What advantages does the FEM simulation offer compared to real tests?
FEM (finite element method) is not a substitute for real tests, but a powerful tool for gaining closer insights and making testing faster, more efficient and more effective.
Prototypes can thus be built even better and in a more targeted manner, as numerous questions can be clarified in advance in the digital twin. With FEM, weak points can be identified at the digital design stage, materials can be compared and load cases can be run through without destroying complex and expensive prototypes.
If a real test shows a result, whether something breaks, vibrates too much or deforms, the FEM analysis shows the why behind the fault: Where are stress peaks? How is the load distributed inside? What happens with temperature, over time, what happens with friction?
A condition can be tested in an experiment. Several situations can be simulated with FEM. Different materials, different load cases, component changes, failure cases (e.g. fracture, elongation, creep).
FEM does not replace every test - but it does allow more targeted, faster and safer development.
A few examples:
- Crash on vehicle restraint system: test duration with preparation approx. 2 months, test costs €30,000; simulation duration with model preparation and optimization approx. 2 weeks; simulation costs €10,000.
- Test of a plastic component for a pressure cycling test: test duration 40 days; simulation duration with model preparation and optimization 10 days.
- Design of pressure test chambers: A mathematical design is essential in order to avert the immense danger to people and infrastructure.