Course detail
Simulation and Optimization (FEM, CFD, MBS)
FSI-ZAW Acad. year: 2027/2028 Summer semester
The course builds upon the knowledge acquired in the course "Mechanics, Durability and Reliability" and further develops the transition from a physical model of a mechanical system to a numerical computational model. Within the context of digital engineering, digital product models, and the digital thread, it emphasizes the principles of Simulation-Driven Design, the integration of simulations into the engineering design process, and their application to support engineering decision-making.
The course focuses on the development and assessment of the validity of linear and nonlinear structural mechanics models, the influence of loading history and load paths, the principle of superposition in linear problems, parameterization, sensitivity analysis, and optimization, including topology optimization. It covers transient structural analyses, computational fluid dynamics (CFD), and coupled multiphysics problems, particularly conjugate heat transfer (CHT) and fundamental fluid–structure interaction (FSI). Emphasis is placed on the verification and validation of numerical models, the selection of an appropriate level of model fidelity, and the assessment of uncertainties in simulation results.
The course further develops deterministic and probabilistic approaches to assessing the reliability of mechanical components and structural details, focusing on limit states, fatigue life, structural stability, and the fundamentals of fracture mechanics. The acquired knowledge and skills are applied to practical engineering problems.
Language of instruction
Czech
Number of ECTS credits
4
Supervisor
Department
Learning outcomes of the course unit
Afer completion of the course, students will be able to:
Develop computational models based on physical models, selecting an appropriate level of idealization and model fidelity according to the purpose of the simulation.
Assess the applicability of linear and nonlinear models, identify significant nonlinearities, evaluate the influence of loading paths, and recognize the limitations of the superposition principle.
Perform and interpret static and transient structural analyses, computational fluid dynamics (CFD) simulations, and coupled multiphysics analyses, including conjugate heat transfer (CHT) and basic fluid–structure interaction (FSI).
Verify and validate numerical models, assess solution sensitivity, numerical errors, model uncertainties, and the credibility of simulation results.
Apply parameterization, sensitivity analysis, and optimization methods, including topology optimization, in the design of mechanical components.
Assess the reliability and limit states of structural details using fatigue analysis, structural stability assessment, fundamentals of fracture mechanics, and probabilistic approaches.
Integrate numerical simulations into the digital engineering design process in accordance with the principles of Simulation-Driven Design and use simulation results to support informed engineering decision-making.
Entry knowledge
– Knowledge of mechanics, dynamics, strength of materials, CAD modelling and material sciences at the level of bachelor's study of mechanical engineering.
Rules for evaluation and completion of the course
Course credit is awarded on the following conditions:
- active taking part in the lectures (max. 10 points),
- solving of assigned tasks and presentation of results (max. 30 points),
- at least it is necessary to get 20 points.
Exam is awarded on the following conditions:
- practical part: methodically correct solution of assigned task (max. 40 points),
- oral exam (max. 20 points),
- together one can obtain up to 100 points, final grade is determined in accordance with ECTS grading scale.
Attendance at practicals is obligatory and checked by the lecturer. One excused absence can be tolerated without compensation. In case of longer absence, compensation of missed lessons depends on the instructions of course supervisor.
Aims
Students will be able to create multiphysical computational models, perform methodologically correct simulations and complex evaluation of the stress state of complex parts and assemblies, taking into account various nonlinearities.
- Ability to perform simple multiphysics simulations of the stress state of complex components and assemblies in the field of mechanical engineering.
- Ability to comprehensively prepare complex geometries, use advanced methods of mesh creation, specify complex boundary conditions and material properties, model parameterization.
- Deepening the experience with the use of software ANSYS Workbench and ANSYS Discovery, deepening skills in the interpretation of simulation results.
- Deepening the skills needed to work with a modern FEM system, either in the form of stand-alone software or an integrated module in the CAD system.
- Understanding the importance of advanced structural analysis in engineering practice.
The study programmes with the given course
Programme N-KSI-P: Mechanical Engineering Design, Master's, compulsory
Type of course unit
Lecture
16 hours, optionally
Syllabus
- Introduction to Finite Element Analysis (FEA) and Computational Modeling in Digital Engineering. Transition from physical models to computational models. Fundamental principles of the finite element method (FEM), types of analyses, geometric idealization, discretization, element types, mesh generation, boundary conditions, and interpretation of simulation results.
- Linear and Nonlinear Static Structural Analysis. Linear elasticity, stress and strain analysis, symmetry, the principle of superposition and its limitations, material, geometric, and contact nonlinearities, loading paths, incremental solution procedures, mesh quality, and convergence. Model verification and validation.
- Structural Stability and Nonlinear Response. Linear buckling analysis, eigenvalues and critical loads, geometrically nonlinear buckling analysis, initial imperfections, post-buckling behavior, loss of stability, and the influence of material nonlinearities and boundary conditions.
- Dynamic Structural Analysis. Modal analysis, natural frequencies and mode shapes, damping, harmonic excitation, resonance, transient linear and nonlinear analyses, implicit and explicit time integration, impact phenomena, and fundamentals of multibody system dynamics (MBS).
- Computational Fluid Dynamics (CFD) and Coupled Multiphysics Analysis. Fundamentals of CFD, fluid flow, boundary conditions and discretization, heat transfer and conjugate heat transfer (CHT), fundamentals of fluid–structure interaction (FSI), and one-way and two-way coupling. Model validity and interpretation of simulation results.
- Parameterization, Sensitivity Analysis, and Optimization. Parametric modeling, design variables, objective functions and constraints, sensitivity analysis, optimization algorithms, response surface methods, topology optimization and its limitations. Applications in Simulation-Driven Design.
- Reliability and Service Life of Mechanical Components. Limit states, safety and reliability, fatigue life, effects of mean stress, stress concentrations, and cyclic loading. Fundamentals of fracture mechanics, crack initiation and propagation. Deterministic and probabilistic approaches to reliability assessment.
- Verification, Validation, and Integration of Simulations into the Engineering Design Process. Computational model verification, mesh convergence, numerical errors, experimental validation, uncertainties and sensitivity of simulation results, and selection of an appropriate level of model fidelity. Integration of simulations, optimization, and reliability assessment into the digital product development process.
Computer-assisted exercise
32 hours, compulsory
Syllabus
Transition from a physical model to a computational model. Geometry preparation, model idealization, selection of element types, mesh generation and mesh quality assessment, definition of material properties, loads, and boundary conditions. Static analysis of a simple mechanical component, evaluation of stresses and deformations, verification of equilibrium, and mesh convergence studies.
Comparison of linear and nonlinear models of a structural detail or mechanical assembly. Application of symmetry and the superposition principle, material and geometric nonlinearities, and contact problems. Influence of loading paths and boundary conditions on simulation results, interpretation of local stress concentrations, and assessment of model validity.
Determination of the critical load of a slender structural component using linear buckling analysis. Subsequent geometrically nonlinear analysis incorporating initial imperfections, comparison of critical loads, deformations, and post-buckling response. Assessment of the influence of geometry, material properties, and boundary conditions.
Modal analysis of a mechanical component or assembly, including natural frequencies and mode shapes. Harmonic response, effects of damping, and resonance. Transient analysis under time-dependent loading, comparison of implicit and explicit solution methods using a simple impact problem. Demonstration of motion simulation of a multibody system (MBS).
CFD simulation of fluid flow in a simple engineering system, including mesh generation, boundary condition specification, and evaluation of velocity, pressure, and pressure losses. Conjugate heat transfer (CHT) analysis, including heat transfer between a fluid and a solid. Demonstration of one-way fluid–structure interaction (FSI), transferring pressure loads from CFD to structural analysis.
Parameterization of geometry, material properties, and loading conditions. Sensitivity analysis, formulation of objective functions and design constraints. Dimensional optimization of a structural component and topology optimization aimed at reducing mass while maintaining the required stiffness. Interpretation of optimization results and assessment of design feasibility and manufacturability.
Fatigue analysis of a typical structural detail based on finite element analysis (FEA) results, identification of critical locations, influence of stress concentrations, mean stress, and cyclic loading characteristics. Basic analysis of a cracked component and evaluation of stress intensity factors. Probabilistic assessment of the influence of variability in material properties and loading parameters on structural reliability.
Comprehensive analysis of a selected mechanical component or assembly. Comparison of analytical and numerical solutions, mesh convergence studies, assessment of modeling uncertainties, and validation using experimental data. Evaluation of design alternatives, optimization, and limit state assessment. Documentation of simulation results within the context of the digital product model and the digital thread.