Chapter 7

7.1 For the simple 4 noded elements it is a violation of displacement compatibility to have a
mid-side node. Some of the elements have mid-side nodes in this model. Use ‘transition’
triangle to go from smaller to larger rectangular elements.

Transition triangle

= Mid-side nodes
7.2 The mesh sizing is not fine enough in the reentrant corner region at C. We need smaller
elements near point C and small radius at C.
7.3 Based on the formulation used here we can not have = 0.5 for the plane strain case as
the denominator in the material property matrices [D] (see Equation (6.1.10) and [K] (see
Equation (6.4.3) becomes zero. A penalty formulation see Reference [7] can be used to
avoid this problem.
7.4 The structure is plane strain if this section represents a cross section of a long structure in
which the loads do not vary in the z direction.
The structure is a plane stress problem if this section is a thin plate type structure with
loads in the plane of the structure only.
Also see Section 6.1 for descriptions of plane stress and plane strain and examples of
each.
7.5 When abrupt changes in thickness at E’s occur from element to element.
7.6 Unit thickness/7.7 (a) best aspect ratio.
7.9 (a) No, as replacing a portion of the patch by a different material with different mechanical
properties will in general produce non-uniform strain under constant state of applied
stress. For rigid body mode tests, however, different mechanical property materials still
result in rigid body displacement.
(b) Yes, the patch can be arbitrary in shape. If we apply a test displacement field of u x = 1,
uy = 0 at the external nodes of a patch of say 4 elements and set the internal nodal force
to zero, then solve for the displacement components at internal node i, these
displacement components should agree with the value of the displacement function at
that node. Also the strain function or field should vanish identically at any point over
each element.
(c) Yes, we can mix triangular and quadrilateral elements in a 2-d patch test as long as the
material properties are the same.
(d) No. Mixing bars with plane elements would alter the constant strain states as the plane
element and bar are of different structural types.
(e) The patch test should be applied when developing new finite elements, to determine if
the element can represent rigid body motion as well as states of constant strain when
these conditions occur.
319
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 7.10 Using Mathcad
A=1 10–4 E = 200 109 L1 = 0.6 [L2] = 1.4

1 –1 0 3.333 107 – 3.333 107 0

E 7 7
[k1] = –1 1 0 [k1] = [k1] A [k1] = – 3.333 10 3.333 10 0
L1
0 0 0 0 0 0

0 0 0 0 0 0
E 7
[k2] = 0 1 –1 [k2] = [k2] A [k2] = 0 1.429 10 –1.429 107
L2
0 –1 1 0 –1.429 107 1.429 107

3.333 107 – 3.333 107 0

7 7
[k] = [k1] + [k2] [k] = – 3.333 10 4.762 10 –1.429 107
0 –1.429 107 1.429 107

Set these 3 values to defined quantities of u1 = u3 = 1 for the rigid body patch test
u1 = 1 u3 = 1 F2 = 0
Guess at F1, F3, and u2 as shown below.
F1 = 1 u2 = 0 F3 = 1
Given Use the given command to create a solve block.
F1 u1
F2 [ k ] u2 Use control and equal sign here.
F3 u3
F1
u2 = Find (F1, u2, F3) Use the ‘Find’ command to find F1, u2, and F3.
F3
F1 = 0 u2 = 1 F3 = 0
The rigid body motion patch test is satisfied as u2 = 1.
Now check the constant strain test. Let u(x) = x for the nodes at the boundaries, i.e.,
u1 = 0 and u3 = 2, Verify that u2 (x = 0.6) = 0.6.
u1 = 0 u3 = 2 F2 = 0 Initial these values
F1 = 1 F3 = 1 u2 = 0 Guesses for these values.
Given
F1 u1
F2 = [ k ] u2
F3 u3

F1
u2 = Find (F1, u2, F3) Use the ‘Find’ command to solve for F1, u2, and F3.
F3

F1 = – 2 107 F3 = 2 107 u2 = 0.6

Now upon solving the system of equations u2 = 0.6 as it should to satisfy the patch test
for constant strain.

320
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 7.12
4 3
5000 lb
3
5
4 2 10 in.
1
5000 lb
1 2
20 in.

INPUT TABLE 1.. BASIC PARAMETERS

NUMBER OF NODAL POINTS. . . . . . . . . . . . . . . 5
NUMBER OF ELEMENTS. . . . . . . . . . . . . . . . . . . 4
NUMBER OF DIFFERENT MATERIALS. . . . . . . 1
NUMBER OF SURFACE LOAD CARDS. . . . . . . . . 0
1 = PLANE STRAIN, 2 = PLANE STRESS . . . . . . 2
BODY FORCES (1 = IN – Y DIREC., 0 = NONE) 0
INPUT TABLE 2.. MATERIAL PROPERTIES
MATERIAL MODULUS OF POISSON’S MATERIAL MATERIAL
NUMBER ELASTICITY RATIO, DENSITY THICKNESS
1 0.3000E+08 0.3000E+00 0.0000E+00 0.1000E+01
INPUT TABLE 3.. NODAL POINT DATA
NODAL
POINT TYPE X Y X-DISP. Y-DISP.
OR LOAD OR LOAD
1 3 0.0000E+00 0.0000E+00 0.0000E+00 0.0000E+00
2 0 0.2000E+02 0.0000E+00 0.5000E+04 0.0000E+00
3 0 0.2000E+02 0.1000E+02 0.5000E+04 0.0000E+00
4 3 0.0000E+00 0.1000E+02 0.0000E+00 0.0000E+00
5 0 0.1000E+02 0.5000E+01 0.0000E+00 0.0000E+00
INPUT TABLE 4.. ELEMENT DATA
GLOBAL INDICES OF ELEMENT NODES
ELEMENT 1 2 3 4 MATERIAL
1 1 2 5 5 1
2 2 3 5 5 1
3 5 3 4 4 1
4 1 5 4 4 1
OUTPUT TABLE 1.. NODAL DISPLACEMENTS
NODE U = X-DISP. V = Y-DISP.
1 0.00000000E+00 0.00000000E+00
2 0.64664544E–03 0.66631597E–04
3 0.61664509E–03 –0.66630528E–04
4 0.00000000E+00 0.000000000E+00
5 0.30527671E–03 0.24373945E–09
OUTPUT TABLE 2.. STRESSES AT ELEMENT CENTROIDS
ELEMENT X Y SIGMA(X) SIGMA(Y) TAU(X, Y)
1 10.00 1.67 1.0000E+03 1.0011E+02 –3.2032E+00
2 16.67 5.00 9.9359E+02 –1.0171E+02 1.2599E–05
3 10.00 8.33 1.0000E+03 1.0011E+02 3.2035E+00
4 3.33 5.00 1.0064E+03 3.0192E+02 2.8124E–04

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 SIGMA(1) SIGMA(2) ANGLE
1.0000E+03 1.0010E+02 –2.0395E–01
9.9359E+02 –1.0171E+02 6.5906E–07
1.0000E+03 1.0010E+02 2.0396E–01
1.0064E+03 3.0192E+02 2.2873E–05

7.13

7.14

1000 lb

322
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 FEM model
56 elements P = 4 kN
75 nodes
14
1 in.
13
2 in.
12
4 in.
10
6 in.
9
8 in.
8
10 in.
7

15 in.

40

20 in.

30 in.

40 in.

STRESS IN PSI AT VARIOUS DISTANCES

ALONG THE TENSILE PLATE WITH A 1000 # LOAD
ELEMENT # 14 28 42 56
STRESS 26 –2026 –2026 26 (AT 1 )
ELEMENT # 13 27 41 55
STRESS –563 –1437 –1437 –563 (AT 2 )
ELEMENT # 11 25 39 53
STRESS –969 –1031 –1031 –969 (AT 4 )
ELEMENT # 10 24 38 52
STRESS –1002 –998 –998 –1002 (AT 6 )
ELEMENT # 9 23 37 51
STRESS –1002 –998 –998 –1002 (AT 8 )
ELEMENT # 8 22 36 50
STRESS –1001 –1000 –1000 –1001 (AT 10 )
ELEMENT # 6 20 34 48
STRESS –1000 –1000 –1000 –1000 (AT 15 )
ELEMENT # 5 21 33 47
STRESS –1000 –1000 –1000 –1000 (AT 20 )
ELEMENT # 3 17 31 45
STRESS –1002 –998 –998 –1002 (AT 30 )
ELEMENT # 1 15 29 43
STRESS –1005 –995 –995 –1005 (AT 40 )

323
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 Stress in plate at various depths (psi)

7.15
Stress
Maximum Principal
lbf
in^2
12821.95
11539.76
10257.56
8975.367
7693.172
6410.977
5128.781
3846.586
2564.391
1282.195
–2955858e-012

Load Case: 1 of 1
lbf
Maximum Value: 12821.95
in^2 Y
lbf
Minimum Value: -2.955858e-012
in^2

Figure. 8

324
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The maximum principal stresses are at the top and bottom of the circular opening of the
connecting rod. The maximum stresses can be seen in Figure 8 above. Using a mesh density of
only 400 (Figure 1- Figure 4) the precision in the area of interest (i. e., where the maximum stress
occurs); see Figure 1 and Figure 4, the precision was about 0.28 further refinement was required.
The mesh was refined to 800 and 1200 then finally to 1600. With the mesh density being 1600 the
precision was less than 0.1 in. the place of interest and can be assumed correct. The maximum
principal stress of about 12822 lb2 was determined.
in.

7.16

7.17
10 in.
lb
1000
in.
10 in.

5 in.
10 in.

20 in

325
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 14000

12000

No Fillet (90 deg. Corner)

10000
0.25 [Link] Fillet

8000

6000

4000

2000

0
400 800 1600 3200
No. of elements
Maximum principal stress vs no. of elements
7.19
15 lbf

Bony material
10 lbf
Implant material

Model Parameters
Implant material modulus of elasticity 1.6 106 psi
Bony material modulus of elasticity 1.0 106 psi
Implant depth below bony material 0.100 in.
400 Mesh Density
Stress
15 lbf Maximum Principal
lbf
10 lbf in.2

Load Case 1 of 1
Maximum Value: 20232.2 lbf2
in.
lbf
Minimum Value: –2.27374e-013 2
in.

326
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 7.20

40,000 lb
local shear
load
8 in.

48 in.

168.45 = 168.45 lb
17
16 34 32 51 48 68 64 85 280.76+576.65 = 857.41 lb
16
33 50 67 84 692.88+935.14 = 1628.02 lb
15 31 47 63
15
32 49 66 83 1037.51+1236.19 = 2272.70 lb
14 30 46 62
14
31 48 65 82 1323.40+ 1480.14 = 2803.54 lb
13 29 45 61
13
30 47 64 81 1547.20+ 1665.32 = 3212.52 lb
12 28 44 60
12
1713.59+1792.07 = 3505.66 lb
11 29 27 46 43 63 59 80
11 1821.21+1860.35 = 3081.56 lb
10 28 26 45 42 62 58 79
10 1870.12+1870.12 = 3740.24 lb
9 27 25 44 41 61 57 78 40,000
9 1860.35+1821.21 = 3681.86 lb
8 26 24 43 40 60 56 77
8 1792.07+1713.59 = 3506.66 lb
7 25 23 42 39 59 55 76
7 1665.32+1547.20 = 3212.52 lb
6 24 22 41 38 58 54 75
6 1480.14+1223.40 = 2803.54 lb
5 23 21 40 37 57 53 74
5 1235.19+1037.51 = 2272.70 lb
4 22 20 39 36 56 52 73
4 935.14+ 692.88 = 1628.02 lb
3 21 19 38 35 55 51 72
3
576.65+ 280.76 = 857.41 lb
2 20 18 37 34 54 50 71
2
1 19 17 36 33 53 49 70 168.45 = 168.45 lb
1
12 18 12 35 12 52 12 69
64 – 12 in. by 1 in. elements
2

From computer program output

PL3
YmaxA = – 0.4993 in. Ymax exact = – 1.152 in. =
3 EI

12
AR = 1
= 24 (56% error due to large aspect ratio)
2

For other results see Example in Section 7.1, Table 7.1

327
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 7.21

7.22

328
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 Stress
Maximum Principal
N
m^2

N
The figure above is the maximum principal stress. The maximum is 3505 The
m^ 2
location of maximum stress occurs at the corners of the hole (with 1 mm radii)

7.23

329
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 7.25

7.26

330
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 The largest principal stress of 6.29 MPa occurs at the top and bottom inside edges of the
hole. The second largest principal stress of 5.67 MPa occurs at the elbow between the
smallest cross section and where the taper begins.

7.28

700 N

Fixed point
Stres
von Mises
lbf
in.2
6.744453e+007
6.070319e+007
5.396186e+007
4.722053e+007
4.047919e+007
3.373790e+007
2.699552e+007
2.025519e+007
1.351385e+007
8772520
31196.21

331
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 7.31

22,400 lb

Figure 1: Mesh with Boundary Conditions and Nodal Force

Stress
von Mises
lbf
in.2
743817.1
669436.9
595056.7
520676.6
446296.4
371916.3
297536.1
223156
148775.8
74395.64
15.4796

Load case 1 of 1
lbf
Maximum value: 743817
in^2
lbf
Minimum value: 15.4796
in^2 1.1222 in. 2.243 3.365

Figure 2: von Mises stresses (psi)

332
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 7.32
600 Mesh Density
Stress
Maximum Principal
Material: Steel 4130 1bf
in^2
Element Shape: Quadrilateral
Mesh Size: 0.3 47674.97
42907.47
Angle: 15 38139.98
33372.48
Geometric Ratio: 1.25 28604.98
Close Factor: 4 23937.49
19069.99
Refinement Factor: 1 14302.49
9534.994
4767.497
4.263256e-014

Load case 1 of 1
lbf
Maximum value: 47675 in^2
Y
lbf
Minimum value: 4.263256 e–014 in^2
0.000 4.636 in. 9.271 13.907

Mesh Density: 25-600

Bracket without Fillet Maximum Principal Stress

lb
in.2
25 Mesh Density 22811.17
50 26114.15
100 27050.65
150 28179.32
200 28967.93
300 28800.52
400 35102.97
500 32852.23
600 33678.14
Bracket with Fillet
25 Mesh Density 47481.11
50 47492.06
100 47502.16
150 47511.98
200 47521.59
300 47832.01
400 47688.08
500 47658.56
600 47674.97

In the FEA world re-entrant corners are a bad thing. These represent an infinite change in
stiffness inside the part, which will result in an infinite stress concentration.

333
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 7.33

7.37
Stress von Mises
lbf
in.2
96002.11
86401.91
76801.7
67201.49
57601.28
48001.08
38406.87
28800.66
19200.45
9500.244
0.0362343

Load Case: 1 of 1
lbf
Maximum Value: 96002.1
in^2
lbf
Minimum Value: 0.0362343
in^2

Figure 3: Maximum Stress Plot

Maximum von Mises stress occurred at the base of the notch in the crimper tool. The
value was 96,002 psi.
7.38
The model is shown first with the boundary and loading conditions were then applied.
The nodes of the far left hex were constrained from all movement. The red surface in the
second figure below was selected and changed to surface 2. This allow the 100 N2 =
cm
dyn
10,000,000 force to be applied to the surface as shown.
cm 2

334
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 Next a material was chosen and an initial guess at the thickness t was made. ASTM A-
514 was chosen, as this is a quenched and tempered steel with a high yield strength and
will allow for the thickness to be minimized. A thickness of 1 cm was chosen as the initial
guess, as this is an easy number to work with and it is compatible with the other wrench
dimensions. A check was then performed to insure that the model properly reflected the
problem. This check is shown below.

Thickness Pressure Stress

Material (cm) N N
cm^2 cm^2
ASTM A 514 1 100 5.03E+08
ASTM A 514 0.1 1000 5.03E+09
Al 3003-H16 0.3175 314.96 1.58E+09
Al 3003-H16 0.4 250 1.26E+09
Al 3003-H16 0.5 200 1.01E+09
Al 3003-H16 0.47625 209.97 1.06E+09

2 2 dyn
Sy 1.72e9 1.15e9 2
3 3 cm

dyn
With a thickness of 0.47625 cm, the stress was found to be 1.06 * 109 .
cm 2

335
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 7.39 Zoomed in of the previous. To simulate a real cut, I inserted a very small radius at
the point of concern.

Small rad

Original design

Load Case: 1 of 1
1bf
Maximum value: 74820
in^2
1bf
Minimum value: 16.788
in^2
Stress
Maximum Principal
lbf
in^2
Maximum principal and von Mises look very similar 4432.624
3996.442
3560.259
3124.077
2687.895
2251.713
1815.531
1379.349
943.1664
506.9842
70.80207

45 Degree
Rounded Edge
Taper Model
Load Case: 1 of 1
Maximum Value: 4432.62 1bf
in^2
1bf
Minimum Value: 70.8021
in^2

336
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 Stress
von Mises
1bf
This geometry gave me the best result and had a better precision than the other configurations. in^2

3822.889
3442.54
3062.19
2631.841
2301.491
1921.142
1540.793
1160.443
780.0937
399.7442
19.39483

1bf
Maximum value: 3822.89
in^2
1bf
Minimum value: 19.3948
in^2 Radius Model
Stress
von Mises
This geometry had some interesting results but the overall stress was 1bf
still higher than the rounded off configuration in^2
4786.803
4316.144
3843.485
3370.826
2898.167
2425.508
1952.849
1480.19
1007.53
534.8713
62.21216

1bf
Maximum value: 4788.8
in^2
1bf
Minimum value: 62.2122
in^2 Relief Holes Model

337
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