SolidWorks Simulation Training

Stephen Benjamin Alcaraz, ECE

stephen@computrends.com.ph
Applications Engineer, CSWE
About this course
• Class Introductions
• Prerequisites
• Course Design Philosophy
• Using this book
• A note about files
• House Rules
 SOLIDWORKS Simulation
Simulation Premium
Simulation Professional
Simulation Standard

Static Fatigue Topology Frequency Optimization Edge Weld Nonlinear Linear

Drop Test Thermal
Connector Static Dynamic

Event-based Pressure 2-D Material Nonlinear

Motion Trend Tracker Buckling Submodeling Composites
Motion Vessel Simplification Web Portal* Dynamic
Contents (Day 1)
Lesson 1: The Analysis Process
Lesson 2: Mesh Controls, Stress Concentrations
and Boundary Conditions
Lesson 3: Assembly Analysis with Contact
Lesson 4: Symmetrical and Free Self-Equilibrated Assemblies
Lesson 5: Assembly Analysis with Connectors and Mesh Refinement
Lesson 6: Compatible/Incompatible Meshes
Lesson 7: Analysis of Thin Components
Contents (Day 2)
Lesson 8: Mixed Meshing Shells & Solids
Lesson 9: Beam Elements
Lesson 10: Mixed Meshing Solids, Beams & Shells
Lesson 11: Design Study
Lesson 12: Thermal Stress Analysis
Lesson 13: Adaptive Meshing
Lesson 14: Large Displacement Analysis
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

Example of a fitting Split the fitting into small tetrahedral pieces and
approximate the deformation on each piece
FEA for structural analysis

Example of a bracket Split the surfaces of bracket into small

triangular pieces and approximate the
deformation on each piece
FEA for structural analysis

Split the members of frame into small

Example of a frame structure straight pieces and approximate the
deformation on each piece
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
• DOF – Degrees of Freedom
 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 =
 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 Small deformation

• The part returns to its original shape if the loads are

removed (no permanent deformation) Large deformation

• Loads are static

• Loads are applied slowly and gradually. Rapidly-
applied loads cause additional displacements, strains,
and stresses
Structural Matrix Equation of Motion

[M] = Mass matrix f = Loads vector

[C] = Damping matrix U = Displacement vector
[K] = Stiffness matrix t = time
Check list for SolidWorks Simulation
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
Lesson 1
• The Analysis Process

110,000 N
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
SolidWorks Simulation interface

CommandManager tab

Simulation Advisor
Study tree
Study tabs
Loads and restraints
Lesson 1: Results
von Mises Stresses in coarse study
Lesson 1: Results
von Mises Stresses in default study
Lesson 1: Results
von Mises Stresses in fine study
Lesson 1: Results
Summary of results – convergence study

Finer Mesh More accurate results More computational time

Lesson 2
• Mesh Controls, Stress Concentrations
and Boundary Conditions
Lesson 2: Topics
• Using SolidWorks Configurations
• Use of mesh controls, automatic transition
• FEA Convergence issues
• Different boundary conditions
fillet configuration no fillet configuration
Loads and restraints
Lesson 2: Results
No fillet configuration
Lesson 2: Results
Stress Results – mesh1, mesh2 and mesh3

1- When increasing the number of elements, will the stresses converge?

2- Why?
Lesson 2: Results
Fillet, Mesh Control

No Mesh Control Mesh Control

Lesson 2: Results
Welded boundary condition

Fixed edge produces unrealistic stresses at the support location.

Lesson 2: Boundary Conditions
• Can greatly simplify the model
• Can also affect results
• Know your assumptions
Lesson 3
• Assembly Analysis with Contact
Lesson 3: Topics
• Assembly Analysis Basics
• Interference Detection
• Global and Local Contact/Gaps conditions
Lesson 3:
Interference Detection
Lesson 3: Global contact
• Default: Bonded

• Global contact conditions

• No penetration
• Bonded (No clearance)
• Allow Penetration

• Component Contact
• Uncheck Global Contact box
• Overrides Global Contact
 Lesson 3: 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
Lesson 3: Local Contact Conditions
• For structural studies • For thermal studies
• No Penetration • Insulated (no contact)
• Bonded • Thermal contact resistance
• Allow Penetration
• Shrink Fit
• Virtual Wall

• Friction at the local level for touching entities

• Initial gap (clearance) can be ignored or
accounted for by specifying it here
 Lesson 3: No Penetration(Advanced Option)

Node to Node Node to Surface Surface to Surface

(initially touching) (more accurate)
Lesson 3: Loads and restraints, mesh
225 N
i) Global No Penetration contact
ii) Local contact

Fixed
225 N
Lesson 3: Results
Von Mises stresses - Global contact (225 N force)

(You can plot stresses in exploded configuration)

Lesson 3: Results
Von Mises stresses – With local contact (4500 N force)

Could we study the stresses on contact surfaces?

Lesson 4
• Symmetrical and Free Self-Equilibrated Assemblies
Lesson 4: Topics
• Analyze shrink-fit problem
• Use of symmetry
• Solver options to eliminate rigid
body modes
Lesson 4: Local Contact Conditions

Contact set (local contact) – 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: Contact
Lesson 4: Boundary conditions
Option 1: Symmetry Option 2: Cyclic Symmetry
Lesson 4: Stabilization options
Lesson 5
• Assembly Analysis with Connectors
and Mesh Refinement
Lesson 5: Topics
• Connectors • Spot Weld (SW Pro)
• Rigid • Edge Weld (SW Pro)
• Spring • Link
• Pin • Bearing
• Elastic Support • Global and local
contact conditions
• Bolt
Connectors

Bolt Pin Bolt (Foundation Bolt)

Boundary conditions and Mesh
Lesson 5: Results
Lesson 6
• Compatible/Incompatible Meshes
Lesson 6: Topics
• Compatible solid element mesh with Bonded contacts
• Incompatible solid element mesh with Bonded contacts
• Simplified bonding for incompatible solid meshes
Lesson 6: Compatible solid mesh

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

Lesson 6: Incompatible solid mesh

Bonding of touching parts is achieved by additional constraint equations.

Lesson 6: Incompatible Bonding Options

Surface based contact. Results at the contact

interface are uniform but solution time is longer.
 Lesson 6: Incompatible Bonding Options

Node based contact. Results at the contact interface

may be patchy but solution time is lower.
Lesson 7
• Analysis of Thin Components
Lesson 7: 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
Lesson 7: Shell offset
• Mid-surface
• Top surface
• Bottom surface
• Ratio

▪ By default, mesh located at mid-plane

▪ Orientation important when defining
shells with different thickness
Lesson 7: Results
Solid Elements – Von Mises Stress
55449 DOF 987978 DOF
Lesson 7: Shell elements
Defined by:
• Existing surface or sheet metal
bodies Mid-plane surface
• Mid-plane surfaces
• Outside/inside faces of solid bodies

Outside faces
Lesson 7: Shell Type

Kirchoff Theory Mindlin Theory

span span
 20 10   20
thickness thickness

Thin shells ignore shear deformation through the thickness of the shell
Lesson 7: Results
Bottom(orange)
Shell Elements (midplane) – Von Mises Stress
Top(gray)
Lesson 7: Results
Shell vs. Solid Elements
Lesson 8
• Mixed Meshing Shells & Solids
Lesson 8: Topics
• Mixed meshing
• Solid-shell bonding
• Shell offset
• Mesh failure diagnostics
Lesson 8: 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.
Lesson 8: Solid and Shell Elements
• Compatibility problems in mixed solid and shell element
meshing
• Use of mixed mesh in simulation
How many DOF How many DOF
does a solid element have? does a shell element have?
Lesson 8: Bonding between solids and shells
• Hinge formed at the connecting edge
• May introduce rigid body modes if not
handled properly Hinge
• Mesh incompatible at the interface
• Bond generated through multi-point
constraints internally (mortar bonding)
Lesson 8: Mesh failure diagnostics
• Incompatible mesh
• Mesh control
• Auto-looping
• Check geometry
• Switch mesher
Lesson 8: Results
Lesson 9
• Beam Elements – Analysis of a Conveyor Frame
Lesson 9: Topics
• Beam elements
• Joints
• Bonding of beams
• Post-processing of beam elements
Lesson 9: Beam elements

6 DOFs
Lesson 9: Joints

• joints are connected to two or more beam members.

• joints are connected to a single member only
Lesson 9: Loads and Fixtures
Lesson 9: Results
 Results for beam elements
• Stress: Axial, bending, worst-case,
torsional, shear
• Displacement
• Axial force diagrams
• Shear & bending moment
diagrams
• Reaction forces & moments
• FOS = Worst-case / Yield Strength
Simply supported with uniform distributed loading
Lesson 10
• Mixed Meshing Solids, Beams & Shells
Lesson 10: Topics
• Mixed Meshing of Solid, Shells and Beams
• Editing Beam Joints
• Bonding of Solid, Shells and Beams elements
• Post-processing of Beam elements
Lesson 10: Solids, Shells and Beam elements
Solid bodies
Shell
Solid bodies of the separator
body modeled as shells

Solid Surfaces Excluded

from analysis
Beam

Beams
Shell

Solid Solid bodies of the cross gussets

modeled as shells

Solid bodies
Lesson 10: Shell Element Alignment
Shell Elements - Alignment
Misaligned shell elements

Incorrect stress result representation

Lesson 10: Bonding of beams

• Beam profile imprinted on target entities

• Accurate results at the interface
Lesson 10: Results
Lesson 11
• Design Study
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
• Review different connectors and fixtures
Lesson 11: Variables
• Dimensions (angular dimension also)
• Load Simulation Data Input
• Material Database
Diameter of hole
is increased
Lesson 11: Constraints
• Constraints - The conditions that the optimized design must satisfy
• A constraint is associated with the initial study
• For static studies. Nodal or element stresses, strains, or
displacements
• For buckling studies. First through tenth buckling load factors
• For frequency studies. First through tenth resonant frequencies
• For thermal studies. Temperatures, temperature gradients, or heat
fluxes
Lesson 11: Design Scenario with loads input
Lesson 11: Results (Loads input)
Lesson 12
• Thermal Stress Analysis
Lesson 12: Topics
• Static analysis with temperature load
• Reference Temperature at Zero Strain
• Temperature dependent material properties
• Soft spring and Inertia relief options
Lesson 12: Results
Averaging across boundaries ON Averaging across boundaries OFF
Lesson 13
• Adaptive Meshing
Lesson 13: Topics

Why and What is Mesh Adaptivity?

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
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
h-Adaptivity - results

98% convergence criteria (2% accuracy) was achieved in 6 iterations

Lesson 13: Results
p-Adaptivity - results

0.05% convergence criteria was/was not achieved in 4 iterations

Lesson 13: Results
Summary
Lesson 14
• Large Displacement Analysis

14,000 N
Lesson 14: Results
Small displacement contact analysis – Incorrect Displacements
Lesson 14: Results
Large displacement contact analysis – Correct Displacements