Introduction to FreeCAD Part 10: Finite Element Method (FEM) WorkBench Tutorial | DigiKey

Welcome to the final episode of our FreeCAD tutorial series! We delve into the powerful world of the Finite Element Method (FEM) and show you how to perform Finite Element Analysis (FEA) using FreeCAD's FEM Workbench to predict the behavior of your designs under various loads and stresses. This is the tenth and final episode in our Introduction to FreeCAD series. You can find the FreeCAD files used in this tutorial in this GitHub repository: https://github.com/ShawnHymel/introduction-to-freecad The written version of this guide can be found here: https://www.digikey.com/en/maker/projects/intro-to-freecad-part-10-finite-element-method-fem-workbench-tutorial/4e56c2854d974e5dbf2d1b41e7b4c828 We'll start by introducing the concept of FEM and how it's used in engineering to simulate and analyze the structural integrity of components. You'll learn how to create a 3D model of a simple bracket in the Part Design workbench, which we'll use as our test subject for the analysis. We'll guide you through assigning material properties—specifically, how to set up PLA plastic for 3D-printed parts—and explain why material selection is crucial for accurate simulations. Next, we'll dive into setting up the simulation by applying constraints and loads to our model. You'll see how to fix certain faces to mimic real-world anchoring and how to apply forces that replicate operational stresses. We’ll show you how to generate a mesh and discuss the importance of mesh quality and element size for accurate results. Once the setup is complete, we'll run the simulation using the CalculiX solver that's built into FreeCAD. We'll walk you through interpreting the results, focusing on displacement and the von Mises stress analysis to identify potential failure points. We'll also discuss the limitations of the von Mises stress, emphasizing that it's most accurate for ductile, isotropic materials and highlighting the caveats when dealing with brittle or anisotropic materials like 3D printed parts. Finally, we'll demonstrate how to improve your design based on the simulation results. You'll learn how adding reinforcements or changing the geometry can significantly reduce stress concentrations and deformation, leading to a more robust and reliable component. By the end of this tutorial, you'll have a solid understanding of how to use FreeCAD's FEM Workbench to enhance your mechanical designs, optimize material usage, and predict potential issues before manufacturing or 3D printing. Whether you're a hobbyist, student, or professional engineer, mastering FEA in FreeCAD is a valuable skill that can elevate your projects to the next level. If you have any questions or want to share your experiences with FEM in FreeCAD, leave a comment below or connect with us on social media using the hashtag #DKFreeCAD.