Computer aided design tools are constantly improving, and as technology steps forward, high end computer simulation tools are become accessible. Finite element analysis (FEA) is one of those tools, and can be very valuable to the product development process. Tricycle has both cutting edge software tools, and the experienced design engineers to leverage the power of FEA, gaining great understanding of product performance while still in the virtual design stage. The biggest advantage to using FEA is that a design can be tested, modified and then retested quickly. This speeds up the process, and removes many of the costs associated with repeated prototyping and physical testing.
FEA application to CAD models can test:
- Strength – is a part strong enough to perform? Is there a safety margin in the worst case?
- Product flex – for snap teeth, flexible parts
- Failure points or weak areas
- Material reduction – to reduce weight or cost without compromising performance
- Drop or impact – failure points
- Material selection – to compare designs made with different materials
- Risk assessment – investigate risk issues or validate DFMA conclusions (what happens if a bolt is missing?)
While extremely powerful, FEA results are theoretical. Care should be taken to ensure that during the process the most accurate loadings and materials are used, and that results are compared to results seen in real testing or products. Comparison, or final physical testing will often be recommended to confirm the results especially where compliance or safety is at risk.