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Simulation by Industry

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How SolidWorks Simulation is applied in industry-leading organizations

How SolidWorks Simulation is applied in industry-leading organizations

Published in: Technology, Business

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  • 1. Consumer Products – Tools Frequency or Dynamics Optimization • Plastic prices track volatile oil prices. Companies learned the hard way in 2005 that • Vibration from engines or motors must not sub-optimal plastic design can eliminate cause unnecessary fatigue to the consumer profitability. • Uncontrolled resonance can cause • Weight reduction for hand held devices is objectionable noise & quality concerns always critical • Vibration from transportation or operation must not cause fasteners, to release or fail Buckling • Consumer use is unpredictable so designΙ © Dassault Systèmes Ι Confidential Information Ι must account for eccentric loading which Fatigue worsens buckling • Repetitive loading over life of product can present fatigue concerns. Heat Transfer or Thermal • Hardware products must be sustain peak performance for a market-driven design life. • Temperatures from motors or engines must not present danger to consumer. • Cold weather and water products typically Drop Test have complex and extreme temperature distributions that can lead to expansion related failure. • Consumers drop products! Perception is usually lack of quality than misuse. • Today’s tool purchasers aren’t demanding Nonlinear longevity as much as robust performance in extreme use. Drop performance has become a critical design consideration. • Contact between assembly components is required for realistic modeling, friction modeling may be required. • Accurate prediction of plastic or custom Motion Simulation materials requires nonlinear material modeling • Size motors for electric products • As designers push the envelope, responses • Optimize mechanism paths and motor loads become increasingly nonlinear. 1
  • 2. Medical Products Frequency or Dynamics Drop Test • Avoid failure of components if dropped during • Avoid excessive shaking / rattling / vibration the assembly process. by making sure that the natural frequency of • Minimize chances of product damage if ultrasonic resonators or a CT scanners is dropped in a care facility. different than the driving piezoelectric components. Nonlinear • Take into account vibration variation caused by rotors in centrifuge systems • To study specialty materials such as the • Minimize noise or perceived vibration and Nitinol shape alloy • Improve the performance of catheters goingΙ © Dassault Systèmes Ι Confidential Information Ι extend the life of machinery due to rotating system imbalance through an artery which experience large deformation. • To study contact interactions between assembly components Heat Transfer or Thermal • To predict buckling or collapse of tubing in bending. Nonlinear buckling and material • Avoid excessive heating on operator properties come into play for these scenarios. accessible surfaces or components by studying the temperature distribution of the entire machine assembly Fatigue • Isolating temperatures generated during • Avoid failure from repetitive or cyclic loads normal operating conditions from affecting and temperatures other components. • To estimate and/or optimize the lifespan of a • Isolating temperatures generated during product assembly processes such as welding from affecting rest of the components of the Optimization machine • To design lighter, smaller, cheaper parts • Study thermal expansion/contraction of without compromising strength or components and resulting thermal stress. performance • Reduce shipping and transportation costs by using lighter parts Flow Simulation • Optimize flow rate of valves and meters Buckling • Study mixing in a drug delivery system to To avoid compressive buckling or collapse of reduce variance slender needles or drug delivery systems 2
  • 3. Manufacturing Equipment Frequency or Dynamics Heat Transfer or Thermal • Vibration from motors and spindles must not • Temperatures from cutting/milling must not impact precision degrade bearings in spindles • Vibration from surrounding environment must • Temperature rise from operation and motor not resonate in cabinet must not impact milling precision due to • Cantilevered work tables must not vibrate due thermal expansion of the system of the work to operating cyclesΙ © Dassault Systèmes Ι Confidential Information Ι Fatigue • All structural members must be designed for Optimization durability • Weight reduction for spindles minimizes • Repetitive loading of automatic tables can inertias and makes precision control of milling present fatigue concerns more reliable • Maximizing stiffness of components in load path improves precision Nonlinear • Contact between assembly components is Drop Test required for realistic modeling • Ensure that spindles or cutting tools can handle reasonable drop heights without damage Flow Simulation Buckling • Thermoformed packaging needs to be heated • Buckling on leveling & support legs is possible and cooled failure mode to watch • Product velocity can cause air flow related • Buckling of unsupported sections of disturbances resulting in mishandling conveyors due to normal operation or misuse • Design of an effective scrap removal system (operator weight) must be avoided. 3
  • 4. Packaging Equipment Frequency or Dynamics Heat Transfer or Thermal • Vibration from plant environment must not • Temperatures required for tray or bag sealing affect precision must not reduce linear bearing life due to • Avoid vibration due to drive motors over-heating • Temperatures from operation must not impact the packaged product Fatigue • All structural members must be designed for durabilityΙ © Dassault Systèmes Ι Confidential Information Ι Optimization Nonlinear • The price of stainless steel has doubled in the past year but equipment is bid months in • Contact between assembly components is advance so material reduction has become required for realistic modeling critical. • Plastic deformation of package components must be predicted to ensure reliable end-use • Multiple plastic & elastomer handling components require nonlinear properties to properly model Buckling Flow Simulation • Buckling on leveling & support legs is possible • Thermoformed packaging needs to be heated failure mode to watch and cooled • Buckling of unsupported sections of • Product velocity can cause air flow related conveyors due to normal operation or misuse disturbances resulting in mishandling (operator weight) must be avoided. 4
  • 5. Construction & Excavation Equipment Frequency or Dynamics Optimization • Avoid frequencies caused by vibration from tracks or travel surface roughness • Global Steel Price Index has DOUBLED in the • Avoid vibration due to engine noise last 5 years! • Weight reduction in all articulated sections is critical for cost and efficiency • Minimizing weld size & length and fastener count results in big savings due to system Fatigue size • All structural members must be designed forΙ © Dassault Systèmes Ι Confidential Information Ι durability Global Steel Price Index Source: CRUspi.com • Repetitive loading of buckets, jaws, and 180 booms must not cause premature failure due 160 Drop Test to fatigue 140 • Bucket or Jaw fracture if dropped on installation can be predicted 120 100 Nonlinear Buckling 80 • Contact between assembly components is 60 • Buckling due to lateral and vertical loads on 1999 2000 2001 2002 2003 2004 2005 required for realistic modeling cantilevered sections is always a concern • Large cantilevered sections must be • Thin members on walkways and ladders must examined for large displacement effects be safe Motion Simulation • Synthesize linkages for desired bucket and fork movement • Size and optimize cylinders, pulleys, and other drive components 5
  • 6. Road Building Equipment Frequency or Dynamics Optimization • Avoid frequencies caused by vibration from • Weight reduction in all articulated sections is tracks or road noise on wheels critical for cost and efficiency • Avoid vibration due to engine noise • Minimizing weld size & length and fastener • Avoid vibration on asphalt silos due to wind count results in big savings due to system shear size • Alternate weight-saving design for fuel efficiency critical FatigueΙ © Dassault Systèmes Ι Confidential Information Ι • All structural members must be designed for Buckling durability • Repetitive loading of bucket and boom must • Buckling due to lateral and vertical loads on not cause premature failure due to fatigue cantilevered sections is always a concern • Repetitive loading of cantilevered fork is a • Thin members on walkways and ladders must fatigue concern be safe • Supports on large silos susceptible to buckling Nonlinear • Contact between assembly components is Heat Transfer or Thermal required for realistic modeling • Asphalt heating temperatures must be • Large cantilevered sections must be controlled to prevent user injury examined for large displacement effects • Asphalt heating must not damage • Deformation of asphalt bin and silo walls bearings, seals, or joints in system requires large displacement effects to calculate properly Drop Test • Bucket fracture if dropped on installation can be predicted 6
  • 7. Material Handling Equipment Frequency or Dynamics Optimization • Avoid frequencies caused by vibration from • Weight reduction in all articulated sections is tracks or road noise on wheels critical for cost and efficiency • Avoid vibration due to engine noise • Minimizing weld size & length and fastener • Avoid vibration on asphalt silos due to wind count results in big savings due to system shear size • Weight reduction for fuel efficiency is critical FatigueΙ © Dassault Systèmes Ι Confidential Information Ι • All structural members must be designed for Buckling durability • Buckling due to lateral and vertical loads on • Repetitive loading of bucket and boom must cantilevered sections is always a concern not cause premature failure due to fatigue • Buckling of extended fork lifting components • Repetitive loading of cantilevered fork is a must be watched fatigue concern Nonlinear Motion Simulation • Contact between assembly components is • Synthesize linkages for desired bucket and required for realistic modeling fork movement • Large cantilevered sections must be • Size and optimize cylinders, pulleys, and other examined for large displacement effects drive components Drop Test • Bucket fracture if dropped on installation can be predicted 7
  • 8. Consumer Products – Electronics Frequency or Dynamics Buckling • Tubular & angle frames are susceptible to • Uncontrolled resonance due to speaker buckling. frequencies can cause objectionable noise & • Consumer use is unpredictable so design quality concerns must account for eccentric loading which • Vibration from transportation or operation worsens buckling must not cause electronics, fasteners, latches or mechanisms to release or fail Heat Transfer or Thermal • Heat from batteries, lights or processors orΙ © Dassault Systèmes Ι Confidential Information Ι other high wattage components must be Fatigue controlled. • Hinge components and controls must • Thermal expansion can impact optics and withstand hundreds of thousands of micro-drive performance. Correct temperature operations. fields are important. • Repetitive loading over life of product can present fatigue concerns Nonlinear • Contact between assembly components is Drop Test required for realistic modeling • Consumers drop products! Perception is • Accurate prediction of plastic or custom usually lack of quality than misuse. materials requires nonlinear material modeling • Rough handling of personal electronics is • As designers push the envelope, responses normal and consumers expect performance to become increasingly nonlinear. continue. Motion Simulation Optimization • Size motors for electric products • Plastic prices track volatile oil prices. • Optimize mechanism paths and motor loads Companies learned the hard way in 2005 that sub-optimal plastic design can eliminate Flow Simulation profitability. • Optimize cooling of critical parts • Weight reduction for hand held devices is always critical • Design and optimize heat sink • Properly position fans and vents 8
  • 9. Consumer Products – Toys Frequency or Dynamics Buckling • Deep sections in bending are susceptible to • Uncontrolled resonance can cause buckling. objectionable noise & quality concerns • Consumer use is unpredictable so design • Vibration from transportation or operation must account for eccentric loading which must not cause electronics, fasteners, latches worsens buckling or mechanisms to release or fail Heat Transfer or Thermal • Temperatures from motors or engines mustΙ © Dassault Systèmes Ι Confidential Information Ι Fatigue not present danger to children. • Toys must be designed for durability and • Cold weather and water products typically unpredictable loading. have complex and extreme temperature • Repetitive loading over life of product can distributions that can lead to expansion present fatigue concerns related failure. Nonlinear Drop Test • Consumers drop products! Perception is • Contact between assembly components is usually lack of quality than misuse. required for realistic modeling • Accurate prediction of plastic or custom materials requires nonlinear material modeling Optimization • As designers push the envelope, responses become increasingly nonlinear. • Plastic prices track volatile oil prices. Companies learned the hard way in 2005 that • Failure mode is a critical design consideration sub-optimal plastic design can eliminate because small pieces pose serious risks to profitability. children. Motion Simulation Fluid Flow Simulation • Size motors for electric products • Provide proper air or water flow for pump- • Optimize mechanism paths and motor loads driven toys for interactive children’s toys 9
  • 10. Consumer Products – Appliances Frequency or Dynamics Buckling • Deep sections in bending are susceptible to • Vibration from engines or motors must not cause buckling. unnecessary fatigue to the consumer • Consumer use is unpredictable so design must • Uncontrolled resonance can cause objectionable account for eccentric loading which worsens noise & quality concerns buckling • Vibration from transportation or operation must not cause fasteners to release or fail Heat Transfer or Thermal Fatigue • Temperatures from motors or engines must notΙ © Dassault Systèmes Ι Confidential Information Ι • Motor driven products must be designed for present danger to consumer. durability. • Cold weather and water products typically have • Repetitive loading over life of product can present complex and extreme temperature distributions that fatigue concerns can lead to expansion related failure. • Hot water or cooking applications must not cause performance problems related to expansion or Drop Test degradation • Consumers drop products! Perception is usually lack of quality than misuse. Nonlinear • Contact between assembly components is required Optimization for realistic modeling • Accurate prediction of plastic or custom materials • Plastic prices track volatile oil prices. Companies requires nonlinear material modeling learned the hard way in 2005 that sub-optimal plastic design can eliminate profitability. • As designers push the envelope, responses become increasingly nonlinear. • The price of stainless steel has doubled in the past year but stainless is still a sought after consumer feature. Fluid Flow Simulation Motion Simulation • Evaluate fluid path and fluid temperature inside appliances • Size motors for electric products • Ensure uniform cooling in refrigeration appliances • Optimize mechanism paths and motor loads • Air flow in personal care devices like blow dryers 10
  • 11. Consumer Products – Fitness & Recreation Frequency or Dynamics Buckling • Deep sections in bending are susceptible to • Vibration from engines or motors must not buckling. cause unnecessary fatigue to the consumer • Consumer use is unpredictable so design must account for eccentric loading which worsens • Uncontrolled resonance can cause buckling objectionable noise, handling, & quality concerns • Vibration from transportation or operation must not cause fasteners, latches or Heat Transfer or Thermal mechanisms to release or fail • Temperatures from motors or engines mustΙ © Dassault Systèmes Ι Confidential Information Ι not present danger to consumer. • Cold weather and water products typically Fatigue have complex and extreme temperature distributions that can lead to expansion • Sport, leisure, and toy products must be related failure. designed for durability. • Repetitive loading over life of product can present fatigue concerns Nonlinear Drop Test • Contact between assembly components is required for realistic modeling • Consumers drop products! Perception is usually lack of quality than misuse. • Accurate prediction of plastic or custom materials requires nonlinear material modeling • As designers push the envelope, responses Optimization become increasingly nonlinear. • Plastic prices track volatile oil prices. Companies learned the hard way in 2005 that sub-optimal plastic design can eliminate profitability. • The price of stainless steel has doubled in the past Motion Simulation year but stainless is still a sought after consumer feature. • Size motors for electric products • Optimize mechanism paths and motor loads Fluid Flow Simulation • Optimize ergonomics in fitness equipment • Aerodynamics of auto mounted equipment, high performance boating and bicycle gear 11