⌘K
CAE Simulation

FEA Methodology: Virtual Structural Validation

Finite Element Analysis (FEA) at Edelweis is not a "black box" process. We employ a high-rigor FEA Methodology that transforms complex mechanical assemblies into discrete mathematical models. By utilizing both Linear Static and Advanced Non-Linear solvers, we predict structural behavior with a level of precision that bridges the gap between digital simulation and physical reality.

1. The Simulation Pipeline

Every simulation follows a strict four-stage protocol to ensure result integrity:

Pre-Processing
  • Geometry Idealization: Removing non-structural features to prevent singularities.
  • Material Mapping: Assigning high-fidelity properties from the Central Library.
  • Mesh Engineering: Utilizing high-order parabolic elements for stress gradients.
Post-Processing
  • Convergence Study: Iterative refinement until variance is <2%.
  • Failure ID: Interpreting Von Mises stress and displacement gradients.

2. Linear Static Analysis

The baseline for most components where loads and deformation are proportional:

  • •
    Yield Verification: Ensuring peak stress remains below the material's elastic limit.
  • •
    Stiffness Mapping: Calculating deflection rates for functional clearances.
  • •
    FoS Visualization: Color-coded plots identifying regions with low safety margins.

3. Non-Linear Analysis (Advanced)

Type Technical Driver Engineering Application
Material Post-yield behavior (Plasticity). Analyzing permanent deformation and crash scenarios.
Geometric Large displacements/strains. Simulating thin-wall buckling and snap-fit assemblies.
Boundary Changing contact zones. Analyzing gear tooth engagement and gasket compression.

4. Verification & Validation (V&V)

  • •
    Reaction Force Audit: Verifying that the sum of reactions matches applied loads (Static Equilibrium).
  • •
    Energy Error Norm: Monitoring strain energy distribution to ensure mesh quality.
  • •
    Singularity Review: Distinguishing between physical risks and mathematical artifacts at sharp corners.

Technical Directives

Directive Protocol
Singularity Management Stress concentrations must be resolved using frictionless contact or local fillets.
Bolt Connector Logic Fasteners must be modeled with beam-elements and Pre-Load values.
Report Transparency All reports must disclose mesh density, solver type, and convergence plots.