• About
    • Who We Are
    • Partners & Providers
    • News & Events
    • The ESRD Blog
    • Careers
    • Contact Us
  • Applications
    • What We Solve
    • Detailed Stress
    • Composites
    • Fracture Mechanics
    • Residual Stress
    • Sim Apps
  • Products
    • What We Develop
    • StressCheck Professional
      • StressCheck Core
      • Solvers
      • Advanced Modules
      • Utilities
      • Academic Licensing
    • StressCheck Apps
      • CAE Handbook
      • StressCheck Tool Box
    • Product Updates
  • Support
    • How We Can Help
    • Training
    • Webinars
    • Quick Start Guide
    • Help Documentation
    • Software FAQ’s
  • Simulation
    • How We Simulate
    • Benchmarks
    • Simulation Governance
    • History of FEA
    • Dictionary & Terms
  • Resources
    • Browse Our Resource Library
    • White Papers
    • Case Studies
    • Product Demos
    • StressCheck Tutorials
Serving the Numerical Simulation community since 1989
  • Contact Us
  • Register
Login
Forgot Password?
Join Us
ESRDESRD
ESRDESRD
  • About
    • Who We Are
    • Partners & Providers
    • News & Events
    • The ESRD Blog
    • Careers
    • Contact Us
  • Applications
    • What We Solve
    • Detailed Stress
    • Composites
    • Fracture Mechanics
    • Residual Stress
    • Sim Apps
  • Products
    • What We Develop
    • StressCheck Professional
      • StressCheck Core
      • Solvers
      • Advanced Modules
      • Utilities
      • Academic Licensing
    • StressCheck Apps
      • CAE Handbook
      • StressCheck Tool Box
    • Product Updates
  • Support
    • How We Can Help
    • Training
    • Webinars
    • Quick Start Guide
    • Help Documentation
    • Software FAQ’s
  • Simulation
    • How We Simulate
    • Benchmarks
    • Simulation Governance
    • History of FEA
    • Dictionary & Terms
  • Resources
    • Browse Our Resource Library
    • White Papers
    • Case Studies
    • Product Demos
    • StressCheck Tutorials

Chaos in the Brickyard Revisited

Home The ESRD BlogChaos in the Brickyard Revisited

Chaos in the Brickyard Revisited

January 15, 2025 The ESRD Blog

By Dr. Barna Szabó
Engineering Software Research and Development, Inc.
St. Louis, Missouri USA


In a letter published in Science in 1963, Bernard K. Forscher used the metaphor of building edifices to represent the construction of scientific models, also called laws. These models explain observed phenomena and make predictions beyond the observations made [1]. Quoting from Forscher’s letter: “The making of bricks was a difficult and expensive undertaking, and the wise builder avoided waste by making only bricks of the shape and size necessary for the enterprise at hand.”

Progress was limited by the availability of bricks. To speed things up, artisans, referred to as junior scientists, were hired to work on brickmaking. Initially, this arrangement worked well. Unfortunately, however, the brickmakers became obsessed with making bricks. They argued that if enough bricks were available, the builders would be able to select what was necessary. Large sums of money were allocated, and the number of brickmakers mushroomed. They came to believe that producing a sufficient number of bricks was equivalent to building an edifice. The land became flooded with bricks, and more and more storage places, called journals, had to be created. Forscher concluded with this cheerless note: “And saddest of all, sometimes no effort was made even to maintain a distinction between a pile of bricks and a true edifice.”

A chaotic brickyard. Image produced by Microsoft Copilot.

This was the situation sixty years ago. Over time, the “publish or perish” ethos intensified within the academic culture, prioritizing quantity over quality. This led to a surge in the production of academic papers, metaphorically akin to “brickmaking.” Additionally, a consensus emerged among researchers regarding what constitutes acceptable ideas and methods worthy of funding and publication. This consensus is upheld by the peer-review systems of granting agencies and journals, which tend to discourage challenges to mainstream views, thereby reinforcing established norms and practices and discouraging innovation. Successful grantsmanship requires that the topics proposed for investigation be aligned with the mainstream.

Stagnation in the Fundamental Sciences

Sabine Hossenfelder, a theoretical physicist, argues that physics, particularly in its foundational aspects, has been stagnant for the past 50 years, even though the number of physicists and the number of papers published in the field have been increasing steadily. In her view, the foundations of physics have not seen significant progress since the completion of the standard model of particle physics in the mid-1970s. She criticizes the field for relying too much on mathematics rather than empirical evidence, which has led to physicists being more heavily focused on the aesthetics of their theories than on nature [2]. She also shared a compelling personal account of her experience with the “publish-or-perish” world in a podcast [3].

I think that one possible explanation for this stagnation is that human intelligence, much like animal intelligence, has its limits. For example, while we can teach dogs to recognize several words, we cannot teach them to appreciate a Shakespearean sonnet. Nobel laureate Richard Feynman famously said: “I think I can safely say that nobody understands quantum mechanics.” We may have to be content with model-dependent realism, as suggested by Hawking and Mlodinow [4].

Stagnation in the Applied Sciences

All of the counter-selective elements identified by Hossenfelder are also present in engineering and applied sciences. However, in these disciplines, the causes of stagnation are entirely man-made. I will focus on numerical simulation, which spans all engineering disciplines and happens to be my own field. First, a brief historical retrospection is necessary.

In numerical simulation, the primary method used for approximating the solutions of partial differential equations is the finite element method (FEM). Interest in this method started with the publication of a paper in 1956, about a year before the space race began. In the following years, research and development activities concerned with FEM received generous amounts of funding. Many ideas, rooted in engineering intuition and informed by prior experience with matrix methods of structural analysis, were advanced and tested through numerical experimentation. Some ideas worked, others did not. Because the theoretical foundations of FEM had not yet been established, it was impossible to tell whether ideas that worked in particular cases were sound or not.

Current engineering practice is dominated by finite element modeling, an intuitive approach rooted in pre-1970s thinking. In contrast, numerical simulation is based on the science of finite element analysis (FEA), which matured later. Although these are conceptually different approaches, the two terms are frequently used interchangeably in engineering parlance. Whereas finite element modeling is an intuition-based practice, numerical simulation demands a disciplined science-based approach to the formulation and validation of mathematical models. The goal is to control both the model-form and approximation errors. An essential constituent of any mathematical model is the domain of calibration [5]. This is generally overlooked in current engineering practice.

During the 1960s and 1970s, when the FEM was still quite immature, several design decisions were made concerning the software architecture for FEM implementations. Although these decisions were reasonable at the time, they introduced limitations that significantly hindered the future development of FEM software, leading to prolonged stagnation.

The theoretical foundations of FEM were developed by mathematicians after 1970. Many important results emerged in the 1980s, leading to FEA becoming a branch of applied mathematics. However, the engineering community largely failed to grasp the importance and relevance of these advances due to a lack of common terminology and conceptual framework. A significant contributing factor was the difficulty and expense involved in upgrading the software infrastructure from the 1960s and 70s. As a result, these developments have not significantly influenced mainstream FEA engineering practices to the present day.

Example: Making Piles of Faulty Bricks

One of the limitations imposed by the software architecture designed for FEM in the 1960s was the restriction on the number of nodes and nodal variables. It was found that some elements were ‘too stiff.’ To address this, the idea of using reduced integration was proposed, meaning that fewer integration points were used than necessary for the integration error to be negligibly small. This approach tried to correct the stiffness problem by committing variational crimes.

Many papers were published showing that reduced integration worked well. However, it was later discovered that while reduced integration can be effective in some situations, it can cause “hourglassing,” that is, zero energy modes. Subsequently, many papers were published on how to control hourglassing. All these papers added to the brickyard’s clutter, and worst of all, hourglassing remains in legacy finite element codes even today.

Challenges and Opportunities

There is a broad consensus that numerical simulation must be integrated with explainable artificial intelligence (XAI). Indeed, XAI has the potential to elevate numerical simulation to a much higher level than would be possible otherwise. This integration can succeed only if the mathematical models are properly formulated, calibrated, and validated. It is essential to ensure that the numerical errors are estimated and controlled.

Legacy FEA codes are not equipped to meet these requirements; nevertheless, claims are being advanced, suggesting fast, easy, and inexpensive simulation that does not require much expertise because AI would take care of that.  These claims should be treated with extreme caution, as they do not come from those who can tell the difference between an edifice and a pile of bricks.


References

[1] Forscher, B. K. Chaos in the Brickyard. Science, 18 October 1963, Vol. 142, p. 339.

[2] Hossenfelder, S. Lost in Math: How Beauty Leads Physics Astray. Basic Books, 2018.

[3] Hossenfelder, S. My dream died, and now I’m here. Podcast: https://www.youtube.com/watch?v=LKiBlGDfRU8&t=12s.

[4] Hawking, S. and Mlodinow, L. The Grand Design. Random House 2010.

[5] Szabó, B. and Actis, R. The demarcation problem in the applied sciences. Computers and Mathematics with Applications. Vol. 162, pp. 206–214, 2024. 


Related Blogs:

  • Where Do You Get the Courage to Sign the Blueprint?
  • A Memo from the 5th Century BC
  • Obstacles to Progress
  • Why Finite Element Modeling is Not Numerical Simulation?
  • XAI Will Force Clear Thinking About the Nature of Mathematical Models
  • The Story of the P-version in a Nutshell
  • Why Worry About Singularities?
  • Questions About Singularities
  • A Low-Hanging Fruit: Smart Engineering Simulation Applications
  • The Demarcation Problem in the Engineering Sciences
  • Model Development in the Engineering Sciences
  • Certification by Analysis (CbA) – Are We There Yet?
  • Not All Models Are Wrong
  • Digital Twins
  • Digital Transformation
  • Simulation Governance
  • Variational Crimes
  • The Kuhn Cycle in the Engineering Sciences
  • Finite Element Libraries: Mixing the “What” with the “How”
  • A Critique of the World Wide Failure Exercise
  • Meshless Methods
  • Isogeometric Analysis (IGA)
Tags: Finite Element ModelingNumerical SimulationReliabilityXAI
4

You also might be interested in

Why is Simulation Governance Essential for the Reliable Deployment of FEA-Based Engineering Simulation Apps?
Simulation governance must be implemented to achieve democratization of simulation.

Why is Simulation Governance Essential for the Reliable Deployment of FEA-Based Engineering Simulation Apps?

May 8, 2018

How can the vision for expanding the use of numerical simulation by persons who do not have expertise in finite element analysis (FEA) be safely realized? The solution lies in the establishment of Simulation Governance through the development and dissemination of expert-designed Engineering Simulation Apps. Read more[...]

Finite Element Libraries: Mixing the “What” with the “How”

Finite Element Libraries: Mixing the “What” with the “How”

Sep 3, 2024

Engineering students first learn statics, then strength of materials, and progress to the theories of plates and shells, continuum mechanics, and so on. As the course material advances from simple to complex, students often think that each theory (model) stands on its own, overlooking the fact that simpler models are special cases of the more complex ones. This view guided the development of the finite element (FE) method in the 1960s and 70s, and ultimately led to legacy FE codes adopting an "element-centric" approach.

Obstacles to Progress
Obstacles to Progress

Obstacles to Progress

Oct 24, 2023

The development of the finite element method (FEM) consists of two main branches: the art of finite element modeling and the science of finite element analysis. Learn why in this blog.

Leave a Reply

We appreciate your feedback!
Cancel Reply

You must be logged in to post a comment.

Looking for Resources?

Interested in a Demo, Evaluation or Purchase?

Have a Software Question, Issue or Feature Request?

Recent News & Events

  • Trustworthiness in Simulation: Credibility or Decision-grade Reliability?
  • Beyond the Black Box: Explainable AI Requires Explainable Simulation
  • Turtle Shells and Legacy Finite Element Codes: Evolutionary Constraints in the Age of Explainable AI

Quick Links

  • Quick Start Guide
  • Documentation
  • Software FAQs
  • Software Demos

Testimonials

  • “A screening of existent commercial and non-commercial tools was carried out in respect to their fracture mechanics capabilities, their design abilities, implementation as well as their complexity. Although, there are many software possibilities, only those within the reach of the author were evaluated. This resulted in the selection of the commercial tool StressCheck. The assessment of crack propagation on compact tension and two stringer specimens governed by the Paris and Forman regimes was satisfactory compared with experimental results using the material data from simple standard specimens.”

    Lloren Llopart Prieto (EADS)
    Doctoral Thesis, "Modelling and analysis of crack turning on aeronautical structures"

Testimonials

“As the United States Air Force continues to extend the service life of their aircraft the Aircraft Structural Integrity Program (ASIP) has had to refine the methods it uses to analyze and predict fatigue crack growth. Through the use StressCheck, coupled with AFGROW, we in A-10 ASIP have been able to more accurately model, predict and analyze critical aircraft structure for the A-10 and other types of structure for non-A-10 system managers. This also allows us within the A-10 to more accurately assess risk for decision makers, streamline aircraft inductions into scheduled maintenance and reduce cost for total life cycle management.”

A-10 ASIP Manager

Member Portal

  • Member Registration
  • Member Login

Contact Us

© 2026 · Engineering Software Research & Development, Inc. | Terms & Conditions | Privacy & Cookie Policy | Software License Agreement | Software Maintenance and Technical Support Policy

Prev Next

We use cookies on our website to give you the most relevant experience by remembering your preferences and repeat visits, as outlined in our Cookie Policy. You may adjust your cookie preferences within .

ESRD
Powered by  GDPR Cookie Compliance
Privacy Overview

This website uses cookies to improve your experience while you navigate through the website. Out of these, the cookies that are categorized as necessary are stored on your browser as they are essential for the working of basic functionalities of the website. We also use third-party cookies that help us analyze and understand how you use this website. These cookies will be stored in your browser only with your consent. You also have the option to opt-out of these cookies. But opting out of some of these cookies may affect your browsing experience.

Strictly Necessary Cookies

Strictly Necessary Cookies should be enabled at all times so that we can save your preferences for cookie settings.