Do you love challenges?
Often when we start working on a project, we require a combination of certain tools handy along with an FEA software. To solve any complex problem effectively, we need to take care of even the smallest details, avoid making silly mistakes and complete the task at hand within a set timeline.
For a CAE engineer, having the right tools at your disposal is necessary for a smooth and seamless workflow.
From excel templates to simulation checklists, through this article, I will provide all the necessary things a CAE engineer must have while working on a problem.
You may bookmark this webpage in advance for future reference.
So, let’s take a look at all the tools we have in our kit one by one. 🤓
1) Diary or a Notepad:
Now, you may find this funny but believe me, a diary is the most important tool you must have at all times. CAE Engineers are problem solvers, and no problem can be solved with a software alone.
In the diary you should,
a) Note down the specific things related to hand calculations, units, Free body diagrams and the physical quantities involved (like Torque, Velocity, Pressure, etc).
b) Write a rough outline of the strategy you are going to implement. For example, if it is linear static analysis, which software you are going to use for pre-processing, how will you do the post-processing, how many resources are available and how much time you'll allot for modeling.
c) Write a brief summary of the project once it is completed. The summary should include key takeaways and new learnings.
2) Material Data sheets:
I assume you are well aware about how important it is to model a material accurately in FEA. If not, no need to worry.
First let’s explore where you can find the material input details like technical data sheets or Specs.
(Note: I’ve listed the top 3 resources for every tool where you can get the required inputs. Each of these 3 resources can be used as alternative for one another in case the required details are not available in one).
Provides a vast database of material data sheets for various engineering materials.
Contains material property data sheets, including mechanical, thermal, and electrical properties.
Provides material data sheets, handbooks and resources for materials and processes.
And this brings us to our next most important tool.
3) Excel templates for common FEA calculations:
When it comes to complex calculations like shear force of beams, moment of inertia of sections, strains in I-shaped columns, it is not possible to memorize all the formulas every time and recall them during tough times.
There is a high chance of making mistakes while in a rush to execute the project within timeline, and it can be difficult to start all over again at the eleventh hour.
These templates provide a foundation for consistent calculations, reducing the risk of errors.
Provides a variety of Excel templates for engineering calculations, including stress and strain. (Shaft-key dimensioning, Welding calculations, Section characteristics, etc).
Offers Excel-based calculation templates for mechanical engineering, including FEA-related calculations. (Bolted joints, Preloads, Stress concentration factors, Mohr's circle, etc).
A resource hub with downloadable FEA calculation templates for different engineering scenarios. (Vibration and Shock load calculations, S-N Diagram, Factor of safety, etc).
4) Unit conversion tools:
NASA lost a Mars Orbiter (worth $125 million) due to an error in unit conversion!
No matter how good you are with hand calculations, you can often feel confused whether you have converted all the quantities into required units correctly. If the project timeline is strict, you may do unit conversions in a hurry and end up screwing up the whole analysis.
It is better to use Unit converters to move through analysis cycles seamlessly and with confidence.
Provides an easy-to-use online tool for converting units across various measurements.
A collection of unit converters for engineers and scientists, covering diverse units.
Offers unit converters specifically tailored for engineering disciplines. This is the most used site among CAE Engineers.
5) CAE Engineer's Checklist:
Whether it is Pre-processing or model setup, Solving or Post-processing, checklists are mandatory to use during all 3 stages.
Below I have mentioned two sources that include the major checkpoints to take into account. You can even create your own custom checklist using these as a reference for various types of analyses.
A check sheet mostly for pre-processing.
This a comprehensive check sheet which covers almost all the important aspects of FEA analysis.
c) If you are looking for a simplified and downloadable checklist in PDF format, visit this post on LinkedIn which I had written a few months ago.
6) Revamp your fundamentals:
CAE is a vast field and as I mentioned earlier, it is impossible to recall all the concepts every time you work on different types of challenges. You might need to revise the respective concepts before starting the work.
The question is, how to do it quickly?
One effective way is by brushing up your knowledge through quizzes, Q and A or solving numerical problems.
For example, if you want to work on a task involving nonlinear analysis or say, you’re going to attend an interview the next day for CAE Analyst position in a company. You must therefore be well versed with types of nonlinearities and the best ways to model it.
You can test if there are gaps in your understanding simply by going through a quiz on nonlinearity or any relevant concept.
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