Computer Aided Engineering (CAE) FEA Case Study: Design Analysis Part Alterations
Design anlaysis - nearly 100% of the time, parts need to be modified for a FEA analysis 
We have dealt with how we are going to perfrom the analysis, the model now needs to be prepared for a geometry based analysis. Creating geometry ready for anlaysis can be very complex due to the number of changes that may be required. Meshing algorithms do not like poor topology (CAD description of the geometry). Hence all 'dubious' modelling (which is usually OK for tooling etc.) is removed and the part simplfied. Simplfying geometry and topology means removing fillets (blends), perhaps chamfers etc. Great care has to be taken since geometry modifications can significalty effect the FEA results, hence the significance of each alteration has to be well understood. The wheel (as shown above) ended up have fillets removed from where the spokes join the rim and each of the different colours shown highlight unique volumes - it is now a multi-volume part. This was done to cater for different materials and simplyfing the 'work' the meshing algorithm has to perfrom to produce a quality mesh without stretch or distortion - the stress analysists enemy! Mesh quality is paramount.