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FEA (Finite Element Analysis) Mistakes to Avoid When Hiring FEA Engineering Services

Posted on April 8, 2024 by faz_business

The idea behind FEA (finite element analysis) is to predict how a design or structure responds to various types of physical forces and study the possibility of failure without using a physical prototype. Everything is done on a computer screen by combining 3D CAD technology and mathematical-based geometry analysis. It is a virtual simulation to visualize the effects of the usage environment on design parts, components, and assemblies made of any known material. Physical forces may include air pressures, water pressures, weights, vibrations, repeated impacts, dynamic loads, static loads, and temperature changes, to name a few.

The purpose of FEA (finite element analysis)

FEA services are meant to replicate both common/likely and worst-case real-life scenarios in the simulation. Under each scenario, the simulation offers comprehensive imagery depicting how a design responds and withstands physical forces until it deforms and breaks. The data is the foundation for discovering the solution that meets pre-defined design requirements like safety, durability, performance, and repairability.

Since all physical products of any industry are affected by the conditions in which they are stored and used, they can be subjected to FEA tests. From the simplest small wooden carvings and complex crude oil pipelines to intricate blood transfusion devices and sophisticated microchips, FEA simulation engineering designers can determine the amount of stress loading under which their building blocks will fail. Manufacturers then use analysis results to improve their products.

Push-button solution

Several popular 3D CAD software packages come equipped with powerful FEA features. Many vendors still offer stand-alone software tools for each functionality, but integrating both technologies simplifies the analysis procedures. FEA simulation can only happen when the engineering design experts subdivide the CAD model into more minor elements in the form of a geometric mesh that represents the building blocks of the design. The “meshing” procedure is an automated process requiring manual inputs for refinements in specific design areas such as joints, connections, and edges.

The simulation also implements a semi-automation principle where users determine design characteristics, including material properties and assembly features, before running the analysis. The mostly automated computational procedure should allow users to perform an FEA simulation. Users can create (or have access to) the CAD model and the appropriate software to activate the simulation program. Thoughtful analysts argue that the idea of a push-button solution can be dangerous, and they almost certainly have a point. Every design is unique.

Two comparably shaped products of different materials should display dissimilar behaviors even when exposed to the same physical force; two distinctive products built from identical materials will also exhibit unalike responses to matching environmental factors. The inclination to run an FEA simulation is irresistible, especially in a hi-tech world where the solution to the problem is just one click away. Any suggestion to imply that automation makes every analyst equal is nonsensical. There will always be design issues to discover and, thereby, engineering problems.

Considering the level of complexity in design intent, materials science, and the physics of structural deformation, FEA is by no means a trivial matter. Just because users can run the analysis does not necessarily mean they should. No degree of automation can make FEA analysis easy, let alone accurate. More importantly, the results of the FEA simulation are approximate at best. They are only as accurate as the engineers determining the design constraints, materials’ parameters, and load thresholds. Take a stress analysis as an example.

Among the first things to define are the types, strength, and direction of strains exerted on the entire model during a typical usage scenario; specific criteria, such as the forces acted upon welded or glued connection as well as the cumulative effect of dynamic and constant loads, are determined next. To come up with realistic approximations, users must input multiple assumptions into the software:

Specific loads are considered likely usage conditions, while others are worst-case scenarios. All have varying degrees of intensity. Some loads only occur during the product assembly process.
Every material acts differently when exposed to external forces. Part properties, including thickness and length, will affect the material’s tensile strength.
Points of connection in the assembly, such as glued edges or welded parts, have different boundary conditions from solid blocks.

Users must have access to an accurate database defining materials’ known characteristics and behaviors under stress, loads, heat, and pressure. In any case, a successful FEA simulation relies on at least the following complex steps:

Assessment: make the correct assumptions and ask the right questions to the software
Validation: ensure the software is mathematically precise enough to generate a workable solution
Interpretation: understand the results and translate the information into product performance data

Software developers and vendors keep on improving accuracy and interface to make the tools more reliable and easier to use. Users still need professional credentials to effectively and accurately utilize the analysis.

Common mistakes when hiring FEA engineering services

FEA is a powerful computational tool to simulate the almost limitless possible deformations in structures as it is exposed to physical forces. It was once considered a domain exclusive to expert engineers and supercomputers. Still, thanks to technological advances and market competition that drive computer prices down, FEA is easily accessible by 3D artists and CAD users anywhere.

In any case, freelance finite element analysis & FEA engineering services exist mainly because only some people are qualified to run the analysis and interpret the results. The much-debated concerns over the democratization of FEA are not entirely baseless. Companies currently looking to outsource product analysis to external FEA consultant services should not fall into the trap of such democratization, leading to the following mistakes:

Incorrect Credentials

For most people, FEA and all its capabilities to predict the structural behaviors of products or materials are almost magic. It was once a black art practiced only by the most educated engineers. Since the rapid development and adoption of CAD technology, FEA has gradually made its way into the computers of typical 3D artists and casual users. Both the pre-processing and post-processing steps are mostly automated within the CAD interface. Familiar menus make operation as easy as it can be.

One of the most significant issues with democratization is that entry-level engineers and 3D product modeling services feel qualified to offer FEA services. Widespread adoption might be a good thing in other technologies, but there is a real danger in hiring a person with incorrect credentials to perform FEA. While most modelers and junior engineers probably have access to the FEA simulation program from their CAD software, they are not supposed to practice the analysis at a professional level.

They can run the simulation and come up with approximations. Still, at the moment, CAD software vendors need to offer a reliable mechanism to warn users that the generated results might be wrong. Even if some software packages do provide warnings, there are no easy-to-follow procedures to discover the underlying issues and fix the problems. The most effective workaround is to consult time-tested engineering experience and knowledge.

Wrong tools for the job

Nearly all major CAD software packages come with structural analysis features ready to deploy. 3D Modeling design firms specializing in 3D design and modeling may think that expanding the business into FEA territory is a good idea because the software has built-in features. The specializations do not fall under the FEA category. Companies or individuals looking to hire FEA services must avoid the firms at all costs.

Integration between modeling and analysis is good, but only when the users are qualified to operate both. Many of the built-in features are stripped-down capabilities of the full-fledged FEA software. The features are not necessarily destructive but tend to omit many customization options in favor of automation. In other words, the analysis generates results by removing actual engineering inputs from the equation.

No modeling option

Firms or freelancers may rely entirely on the included features (in the CAD software) and automated functions. They have a model from the client, run the FEA simulation, and deliver analysis results within an hour. Every client needs to understand that a slight deviation in dimensions, load points, and angles can change the results to a great extent. Depending on how they were built in the first place, some models might be sensitive to minor variable alterations.

A typical stress analysis on a model may take 10 minutes or so using powerful computers. However, a true FEA professional will build dozens (if not more) of model variations to determine the proper constraints and structural behaviors based on in-depth engineering knowledge of material properties. Until the model is rebuilt multiple times with perturbations, it isn’t easy to accurately predict its structural behaviors. Repeated simulations with varying engineering parameters and boundary levels are indispensable for accuracy.

Lack of documentation

FEA documentation must provide enough details to allow clients to reproduce the results. Every project has documentation requirements but should contain at least model identification, source geometry, model assumptions, simulation parameters, and validation. Although the focus is on the results, proper documentation ensures the model and design remain traceable from the client’s standpoint. FEA aims to visualize the structural behavior of a model, and the client must be able to gain clear insights from the analysis at the end of the process.

Assigning the task of FEA simulation to an unqualified person (whether as a cost-saving measure or due to an uninformed hiring decision) can be hazardous instead of advantageous. A qualified consultant has real-world engineering experience, specifically in the field related to your models or products. FEA enables companies to solve complex structural design problems, but only if the consultant performing the analysis has a working knowledge of engineering practices.

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The Cost of Hiring a Mechanical Engineering Contractor vs. Full-Time Salaried Employee

Posted on April 2, 2024 by faz_business

In some situations, hiring an independent mechanical engineering contractor is better than hiring a full-time salaried employee with the same qualifications. However, employers must understand the difference between full-time and contract workers to determine the best hiring decision. Since most of the distinctions affect the employer financially, refer to the “employee status” classification established by the Internal Revenue Service.

In general, hired contractors are also your employees as they provide services for you but are not formally part of your company. Contractors pay their taxes on the money received for services provided. Alternatively, full-time salaried employees are part of the company’s in-house team. As their employer, you are responsible for overseeing their performance and work conduct and legally handling the withholding and reporting of their taxes. The following classification description can serve as a valuable reference to prevent overpayment, errors in distinguishing between these categories, and the potential incurring of substantial legal penalties.

Independent contractors

For the sake of simplicity, think of an independent contractor as another company. The employer pays for the services provided, whether on a one-time project or an ongoing basis, but the contractor remains independent of your business. A contractor must not abide by your company’s day-to-day operations and will perform the commissioned duties without strict supervision.

Depending on the terms of the agreement, the contractor may never need to show up at the office. The person can do the job from a separate location. For instance, when hiring a freelance finite element analysis & FEA engineering services consultant, the entire task is conducted through computer simulation, and the resulting data is swiftly transmitted as a digital file, eliminating the need for a physical office presence. The work can start immediately once the employer and the contractor agree on the project parameters (including job description and fee). Unless otherwise noted in the agreement, contractors are aware of the following responsibilities:

File and pay taxes (local, state, and federal) on the payment received from the employer
Supply the tools and equipment necessary for the completion of the project on their own
Have their insurance needs covered
Invoice the employer
Expect only to receive payment as stated in the agreement

When an employer and a mechanical engineer sign the contract, it is safe to assume that both parties understand and accept all terms mentioned in the document. In addition to the project brief and payment schedule, the contract may include clauses about deliverables, project milestones, deadlines, and revisions, to name a few.

Full-time employee

The IRS will classify a worker (who provides services for your business) as a full-time employee if you are legally allowed to dictate when, where, and how the person should perform their duties. In other words, the employer must continually direct, supervise, and oversee how the work is done. Another big difference between a full-time employee and an independent mechanical engineering contractor is taxation. The employer is required by law to report the taxes on the employee.

There are three criteria based on which the IRS classifies a worker as a full-time employee:

Financial control: the employer is responsible for payroll taxation (including Social Security and Medicare) and determines paid leave as well as vacation
Relationship: the employee is involved in ongoing business relationships with clients or customers and co-workers
Behavioral management: to a certain degree, the employer may decide the work schedules and methods performed by the employees

Full-time employees most likely work at the location listed as the company’s address. The company makes available the tools and supplies necessary for the employees to perform the duties assigned. Employees are entitled to wages, workers’ compensation insurance, and overtime. The company is also responsible for fringe benefits like retirement plans and health insurance.

Cost of contract workers

Suppose you must hire a freelance mechanical engineering service with the same qualifications as a full-time employee to do the same services. In that case, the hourly rate is likely higher for the former. However, whether or not the contractor costs less in the long run depends entirely on the business needs.

The typical payment process for a contractor differs from the conventional payroll model. A contractor may accept a lump sum, a percentage of the project’s cost, or an hourly rate payment schedule. Regardless of the methods used, the procedure is quite simple. An employer and the hired contractor agree on the project parameters explicitly mentioned in the signed contract, including the scope of work and salary. The payment is made once all the job requirements are met. Mechanical engineering may ask for an upfront deposit or a portion of the total wage as a retainer. Generally, both parties fulfill their roles in the agreement; the contractors get the job done, and the employer provides the compensation. Although you don’t have to handle the taxation requirement for the contractor, you are still required to supply Form 1099 for the payments made.

Cost of full-time employees

An employer controls a full-time employee’s payment schedule and work performance, as well as the administrative details of the taxation. Salary employees are paid a set amount regularly per period, such as monthly, bi-weekly, or weekly. They receive overtime pay for any day they work longer than the scheduled hours. If the duties for the day are completed quicker than expected, they receive the full salary nonetheless. Hourly employees use a timesheet to log the hours worked. The wage equals the hours spent working. Either way, the paychecks are given weekly or monthly.

The employer withholds a portion of the employee’s salary for taxation and benefits purposes. The employees have agreed to authorize the payment of taxes with each paycheck. They can only worry about taxes at least once the time comes for filing tax returns, usually in April each year.

Extra Cost

There are at least three types of indirect costs associated with hiring a full-time employee:

Fringe benefits: payments for retirement plans, healthcare, paid leave, and worker’s compensation
Administrative: expenses attributed to accounting fees, legal fees, and administrative workers’ salaries
Overhead: the business operational cost that cannot be attributable to a specific project, like office supplies, computer maintenance, hosting services, utility bills, and office rent.

According to Clarity 2022: Government Contracting Industry Study compiled by Deltek, the median percentage values for the indirect costs are 30% for fringe, 22% for general and administrative, and 25% for overhead. Cumulatively, the values equal to (1 + 0.3) x (1 + 0.22) x (1 + 0.25) = 1.98 cost multiplier.

Cost comparison

Even if a mechanical engineering contractor and a full-time employee have the same rate of $60 per hour, the total expense incurred for the latter is more significant. Here is a simple breakdown of the calculation:

Employee Status	Hourly rate	Work Hours per Week	Week	Annual Work Hours	Annual Salary	Cost Multiplier	Total Cost
Contractors	$60	40	52	2080	$124,800	1	$124,800
Full-time	$60	40	52	2080	$124,800	1.98	$247,104

Using the median rate for the indirect cost (multipliers), a full-time employee costs almost twice as much as an independent contractor or nearly double the base salary. Unless the project runs for an entire year, the cost of hiring a contract worker can be much lower. However, every business has many long-term projects in which workers require close supervision. Only some mechanical engineering contractors can replace the equivalent full-time employee. As a company grows more prominent, it is not feasible to keep hiring mechanical engineering contractors for new product design services, prototype design engineering services, oversee a manufacturing process, or investigate equipment failures on behalf of the employer.

Payrate

Mechanical engineering is a high-paying profession. The Bureau of Labor Statistics (BLS) states that the average annual salary of a full-time mechanical engineer in the United States is $95,300 or an hourly rate of $45.82. The wage varies widely among different industries. For example, a mechanical engineer working in metalworking machinery manufacturing earns around $40 per hour. Still, an equally qualified professional hired by a crude oil company is paid an hourly rate of between $60 and $75. Sitting in the middle includes the architectural and engineering services industry, which offers an average hourly wage of $48.46, and R&D services, with an average pay of $54.78 per hour.

On the freelancers’ side, a mechanical engineering contractor may cost between $50 – $80 per hour in the United States and Canada. A professional with an experience level of more than ten years in the industry may charge between $100-200 per hour, depending on the scope of work. If the professional is based outside North America, you will likely get a lower rate (but not necessarily a better deal). For instance, the typical hourly rate for a freelance mechanical engineer in India goes from $30 to $50.

Mechanical Engineering Hourly Rates

Location/Experience Level	Industry or Category	Average Hourly Rate
United States	Overall Average	$45.82
United States	Metalworking Machinery Manufacturing	$40
United States	Crude Oil Industry	$60 – $75
United States	Architectural and Engineering Services	$48.46
United States	R&D Services	$54.78
United States & Canada	Freelance (Entry Level)	$50 – $80
United States & Canada	Freelance (Over 10 Years’ Experience)	$100 – $200
India	Freelance Mechanical Engineer	$30 – $50

This table provides approximate information on hourly rates in the field of mechanical engineering. These figures can vary based on individual qualifications and specific job requirements.

How Cad Crowd can assist

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