FE Model Verification Checklist

Purpose

For verifying that the FE model has been solved correctly before results are used for engineering decisions.

Equilibrium Checks

• Do reaction forces balance applied loads to within 1% in each direction? — The first check — if this fails, stop
• Are reaction force distributions consistent with the expected load path? — Not just the sum, but the distribution
• For contact models, does the net contact force balance the applied normal load? — Contact equilibrium

Hand Calculation Comparison

• Is there a hand calculation or analytical solution for comparison at a simple section? — P/A, Mc/I, or beam formula
• Does the FE nominal stress match the hand calculation within an expected tolerance? — Within 5% for a clean section
• Is the global displacement consistent with an order-of-magnitude estimate? — Check before trusting local stress

Mesh Convergence

• Has mesh convergence been demonstrated for the specific output used for design? — Not just displacement
• Are at least three mesh densities shown approaching an asymptote? — Coarse, medium, fine
• Is the change between the two finest meshes below the acceptance criterion? — Typically 5% for design, 2% for qualification
• If Richardson extrapolation is used, is the convergence rate recorded? — And the estimated remaining error

Singularity and Sensitivity

• Has the peak stress location been tested for singularity by local mesh refinement? — If stress increases unboundedly, it is singular
• Has a sensitivity study been performed on the most uncertain assumptions? — Friction, boundary stiffness, preload
• Are the most sensitive assumptions identified and documented? — Which inputs control the answer

Physical Checks

• Is the deformed shape physically sensible — no artefacts or non-physical motion? — Visual check is non-negotiable
• Does the total model mass match the design mass? — Within 2%
• Are there no solver warnings or error messages unresolved? — Check the message file

Related Knowledge

• FEA Best Practices: Model Verification
• FEA Best Practices: Sensitivity Studies
• How to Verify an FE Model