Simplification of Complex Structural Dynamic Models: A Case Study Related to a Cantilever Beam and a Large Mass Attachment

Large attachments can dramatically affect the dynamic response of an assembled structure. In various industrial sectors, e.g., the automotive, aircraft, and shipbuilding industries, it is often necessary to predict the dynamic response of assembled structures and large attachments in early-stage engineering design. To deal with this, it is often the finite element method (FEM) that is used in the vibrational analysis. Despite the advent of large-scale computer availability, it is still commonplace, and often necessary, to reduce the model-size with large attachments to acceptable levels for computer time-scale or memory-size limitations. This article discusses the simple methodology of replacing large and sometimes complicated attachments by using a simplified boundary condition. This methodology is well-known in certain sectors of computer-aided design, but here we are able to present a comprehensive discussion from laboratory measurements, finite element analysis and a simplified perspective. Given the availability of experimental data, the errors produced by these methodologies may then be determined by a structure that has a strictly defined geometry and known material properties within a certain tolerance. To demonstrate these effects, an experimental modal analysis is performed on a structure consisting of a beam and a large mass attachment, which is then validated by each of the finite element models that include the relevant approximate ideal boundary conditions. Various approximating boundary conditions are investigated, and quantifiable results are discussed. One of the conclusions confirms the recommendation that rotary inertia terms should be included as a boundary condition wherever possible when large attachments are approximated by an offset mass defined at a point