CAD and FEA

BTT acknowledges the advantages that accompany computer aided design (CAD) and finite element analysis (FEA) and thus utilises these tools extensively across a wide range of compliance and validation projects. The advantages of properly conducted FEA mean that BTT can provide clients with a cost and time saving alternative to physical testing. This becomes especially prominent when a design requires multiple iterations.

What can BTT model in CAD software?

BTT has experience recreating all forms of vehicle and trailer chassis and mechanical connections between vehicles within CAD software. Our team has the capacity to use SolidWorks, SolidWorks Simulation, Autodesk® Inventor® Professional and Autodesk® Inventor® Nastran. Here we can model client provided 2D drawings and 3D models, on‑site measurements and design proposals. Please note that our team is not restricted to 3D models produced in SolidWorks or Inventor as relevant files can be exported into the correct format. Modelling practises are also transferable and thus BTT is comfortable modelling all client proposals within SolidWorks and Inventor, enabling the assessment of more niche products.  

What is FEA?

Some clients may be unfamiliar with what FEA is and how it works. In short, FEA is a computerized technique that predicts how products react to applied forces, along with other physical effects like heat, fluid flow and vibration. The technique works by breaking down an object into thousands of smaller constituent parts, often referred to as finite elements. Based on analysis type (discussed below) each element is simplified using certain relationships – often the linear relationship between stress and strain or force and displacement. Elements are then linked together using compatibility or continuity equations, thus producing a large system of equations that can be assembled and solved in matrix form.

What can be assessed using FEA and when does BTT utilise FEA?

BTT use FEA to solve various boundary value problems (BVPs). These are mathematical problems in which the quantity of interest is defined by a differential equation throughout a region, with initial values only known in specific areas. Almost all client designs can be assessed as a BVP. In general, BTT turn to physical testing when standards relevant to a project are unable to be validated computationally. Fortunately, our team has had experience complying designs to most standards and thus typically know prior to assessing a design what testing processes should be undertaken. Here you can find additional information regarding how BTT can help determine what assessment processes are relevant to you.

The most common boundary value problem assessed by BTT concerns stress analysis under steady state (static) or time dependent (dynamic) conditions. Heat transfer, fluid flow and electric and magnetic potential analyses can also be ran through SolidWorks and Inventor. Our team has significant experience running linear, non‑linear and multi‑axial fatigue simulations. We produce models with representative welds, connectors and contacts thus can analyse any number of static and dynamic designs.

Clients may wonder whether connectors can be analysed through FEA. BTT typically utilise 2D calculation processes to assess suitability of bolted connectors and welds. Nonetheless, BTT can integrate FEA into bolted joint and weld analysis in order to assess more complex joint configurations to suit client needs.

Why should you choose BTT to complete CAD/FEA assessments on your behalf?

CAD and especially FEA can be daunting for individuals and businesses who have had little exposure in these areas. Poor understanding of FEA processes and limitations of FEA can result in unrepresentative results. This can lead to overengineered products or, in worst case scenarios, physical products that do not meet relevant standards. BTT have the capability to complete physical testing when standards relevant to a project are unable to be validated computationally. Fortunately, our team has had experience complying designs to most standards and thus typically know prior to assessing a design what testing processes should be undertaken. Here you can find additional information regarding how BTT can help determine what assessment processes are relevant to you. We can assign any combination of material properties to a model, have experience constraining models such that simplifications are representative, and load models according to relevant ADR, VSB and performance standard requirements. It is also within BTT’s capabilities to validate designs with reference to internal standards relevant to a project.

BTT aims to streamline CAD/FEA processes by providing clients with our wealth of knowledge in these areas. Having worked with CAD/FEA for several decades cumulatively, BTT ensures clients are provided assessment results representative of real-world applications. These results are typically obtained faster and at a lower cost than if processes were conducted internally. Furthermore, BTT’s experience with Engineering Design, which can be read about here, eases the entire process from concept to final product.

How can BTT help?

If you are a client wishing to pursue FEA for a concept, completed prototype, currently non-compliant or not validated vehicle, trailer or component, we would love to hear from you. Please get in contact with us here and one of our team will respond directly with information on what we can offer.