Methods & validation

Methods and quality assurance.

Model setup, numerical checks, reference cases and comparison with measurements are planned around the engineering task.

FEA structural analysis of an excavator boom
Verification steps

Verification steps for numerical models.

01

Project model

Geometry, properties, load cases, boundaries and target quantities are derived from the engineering decision and documented.

02

Numerical checks

Mesh, convergence, balance quantities and sensitivities are checked in proportion to the risk and decision.

03

Benchmark reproduction

A standardized case checks a specific model and solver configuration against a published target value.

04

Measurement correlation

Only a documented comparison with suitable measurements evaluates predictive quality for the specific physical application.

FEA benchmarks

NAFEMS reference cases through two meshing paths.

The table presents four reference cases calculated with CalculiX and meshes generated in Gmsh or Netgen.

CaseQuantityReferenceGmsh + CalculiXNetgen + CalculiX
NAFEMS LE1σyy92.7 MPa91.248 MPa (−1.566%)92.943 MPa (+0.262%)
NAFEMS LE2two stress values60.0 / 60.0 MPa60.97 / 62.49 MPa (+1.62 / +4.15%)59.47 / 62.64 MPa (−0.88 / +4.40%)
NAFEMS LE3x displacement185 mm185.66 mm (+0.36%)184.51 mm (−0.27%)
NAFEMS LE4meridional / hoop stress−50.0 / +50.0 MPa−50.202 / +50.337 MPa (+0.40 / +0.67%)−51.584 / +48.469 MPa (+3.17 / −3.06%)

Aerodynamic comparison case

NACA 0012 with XFOIL: comparison, not a CFD benchmark.

The published case compares lift, drag and pressure trends for a NACA 0012 airfoil. Because it contains no numerical error table or unambiguous experimental-series citation, we deliberately label it an XFOIL comparison case.

Reynolds number
6 × 10⁶
Mach number
0.15
Air density
1.225 kg/m³
Dynamic viscosity
1.80 × 10⁻⁵ kg/(m·s)
Selected toolchain

Software and computational tools.

Solver, meshing path and post-processing are selected for the physics, available data and required level of detail.

01

OpenFOAM

CFD solver ecosystem for flow and heat-transfer models

02

CalculiX

Solver for structural and thermal finite-element models

03

Gmsh & Netgen

Meshing and preprocessing for selected computational models

04

ParaView

Quantitative post-processing and visualization of result fields

05

XFOIL

2-D airfoil analysis within the method’s assumptions

06

Linux & Python

Automation, reproducibility and variant execution

Project standard

What a traceable handover contains.

  1. 01Engineering question, model boundary and decision criterion
  2. 02Geometry version, data sources and units
  3. 03Material models, boundary conditions and load cases
  4. 04Mesh and solution strategy with relevant quality checks
  5. 05Result quantities, variants, sensitivities and residual risks
  6. 06Clear separation of simulation, benchmark and measurement evidence

Methods proportional to risk

Which engineering question should the model answer?

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