Simulation Professional - What each module can do for me

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Simulation Professional - What each module can do for me

  1. 1. Getting Started with GoToWebinar 1. Listening to Audio • Dial in using the number provided • Listen through your computer speakers or headphonesΙ © Dassault Systèmes Ι Confidential Information Ι 2. Ask questions by entering them in the space provided [Enter a question for staff] 3. To minimize webinar control panel, click the small orange arrow. 1
  2. 2. Simulation Professional What each Simulation module can do for me?Ι © Dassault Systèmes Ι Confidential Information Ι Gerry Kyle Joe Galliera DS SolidWorks Corp. November 29, 2011 2
  3. 3. Your SolidWorks Simulation Team  Your SolidWorks Value-Added Reseller (VAR)  Gerry Kyle – Simulation Sales Manager  20+ year’s in the CAE industryΙ © Dassault Systèmes Ι Confidential Information Ι  12+ years with COSMOS/M and SolidWorks  Joe Galliera – Simulation Tech Manager  Over 15 years of experience with CAE tools  Helped hundreds of customers successfully implement simulation solutions 3
  4. 4. SolidWorks Simulation customers  SolidWorks has more simulation customers than any other analysis company in the market 80% of our Simulation customers experienced an increaseΙ © Dassault Systèmes Ι Confidential Information Ι in product quality 80% of your cost, quality, and performance is established at the design phase, early detection of issues is critical. 57% report fewer field failures 100% showed time savings and advantages to using simulation 4
  5. 5. Companies can Differentiate with Simulation Survey of 620 companies.  Use of Simulation remains a highly differentiated strategy  Perform more iterative assessmentsΙ © Dassault Systèmes Ι Confidential Information Ι of product performance Recommendations for Action  Perform more simulation of product performance in the design phase.  Provide CAD-embedded or CAD- driven simulation capabilities to engineers The Aberdeen Group report 5
  6. 6. Sunrise Medical  Company: Quickie P-222 Powered Wheelchair  leading provider of rehabilitation products and assistive technology devices for people with disabilities, and patient care products used in nursing homes, hospitals and homecare settingsΙ © Dassault Systèmes Ι Confidential Information Ι  Challenge:  Find a reliable, easy-to-use, inexpensive & feature rich CAD system  Make the transition to 3D  Run on NT workstations  SolidWorks Benefits:  Decreased design time by 45%  Saved $40-50,000 in prototyping  Reduced errors by 50% “SolidWorks won our CAD evaluation because it was the one CAD software that did everything the  Increased sales by over 50% sales representative promised it would” Darin Trippensee, Project Engineer 6
  7. 7. Windsave Glasgow, UK  Company: Founded in 2002 in Glasglow, Windsave is the largest micro wind turbine installer in the UK and is at the forefront of a movement to bring green energy choices to consumers.  Challenge: The company needed to standardise on a CAD system that would improve their overall performance and efficiency, to refine the technology and accelerateΙ © Dassault Systèmes Ι Confidential Information Ι development of its wall mounted micro-wind turbine system to reduce the amount of power a home or business draws from the national electricity grid.  Key Benefits: Windsave has reduced the number of prototypes to test new products or features from four to one, saving up to £3,000, using SolidWorks and SolidWorks Simulation. The company have reduced the prototype production and testing process from eight weeks to two. “With SolidWorks and SolidWorks Simulation, we’ve As the company expands sales internationally in 2009, the team will explore the been able to refine the action of the tailfin so that it is possibility of mounting smaller versions of the micro turbines on street lights so more efficient and aerodynamic. municipalities can cut energy costs. Additionally, prototyping costs and time kept adding up with Pro/ENGINEER. SolidWorks and SolidWorks Simulation allow us to produce and test a sample on screen to see if we’ve over- or under-engineered it. That’s a huge benefit when optimising a design.” Mike Lumsdaine, mechanical engineer 7
  8. 8. Center Rock, Inc. - USA  Company: Center Rock, Inc, is a leading manufacturer of drilling supply equipment. The company’s drill bits played a significant role in the rescue of 33 Chilean miners, who were trapped 2,000 feet underground for two months at the San José Mine in Chile.  Challenge:Ι © Dassault Systèmes Ι Confidential Information Ι Efficiently increase the number of drilling products offered, while maintaining the flexibility to resolve engineering challenges and redesign drill bits on the fly in situations such as the rescue of the trapped Chilean miners.  SolidWorks Benefits: • Reached miners two months ahead of projections • Redesigned drill bit in three days “SolidWorks Flow Simulation allowed us • Cut design cycles by 66 percent to reconfigure the tool and reach the • Quadrupled product offering miners faster.” Rudy Lyon Senior Engineer and Product Development Manager 8
  9. 9. Gaumer Process- USA  Company:  When companies in the process industries, including oil, gas, food-processing, wastewater treatment, and petrochemical companies, have electric process heating needs, Gaumer Process often tops their list. That’s because the Houston-based manufacturer helped to develop electricΙ © Dassault Systèmes Ι Confidential Information Ι process heater technology over the last 30 years, acquiring several patents for its electric process heaters, systems, and controls. “With SolidWorks Simulation software, we were able to  Challenge: study and test six different concepts and reach an optimized design in less than three months. We  Simulate the flow dynamics, heat transfer, and structural eliminated more than two years of costs, saved characteristics of electric process heaters to trim material, cut $100,000 on prototyping, and produced a patented idea costs, and accelerate development. for enhancing heat transfer. That’s the kind of advantage that helps us beat our competition.”  SolidWorks Benefits: Craig Tiras, P.E. Vice President of Engineering and Design  Cut development cycle from three years to three months  Saved $100,000 in prototyping costs  Reduced material costs by 75 percent  Enhanced visualization of system performance 9
  10. 10. Your time, your companies reputation & your profits Moving forward…  Drawing board to 2D  2D to 3D  3D to parametric 3D  To SolidWorksΙ © Dassault Systèmes Ι Confidential Information Ι  To virtual testing with SolidWorks simulation  Each step keeps you ahead of the competition and in a position to lower costs and improve sales  Here are some examples of all the different industries and application used by our simulation customers. 16
  11. 11. 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 17
  12. 12. 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. 18
  13. 13. 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 19
  14. 14. 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. 20
  15. 15. SolidWorks Product Design & Simulation Tools Flow Electronics HVAC Flow Sustainability Sustainability Non linear Dynamics Composites Premium SimulationΙ © Dassault Systèmes Ι Confidential Information Ι Thermal Fatigue Drop Test Optimize Frequency Buckling Pressure Motion Pro Professional Vessel Simulation Motion Routing ScanTo3D TolAnalyst CircuitWorks Premium SolidWorks eDrawings Workgroup Task Design Feature PhotoView Toolbox Utilities Pro Scheduler Checker Works Professional PDM Content SolidWorks Rx Explorer Standard Central 28
  16. 16. How do you know you have the best design?  A few examplesΙ © Dassault Systèmes Ι Confidential Information Ι Which angle? Which material? 3 or 4 holes? What thickness? Which tube size? 2 or 1 Ribs? Which ribs? 29
  17. 17. Cost of Prototyping Physical Prototyping Virtual Prototyping Labor Labor Duration Cost HW Cost Duration Cost HW Cost Initial Prototype 1 week $800 $2,000 4 hours $200 $0Ι © Dassault Systèmes Ι Confidential Information Ι 1st Design Iteration 1 day $800 $500 2 hours $200 $0 2nd Design Iteration 1 day $800 $500 2 hours $200 $0 3rd Design Iteration 1 day $800 $500 2 hours $200 $0 4th Design Iteration 1 day $800 $500 2 hours $200 $0 5th Design Iteration 1 day $800 $500 2 hours $200 $0 6th Design Iteration 1 day $800 $500 2 hours $200 $0 Total 2 weeks $10,600 2 days $1,600 30
  18. 18. Physical v. Virtual PrototypingΙ © Dassault Systèmes Ι Confidential Information Ι  Finite discrete data points  Virtually unlimited data points  Physically intrusive for maximum design insight  Long lead times  Quick design changes with  Expensive equipment CAD model  Long setup and testing  Multiple what-if scenarios  Inexpensive test equipment 31
  19. 19. Ι © Dassault Systèmes Ι Confidential Information Ι Design A Better Frame32
  20. 20. Ι © Dassault Systèmes Ι Confidential Information Ι Design A Better Frame33 Which is stronger?
  21. 21. Design A Better FrameΙ © Dassault Systèmes Ι Confidential Information Ι How much stronger? (Is it worth the extra material, time, cost?) 34
  22. 22. Design A Better Frame Safety Factor 2.659 Safety Factor 13.08Ι © Dassault Systèmes Ι Confidential Information Ι Adding corner supports improves the safety factor 5X 35
  23. 23. Design A Better Frame Which is Best? Same Material Same Number of Cut, Same Number of WeldsΙ © Dassault Systèmes Ι Confidential Information Ι 30° 45° 60° 36
  24. 24. Design A Better Frame • 5 Minutes: Build Configurations • 5 Minutes: Define StudiesΙ © Dassault Systèmes Ι Confidential Information Ι • 6 Minutes: Run All Four Studies • 1 Minute: Make Your Design Decision 37
  25. 25. Design A Better Frame Better Good Best Max Deflection: 0.181mm Max Deflection: 0.147mm Max Deflection: 0.118mm Safety Factor: 13.19 Safety Factor: 13.08 Safety Factor: 14.21 30° 45° 60°Ι © Dassault Systèmes Ι Confidential Information Ι 38
  26. 26. Ι © Dassault Systèmes Ι Confidential Information Ι Frame Demo39
  27. 27. Design a Better GuardΙ © Dassault Systèmes Ι Confidential Information Ι You know the 1100 RPM speed of the blade (18.3 Hz) Will the guard excessively vibrate? ? 40
  28. 28. Ι © Dassault Systèmes Ι Confidential Information Ι Which Design is Better?41
  29. 29. Design a Better Guard Initial Design Frequency Goal SW Simulation reports >23.8 Hz 16.6 12.4 10.2 Hz 5.0 Hz Hz 18.8Ι © Dassault Systèmes Ι Confidential Information Ι Initial Design Will Vibrate Excessively  42
  30. 30. Design a Better Guard Design Change 1: SW Simulation Increase overall wall thickness from 3 to 4 mm Frequency Goal reports (Increases weight 30% over initial design) >23.8 Hz 20.6 15.4 10.2 Hz 5.0 Hz Hz 25.2Ι © Dassault Systèmes Ι Confidential Information Ι Design Will Not Vibrate Excessively  43
  31. 31. Design a Better Guard Design Change 2: SW Simulation Use 3mm wall thickness and add external ribs Frequency Goal reports (Increases weight 1% over initial design) >23.8 Hz 13.9 9.8 5.6 Hz 2.0 Hz Hz 19.5Ι © Dassault Systèmes Ι Confidential Information Ι Design Will Vibrate Excessively  44
  32. 32. Design a Better Guard Design Change 3: SW Simulation Use 3mm wall thickness and added internal ribs Frequency Goal reports (Increases weight 1% over initial design) >23.8 Hz 13.9 9.8 5.6 Hz 2.0 Hz Hz 27.7Ι © Dassault Systèmes Ι Confidential Information Ι Design Will Not Vibrate Excessively  45
  33. 33. Design a Better GuardΙ © Dassault Systèmes Ι Confidential Information Ι Best Design • 30 minutes • 4 design iterations • 0 prototypes  46
  34. 34. Ι © Dassault Systèmes Ι Confidential Information Ι Saw Guard Demo47
  35. 35. Linear Static  SolidWorks Simulation  Providing stress, strain, and displacement analysis capabilities for parts and assemblies, this design validation and optimization tool enables you to identifies areas prone to weakness and failure.Ι © Dassault Systèmes Ι Confidential Information Ι  This tool enables the engineer to determine if a product is over or under designed. Also ensure that unique industry safety factors are met.  SolidWorks Simulation software helps improve quality by indicating how product designs will behave before they are built. Help your customers design better products. 48
  36. 36. SolidWorks Motion  SolidWorks Motion is kinematic and dynamic simulation. It provides all the resultant kinematic values, such as time-varying displacement, velocity and acceleration, for all moving bodies and resultant dynamics loads on all joints, such as force, torque and power.Ι © Dassault Systèmes Ι Confidential Information Ι  This software enables you to study the physics of moving assemblies. With SolidWorks Motion, you can estimate peak motor torque, analyze robotic performance during operation, size motors/actuators, and determine power consumption. In addition to laying out linkages and developing cams, you can analyze gear drives, size springs/dampers, determine how contacting parts behave, and minimize force imbalances in rotating systems. 49
  37. 37. Natural Frequency and Resonance  Avoid product failure due to excessive shaking or rattling or vibration.  Natural frequency is how quickly a system will move back and forth (or oscillate).  Can be used to compare the relative stiffness of design variationsΙ © Dassault Systèmes Ι Confidential Information Ι (even if they are not interested in vibration). 50
  38. 38. Thermal  Transient and Steady State Thermal problems solves the solid Conduction problem and you can apply Convection and Radiation conditions to the model.  The outputs of a thermal study are temperature, temperature gradient and heat flux distributions.Ι © Dassault Systèmes Ι Confidential Information Ι  Heat transfer effects due to:  Conduction, convection, radiation (i.e. all types of heat transfer)  Time-dependent conditions lead to Transient solutions  Temperature-dependent material properties  Use temperature results from a Thermal study to a Static loading:  Thermal stresses  Expansion and Contraction thermal displacements 51
  39. 39. Fatigue  Help determine product life  Predict if the product will be durable enough to withstand repeated loading or usage  Modify existing design to extend working life  Identify critically damaged areasΙ © Dassault Systèmes Ι Confidential Information Ι  Life, percent total damage, load factor of safety  Damage chart  Input unique fatigue (S-N) material curves for different material types 52
  40. 40. Buckling  Buckling analysis is recommended:  If structure has high compressive loads or weight.  If structure is long and slender  Typically if structure has thin wallsΙ © Dassault Systèmes Ι Confidential Information Ι  Buckling involves lack of stability in a structure subject to compressive forces.  Often a very sudden and unexpected failure!  Standing on a empty can of soda that is propped up on ground level will require Buckling Analysis 53
  41. 41. Optimization  Reduce cost, weight  Lightest possible design  Automatically find the best design based on design intent  Put constraints such that optimum design stay withinΙ © Dassault Systèmes Ι Confidential Information Ι allowable stress limits  The basic goal of optimization is to create a better and more valuable product than those already exist. Create 3D CAD Build Virtual Prototype Simulate Performance Validate Simulation Optimize Design 54
  42. 42. Steering Bracket Design  Goals – Design for strength – Keep stress below 2600 psi – Design Optimization – Reduce weight of the part – Design for life – One season of 10~20 ralliesΙ © Dassault Systèmes Ι Confidential Information Ι – Frequency Check – Frequency range > 400Hz (24,000 RPM) The part is from a Group N rally car (modified road cars) 58
  43. 43. SolidWorks Product Design & Simulation Tools Flow Electronics HVAC Flow Sustainability Sustainability Non linear Dynamics Composites Premium SimulationΙ © Dassault Systèmes Ι Confidential Information Ι Thermal Fatigue Drop Test Optimize Frequency Buckling Pressure Motion Pro Professional Vessel Simulation Motion Routing ScanTo3D TolAnalyst CircuitWorks Premium SolidWorks eDrawings Workgroup Task Design Feature PhotoView Toolbox Utilities Pro Scheduler Checker Works Professional PDM Content SolidWorks Rx Explorer Standard Central 59
  44. 44. Thank you! We would like to thank you for attending this webinar on SolidWorks Simulation Pro!Ι © Dassault Systèmes Ι Confidential Information Ι  Gerry Kyle – Simulation Sales Manager  Gerry.Kyle@3ds.com  Joe Galliera – Simulation Tech Manager  Joe.Galliera@3ds.com 60

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