Parametric FEA & Mesh Convergence Automation

Why FEA Automation Matters

Running a single Finite Element Analysis (FEA) simulation is rarely sufficient. Engineers must perform mesh convergence studies and parametric thickness sweeps to ensure stresses are independent of element size.

Warning Always Check Mesh Convergence Coarse meshes artificially stiffen structural models and under-predict peak Von Mises stress near fillets and holes.

Step-by-Step Worked Example

Simulate an automated parametric thickness sweep for a cantilever bracket under tip loading:

force_N = 1500.0
width_m = 0.04
thicknesses_m = [0.004, 0.006, 0.008, 0.010]

for t in thicknesses_m:
    area = width_m * t
    axial_stress_MPa = (force_N / area) / 1e6
    print(f"Thickness: {t*1000:4.1f} mm -> Axial Stress: {axial_stress_MPa:6.2f} MPa")

Real-World Engineering Application

Automating Ansys Mechanical parameter tables in Python lets you evaluate 50 geometry candidates overnight and automatically filter designs that exceed allowable yield stress.