Parametric FEA Simulation Engine & 3D Viewer

A scientific finite element analysis modeling framework with ANSYS APDL automation, Python numerical solvers, and an interactive 3D WebGL specimen viewer for composite materials research.

The Problem

Replicating experimental direct-tension tests on reinforced composite specimens in commercial FEA software is notoriously labor-intensive, error-prone when building manual meshes, and computationally slow for iterative parameter sweeps.

The Approach

Developed a complete parametric modeling pipeline: automated ANSYS Mechanical APDL generation scripts, Workbench Python macros, and a standalone 3D finite element numerical solver in Python that performs mesh convergence and material damage modeling without requiring proprietary GUI licenses.

Key Architectural Decision

Implemented an independent, client-side WebGL 3D specimen viewer (zero plugin dependencies) that allows researchers and non-technical stakeholders to inspect the transparent composite dogbone body, pinned UTM clevis fixtures, and internal embedded wire mesh geometry directly in the browser.

Tradeoffs & Constraints

Full 3D non-linear continuum plasticity calculations can take hours on dense meshes. Introduced a multi-fidelity solver: a fast 1D/2D parametric spring-element matrix engine for instantaneous sensitivity studies and full 3D solid continuum modeling for final stress state convergence.

Engineering Overview

This project provides an audit-grade numerical simulation engine developed to replicate direct tension experiments of structural ferrocement composites and isolated welded wire mesh under uniaxial loading.

Architecture & Solver Pipeline

Parametric Geometry Generator: Generates exact dogbone profiles (700mm length, 40mm thickness, 50mm central gauge, clevis gripping pin holes) and positions embedded mid-plane reinforcement meshes.
ANSYS MAPDL Deck Automation: Generates clean, reproducible .inp input decks with mapped brick meshing, boundary constraint definitions, and non-linear solver controls.
Standalone Python Solver: Built with NumPy and SciPy to execute linear and non-linear structural compliance iterations directly from the terminal without software licensing bottlenecks.
Interactive 3D WebGL Inspector: Renders real-time hardware geometries, wire mesh placements, and stress heatmaps in client browsers.

Quantitative Validation

The numerical engine was audited against published empirical testing standards, achieving precise calibration for uncracked elastic modulus ($E_m$), cracked stiffness ($E_{cr}$), and ultimate tensile failure thresholds.