TRN 2009 CG Sim

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Position: Horizontal
5.86” & Vertical .46”,
both from top left corner
SolidWorks Simulation Training

SolidWorks 2009
Image courtesy of National Optical Astronomy

Observatory, operated by the Association of Universities
for Research in Astronomy, under cooperative
agreement with the National Science Foundation.
About this course
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 Prerequisites
 Course Design Philosophy
 Using this book
 A note about files
 Conventions used in this book
 Class Introductions
© 2007 SolidWorks Corp. Confidential. 2

Design Validation Products
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SolidWorks Simulation
Simulation Premium
Simulation Professional
SolidWorks
Vibration
Premium & Buckling Drop Test Nonlinear
Thermal
SolidWorks
Analysis
Flow Simulation
Static
Fatigue Optimization
Analysis Analysis Motion Dynamics
Simulation

What is Finite Element Analysis?
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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
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CAD Model Stress Results

Building the FEA Model - Restraints
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 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
 Restraints used to reduce the size of the

problem to a component level or
subassembly level

Building the FEA Model - Loads
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 Loads applied to exterior surfaces of the

model:
– Forces on Surfaces or Edges or Points
– Torque, Moment
– Pressure
 Loads acting on entire model:

– Gravity, Centrifugal force
– Thermal loads

FEA for structural analysis
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Example of a fitting
Split the fitting into small
tetrahedral pieces and
approximate the deformation
© 2007 SolidWorks Corp. Confidential.
on each piece 8
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Example of a bracket
Split the surfaces of bracket
into small triangular pieces and
on each piece 9
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Example of a frame structure

Split the members of frame into
small straight pieces and
on each piece 10
Mesh, Nodes, Elements, …
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 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

Using Stress Results to Validate Design
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 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 =

Assumptions in Linear, Static Analyses
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 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. Rapidly-
applied loads cause additional displacements,
strains, and stresses

Check list for SolidWorks Simulation Analysis
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1. Material?
– Steel 1040
2. Physical Working Condition?
– Pressure or force
– Bolted or Welded
3. Modeling in SolidWorks
Simulation
– TRAINING
4. Is my Design OK (Results)
– Factor of Safety
– Stress

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5.86” & Vertical .46”,
Lesson 1
The Analysis Process

Lesson 1 Topics
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 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

Lesson 1 Results
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von Mises Stresses in coarse study

Lesson 1 Results
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von Mises Stresses in default study

Lesson 1 Results
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von Mises Stresses in fine study

Lesson 1 Results
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Summary of results – convergence study
Finer mesh More accurate results More computational time

Exercise 1: Bracket
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Exercise 2: Compressive Spring Stiffness
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F 0.1
k  3
 255.7 N m
u 0.3907  10
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5.86” & Vertical .46”,
Lesson 2
Mesh Controls, Stress

Concentrations and Boundary
Conditions

Lesson 2 Topics
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 Using Configurations from SolidWorks

 Use of mesh controls, automatic transition
 FEA Convergence issues
 Different boundary conditions
fillet no fillet
configuration configuration

Lesson 2 Results
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No fillet configuration

Lesson 2 Results
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Stress Results – mesh1, mesh2 and mesh3

160
140
120
VonMises stress [MPa]
100
80
60
40
20
0
mesh1 mesh2 mesh3
1- When increasing the number of elements, will

the stresses converge?
2- Why?
Lesson 2 Results
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Fillet, Mesh Control
No Mesh Control With Automatic Transition

Lesson 2 Results
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Welded boundary condition
Fixed edge produces unrealistic stresses at the support location.

Lesson 2 – Understanding Boundary Conditions
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 Can greatly simplify the model

 Can also affect results
 Know your assumptions

Exercise 3: C-bracket
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No fillet Filleted edge

Exercise 3
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Fixed hole
Stress concentrations

Exercise 4: Bone Wrench
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Exercise 5: Foundation Bracket
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0.5 mm

Exercise 5: Foundation Bracket
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0.5 mm

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5.86” & Vertical .46”,
Lesson 3
Assembly Analysis with Contact

Lesson 3 Topics
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 Assembly Analysis Basics

 Interference Detection
 Global and Local Contact/Gaps
conditions

Contact/Gap Hierarchy
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Lesson 3 Results
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Von Mises stresses - No contact (225 N force)
(You can plot stresses in exploded configuration)

Lesson 3 Results
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Von Mises stresses – With contact (4000 N force)
Could we study the stresses on contact surfaces? 39

Exercise 6: Two Ring Assembly
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5.86” & Vertical .46”,
Lesson 4
Symmetrical and Free Self-Equilibrated

Assemblies

Lesson 4 Topics
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 Analyze shrink-fit problem

 Use of symmetry
 Review stress results in local
coordinate systems
 Solver options to eliminate rigid body
modes

Local Contact Conditions
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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)
Lesson 4 Results
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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 jump in radial stresses?
Exercise 7: Chain Link
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Exercise 8: Chain Link 2
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Incorrect solution
Correct solution

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5.86” & Vertical .46”,
Lesson 5
Assembly Analysis with Connectors

Lesson 5 Topics
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Connectors
•Rigid
•Spring
•Pin
•Elastic Support
•Bolt
•Spot Weld
•Link
•Bearing
Global and local contact conditions

Lesson 5 Results
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Exercise 9 & 10
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Exercise 11: Shock Absorber
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Simplify the model

1. Suppress the original
helical spring from the
analysis.
2. Introduce “Spring
Connector”.

Exercise 11: Shock Absorber
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Exercise 12: Spot Welds
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Connector types – Spot Welds
Spot Welds
Spot Welds

Exercise 12: Spot Welds
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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?
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5.86” & Vertical .46”,
Lesson 6
Compatible/Incompatible Meshing

Lesson 6 Topics
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 Compatible solid element mesh with

Bonded contacts
 Incompatible solid element mesh
with Bonded contacts
 Advanced bonding for incompatible
solid meshes
 Compatible/Incompatible mesh with
No Penetration conditions

Compatible solid mesh
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Bonding of touching parts is achieved by imprinting and merging the nodes.

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

Compatible solid mesh – No Penetration
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Global option: Compatible Global option: Incompatible
Mesh compatibility settings effects the mesh shape at all No Penetration, Node
to node contact interfaces.

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5.86” & Vertical .46”,
Lesson 7
Assembly Analysis Mesh Refinement

Lesson 7 Topics
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 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

Lesson 7 Results
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Draft mesh: mesh parameters and results
Mesh parameters and not ideal leading to

excessive von Mises stress results

Lesson 7 Results
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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.) 63
Exercise 13: Bolt Connectors
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5.86” & Vertical .46”,
Lesson 8
Analysis of Thin Components

Lesson 8 Topics
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 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

Lesson 8 Results
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Solid Elements – Von Mises Stress
(1 element per thickness) (2 element per thickness)
56259 DOF 878652 DOF

Shell Element Alignment
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Shell Elements - Alignment
Misaligned shell elements
Incorrect stress result representation

Lesson 8 Results
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Shell Elements (midplane) – Von Mises Stress Bottom

(orange)
Top (gray)
Top Bottom
Lesson 8 Results
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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 15
Case Study: Joist Hanger
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Shell elements
generated
Automatically for
sheet metal
features

Exercise 14: Bracket
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Exercise 15: Shell Mesh Using Outer/Inner Faces
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Shell Elements (surfaces) – Von Mises Stress Bottom

(orange)
Top (gray)
Top Bottom
Exercise 16: Spot Welds - Shell mesh
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Spot Welds - shell model - stress results
Both solid and shell models predict similar behavior. Which one would you choose?

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5.86” & Vertical .46”,
Lesson 9
Mixed Meshing Shells & Solids

Lesson 9 Topics
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Why Mixed Meshing?
Some design assemblies may contain “bulky” parts suitable for solid mesh,
as well as thin parts ideal for shell elements.

Solid and Shell Elements
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 Compatibility problems in mixed solid and

shell element meshing
 Use of mixed mesh in analysis
How many DOF does a How many DOF does a

solid element have? shell element have?

Lesson 9 Results
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Why are the stresses highest at the base near the support and bonded
contacts?
Exercise 17
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5.86” & Vertical .46”,
Lesson 10
Mixed Meshing Solids, Beams & Shells

Lesson 10 Results
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Exercise 18: Beam Elements
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Exercise 19: Cabinet
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5.86” & Vertical .46”,
Lesson 11
Design Scenarios

Lesson 11 Topics
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 Design Scenarios – 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 rod
– Moving on a bumpy road
– Moving at a constant speed on a banking
– Different loads in different directions
 Review different connectors and restraints

Design Scenario with loads input
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Lesson 11 Results (Loads input)
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Design Scenario with geometry input
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Lesson 11 Results (Geometry input)
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Exercise 20: Design Scenarios
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5.86” & Vertical .46”,
Lesson 12
Thermal Stress Analysis

Lesson 12 Topics
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 Static analysis with temperature load

 Use of various contact conditions
 Temperature dependent material properties
 Soft spring and Inertia relief options

Lesson 12 Results
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Averaging across boundaries ON Averaging across boundaries OFF

Lesson 12 Results
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Axial strain at the sensor locations

Lesson 12 Results
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5.86” & Vertical .46”,
Lesson 13
Adaptive Meshing

Lesson 13 Topics
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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

Adaptive Finite Element Analysis
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h-Adaptivity, p-Adaptivity
Refining the mesh (h-Adaptivity)
Changing the “order” of elements (p-Adaptivity)
… 5th order
1st order 2nd order

(Draft Quality) (High Quality)

Lesson 13 Results
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h-Adaptivity - results
98% convergence criteria (2% accuracy) was achieved in 4 iterations

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

Lesson 13 Results
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Summary
Max. displacement difference: 1.6%

Max. Von Misses stress difference: 28%
Which method would you use?

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5.86” & Vertical .46”,
Lesson 14
Large Displacement Analysis

Lesson 14 Topics
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 Surface contact
 Contact analysis with the large
displacement option
 Evaluate mesh adequacy for
modeling bending stresses
 Limitations of the linear material
model

Lesson 14 Results
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Small displacement contact analysis – Incorrect Displacements

Lesson 14 Results
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Large displacement contact analysis – Correct Displacements

TRN 2009 CG Sim

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VAR logo here

SolidWorks Simulation Training

Image courtesy of National Optical Astronomy

© 2007 SolidWorks Corp. Confidential. 2

© 2007 SolidWorks Corp. Confidential. 3

Curved path is approximated

© 2007 SolidWorks Corp. Confidential. 4

CAD Model Stress Results

© 2007 SolidWorks Corp. Confidential. 5

 Represent how the given model is

 Restraints used to reduce the size of the

© 2007 SolidWorks Corp. Confidential. 6

 Loads applied to exterior surfaces of the

 Loads acting on entire model:

© 2007 SolidWorks Corp. Confidential. 7

Example of a frame structure

 MESH – Approximate representation of the

© 2007 SolidWorks Corp. Confidential. 11

 Stresses at a point are defined by 6 quantities – 3 normal

 Von Mises “Equivalent” Stress =

VON is independent of coordinate system

 Principal Stresses – 3 normal stresses specified in a special

© 2007 SolidWorks Corp. Confidential. 12

 Response is proportional to the applied loads

 Material is linearly elastic

 Loads are static

© 2007 SolidWorks Corp. Confidential. 13

© 2007 SolidWorks Corp. Confidential. 14

The Analysis Process

Image courtesy of National Optical Astronomy

 Introduction to the Simulation interface

 Perform linear static analysis – Static study

© 2007 SolidWorks Corp. Confidential. 16

von Mises Stresses in coarse study

© 2007 SolidWorks Corp. Confidential. 17

von Mises Stresses in default study

© 2007 SolidWorks Corp. Confidential. 18

von Mises Stresses in fine study

© 2007 SolidWorks Corp. Confidential. 19

Summary of results – convergence study

Finer mesh More accurate results More computational time

© 2007 SolidWorks Corp. Confidential. 20

© 2007 SolidWorks Corp. Confidential. 21

Mesh Controls, Stress

Image courtesy of National Optical Astronomy

 Using Configurations from SolidWorks

© 2007 SolidWorks Corp. Confidential. 24

© 2007 SolidWorks Corp. Confidential. 25

Stress Results – mesh1, mesh2 and mesh3

1- When increasing the number of elements, will

Fillet, Mesh Control

No Mesh Control With Automatic Transition

© 2007 SolidWorks Corp. Confidential. 27

Welded boundary condition

Fixed edge produces unrealistic stresses at the support location.

© 2007 SolidWorks Corp. Confidential. 28

 Can greatly simplify the model

© 2007 SolidWorks Corp. Confidential. 29

No fillet Filleted edge

© 2007 SolidWorks Corp. Confidential. 30

© 2007 SolidWorks Corp. Confidential. 31

© 2007 SolidWorks Corp. Confidential. 32

© 2007 SolidWorks Corp. Confidential. 33