ENG3022 - Finite Element Analysis for High Value Manufacturing (2023)

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MODULE TITLEFinite Element Analysis for High Value Manufacturing CREDIT VALUE15
MODULE CODEENG3022 MODULE CONVENERDr Julian Mauricio Londono Monsalve (Coordinator)
DURATION: TERM 1 2 3
DURATION: WEEKS 11 0
Number of Students Taking Module (anticipated) 90
DESCRIPTION - summary of the module content

This module will provide a hands on introduction to Finite Element Analysis for modelling complex structures and materials. This helps to maximise the performance of our designs by analysing the suitability of materials and equipment before and during manufacturing. It will provide a elementary foundation in the mathematical foundations of finite element analysis, building on the stiffness matrix approaches introduce in "Modelling of Engineering Systems", however it focuses on an introduce to using finite element analysis using a commercial finite element package (ANSYS) to evaluate the manufacturability of different materials to enhance the design and early evaluation of critical design parameters.  The module will be 100% coursework with a series of coursework deliverables, two short worksheet coursework, which test fundamental understanding, one larger coursework, testing how FEM can be used for engineering design.

This module is suitable for all Engineering students who have taken the prerequisite ENG2009 Modelling of Engineering Systems.

 

AIMS - intentions of the module

The aim of this module is making the students familiarised with different FEA applications required for the design and manufacturing including stress analysis, thermal analysis, vibration, and impact & crash analysis. These types of evaluations will help to achieve high value manufacturing by minimising the waste, and required design cycles, for an optimal high-quality product.  Such evaluations also help to validate and certify the designs for manufacturing. 

INTENDED LEARNING OUTCOMES (ILOs) (see assessment section below for how ILOs will be assessed)
ILO #1  Understand finite element analysis of a bar, truss and plane strain triangles. SM2m, SM3m, SM4m, SM5m, EA3m, EA6m, D4m, D6m, G3m, SM2p, SM3p, EA3p, D4p, D6p, G3p
 
ILO #2 Understand the key concepts of model validation, finite element approximation and convergence.
 
ILO #3 Understand the basic theory, and mathematical assumptions of bar, plate, shell and solid elements.
 
ILO #4 Understand basic solution strategies for linear, nonlinear, implicit, explicit problems and which would be used for each type of problem.
 
ILO #5 Be able setup linear analysis for complex structure, including those imported from CAD packages. D7m
 
ILO #6 Be able to perform a simple eigenvalue analysis, for a structural stability or dynamics problem.
 
ILO #7 Understand and quantify the modelling assumptions made, when solving real world problems. SM6m
 
ILO #8 Improve writing Skills and report presentation skills
 
ILO #9 Examples of manufacturing methods for different materials and designs
 
ILO #10 Understand the main manufacturing methods and techniques with providing suggestions for different designs based on the FEA simulations 
 
ILO #11 Examples of the choice of materials for high value manufacturing
 
 
 
SYLLABUS PLAN - summary of the structure and academic content of the module
1: Bar, Beam, Plate and Shell Elements: basic concepts, derivations and approximations.
 
2: Shape Functions, meshing procedure..
 
3: Overview of Finite Element Procedure.
 
4: Element Stiffness Matrix to Global Stiffness Matrix, load vector etc.
 
5: Solutions to linear, nonlinear and eigenvalue problems.
 
6: Methods for Validation.
 
7: Applying Different Material Models: Isotropic, Anisotropic Elasticity + simple nonlinear.
 
8: Applying / Assessing Failure Criteria.
 
9: Manufacturing methods for different materials and designs
 
10. Manufacturability analysis based on developing finite element simulations
 
11. Analysing the Suitability of materials and equipment for high value manufacturing
 
LEARNING AND TEACHING
LEARNING ACTIVITIES AND TEACHING METHODS (given in hours of study time)
Scheduled Learning & Teaching Activities 48.00 Guided Independent Study 102.00 Placement / Study Abroad 0.00
DETAILS OF LEARNING ACTIVITIES AND TEACHING METHODS
Category Hours of study time Description
Scheduled Learning and Teaching Activities 12 Lectures
Scheduled Learning and Teaching Activities 24 Tutorials Computer FEM labs
Guided Independent Study 102 Reading lecture notes; working exercises

 

ASSESSMENT
FORMATIVE ASSESSMENT - for feedback and development purposes; does not count towards module grade
Form of Assessment Size of Assessment (e.g. duration/length) ILOs Assessed Feedback Method
None      

 

SUMMATIVE ASSESSMENT (% of credit)
Coursework 0 Written Exams 0 Practical Exams
DETAILS OF SUMMATIVE ASSESSMENT
Form of Assessment % of Credit Size of Assessment (e.g. duration/length) ILOs Assessed Feedback Method
Coursework - Finite Element Analysis Worksheet 50 two weeks, individual report/5 pages 1-8 Written feedback
Coursework - Large Finite Element – Design for manufacturing  Challenge mini project 50 4 weeks, group report/8 pages 1-2, 4-11 Written feedback

 

DETAILS OF RE-ASSESSMENT (where required by referral or deferral)
Original Form of Assessment Form of Re-assessment ILOs Re-assessed Time Scale for Re-assessment
All the above 

Coursework -  FEM for High Value Manufacturing mini project 2

 1-11 August Ref/Def period

 

RE-ASSESSMENT NOTES

Reassessment will be by a single piece of coursework worth 100% of the module mark only. For deferred candidates, the module mark will be uncapped. For referred candidates, the module mark will be capped at 40%.

 

RESOURCES
INDICATIVE LEARNING RESOURCES - The following list is offered as an indication of the type & level of
information that you are expected to consult. Further guidance will be provided by the Module Convener

Basic reading:

 

ELE:

 

Web based and Electronic Resources:

 

Other Resources:

 

Reading list for this module:

There are currently no reading list entries found for this module.

CREDIT VALUE 15 ECTS VALUE 7.5
PRE-REQUISITE MODULES None
CO-REQUISITE MODULES None
NQF LEVEL (FHEQ) 6 AVAILABLE AS DISTANCE LEARNING No
ORIGIN DATE Wednesday 08 June 2022 LAST REVISION DATE Thursday 26 January 2023
KEY WORDS SEARCH Finite Element Analysis; High Value Manufacturing; Simulation; Design for manufacturing