Solidworks Simulation Training Chapter 3

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SolidWorks Simulation Training

SolidWorks 2012
About this course
Prerequisites
Course Design Philosophy
Using this book
A note about files
Conventions used in this book
Class Introductions
Design Validation Products

Simulation Premium
SolidWorks
Premium
Simulation Professional
Frequency/
Buckling
Nonlinear
Fatigue
Optimization
Static
Composites
SolidWorks
Motion
Thermal
Drop Test
Pressure
Vessel
Advanced
Dynamics
What is Finite Element Analysis?

Example: Brick road from home to mailbox measure the distance of a
curved path using yard stick
Curved path is approximated by straight segments

Measure using a yard stick
Building the FEA Model

CAD Model
Stress Results
Building the FEA Model - Fixtures
Represent how the given model is attached to the rest of the world
Fixed on a Surface or Edge or Point
Allow Sliding or Rotation
Fixtures used to reduce the size of the problem to a component

level or subassembly level
Building the FEA Model - Loads
Loads applied to exterior surfaces of the model
Forces on Surfaces or Edge or Points

Torque, Moment
Pressure
Loads acting on entire model
Gravity, Centrifugal force

Thermal loads
FEA for structural analysis
Split the fitting into small tetrahedral

pieces and approximate the
deformation on each piece
Example of a fitting
Example of a bracket
Split the surfaces of bracket into small

triangular pieces and approximate the
9
Example of a frame structure
Split the members of frame into small

straight pieces and approximate the
10
Mesh, Nodes, Elements,
MESH Approximate representation of the

CAD geometry using Tetrahedra or Triangles
ELEMENTS Tetrahedra or Triangles in the
Mesh
NODES - Points at which different elements are
jointed together; nodes are the locations where
values of unknowns (usually displacements)
are to be approximated
11
Using Stress Results to Validate Design

Stresses at a point are defined by 6 quantities 3 normal stress and
3 shear stresses depend on orientation of coordinate system
Von Mises Equivalent Stress =
VON is independent of coordinate system

Principal Stresses 3 normal stresses specified in a
special coordinate system for which shear stresses
are zero
Factor of Safety =
12
Assumptions in Linear, Static Analyses

Response is proportional to the applied loads
If you double the load, deformation also gets
doubled
If you remove the load, model has no deformation
Material is linearly elastic
The part returns to its original shape if the loads are
removed (no permanent deformation)
Loads are static
Loads are applied slowly and gradually. Rapidlyapplied loads cause additional displacements,
strains, and stresses
13
Small deformation
Large deformation
Check list for SolidWorks Simulation
1.
Material?
2.
Steel 1040
Physical Working Condition?
3.
Pressure or force
Bolted or Welded
Modeling in SolidWorks Simulation
4.
TRAINING
Is my Design OK (Results)
Factor of Safety
Stress
14
Lesson 1
The Analysis Process
15
Lesson 1 Topics
Introduction to the Simulation interface
Perform linear static analysis Static
study
Material properties
Restraints
Loads
Mesh
Run
Influence of mesh density on displacement
and stress results
Post-processing
16
SolidWorks Simulation interface

CommandManager tab
Analysis library
Toolbar
Study tree
Simulation Advisor
Study tabs
17
Loads and restraints
18
Lesson 1: Results
von Mises Stresses in coarse study
19
Lesson 1: Results
von Mises Stresses in default study
20
Lesson 1: Results
von Mises Stresses in fine study
21
Lesson 1: Results
Summary of results convergence study
Finer mesh More accurate results
22
More computational time
Lesson 1 Results
Comparison with analytical
Which result is correct???
23
Exercise 1: Bracket
24
Exercise 2: Compressive Spring Stiffness
F
0 .1
234.7 N m
3
u 0.426 10
25
Exercise 3: Container Handle
26
Lesson 1: Questions
27
Lesson 2
Mesh Controls, Stress Concentrations and Boundary Conditions
28
Lesson 2: Topics
Using SolidWorks Configurations

Use of mesh controls, automatic transition
FEA Convergence issues
Different boundary conditions
fillet configuration
no fillet configuration
29
Loads and restraints
30
Lesson 2: Results
No fillet configuration
31
Lesson 2: Results
Stress Results mesh1, mesh2 and mesh3
1- When increasing the number of elements, will the stresses converge?

2- Why?
32
Lesson 2: Results
Fillet, Mesh Control
No Mesh Control
Mesh Control
33
Lesson 2: Results
Welded boundary condition
Fixed edge produces unrealistic stresses at the support location.

34
Lesson 2: Boundary Conditions
Can greatly simplify the model

Can also affect results
Know your assumptions
35
Exercise 4: C-bracket
No fillet
Filleted edge
36
Exercise 4
Fixed hole
Stress concentrations
37
Exercise 5: Bone Wrench
38
Exercise 6: Foundation Bracket
0.5 mm
39
Exercise 6: Foundation Bracket
0.5 mm
40
Lesson 2: Questions
41
Lesson 3
Assembly Analysis with Contact
42
Lesson 3: Topics
Assembly Analysis Basics
Interference Detection
Global and Local Contact/
Gaps conditions
43
Interference Detection
44
Global contact
Default: Bonded
Global contact conditions
No penetration
Bonded (No clearance)
Allow Penetration
Component Contact
Uncheck Global Contact box

Overrides Global Contact
45
Contact/Gap Hierarchy
Global and Component contact apply only to initial touching areas

Global contact for most common condition, component and local
contact as needed
46
Local Contact Conditions
For structural studies
No Penetration
Bonded
Allow Penetration
Shrink Fit
Virtual Wall
For thermal studies

Insulated (similar to Free in a static study)
Thermal contact resistance
Friction at the local level for touching entities

Initial gap (clearance) can be ignored or accounted for by specifying it
here
47
Loads and restraints, mesh

225 N
i)
ii)
Global No Penetration contact

Local contact
Fixed
225 N
48
Lesson 3: Results
Von Mises stresses - Global contact (225 N force)
(You can plot stresses in exploded configuration)

49
Lesson 3: Results
Von Mises stresses With local contact (4500 N force)
Could we study the stresses on contact surfaces?
50
Exercise 7: Two Ring Assembly
51
Lesson 3: Questions
52
Lesson 4
Symmetrical and Free Self-Equilibrated Assemblies
53
Lesson 4: Topics
Analyze shrink-fit problem

Use of symmetry
Review stress results in local coordinate
systems
Solver options to eliminate rigid body
modes
54
Local Contact Conditions
Contact conditions (global & local) review
Contact conditions (local only) Shrink fit

1 - Program creates a shrink fit condition between selected faces.
2 - The faces may or may not be cylindrical.
(NOTE: Virtual wall a sliding support (roller), with friction and wall elasticity capability)
55
Boundary conditions
56
Contact and Mesh
57
Lesson 4: Results
Hoop stress (using local cylindrical coordinates)
Why is there a jump in the hoop stress value across the interface?
Would the assembly experience a similar jump58in radial stresses?
Exercise 8: Chain Link
59
Exercise 9: Chain Link 2
Incorrect solution
Correct solution
60
Lesson 5
Assembly Analysis with Connectors
61
Lesson 5: Topics
Connectors
Rigid
Spring
Pin
Elastic Support
Bolt
Spot Weld
Edge Weld
Link
Bearing
Global and local contact conditions
62
Connectors
Spring
Pins (three in all)
63
Boundary conditions and Mesh

225 N
Fixed
225 N
64
Lesson 5: Results
65
Exercise 10 & 11
66
Exercise 12: Shock Absorber

Simplify the model
1. Suppress the original

helical spring from the
analysis.
2. Introduce Spring Connector.
67
Exercise 12: Shock Absorber
68
Exercise 13: Spot Welds

Connector types Spot Welds
Spot Welds
Spot Welds
69
Exercise 13: Spot Welds
Spot Welds - solid models - stress results
We notice high stresses in the vicinity of welds. Would the subsequent mesh refinement in these regions
bring more accurate stress distribution?
70
Lesson 6
Compatible/Incompatible Meshing
71
Lesson 6: Topics
Compatible solid element mesh with Bonded contacts

Incompatible solid element mesh with Bonded contacts
Simplified bonding for incompatible solid meshes
72
Compatible solid mesh
Bonding of touching parts is achieved by imprinting and merging the nodes.

73
Incompatible solid mesh
Bonding of touching parts is achieved by additional constraint equations.

74
Incompatible solid mesh: More Accurate

Bonding
Surface based contact. Results at the contact interface are uniform

but solution time is longer.
75
Incompatible solid mesh: Simplified

Bonding
Node based contact. Results at the contact interface may be

patchy but solution time is lower.
76
Lesson 7
Assembly Analysis Mesh Refinement
77
Lesson 7: Topics
Analyze larger assembly using solid
elements
Remote load feature
Define multiple contact conditions
Nontraditional contact and connector use
Analyze mesh quality and question the
results of the simulation
78
Remote loads
Load (Direct transfer)

Load/Mass (Rigid connection)
Displacement (Rigid connection)
79
Bolt connectors
Bolt type
Tight fit
Material
Pre-load
Bolt series
80
Virtual wall
Type of contact that replaces modeling a

component
Rigid or Flexible
81
Lesson 7: Results
Draft mesh: mesh parameters and results
Mesh parameters are not ideal leading to

excessive von Mises stress results
82
Lesson 7: Results
High mesh: mesh parameters and results
Mesh parameters improved, so did the results of

the simulation.
(NOTE: The time required to complete the simulation increased as well.)
83
Exercise 14: Bolt Connectors
84
Exercise 15: Awning
85
Lesson 7: Questions
86
Lesson 8
Analysis of Thin Components
87
Lesson 8: Topics
Shell Elements
Mid-plane and surface shell element meshing
Alignment of shell mesh
Evaluating mesh sizes
Evaluating results for shell elements
Reaction forces
Solid vs. Shell meshing
88
Lesson 8: Results
Solid Elements Von Mises Stress
55449 DOF
987978 DOF
(2 element per thickness)
(1 element per thickness)
89
Shell elements
Defined by:
Existing surface or sheet metal
bodies
Mid-plane surfaces
Outside/inside faces of solid bodies
Mid-plane surface
Outside faces
90
Shell Type
Kirchoff Theory
span
20
thickness
Mindlin Theory
span
10
20
thickness
Thin shells ignore shear deformation through the thickness of the shell
91
Shell Element Alignment

Shell Elements - Alignment
Misaligned shell elements
Incorrect stress result representation
92
Lesson 8: Results
Shell Elements (midplane) Von Mises Stress
Bottom
(orange)
Top (gray)
93
Lesson 8: Results
Shell vs. Solid Elements
Shell elements can greatly decrease the required computational time.
Modeling with shell elements is more demanding than with solids.

* See results of Exercise 16
94
Case Study: Joist Hanger
Shell elements generated

automatically for sheet metal
features
95
Exercise 16: Bracket
96
Exercise 17: Shell Mesh Using Outer/Inner Faces

Shell Elements (surfaces) Von Mises Stress
Bottom
(orange)
Top (gray)
Top
Bottom
97
Exercise 18: Spot Welds - Shell mesh
Spot Welds - shell model - stress results
Both solid and shell models predict similar behavior. Which one would you choose?
98
Exercise 19: Edge Weld Connector
Edge Welds - shell model weld bead sizes
Design the size of the edge weld beads.
99
Exercise 20: Container Handle Weld
Self-guided exercise
Design double sided fillet welds connecting the container handle to the square plates.
100
Lesson 8: Questions
101
Lesson 8: Questions
102
Lesson 9
Mixed Meshing Shells & Solids
103
Lesson 9: Topics
Mixed meshing
Solid-shell bonding
Shell offset
Mesh failure diagnostics
104
Mixed meshing
Why Mixed Meshing?
Some design assemblies may contain bulky parts suitable for solid mesh, as well as thin
parts ideal for shell elements.
105
Solid and Shell Elements
Compatibility problems in mixed solid and shell element meshing

Use of mixed mesh in simulation
How many DOF does a solid
element have?
How many DOF does a shell

element have?
106
Bonding between solids and shells
Hinge formed at the connecting edge

May introduce rigid body modes if not
handled properly
Mesh incompatible at the interface
Bond generated through multi-point
constraints internally (mortar bonding)
107
Hinge
Shell offset
Mid-surface
Top surface
Bottom surface
Ratio
By default, mesh located at mid-plane

Orientation important when defining
shells with different thickness
108
Mesh failure diagnostics
Incompatible mesh
Mesh control
Auto-looping
Check geometry
Switch mesher
109
Lesson 9: Results
Why are the stresses highest at the base near the support and bonded contacts?
110
Exercise 21: Mixed Mesh Analysis
111
Lesson 9: Questions
112
Lesson 10
Mixed Meshing Solids, Beams & Shells
113
Lesson 10: Topics
Beam elements
Joints
Bonding of beams
Post-processing of beam elements
114
Beam elements
6 DOFs
115
Joints
joints are connected to two or more beam members.

joints are connected to a single member only
116
Bonding of beams
Bond joints or entire beam to

target entities
Beam profile imprinted on target entities
Accurate results at the interface
117
Lesson 10: Results
118
Results for beam elements
Stress: Axial, bending,

worst-case, torsional, shear
Displacement
Axial force diagrams
Shear & bending moment
diagrams
Reaction forces & moments
Simply supported with uniform distributed loading

119
Exercise 22: Beam Elements
120
Exercise 23: Cabinet
121
Exercise 24: Frame Rigidity
122
Exercise 24: Frame Rigidity
123
Lesson 11
Design Study
124
Lesson 11: Topics

Design Study performing several studies for different
input data (model geometry or loads)
Stresses in vehicle suspension when vehicle is:
Stationary and loaded

Moving at constant acceleration on a smooth road
Moving on a bumpy road
Moving at a constant speed on a banking road
Different loads in different directions
Review different connectors and fixtures
125
Design Scenario with loads input
126
Lesson 11: Results (Loads input)
127
Design Scenario with geometry input
128
Lesson 11: Results (Geometry input)
129
Exercise 25: Design Scenarios
130
Lesson 12
Thermal Stress Analysis
131
Lesson 12: Topics
Static analysis with temperature load

Use of various contact conditions
Temperature dependent material properties
Soft spring and Inertia relief options
132
Lesson 12: Results

Averaging across boundaries ON
Averaging across boundaries OFF
133
Lesson 12: Results
Axial strain at the sensor locations
134
Lesson 12: Results
135
Lesson 13
Adaptive Meshing
136
Lesson 13: Topics

Why and What is Adaptivity?
What do FEM results depend on?

1. Mesh
2. Type and order of the elements used (Draft or High quality)
3. Other phenomena (numerical errors, modeling errors etc.)
What is our Goal? Is it just to obtain a solution?
Make sure our results are close to some defined accurate solution.
(typical parameter is strain energy density)
How to achieve it?
1. Modify and refine the mesh topology
h-adaptivity
2. Modify the order of elements
p-adaptivity
137
Adaptive Finite Element Analysis

h-Adaptivity, p-Adaptivity
Refining the mesh (h-Adaptivity)
Changing the order of elements (p-Adaptivity)
1st order
(Draft Quality)
5th order
2nd order
(High Quality)
138
Lesson 13: Results
h-Adaptivity - results
98% convergence criteria (2% accuracy) was achieved in 6 iterations

139
Lesson 13: Results
p-Adaptivity - results
0.05% convergence criteria was/was not achieved in 4 iterations

140
Lesson 13: Results
Summary
Max. displacement difference: 0.2%

Max. Von Misses stress difference:10%
Which method would you use?

141
Lesson 14
Large Displacement Analysis
142
Lesson 14: Topics
Surface contact
Contact analysis with the large
displacement option
Evaluate mesh adequacy for modeling
bending stresses
Limitations of the linear material model
143
Lesson 14: Results
Small displacement contact analysis Incorrect Displacements
144
Lesson 14: Results
Large displacement contact analysis Correct Displacements
145
Lesson 14: Questions
146

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