Challenges in Correlating FEA and DIC Measurements: A Case Study on CNC Gantry Design

Abstract

Integrating Finite Element Analysis (FEA) and Digital Image Correlation (DIC) has become a standard approach in experimental validation of structural designs. However, discrepancies between FEA predictions and DIC measurements remain challenging, particularly in dynamic systems. This study explores the correlation challenges encountered in a CNC gantry's structural design and vibration analysis. A detailed FEA was performed to predict the structural rigidity characteristics, while experimental validation was conducted using DIC. Significant deviations were observed between numerical and experimental results, highlighting the limitations of FEA modeling assumptions and potential errors in DIC calibration. The study further investigates potential sources of mismatch, including boundary conditions, material properties, etc. The findings emphasize the need for refined simulation techniques and improved experimental setups for better correlation. This research provides valuable insights into the practical limitations of combining FEA and DIC, offering recommendations for enhancing accuracy in future studies.