This is fine and good when FEA is applied appropriately. However, the popularity of finite element analysis can condition engineers to look just for red spots in simulation output, without really understanding the essence or funda at play. By following basic rules of thumb, such danger points can often be anticipated and avoided without total reliance on computer simulation. Maximum stresses are often located at loading points, supports, joints, or maximum deflection points. Stress Concentrations Stress concentrations are usually located near corners, holes, crack tips, boundaries, between layers, and where cross-section areas change rapidly.
Sound design avoids rapid changes in material or geometrical properties.
For example, when a large hole is removed from a structure, a reinforcement composed of generally no less than the material removed should be added around the opening. The addition of safety factors to designs allow engineers to reduce sensitivity to manufacturing defects and to compensate for stress prediction limitations. In Post-Manufacturing Stages Despite the best efforts of design and manufacturing engineers, unanticipated failure may occur in parts after design and manufacturing. In order for projects to succeed, these failures must be diagnosed and resolved quickly and effectively. Often, the failure is caused by a singular factor, rather than an involved collection of factors.