshed with an increasing number of elements. For B21 elements (linear), the number of elements was increased from 1 through 20 and the deflection in the y-direction was recorded using each mesh. For B22 elements (quadratic) the number of elements was increased from 1 through 10. At that point, it was determined the results had already converged, and the mesh refinement was terminated. It should be noted that Abaqus automatically added additional nodes to the 1D model. This was not observed with the 2D or 3D models. 2D The 2D model was created by creating a planar shell twelve inches long and 2 inches wide. The steel material properties were defined in the property module and the thickness of 1 inch was applied in the section properties. In the load module, the left end of the beam was considered fixed (encastre) and a 500 pound load was placed at the center of the beam on the right end. The beam was meshed with quadrilateral elements. For S4, S4R, and S8R elements, the mesh was created by creating a single lengthwise element. The model was solved and the deflection in the y-direction was recorded. The mesh was then refined by doubling the number of elements and the new deflection was recorded. This process was repeated up to 1024 lengthwise elements. Some hourglassing was observed with 1028 S8R elements DeFaria 8 3D The 3D model was created by creating a solid extrusion twelve inches long, 2 inches wide, and 1 inch deep. The steel material properties were defined in the property module. In the load module, the left face of the beam was considered fixed (encastre) and a 500 pound load was placed in the center of the right face. The beam was meshed with hexahedral elements. For C3D8, C3D8R, C3D20, and C3D20R elements, the mesh was created by creating a single lengthwise element. The model was solves and the deflection in the y-direction was recorded. The mesh was then refined by doubling the number of elements and the new deflection was recorded. This process was repeated up to 512 lengthwise elements. Some hourglassing was observed at 512 reduced integration elements. DeFaria 9 Results The recorded deflections were noted in Microsoft Excel, and graphed as a function of the number of lengthwise elements. In each case below, the horizontal axis is logarithmic. 1D 1D Mesh Refinement Exact B21 B22 0.0585 0.058 0.0575 Deflection (inches) 0.057 0.0565 0.056 0.0555 0.055 0.0545 0.054 1 2 4 8 16 Number of (Lengthwise) Elements As shown in the graph above, both the linear (B21) and quadratic (B22) elements converged to a value which was within 0.5% of the actual value. Although better accuracy was noted with some of the other models presented later, this accuracy is impressive considering the minimal resources necessary to evaluate a simple one-dimensional system. The graph above also highlights the accuracy difference between linear and quadratic elements. Using only a single quadratic element, the model was within 0.5% of the exact value, whereas using a single linear element the displacement was within 5.5% of the exact value. This is an order of magnitude in precision. DeFaria 10 2D 2D Mesh Refinement Actual S4 S4R S8R 0.06 Deflection (inches) 0.055 0.05 0.045 0.04 1 2 4 8 16 32 64 128 256 512 1024 Number of (Lengthwise) Elements Similar to what was observed in the 1D case, the quadratic elements (S8R) were far more accurate at the beginning than the linear elements (S4, S4R). With a single quadratic element, the deflection was found to be within 1.5% of the actual value, while a single linear element was only within 25% of the actual value. As the number of S8R elements increased, the accuracy increased, until approximately 512 elements, when minor hourglassing was observed. It should be noted there is no option for a quadratic element without reduced integration to compare these values with. The linear elements can be used to compare the results of reduced integration. The reduced integration elements (S4R) were more accurate than the traditional elements (S4) throughout all of the evaluated meshes. Using 1024 elements, the traditional elements resulted in a deflection that was within 0.14% of the actual value, and the reduced integration elements resulted in a deflection that was within 0.06% the actual value. The reduced integration elements (S4R) resulted in the highest accuracy of all element types evaluated in this study. DeFaria 11 3D 3D Mesh Refinement Actual C3D8 C3D8R C3D20 C3D20R 0.09 0.08 0.07 Deflection (inches) 0.06 0.05 0.04 0.03 0.02 0.01 0 1 2 4 8 16 32 64 128 256 512 Number of (Lengthwise) Elements The three-dimensional model provided the only opportunity to compare both linear and quadratic elements with both reduced and traditional integration. The reduced integration elements were both more accurate than the traditional elements initially. The linear reduced integration element (C3D8R) was within 0.1% of the actual value, while the quadratic integration element (C3D20R) was within about 4%. These accuracies are much better than the traditional linear element (C3D8, 98%) and the traditional quadratic (C3D20, 26%). As the mesh was refined the C3D20R element became more accurate, until 512 elements were used and minor hourglassing was experienced; however, the C3D8R elements continued to become more inaccurate, and never truly converged compared to the other element types. In comparison between linear and quadratic elements, the quadratic elements were much more accurate. The values that the quadratic elements converged upon were within 0.5% and 1.5% of the actual value. In this case, the traditional quadratic element was more accurate than the reduced integration element due to the hourglassing discussed above. DeFaria 12 1D, 2D, 3D Comparison Linear Element Comparison by Geometry Actual B21 S4 C3D8 0.07 0.06 Deflection (inches) 0.05 0.04 0.03 0.02 0.01 0 1 2 4 8 16 32 64 128 256 512 1024 Number of (Lengthwise) Elements The graph above compares traditional linear elements in each of the three geometries. Minor differences in how the software interprets boundary conditions in loads in 1D/2D/3D may affect the convergence value. However, the left-hand side of the graph, depicting the low-element count results paints a clear picture: reducing the degrees of freedom increases the accuracy of the analysis. With only a single element, the 1D, 2D, and 3D models were within 0.5%, 26%, and 98% of the actual value, respectively. Mesh refinement greatly reduces these gaps, but a simpler model is solved more accurately by the software. DeFaria 13 Conclusion This study evaluated a cantilever beam as a 1D, 2D, and 3D model and compared linear and quadratic elements in all three model spaces, as well as reduced integration elements with traditional elements. The table below lists all the element types evaluated and presents the final variance from the actual value at the maximum number of elements (20 for 1D, 1028 for 2D, 512 for 3D). Geometry 1D 2D 3D Element Type B21 B22 S4 S4R S8R C3D8 C3D8R C3D20 C3D20R Order Linear Quadratic Linear Linear Quadratic Linear Linear Quadratic Quadratic Description # of Integration Nodes 2 3 4 4 Reduced 8 Reduced 8 8 Reduced 20 20 Reduced Variance from Actual Value at Max # of Elements + 00.5163 % + 00.5311 % - 00.1358 % + 00.0623 % + 00.9789 % + 07.7670 % + 44.3150 % - 00.4698 % + 01.6653 % In respect to model geometry, generally speaking, reducing the number of nodes and degrees of freedom also reduces the computational cost and increases the accuracy of the model. In practical applications, engineers should simplify models if possible to generate and accurate, reliable, and costeffective solution. In respect to linear versus quadratic elements, quadratic elements are nearly always more accurate which agrees with the theory. Quadratic elements were more accurate in both 3D cases, and the values were nearly identical in the 1D case. In the 2D case the linear element was more accurate than the quadratic, but this is due to minor hourglassing due to the use of reduced integration elements. A quadratic element without reduced integration is not an option in Abaqus for 2D models. In respect to reduced integration elements, they are always more accurate than traditional elements when a low number of elements is used; however, as the mesh is refined, they are nearly always less accurate. This failure with a high number of elements is due to hourglassing. Use of reduced integration elements is likely acceptable when a quick evaluation is needed, or for preliminary runs of the model to determine baseline acceptance. When a higher degree of accuracy is required, reduced integration elements should not be selected. This study also highlighted the importance of mesh refinement. Without mesh refinement, an engineer is simply accepting any random point along the line as the answer. However, in some situations, the answer received with a course mesh is significantly different than that with a fine mesh. The S4R element was the most accurate overall, but with using only 1 S4R element, the result was within 24% of the actual value. Refining the mesh to ensure the values are heading towards convergence is an important step in developing confidence in the results of finite element analysis. DeFaria 14 References American Forest & Paper Association. (2007). Beam Design Formulas with Shear and Moment Diagrams. National Design Specification for Wood Construction. Washington, DC: American Wood Council. American Institute of Steel Construction. (2005). Steel Construction Manual. American Institute of Steel Construction. Dassault Systemes Simulia Corp. (2013). Abaqus/CAE User's Guide. Abaqus 6.13. Providence, Rhode Island. Dunn, D. J. (n.d.). Mechanics of Solids - Beams Tutorial 3, The Deflection of Beams. Retrieved May 02, 2015, from FreeStudy: http://www.freestudy.co.uk/statics/beams/beam%20tut3.pdf Gutierrez-Miravete, E. (2015, May 11). Index. Retrieved May 13, 2015, from Introduction to Finite Elements: http://www.ewp.rpi.edu/hartford/~ernesto/S2015/IFEM/ The Welding Institute. (2015). FAQ: What is reduced integration in the context of finite element analysis? Retrieved April 30, 2015, from The Welding Institute: http://www.twi-global.com/technicalknowledge/faqs/structural-integrity-faqs/faq-what-is-reduced-integration-in-the-context-offinite-element-analysis/ Timoshenko, S., & Goodier, J. N. (1951). Chapter 3, Two-Dimensional Problems in Rectangular Coordinates. In Theory of Elasticity (pp. 29-44). McGraw-Hill Book Company. DeFaria 15 Appendix – Result Tables 1D # of Elements 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 B21 Deflection (in) 0.05451765 0.05705882 0.05752941 0.05769412 0.05777035 0.05781176 0.05783673 0.05785294 0.05786405 0.05787200 0.05787788 0.05788235 0.05788583 0.05788860 0.05789082 0.05789265 0.05789416 0.05789543 0.05789649 0.05789741 % of actual 94.6487% 99.0605% 99.8774% 100.1634% 100.2957% 100.3676% 100.4110% 100.4391% 100.4584% 100.4722% 100.4824% 100.4902% 100.4962% 100.5010% 100.5049% 100.5081% 100.5107% 100.5129% 100.5147% 100.5163% B22 Deflection (in) 0.05790616 0.05790595 0.05790591 0.05790590 0.05790589 0.05790589 0.05790589 0.05790589 0.05790589 0.05790589 0.05790589 0.05790589 0.05790589 0.05790589 0.05790589 0.05790589 0.05790589 0.05790589 0.05790589 0.05790589 % of actual 100.5315% 100.5312% 100.5311% 100.5311% 100.5311% 100.5311% 100.5311% 100.5311% 100.5311% 100.5311% 100.5311% 100.5311% 100.5311% 100.5311% 100.5311% 100.5311% 100.5311% 100.5311% 100.5311% 100.5311% 2D # of Elements 1 2 4 8 16 32 64 128 256 512 1024 S4 Deflection (in) % of actual 0.04257879 73.9215% 0.05227075 90.7478% 0.05585212 96.9655% 0.05699317 98.9465% 0.05736917 99.5993% 0.05743067 99.7060% 0.05751153 99.8464% 0.05751923 99.8598% 0.05752116 99.8631% 0.05752165 99.8640% 0.05752177 99.8642% S4R Deflection (in) 0.04358575 0.05369245 0.05652184 0.05729374 0.05753655 0.05748225 0.05762911 0.05763422 0.05763550 0.05763583 0.05763590 % of actual 75.6697% 93.2161% 98.1282% 99.4683% 99.8898% 99.7956% 100.0505% 100.0594% 100.0616% 100.0622% 100.0623% S8R Deflection (in) % of actual 0.05678657 98.5878% 0.05705557 99.0548% 0.05729967 99.4786% 0.05739415 99.6426% 0.05743768 99.7182% 0.05747188 99.7776% 0.05751752 99.8568% 0.05757328 99.9536% 0.05766518 100.1132% 0.05783490 100.4078% 0.05816386 100.9789% DeFaria 16 3D # of Elements 1 2 4 8 16 24 32 64 128 256 512 C3D8 Deflection (in) 0.00103100 0.00391180 0.01312751 0.03206815 0.05026453 0.05619560 0.05862415 0.06118198 0.06185892 0.06203071 0.06207382 % of actual 1.7899% 6.7913% 22.7908% 55.6739% 87.2648% 97.5618% 101.7780% 106.2187% 107.3940% 107.6922% 107.7670% C3D8R Deflection (in) % of actual 0.05748955 99.8082% 0.07096117 123.1965% 0.07508980 130.3642% 0.07627323 132.4188% 0.07682697 133.3802% 0.07713806 133.9202% 0.07740237 134.3791% 0.07835814 136.0384% 0.08021381 139.2601% 0.08398886 145.8140% 0.08312544 144.3150% # of Elements 1 2 4 8 16 24 32 64 128 256 512 C3D20 Deflection (in) % of actual 0.04245245 73.7022% 0.05230047 90.7994% 0.05560777 96.5413% 0.05666790 98.3818% 0.05705437 99.0527% 0.05716575 99.2461% 0.05721729 99.3356% 0.05728694 99.4565% 0.05731603 99.5070% 0.05732640 99.5250% 0.05732942 99.5302% C3D20R Deflection (in) % of actual 0.05521088 95.8522% 0.05609409 97.3856% 0.05670690 98.4495% 0.05700196 98.9617% 0.05718949 99.2873% 0.05727248 99.4314% 0.05732628 99.5248% 0.05746246 99.7612% 0.05764943 100.0858% 0.05796485 100.6334% 0.05855921 101.6653%