Hand calculations are good.
Laptop Battery It is very important that design engineers do hand calculations. It is very important that engineering expert witnesses do hand calculations.
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Thinkpad For everything but the simplest of part geometries, hand calculations of stress are generally rough estimates. Often they are only in the ballpark of the true maximum stress levels. Sometimes they are only in the ballpark of the average stress levels, and miss the highest stresses entirely.
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Microsoft In the span of 50 years, finite element analysis has gone from esoteric research topic to widely available, widely applied mature technology. In the 1980's, FEA required extremely expensive mainframe computers, very expensive FEA codes and highly trained analysts, and was still implemented at many large corporations. In the 1990's, Unix workstations provided distributed FEA processing and FEA packages went mainstream, lowering entry costs. A seat of hardware and software still cost many tens of thousands of dollars, and highly trained analysts were still required, and still FEA spread to thousands of companies. In the 2000's, lower priced FEA packages run well on medium to high-end personal computers, and FEA usage continues to grow. Highly trained analysts are still needed to consistently obtain accurate results, a fact unfortunately ignored by too many in the industry.
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Laptop Computers Why does FEA usage continue to grow when all of these companies already have hand calculations? Because, when applied correctly, FEA works. It delivers accurate stress estimates for parts with geometry too complicated for hand calculations alone, which describes most of today's parts. Accuracy means that localized stress concentrations can be removed. Accuracy means one less uncertainty, meaning that a lower factor of safety can be considered--resulting in lower weight, lower cost parts that are still stronger and have longer life cycles. Accuracy means that an expert witness can pinpoint areas of concern, and can often nail down the why's and how's of a part failure. As discussed in previous issues of Courtroom FEA, this will often point the finger at the responsible party, be it designer, manufacturer or end user. Accuracy can mean reduced lab testing by concentrating the investigation on the suspect areas. Accuracy means credibility.
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Laptop Computer FEA has internal checks that a good analyst needs to apply to verify the results. Hand calculations provide a rough estimate of the results, and the hand calculations and FEA had better match within their accuracies. If not, something is wrong with one or both of them, and the analyst had better correct that. Once they do match, hand calculations are an external check of the detailed FEA results. Hand calculations are good.
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Desktop Computer But they aren't good enough in a high stakes courtroom battle.
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Lenovo Steve Roensch is a mechanical engineering consultant with more than 20 years of professional experience. He has analyzed hundreds of product designs and has served as an expert witness across many industries, including giving depositions and court testimony. Learn more about mechanical engineer expert witness services at www.FiniteElement.com.
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Travelstar
Steve Roensch is a mechanical engineer with 23 years of professional experience in failure analysis and litigation consulting. He has analyzed hundreds of product designs and has provided expert witness services across many industries, including giving depositions and court testimony.
Mr. Roensch has provided litigation consulting in the energy, construction, industrial, transportation, commercial, utility and residential industries. He has supplied legal team technical support, and has given depositions and testified in court and arbitration hearings.
Mr. Roensch specializes in analyzing the physical stresses that arise in a product under various loading conditions, and in determining if the design is sufficient to survive such loads. He investigates product failures and accidents from a fundamental engineering perspective, often applying finite element analysis. He documents his efforts thoroughly from the start, for concise presentation to the legal team, other experts and the jury. Complex engineering principles are explained using everyday concepts that everyone can understand. Color stress plots and animations are used whenever possible to convey complicated engineering results in an easy to understand visual format.
Learn more about mechanical engineer expert witness services at www.FiniteElement.com.
