A collection of advanced FEA simulations in structural analysis, material behavior, and engineering applications.

This repository presents a comprehensive collection of Finite Element Analysis (FEA) case studies, demonstrating various engineering applications using Ansys and other numerical simulation tools. The examples include:

• Structural mechanics simulations
• Material failure analysis
• Thermal and fluid interactions
• Nonlinear and dynamic analyses
• Custom scripting and automation in FEA

• Objective: Evaluate deflection, shear, and moment in a simply supported I-beam under concentrated and distributed loads. Compare analytical and FEA results.
• Methods: Linear static analysis using line elements. Simply supported boundary condition on one end and roller support on the other.
• Results: Visualization of deflection, shear, and moment diagrams. Close agreement between analytical and FEA results.

• Objective: Analyze deflections at each joint of a wooden truss bridge under given loading conditions.
• Methods: Finite element analysis using truss and beam elements. Different boundary condition applications, including pinned and roller supports, are explored. Apply pinned support boundary conditions using three methods: simply supported, displacement, and remote displacement.
• Results: Comparison of deflections for different support conditions and validation with theoretical predictions.

• Source: Chen X, Liu Y. Finite Element Modeling and Simulation with ANSYS Workbench. CRC Press; 2018: Case Study 2.6.

• Objective: Evaluate deformations and stresses in a two-story structural steel frame under uniform loading, with and without a deck on the first floor.
• Methods: 3D beam element analysis using Ansys Workbench. The importance of correct I-beam alignment in DesignModeler or SpaceClaim is highlighted.
• Results: Stress and deformation distributions. Comparison of frame deformations with and without a deck on the first floor.

• Source: Chen X, Liu Y. Finite Element Modeling and Simulation with ANSYS Workbench. CRC Press; 2018: Case Study 3.6.

• Objective: Analyze the deformation and von Mises stress of a stainless steel wrench under applied torque.
• Methods: 2D plane stress vs. full 3D solid modeling for comparative evaluation.
• Results: 2D and 3D model results are compared, showing that stress differences are more significant than displacement variations.

• Source: Chen X, Liu Y. Finite Element Modeling and Simulation with ANSYS Workbench. CRC Press; 2018: Case Study 4.5.

• Objective: Investigate deformation and von Mises stress in a concrete garden fountain under hydrostatic pressure.
• Methods: Axisymmetric finite element modeling using a 2D slice of the 3D geometry. Adaptive meshing is applied to improve solution accuracy and convergence.
• Results: Stress and deformation contours. Validation of axisymmetric approach.

• Source: Chen X, Liu Y. Finite Element Modeling and Simulation with ANSYS Workbench. CRC Press; 2018: Case Study 5.8.

• Objective: Assess structural integrity of a glass vase under hydrostatic pressure.
• Methods: Finite element analysis of a thin-walled glass structure with uniform thickness.
• Results: Maximum deformation and stress distribution under fluid pressure effects.

• Source: Chen X, Liu Y. Finite Element Modeling and Simulation with ANSYS Workbench. CRC Press; 2018: Case Study 6.5.

• Objective: Determine deformation and von Mises stress distributions in a base stand assembly under given load and boundary conditions.
• Methods: Apply no-separation contact conditions. Align pin with base leg for axisymmetric study.
• Results: Stress and deformation contours. Validation of contact conditions.

• Source: Chen X, Liu Y. Finite Element Modeling and Simulation with ANSYS Workbench. CRC Press; 2018: Case Study 7.3.

• Objective: Find natural frequencies, vibration modes, and frequency response of an acoustic guitar under harmonic pressure loading.
• Methods: Use 3D shell vs solid elements. Apply fixed boundary conditions and harmonic pressure load.
• Results: First ten natural frequencies. Visualization of first five vibration modes and frequency response.

• Source: Chen X, Liu Y. Finite Element Modeling and Simulation with ANSYS Workbench. CRC Press; 2018: Case Study 8.2.

• Objective: Study steady-state and transient thermal responses of an aluminum heat sink under heat flux and forced convection.
• Methods: Apply heat flux and convective boundary conditions. Perform steady-state and transient analyses.
• Results: Temperature distributions and thermal stress responses. Transient thermal behavior over 180 seconds.

• Source: Chen X, Liu Y. Finite Element Modeling and Simulation with ANSYS Workbench. CRC Press; 2018: Case Study 9.4.

• Objective: Analyze airflow patterns, pressure, and velocity distributions around a truck at 40 km/hr.
• Methods: Use CFX and Fluent for fluid analysis. Apply inlet, outlet, openning/symmetry, and wall non-slip boundary conditions.
• Results: Flow patterns, pressure, and velocity contours. Comparison of CFX and Fluent results.

• Source: Chen X, Liu Y. Finite Element Modeling and Simulation with ANSYS Workbench. CRC Press; 2018: Case Study 10.6.

• Objective: Perform topology and parametric optimization to achieve 75% weight reduction while meeting deformation constraints.
• Methods: Apply downward force and fixed boundary conditions. Use topology and parametric optimization tools.
• Results: Optimized geometry with reduced weight. Validation of deformation constraints.

• Source: Chen X, Liu Y. Finite Element Modeling and Simulation with ANSYS Workbench. CRC Press; 2018: Case Study 11.3.

• Objective: Evaluate static, fatigue, and buckling failures in a dog-bone-shaped specimen under static and cyclic loading.
• Methods: Apply static pressure and cyclic loads. Perform static, fatigue, and buckling analyses.
• Results: Plastic deformation, fatigue life, and buckling mode shapes. Validation of failure criteria.

• Source: Chen X, Liu Y. Finite Element Modeling and Simulation with ANSYS Workbench. CRC Press; 2018: Case Study 12.4.

• Objective: Verify structural integrity of an aluminum control box cover under external pressure (1.0 MPa).
• Methods: Static structural analysis using a STEP model to evaluate stress distribution.
• Results: Assessment of deformation and safety factor.

• Source: ANSYS Mechanical Application Introductory Training Course (2015, ANSYS, Inc.)

• Objective: Analyze the interaction between a spur gear and rack under a 2500 N hand press force.
• Methods: Plane stress analysis (thickness = 12 mm), evaluating force on the rack or moment on the gear.
• Results: Contact stress distribution and gear deflection.

• Source: ANSYS Mechanical Application Introductory Training Course (2015, ANSYS, Inc.)

• Objective: Simplify the creation of multiple beam connections between two plates using automation.
• Methods: Object Generator in ANSYS Mechanical, applying a 1000 N force to the bottom plate.
• Results: Efficiency comparison between manual and automated beam connections.

• Source: ANSYS Mechanical Application Introductory Training Course (2015, ANSYS, Inc.)

• Objective: Optimize preprocessing time by using named selections and Object Generator.
• Methods: Automating body sizing and fixed support conditions to improve model setup.
• Results: Reduction in setup time and improved workflow efficiency.

• Source: ANSYS Mechanical Application Introductory Training Course (2015, ANSYS, Inc.)

• Objective: Generate an optimized mesh for a symmetric assembly using multiple meshing techniques.
• Methods: Patch Independent, Patch Conforming, Sweep, Hex Dominant, and Face Meshing methods.
• Results: Mesh quality evaluation and efficiency comparison.

• Source: ANSYS Mechanical Application Introductory Training Course (2015, ANSYS, Inc.)

• Objective: Analyze the effects of different meshing sequences on computational accuracy.
• Methods: Comparing meshing order using various element types.
• Results: Impact of meshing order on analysis convergence and accuracy.

• Objective: Compare meshing efficiency and accuracy using different methods.
• Methods: Evaluating automatic meshing with slicing against multi-zone meshing without slicing.
• Results: Element quality, computational time, and solution accuracy.

• Objective: Evaluate different meshing techniques for complex geometries.
• Methods:
  • Sweep without inflation
  • Sweep with inflation
  • Multi-zone
  • Layered tetrahedrons
• Results: Comparison of mesh refinement, accuracy, and computational cost.

• Objective: Improve mesh quality in models with geometry defects using mesh controls.
• Methods: Implementing pinch and virtual topology to refine meshing.
• Results: Enhanced element quality and better stress convergence.

• Source: ANSYS Mechanical Application Introductory Training Course (2015, ANSYS, Inc.)

• Objective: Address non-physical results in a piston-valve assembly due to initial gaps.
• Methods:
  • Solve without interface treatment (baseline).
  • Apply contact offset to close the gap and analyze results.
• Results: Comparison of results with and without interface treatment.

• Source: ANSYS Mechanical Application Introductory Training Course (2015, ANSYS, Inc.)

• Objective: Replace traditional contact definitions with joints in an assembly.
• Methods: Using ANSYS automatic joint feature and modifying joint definitions before solving.
• Results: Reduced computational cost and improved analysis efficiency.

• Source: ANSYS Mechanical Application Introductory Training Course (2015, ANSYS, Inc.)

• Objective: Analyze the base of a vehicle jack under applied loads.
• Methods:
  • Simulating vehicle weight using a point mass.
  • Applying lateral loads using remote forces.
• Results: Structural response under realistic load conditions.

• Source: ANSYS Mechanical Application Introductory Training Course (2015, ANSYS, Inc.)

• Objective: Simulate hook displacement using constraint equations.
• Methods: Constructing an equation to relate Y-displacement to X-displacement.
• Results: Prediction of hook deflection during assembly.

• Source: ANSYS Mechanical Application Introductory Training Course (2015, ANSYS, Inc.)

• Objective: Evaluate the structural behavior of an impeller pump under load.
• Methods:
  • Applying a 100 N bearing load to the pulley.
  • Checking impeller deflection and material stress limits.
• Results: Deformation analysis and material safety assessment.

• Source: ANSYS Mechanical Application Introductory Training Course (2015, ANSYS, Inc.)

• Objective: Simulate flange fasteners using beam elements and assess structural response.
• Methods:
  • Body-to-body bolt simulation.
  • Applying a remote force (1000 N) at Z = 100 mm.
• Results: Stress distribution and structural performance evaluation.

• Source: ANSYS Mechanical Application Introductory Training Course (2015, ANSYS, Inc.)

• Objective: Investigate modal frequencies of a machine frame under different constraints.
• Methods:
  • Modal analysis with all 8 mounting holes constrained.
  • Second analysis with only 4 corner holes constrained.
• Results: Comparison of mode shapes and natural frequencies.

• Source: ANSYS Mechanical Application Introductory Training Course (2015, ANSYS, Inc.)

• Objective: Compare heat transfer effects on a pump housing made of plastic vs. aluminum.
• Methods:
  • Applying boundary conditions:
    • 60°C at the mounting face.
    • 90°C internal temperature.
    • Convection at 20°C external surface.
• Results: Thermal expansion and stress comparison.

• Source: ANSYS Mechanical Application Introductory Training Course (2015, ANSYS, Inc.)

• Objective: Perform a sequential analysis of a pipe clamp under multiple loading steps.
• Methods:
  • Step 1: Bolt pretension (locked in later steps).
  • Step 3: Internal pressure applied.
  • Step 4: Axial force applied.
• Results: Structural response under multi-step loading.

• Source: ANSYS Mechanical Application Introductory Training Course (2015, ANSYS, Inc.)

• Objective: Analyze how different mesh densities affect the quality of FEA results.
• Methods: Perform simulations using various mesh sizes to compare stress and deformation.
• Results: Evaluation of tensile and bending loads on the web section.

• Source: ANSYS Mechanical Application Introductory Training Course (2015, ANSYS, Inc.)

• Objective: Verify linear buckling results for a steel pipe against handbook calculations.
• Methods: Apply a compressive load of 10,000 lbf to a fixed-free pipe model and determine its factor of safety.
• Results: Comparison of numerical and analytical buckling loads.

• Source: ANSYS Mechanical Application Introductory Training Course (2015, ANSYS, Inc.)

• Objective: Improve accuracy by solving a full model (coarse mesh) and a submodel (fine mesh).
• Methods: Use ANSYS to extract a portion of the full model and refine the mesh for detailed analysis.
• Results: Comparison of coarse mesh full-model results with fine mesh submodel results.

• Source: ANSYS Mechanical Application Introductory Training Course (2015, ANSYS, Inc.)

• Objective: Assess the structural integrity of a roll cage under impact loading.
• Methods: Finite element simulation of impact forces and stress distribution.
• Results: Identification of high-stress areas and deformation under loading.

• Objective: Study the dynamic response of a bridge structure under transient loading.
• Methods: Time-dependent simulation of varying loads and their effects on stress and displacement.
• Results: Visualization of transient response behavior.

• Objective: Evaluate the risk of buckling failure in a transmission tower.
• Methods: Finite element analysis of compression-induced buckling.
• Results: Identification of weak points and safety factor assessment.

• Objective: Compare natural frequencies in a roll cage with and without prestress effects.
• Methods: Modal analysis under two conditions: free vibration and prestressed state.
• Results: Influence of preloading on natural frequencies.

• Objective: Evaluate vibration response using full and superposition harmonic analysis.
• Methods: Conduct modal analysis followed by harmonic analysis.
• Results: Comparison of harmonic response in full mode and superposition approach.

• Objective: Analyze the effects of random vibration on a compression spring.
• Methods: Perform modal analysis followed by random vibration analysis.
• Results: Evaluation of spring deformation and stress distribution under random loading.

• Objective: Assess seismic response of a steel frame structure.
• Methods: Use response spectrum analysis to estimate peak responses.
• Results: Evaluation of structural stability under seismic loading.

• Objective: Predict fatigue life of a crankshaft under cyclic loading.
• Methods: Finite element analysis of stress cycles and damage accumulation.
• Results: Estimation of fatigue life and failure zones.

• Objective: Analyze deformation and stresses in a racing car frame.
• Methods: Finite element simulation of impact and loading conditions.
• Results: Identification of weak sections and structural improvements.

• Source: Dechaumphai and Sucharitpwatskul. Finite element analysis with ANSYS workbench. Alpha Science International Limited, 2018, Ch.3.

• Objective: Evaluate stress distribution in a motorcycle chain wheel.
• Methods: Apply torque and chain resistance force to analyze stress.
• Results: Identification of high-stress zones and failure risks.

• Source: Dechaumphai and Sucharitpwatskul. Finite element analysis with ANSYS workbench. Alpha Science International Limited, 2018, Ch.4.

• Objective: Assess deformation and stress in a shelf angle bracket.
• Methods: Simulate wall-mounted loading conditions.
• Results: Determination of maximum stress points and deformation.

• Source: Dechaumphai and Sucharitpwatskul. Finite element analysis with ANSYS workbench. Alpha Science International Limited, 2018, Ch.5.

• Objective: Analyze an aircraft structural component under offset loading.
• Methods: Apply internal constraints and offset force, assess deflection and stress.
• Results: Structural integrity assessment and design verification.

• Source: Dechaumphai and Sucharitpwatskul. Finite element analysis with ANSYS workbench. Alpha Science International Limited, 2018, Ch.6.

• Objective: Determine natural frequencies and mode shapes of a passenger car frame.
• Methods: Perform modal analysis using FEA.
• Results: Identification of primary vibration modes.

• Source: Dechaumphai and Sucharitpwatskul. Finite element analysis with ANSYS workbench. Alpha Science International Limited, 2018, Ch.7.

• Objective: Investigate the possibility of buckling in a detergent bottle.
• Methods: Analyze compressive loading and hydrostatic pressure effects.
• Results: Assessment of structural stability and design recommendations.

• Source: Dechaumphai and Sucharitpwatskul. Finite element analysis with ANSYS workbench. Alpha Science International Limited, 2018, Ch.8.

• Objective: Estimate the lifespan of a piston rod under cyclic loading.
• Methods: Finite element fatigue analysis.
• Results: Prediction of failure locations and lifespan.

• Source: Dechaumphai and Sucharitpwatskul. Finite element analysis with ANSYS workbench. Alpha Science International Limited, 2018, Ch.8.

• Objective: Analyze temperature distribution, deformation, and thermal stresses in an engine cylinder.
• Methods: Simulate internal pressure, heat flux, and convection effects.
• Results: Evaluation of thermal stress and deformation.

• Source: Dechaumphai and Sucharitpwatskul. Finite element analysis with ANSYS workbench. Alpha Science International Limited, 2018, Ch.9.

➡ View Full List of Examples

git clone https://github.com/a-dorgham/FEA_Ansys.git
cd FEA_Ansys

Each case study contains input files, and results. Follow the source instructions to run the simulations in Ansys Workbench, APDL, or Python scripting.

Contributions are welcome! Feel free to submit feature requests, enhancements, or new case studies via pull requests. If you encounter issues, open a discussion or raise an issue.

This repository is licensed under the MIT License. See LICENSE for details.

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