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  • 8/19/2019 Choose the Best Element Size to Yield Ac

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    British J ournal of Engineering and T echnology

    ISSN: 2326 – 425X URL: http://www.bjet.baar.org.uk

    Vol. 1, No. 7, pp 13-28, MAY 2013

     

    CHOOSE THE BEST ELEMENT SIZE TO YIELD  ACCURATE FEA RESULTS

    WHILE REDUCE FE MODEL’S COMPLEXITY

    Yucheng Liu, PhD, PE

     Assistant Professor and Graduate Coordinator

    Department of Mechanical EngineeringUniversity of Louisiana at Lafayette

    Lafayette, LA 70504, USA

    ABSTRACT

    n finite element models, element size is a critical

    issue which closely relates to the accuracy of the finite element models while directly determines

    their complexity level. Thus, a primary problem in creating finite element model is to choose appropriate element size

    which can yield correct simulation results while reduces

    the model’s complexity as much as possible. This paper presents a systematic study on finding the effects of finiteelement size on the accuracy of numerical analysis results,

    based on which brief guidelines of choosing the bestelement size in finite element modeling are provided. Static,

    modal, and impact analysis are involved in this study todiscuss the effects of element size in numerical analysis.

     Keywords:  Element size, mesh density, static analysis,

    impact analysis, modal analysis

    I

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    British J ournal of Engineering and T echnology

    ISSN: 2326 – 425X URL: http://www.bjet.baar.org.uk

    Vol. 1, No. 7, pp 13-28, MAY 2013

     

    1.  Introduction

    In finite element analysis (FEA), the accuracy of the FEA results and requested computing time are

    determined by the finite element size (mesh density). According to FEA theory, the FE models with fine

    mesh (small element size) yield to highly accurate results but may take longer computing time. On the

    contrary, those FE models with coarse mesh (large element size) may lead to less accurate results but do

    save more computing time. Also, small element size will increase the FE model’s complexity which is only

    used when high accuracy is required. Large element size, however, will reduce the FE model’s size and is

    extensively used in simplified models in order for providing a quick and rough estimation of designs. Due to

    its importance, in generating FEA models, the foremost problem is to choose appropriate elements size so

    that the created models will yield accurate FEA results while save as much computing time as possible. The

    objective of this paper is to present guidelines for choosing optimal element size for different types of finite

    element analyses. In order to achieve that goal, in this study, a series of static, modal, and impact analyses

    were performed on thin-walled beam and plate models to reveal the effects of the element size on the

    accuracy of the FEA results. An explicit solver, LS-DYNA, was used for modeling and analyses involved in

    this work [1]. The paper is organized as follows: section 2 provides the background for this study, which briefly reviewed previous related literature; section 3 explains the theoretical fundamentals of the applied

    finite element; sections 4 to 6 discuss the effects of element size on the accuracy of static analysis, impact

    analysis, and modal analysis, respectively; section 7 concludes the whole paper with guidelines of choosing

    the best mesh density for different type of FEA presented.

    2.  Background

    A number of investigators have studied the effects of elements size on the accuracy of numerical results of

    different types of analysis and important conclusions have been drawn from previous research. Brocca and

    Bazant [2] presented a finite element study of the size effect of compressive failure of geometrically similar

    concrete columns of different sizes. It was observed from their analyses that the increasing elements size

    caused reduction in nominal strength. However, a quantitative analysis showing the relationship between the

    elements size and the nominal strength was still needed. Ashford and Sitar [3] evaluated the accuracy of the

    computed stress distribution near the free surface of vertical slopes as a function of the element size. A

     parametric study was carried out comparing stresses computed using FEA to those obtained from a physical

    model composed of photoelastic material. It was found that for a slope height H, an element height of H/10

    is adequate for the study of stresses deep within the slope. However, for cases where tensile stresses in the in

    the vicinity of the slope face which are critical, element heights as small as H/32 are necessary. Saouma et

    al. [4] discussed size effect in nonlinear finite element analysis with a metal-reinforced ceramics composite

    material. In their study, a size effect investigation was numerically performed and the range of crack sizes

    was presented, for which linear elastic fracture mechanics, nonlinear fracture mechanics or plasticity-basedmodels were applicable. Masakazu [5] conducted a numerical analysis of the size effect on the shear

    strength of reinforced concrete (RC) beams through tow-dimensional nonlinear FEA, which was applied to

    the simulation of RC members in flexure and shear failure. Three RC beam models with different sizes were

    analyzed and the size effects on strain of reinforcement, strain of concrete, descriptive mode, and crack

    situation were observed from the simulation and discussed. Perillo-Marcone et al. [6] assessed the effect of

    mesh density on material property discretization and the resulting influence on the predicted stress

    distribution through analyzing a three-dimensional, quantitative computed tomography based FE model of a

     proximal implanted tibia. Significant variations were observed in the modulus distributions between the

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    British J ournal of Engineering and T echnology

    ISSN: 2326 – 425X URL: http://www.bjet.baar.org.uk

    Vol. 1, No. 7, pp 13-28, MAY 2013

     

    coarsest and finest mesh densities. Poor convergence of the material property distribution occurred when the

    element size was significantly larger than the pixel size of the source computerized tomography (CT) data.

    From those results, they found an optimal element size of 1.4 mm on the contact surfaces which was enough

    to properly describe the stiffness, stress and risk ratio distributions within the bone for that particular case.

    Zmudzki et al. [7] discussed the influence of mesh density on the results of FE model analysis of mechanical biocompatibility of dental implants. It was found that the increasing of mesh density leads to an

    overestimation of loading stresses values and furthermore to an unjustified increase of pillar’s diameter. At

    the other hand, too large elements might lead through an underestimation of loading stress level, to

    overloading atrophy of bone tissue or to implant loss. From that work it can be found that a guideline of

    choosing appropriate element size for certain finite element analysis is highly demanded. Roth and Oudry

    [8] touched the influence of element size on the accuracy of dynamic analysis results and they mentioned

    that for dynamic analysis, the minimum number of element required for correct simulation is according to

    the loading case and material properties. Li et al. [9] investigated the sensitivity of the structural responses

    and bone fractures of the ribs to mesh density in order to provide guidelines for the development of FE

    thorax models used in impact biomechanics. It was demonstrated in their research that rib FE models

    consisting of 2000-3000 trabecular hexahedral elements (weighted element length 2-3 mm) and associated

    quadrilateral cortical shell elements with variable thickness more closely predicted the rib structural

    responses and bone fracture force-failure displacement relationships observed in the experiments. Based on

    the previous work and achievements, a systematic investigation is conducted here to fully discuss the size

    effect on simulation accuracy of static, modal, and impact analysis for fundamental structural components

    such as plates and beams.

    3. 

    Finite Element Formulation

    All finite element models involved in this study were meshed with the full integration shell element: 4-node

    Belytschko-Tsay shell element with five integration points through the thickness. Such element is based on acombined co-rotational and velocity-strain formulation, among which the co-rotational portion of the

    formulation avoids the complexities of nonlinear mechanics by embedding a coordinate system in the

    element, and the choice of velocity-strain formulation facilitates the constitutive evaluation. In that element,

    the velocity of any point in the shell is determined as:

      3ˆe zvvm   (1)

    where vm

     is the velocity of the mid-surface, θ is the angular velocity vector, and  ẑ is the distance along the

    fiber direction (thickness) of the shell element.

    The velocity strain displacements need to be evaluated at the quadrature points within the element and

    standard bilinear nodal interpolation is used to define vm, θ, and the elements coordinates ( x̂ , ŷ , ẑ ). The

    velocity strains are found to be

     y x x x

     N  zv

     x

     N d     ̂

    ˆˆˆ

    ˆˆ

    ,  x y y

     y

     N  zv

     y

     N d     ̂

    ˆˆˆ

    ˆˆ

    ,

     

      

     

     x y y x xy x

     N 

     y

     N  zv

     x

     N v

     y

     N d       ˆ

    ˆˆ

    ˆˆˆ

    ˆˆ

    ˆˆ2  

     y z xy  N v x

     N d     ̂ˆ

    ˆˆ2  

    ,  x z yz  N v

     y

     N d     ̂ˆ

    ˆˆ2  

      (2)

    In Eqn. (2), N is the shape function of the element. Constitutive evaluations are then obtained by using the

     presented velocity-strain displacement relations.

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    ISSN: 2326 – 425X URL: http://www.bjet.baar.org.uk

    Vol. 1, No. 7, pp 13-28, MAY 2013

      

    4.  Static Analysis

    Static analyses were performed on a rectangular steel plate with the dimension 300 mm × 200 mm and a

    thickness of 3 mm. Material properties of the steel are listed in Table 1. During the analyses, one end of the

     plate was fully constrained and a 1 N·m moment was applied at the other end for a duration of 1 second. 10

    time steps were used to record the data so that 10 data points were collected during the analysis. A series of

    FE models were generated for that plate whose long side was meshed from 2 (coarsest mesh) to 160 (finest

    mesh) divisions (Fig. 1).  Von mises stress and bending deformation yielded from each model were

    calculated and compared to study the influence of element size on the static analysis results. Static analysis

    results and comparisons are listed in Table 2. In that table, it is assumed that the FE model with the finest

    mesh generated the most accurate results and percentage approximate errors were calculated by comparing

    other results to the most accurate ones. It also needs to be mentioned that the using of full integration

    Belytschko-Tsay shell element can effectively prevent the shear locking, which usually occurs in lower

    order elements when those elements are subjected to bending.

    Several observations were made by comparing those results. (1) The errors of bending deformation are farlower than the errors of von Mises stress. According to FEA theory, stresses are not predicted as accurately

    as the displacements because they are calculated from the displacements and it is assumed that the stresses

    are constant over the element. (2) The difference of von Mises stress generated from the model with 10

    elements along the long side of the plate and from the finest mesh model is less than 1%, which is

    acceptable in engineering simulation. However the computing time for the coarse mesh model is only 3 sec,

    which is less than 1/40 of the time cost by the finest mesh model. It can also be observed from Fig. 2 that

    when the number of elements on the long side is higher than 60, the increase of mesh density does not

    significantly improve the accuracy of von Mises stress any more. Such phenomenon was also observed in

    comparing other static analysis results. (3) Fig. 3 shows the stress distribution and Fig. 4 compares the

     bending deformation yielded from the coarsest mesh model (with 2 divisions) and the finest mesh model(with 160 divisions). From Fig. 4 it can be found that even the coarsest mesh model generated a bending

    deformation close to the finest mesh model (error = 0.22%), it failed to display a smooth and continuous

     bending mode because its less number of elements. An FE model with finer mesh is still needed to correctly

    simulate the bending behavior of the steel plate. Similar conclusion can be drawn from the Fig. 3. (4) It can

     be concluded that for static analysis, the FE model whose longest side is meshed by 10 elements can give us

    optimal combination of accuracy and efficiency.

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    Vol. 1, No. 7, pp 13-28, MAY 2013

      

    Table 1. Steel material properties

    Material Properties

    Young’s modulus 207GPa

    Density 7830kg/m3 

    Yield stress 200MPa

    Ultimate stress 448MPa

    Hardening modulus 630MPa

    Poisson’s ratio 0.3

    Table 2. Static analysis results and comparisons

    # of division von Mises stress % Bending deformation % Computing time

    2 6.290 MPa 5.08 0.6456 mm 0.22 3 sec

    5 6.370 MPa 3.88 0.6457 mm 0.23 3 sec

    10 6.580 MPa 0.76 0.6435 mm 0.11 3 sec

    20 6.570 MPa 0.85 0.6442 mm 0 3 sec

    30 6.607 MPa 0.30 0.6442 mm 0 3 sec

    40 6.613 MPa 0.21 0.6442 mm 0 4 sec

    50 6.607 MPa 0.30 0.6442 mm 0 6 sec

    60 6.620 MPa 0.11 0.6442 mm 0 7 sec

    70 6.621 MPa 0.09 0.6442 mm 0 9 sec

    80 6.616 MPa 0.16 0.6442 mm 0 13 sec

    90 6.624 MPa 0.05 0.6442 mm 0 18 sec

    100 6.624 MPa 0.04 0.6442 mm 0 26 sec

    120 6.626 MPa 0.01 0.6442 mm 0 40 sec

    140 6.623 MPa 0.06 0.6442 mm 0 66 sec

    160 6.627 MPa 0.6442 mm 124 sec

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    Vol. 1, No. 7, pp 13-28, MAY 2013

     

    (a) (b)Figure 1. FEA steel plate model (a) coarsest mesh (b) finest mesh

    Figure 2. Element size vs accuracy for maximum von Mises stress

    0.00

    1.00

    2.00

    3.00

    4.00

    5.00

    6.00

    0 20 40 60 80 100 120 140 160 180

       E   r   r   o   r    (   %    )

    # of Mesh Elements along Plate Length

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    Vol. 1, No. 7, pp 13-28, MAY 2013

     

    (a) (b)Figure 3. Stress distribution of (a) coarsest mesh model (b) finest mesh model

    (a) (b)Figure 4. Bending of (a) coarsest mesh model (b) finest mesh model

    5. 

    Impact Analysis

    After static analysis, impact analyses were carried out on a thin-walled steel beam with a square cross

    section, whose dimension is 120 mm × 120 mm and wall thickness is 3 mm. During the analyses, this beam

    impacted a rigid wall at 15 m/s and buckled. A series of FE models were generated for that beam whoseaxial direction was meshed from 2 (coarsest mesh) to 120 (finest mesh) divisions. The crash time was set as

    0.01 seconds. Impact force, absorbed energy, and global displacement were computed for each FE model

    and compared in Table 3, where the approximate error was calculated based on comparing each result to the

    results yielded from the finest-meshed beam model. Fig. 5 displays the crushed model with coarsest mesh (2

    divisions), medium mesh (60 divisions), and finest mesh (120 divisions). The effects of elements size on the

    accuracy of important impact analysis results are plotted through Figs. 6 to 8. It needs to be mentioned that

    hourglass modes (nonphysical, zero-energy modes of deformation that produce zero strain and no stress) did

    not occur in these impact analyses. This is because that our models are meshed using Belytschko-Tsay shell

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    element with five integration points through the thickness, while the hourglass modes occur only in under-

    integrated (single integration point) shell elements. A default algorithm provided by LS-DYNA was also

    selected to inhibit hourglass modes.

    After comparing the listed results, following declaration can be made. (1) The errors generated during the

    impact analyses were higher than those yielded from the static analyses. This is because that the impact

    analysis dose involve fast, transient loading and it much more complicated than the static analysis. (2)

    Similar to the static analysis, the finite element models predicted the displacement more accurate, which was

    due to the same reason. (3) In general, the errors in predicting the absorbed energy were far lower than those

    in estimating the impact force. A possible explanation is that the absorbed energy is related to the mass and

    instantaneous velocity of the beam models, while the impact force is related to their mass and instantaneous

    acceleration. There was no error in calculating the mass because different FE models faithfully represent the

    volume and density of the steel thin-walled beam model. However, the velocity is calculated as the first time

    derivative of the displacement and the acceleration is calculated as the first time derivative of the velocity,

    therefore, the errors generated in calculating the velocity are transferred to the step of calculating the

    acceleration. Due to this reason, it is understandable that the FE models predicted the absorbed energy moreaccurate than the impact force. (4) In predicting the impact force, the beam model has to be meshed into 80

    divisions longitudinally so that the approximate error would drop to below 10%, an accepted level in impact

    simulation [10]. However, to reach the same accurate level, the beam model only has to be meshed into 20

    divisions for predicting the absorbed energy and maximum displacement. (5) Similar to Fig. 4, it can be seen

    from Fig. 5 that in impact analysis, the FE model with fewer number of elements could not correctly reflect

    the real progressive buckling mode of the thin-walled steel beam. In other words, a certain number of finite

    elements are required to correctly simulate the crash behavior and response of engineering structures during

    the impact analysis. (6) In conclusion, in order to correctly simulate the crash process and predict important

    impact results while saving as much computing time, the thin-walled beam model has to be meshed into 80

    divisions along its axis. Table 3 also reveals that the optimal FE model with 80 divisions along its axis onlytook less than 1/10 of the computing time requested by the finest mesh model.

    Table 3. Impact analysis results and comparisons

    # of division Impact force % Absorbed energy % Displacement % Computing time

    2 90.88 kN 1577 41.48 kJ 119 48.65 mm 48.7 1 sec

    5 61.39 kN 1033 39.99 kJ 106 50.03 mm 47.3 1 sec

    10 19.02 kN 251 22.88 kJ 21.0 65.67 mm 30.8 1 sec

    20 10.09 kN 86.2 20.19 kJ 6.83 85.5 mm 9.88 2 sec

    30 9.32 kN 72.1 19.85 kJ 5.00 88.9 mm 6.32 5 sec

    40 9.46 kN 74.7 19.85 kJ 5.02 91.36 mm 3.70 9 sec

    50 9.65 kN 78.1 17.33 kJ 8.30 93.33 mm 1.62 14 sec60 9.82 kN 81.4 19.97 kJ 5.62 97.37 mm 2.63 21 sec

    70 8.85 kN 63.3 19.84 kJ 4.95 96.88 mm 2.11 68 sec

    80 5.26 kN 2.86 19.86 kJ 5.08 96.33 mm 1.53 111 sec

    90 5.31 kN 2.02 19.45 kJ 2.87 93.44 mm 1.51 198 sec

    100 5.35 kN 1.21 19.32 kJ 2.19 94.43 mm 0.47 357 sec

    120 5.42 kN 18.90 kJ 94.87 mm 1198 sec

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    (a) (b) (c)

    Figure 5. Deformed beam models with (a) coarsest mesh, (b) medium mesh, and (c) finest mesh

    Figure 6. Element size vs accuracy for maximum impact force

    0.00

    200.00

    400.00

    600.00

    800.00

    1000.00

    1200.00

    1400.00

    1600.00

    1800.00

    0 20 40 60 80 100 120 140

       E  r  r  o

      r   (   %   )

    # of Mesh Elements along Beam Model

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    Figure 7. Element size vs accuracy for maximum absorbed energy

    Figure 8. Element size vs accuracy for maximum displacement

    0.00

    20.00

    40.00

    60.00

    80.00

    100.00

    120.00

    140.00

    0 20 40 60 80 100 120 140

       E  r  r  o  r   (   %

       )

    # of Mesh Elements along Beam Model

    0.00

    10.00

    20.00

    30.00

    40.00

    50.00

    60.00

    0 20 40 60 80 100 120 140

       E

      r  r  o  r   (   %   )

    # of Mesh Elements along Beam Model

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    6.  Modal Analysis

    Finally, modal analyses were conducted on above plate and beam models to determine their natural

    frequencies and mode shapes during free vibration. It is common to use the FEA to perform this analysis and

    the influences of the element size on the modal analysis results are discussed here. In this study, only the

    lowest frequencies are listed and compared for each model because the lowest frequencies are related to the

    most prominent modes at which the model will vibrate, dominating all the other higher frequency modes. In

     performing the modal analysis, the steel plate was constrained on its short edge and the thin-walled steel

     beam was constrained at its end. Table 4 only lists the lowest natural frequency calculated for each finite

    element model. Fig. 9 plots the corresponding mode shapes of the coarsest meshed plate model and the

    finest meshed plate model. Fig. 10 displays the mode shapes of the coarsest and finest meshed thin-walled

     beam model.

    From the displayed results it can be seen that developed FEA models correctly predicted the lowest natural

    frequencies, with all the errors lower than 10%. The approximation error yielded from coarse models such as

    the thin-walled plate model with 5 divisions and the thin-walled box beam model with 10 divisions are below 1%. This is because the modal analysis results such as natural frequencies and mode shapes of a

    model during free vibration are only depend on the model’s mass and stiffness matrix. An FEA model can

    accurately predict its modal analysis results as long as it faithfully represents the model’s mass and stiffness.

    Fig. 9 displays mode shapes of thin-walled plate models with different numbers of meshes. It is found that

    the FEA models with different element size correctly plot the mode shape of the thin-walled plate and

     predict the deflection of that mode shape. Table 5 lists deflections of the mode shapes respect to the lowest

    natural frequency of several FEA models, which are very close to each other.

    However, from Fig. 10 it can be seen that even though FEA thin-walled box models with coarse mesh can

    correctly compute the natural frequency values, nevertheless, in order to closely simulate the mode shapes,

    more finite elements are still required. It also deserves to be mentioned that the computing times for the FEA

    models with different mesh density are not listed in Table 4. This is because the finite element modal

    analysis is very fast. To finish one modal analysis, the coarsest mesh models took 1 second, the thin-walled

     plate model with 140 divisions took 14 seconds and the thin-walled box beam model with 120 divisions took

    12 seconds. Therefore, in deciding the optimal element size for the modal analysis, the computing time is

    not an important issue.

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    Table 4. Modal analysis results and comparisons

    Thin-walled steel plate Thin-walled steel box beam

    # of division1

    st Natural

    frequencyDifference % # of division

    1st Natural

    frequencyDifference %

    2 27.0506 Hz 2.6351 2 19.4889 Hz 9.5836

    5 27.6131 Hz 0.6105 5 17.5380 Hz 1.3860

    10 27.7530 Hz 0.1069 10 17.9067 Hz 0.6871

    20 27.7715 Hz 0.0403 20 17.7746 Hz 0.0557

    30 27.7758 Hz 0.0248 30 17.7679 Hz 0.0933

    40 27.7767 Hz 0.0216 40 17.7726 Hz 0.0669

    50 27.7767 Hz 0.0216 50 17.7685 Hz 0.0900

    60 27.7773 Hz 0.0194 60 17.7780 Hz 0.0365

    70 27.7775 Hz 0.0187 70 17.7295 Hz 0.3093

    80 27.7776 Hz 0.0184 80 17.7949 Hz 0.0585

    90 27.7780 Hz 0.0169 90 17.8008 Hz 0.0917

    100 27.7783 Hz 0.0158 100 17.7731 Hz 0.0641

    120 27.7791 Hz 0.0130 120 17.7845 Hz

    140 27.7804 Hz 0.0083 140

    160 27.7827 Hz 160

    Table 5. Deflection of lowest frequency mode shapes of thin-walled plate models

    # of division Deflection Difference %

    2 1654 mm 2.19

    5 1683 mm 0.47

    10 1689 mm 0.12

    100 1691 mm 0

    160 1691 mm

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    (a) 2 elements (b) 5 elements

    (c) 10 elements(d) 160 elements

    Figure 9. Lowest frequency mode of plate with different element size

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    (a) 2 elements(b) 5 elements

    (c) 10 elements(d) 120 elements

    Figure 10. Lowest frequency mode of beam models with different element size

    7. 

    Uniqueness of this Study

    Several investigators have performed sound research in revealing the effects of mesh density on the FE

    results of computer simulation of linear and nonlinear problems. D’Amours et al. [11] presented an analysis

    of crush response of hydroformed aluminum tubes. From the FE simulation, they found that in certain

    instances, it may be better to use a fine mesh size for the hydroforming model and remap forming results tocoarser mesh sizes for crashworthiness models to save computational time. Aramayo [12] developed a FE

    model of a Ford Explorer SUVwith arbitrary element size and size distribution. The general model was used

    for frontal impact analysis with different scenarios, and the simulation results were verified by comparing

    with experimental results of crash tests. In developing the FE model, the mesh density was parameterized in

    different regions so that a fine mesh was employed in one half of the front of the object and a coarse mesh

    elsewhere. Donadon and Iannucci [13] presented an objective algorithm for strain softening material models.

    In order to evaluate the performance of the algorithm, a mesh sensitivity study was performed where a

    simple coupon test simulation was performed on the virtual coupon models with six different mesh densities.

    On comparing the structural response obtained using the different mesh types, it was found that the energy

    dissipated in the formation of crack is mesh insensitive. Makino [14] examined the performance on the fine

    mesh model and developed a 10-million shell elements car model in order to achieve the good accuracy in

    crash analysis by LS-DYNA. Comparing with aforementioned research, the uniqueness of the present study

    lies on following areas. (1) Despite the well known fact that fine mesh leads to higher accuracy while the

    coarse mesh improves the computing efficiency, this study demonstrates how the element size affect the

    accuracy and efficiency through a series of simulations and presents a primary guideline of choosing the

    optimal element size for different type of analysis. (2) Instead of only focusing on impact analysis, this

    research completely studies the effects of mesh density through static, impact, and modal analysis.

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    ISSN: 2326 – 425X URL: http://www.bjet.baar.org.uk

    Vol. 1, No. 7, pp 13-28, MAY 2013

      

    8.  Conclusion

    In this study, the effects of element size on accuracy of finite element models and simulation results were

    thoroughly investigated through static analysis, impact analysis, and modal analysis. It was found that for

    static analysis that assumes steady loading and response conditions, each side of a plate model should be

    discretized into 10 divisions in order to obtain satisfied results (with approximation error < 1% in our

    example) consuming less computer resources and computing time. For impact analysis which involves fast,

    transient loading and considers dynamic structural response, a thin-walled beam model has to be meshed

    into 80 divisions along its axis in order to simulate its crash response efficiently and correctly (with

    approximation error < 10%). For modal analysis, the selection of the best element size is not very urgent

     because (1) the FEA models with less number of elements can correctly predict the natural frequencies (with

    approximation error < 1%) and (2) even the FEA models with finest mesh cost no more than 20 seconds to

    complete a modal analysis. Nevertheless, it is suggested to apply 10 divisions on the box beam models to

    correctly simulate their mode shapes in lowest natural frequencies.

    The presented results reveal that different types of structural analysis require appropriate mesh generationschemes. The optimal mesh density for static, impact and modal analysis can be used as guidelines in

    creating other finite element models for structural analysis, which will lead to accurate and efficient

    computer simulations.

    One deficiency of this study is that the authors did not develop mathematical models to visually show the

    relationships among element size, accuracy of results, and computing time for different analyses. This is

     because that in any type of analysis, more than one type of result will be extracted and studied (this paper

    only lists a few type of results as an example). As demonstrated in the paper, the element size has different

    influence on different types of results. Therefore, it is neither possible nor necessary to derive mathematical

    models for each type of result to show the influences of the element size. Another shortcoming of the FEA

    models presented in this paper is that those models use automatic mesh only. Advanced mesh techniques

    such as adaptive mesh are not considered. Also, this paper only discusses the structures with regular shape.

    The mesh strategy recommended here can be applied to model more complicated structures with irregular

    shapes and even engineering assembly for further validation. In the future, effects of adaptive mesh need to

     be considered in studying the influences of element size on the accuracy of FEA results. The present study

    can be applied to nonstructural problems such as heat transfer problem and fluid flow problem.

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    British J ournal of Engineering and T echnology

    ISSN: 2326 – 425X URL: http://www.bjet.baar.org.uk

    Vol. 1, No. 7, pp 13-28, MAY 2013

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