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- 1. 1 Ι © Dassault Systèmes Ι Confidential Information Ι SolidWorks Simulation Training SolidWorks 2012
- 2. 2 Ι © Dassault Systèmes Ι Confidential Information Ι Prerequisites Course Design Philosophy Using this book A note about files Conventions used in this book Class Introductions About this course
- 3. 3 Ι © Dassault Systèmes Ι Confidential Information Ι Simulation Premium Simulation Professional Design Validation Products Frequency/ Buckling Thermal SolidWorks Premium Static SolidWorks Motion Drop Test Fatigue Nonlinear Optimization Pressure Vessel Composites Advanced Dynamics
- 4. 4 Ι © Dassault Systèmes Ι Confidential Information Ι 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
- 5. 5 Ι © Dassault Systèmes Ι Confidential Information Ι Building the FEA Model CAD Model Stress Results
- 6. 6 Ι © Dassault Systèmes Ι Confidential Information Ι 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 - Fixtures
- 7. 7 Ι © Dassault Systèmes Ι Confidential Information Ι 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 Building the FEA Model - Loads
- 8. 8 Ι © Dassault Systèmes Ι Confidential Information Ι FEA for structural analysis Example of a fitting Split the fitting into small tetrahedral pieces and approximate the deformation on each piece
- 9. 9 Ι © Dassault Systèmes Ι Confidential Information Ι FEA for structural analysis Example of a bracket Split the surfaces of bracket into small triangular pieces and approximate the deformation on each piece
- 10. 10 Ι © Dassault Systèmes Ι Confidential Information Ι FEA for structural analysis Example of a frame structure Split the members of frame into small straight pieces and approximate the deformation on each piece
- 11. 11 Ι © Dassault Systèmes Ι Confidential Information Ι 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 Mesh, Nodes, Elements, …
- 12. 12 Ι © Dassault Systèmes Ι Confidential Information Ι 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 = Using Stress Results to Validate Design
- 13. 13 Ι © Dassault Systèmes Ι Confidential Information Ι 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 Assumptions in Linear, Static Analyses Small deformation Large deformation
- 14. 14 Ι © Dassault Systèmes Ι Confidential Information Ι 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 Check list for SolidWorks Simulation
- 16. 16 Ι © Dassault Systèmes Ι Confidential Information Ι 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 Topics
- 17. 17 Ι © Dassault Systèmes Ι Confidential Information Ι SolidWorks Simulation interface Study tree Study tabs Toolbar Simulation Advisor CommandManager tab Analysis library
- 19. 19 Ι © Dassault Systèmes Ι Confidential Information Ι von Mises Stresses in coarse study Lesson 1: Results
- 20. 20 Ι © Dassault Systèmes Ι Confidential Information Ι Lesson 1: Results von Mises Stresses in default study
- 21. 21 Ι © Dassault Systèmes Ι Confidential Information Ι Lesson 1: Results von Mises Stresses in fine study
- 22. 22 Ι © Dassault Systèmes Ι Confidential Information Ι Finer mesh More accurate results More computational time Lesson 1: Results Summary of results – convergence study
- 23. 23 Ι © Dassault Systèmes Ι Confidential Information Ι Comparison with analytical Which result is correct??? Lesson 1 Results
- 25. 25 Ι © Dassault Systèmes Ι Confidential Information Ι Exercise 2: Compressive Spring Stiffness m N u F k 7 . 234 10 426 . 0 1 . 0 3
- 28. 28 Ι © Dassault Systèmes Ι Confidential Information Ι Lesson 2 Mesh Controls, Stress Concentrations and Boundary Conditions
- 29. 29 Ι © Dassault Systèmes Ι Confidential Information Ι no fillet configuration Using SolidWorks Configurations Use of mesh controls, automatic transition FEA Convergence issues Different boundary conditions Lesson 2: Topics fillet configuration
- 31. 31 Ι © Dassault Systèmes Ι Confidential Information Ι Lesson 2: Results No fillet configuration
- 32. 32 Ι © Dassault Systèmes Ι Confidential Information Ι 1- When increasing the number of elements, will the stresses converge? 2- Why? Lesson 2: Results Stress Results – mesh1, mesh2 and mesh3
- 33. 33 Ι © Dassault Systèmes Ι Confidential Information Ι No Mesh Control Lesson 2: Results Fillet, Mesh Control Mesh Control
- 34. 34 Ι © Dassault Systèmes Ι Confidential Information Ι Fixed edge produces unrealistic stresses at the support location. Lesson 2: Results Welded boundary condition
- 35. 35 Ι © Dassault Systèmes Ι Confidential Information Ι Can greatly simplify the model Can also affect results Know your assumptions Lesson 2: Boundary Conditions
- 36. 36 Ι © Dassault Systèmes Ι Confidential Information Ι Exercise 4: C-bracket No fillet Filleted edge
- 37. 37 Ι © Dassault Systèmes Ι Confidential Information Ι Exercise 4 Stress concentrations Fixed hole
- 39. 39 Ι © Dassault Systèmes Ι Confidential Information Ι Exercise 6: Foundation Bracket 0.5 mm
- 40. 40 Ι © Dassault Systèmes Ι Confidential Information Ι Exercise 6: Foundation Bracket 0.5 mm
- 43. 43 Ι © Dassault Systèmes Ι Confidential Information Ι Assembly Analysis Basics Interference Detection Global and Local Contact/ Gaps conditions Lesson 3: Topics
- 45. 45 Ι © Dassault Systèmes Ι Confidential Information Ι Default: Bonded Global contact conditions No penetration Bonded (No clearance) Allow Penetration Component Contact Uncheck Global Contact box Overrides Global Contact Global contact
- 46. 46 Ι © Dassault Systèmes Ι Confidential Information Ι 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
- 47. 47 Ι © Dassault Systèmes Ι Confidential Information Ι 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 Local Contact Conditions
- 48. 48 Ι © Dassault Systèmes Ι Confidential Information Ι Loads and restraints, mesh 225 N 225 N Fixed i) Global No Penetration contact ii) Local contact
- 49. 49 Ι © Dassault Systèmes Ι Confidential Information Ι Von Mises stresses - Global contact (225 N force) (You can plot stresses in exploded configuration) Lesson 3: Results
- 50. 50 Ι © Dassault Systèmes Ι Confidential Information Ι Could we study the stresses on contact surfaces? Von Mises stresses – With local contact (4500 N force) Lesson 3: Results
- 51. 51 Ι © Dassault Systèmes Ι Confidential Information Ι Exercise 7: Two Ring Assembly
- 53. 53 Ι © Dassault Systèmes Ι Confidential Information Ι Lesson 4 Symmetrical and Free Self-Equilibrated Assemblies
- 54. 54 Ι © Dassault Systèmes Ι Confidential Information Ι Analyze shrink-fit problem Use of symmetry Review stress results in local coordinate systems Solver options to eliminate rigid body modes Lesson 4: Topics
- 55. 55 Ι © Dassault Systèmes Ι Confidential Information Ι 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)
- 58. 58 Ι © Dassault Systèmes Ι Confidential Information Ι Lesson 4: Results Why is there a jump in the hoop stress value across the interface? Would the assembly experience a similar jump in radial stresses? Hoop stress (using local cylindrical coordinates)
- 60. 60 Ι © Dassault Systèmes Ι Confidential Information Ι Exercise 9: Chain Link 2 Incorrect solution Correct solution
- 61. 61 Ι © Dassault Systèmes Ι Confidential Information Ι Lesson 5 Assembly Analysis with Connectors
- 62. 62 Ι © Dassault Systèmes Ι Confidential Information Ι Connectors Rigid Spring Pin Elastic Support Bolt Spot Weld Edge Weld Link Bearing Global and local contact conditions Lesson 5: Topics
- 64. 64 Ι © Dassault Systèmes Ι Confidential Information Ι Boundary conditions and Mesh 225 N 225 N Fixed
- 67. 67 Ι © Dassault Systèmes Ι Confidential Information Ι Exercise 12: Shock Absorber Simplify the model 1. Suppress the original helical spring from the analysis. 2. Introduce “Spring Connector”.
- 69. 69 Ι © Dassault Systèmes Ι Confidential Information Ι Exercise 13: Spot Welds Connector types – Spot Welds Spot Welds Spot Welds
- 70. 70 Ι © Dassault Systèmes Ι Confidential Information Ι 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?
- 72. 72 Ι © Dassault Systèmes Ι Confidential Information Ι Compatible solid element mesh with Bonded contacts Incompatible solid element mesh with Bonded contacts Simplified bonding for incompatible solid meshes Lesson 6: Topics
- 73. 73 Ι © Dassault Systèmes Ι Confidential Information Ι Bonding of touching parts is achieved by imprinting and merging the nodes. Compatible solid mesh
- 74. 74 Ι © Dassault Systèmes Ι Confidential Information Ι Bonding of touching parts is achieved by additional constraint equations. Incompatible solid mesh
- 75. 75 Ι © Dassault Systèmes Ι Confidential Information Ι Incompatible solid mesh: More Accurate Bonding Surface based contact. Results at the contact interface are uniform but solution time is longer.
- 76. 76 Ι © Dassault Systèmes Ι Confidential Information Ι Incompatible solid mesh: Simplified Bonding Node based contact. Results at the contact interface may be patchy but solution time is lower.
- 77. 77 Ι © Dassault Systèmes Ι Confidential Information Ι Lesson 7 Assembly Analysis Mesh Refinement
- 78. 78 Ι © Dassault Systèmes Ι Confidential Information Ι 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: Topics
- 79. 79 Ι © Dassault Systèmes Ι Confidential Information Ι Load (Direct transfer) Load/Mass (Rigid connection) Displacement (Rigid connection) Remote loads
- 80. 80 Ι © Dassault Systèmes Ι Confidential Information Ι Bolt type Tight fit Material Pre-load Bolt series Bolt connectors
- 81. 81 Ι © Dassault Systèmes Ι Confidential Information Ι Type of contact that replaces modeling a component Rigid or Flexible Virtual wall
- 82. 82 Ι © Dassault Systèmes Ι Confidential Information Ι Lesson 7: Results Draft mesh: mesh parameters and results Mesh parameters are not ideal leading to excessive von Mises stress results
- 83. 83 Ι © Dassault Systèmes Ι Confidential Information Ι 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.) Lesson 7: Results
- 87. 87 Ι © Dassault Systèmes Ι Confidential Information Ι Lesson 8 Analysis of Thin Components
- 88. 88 Ι © Dassault Systèmes Ι Confidential Information Ι 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: Topics
- 89. 89 Ι © Dassault Systèmes Ι Confidential Information Ι 55449 DOF Lesson 8: Results Solid Elements – Von Mises Stress 987978 DOF (1 element per thickness) (2 element per thickness)
- 90. 90 Ι © Dassault Systèmes Ι Confidential Information Ι Defined by: Existing surface or sheet metal bodies Mid-plane surfaces Outside/inside faces of solid bodies Shell elements Outside faces Mid-plane surface
- 91. 91 Ι © Dassault Systèmes Ι Confidential Information Ι Shell Type Kirchoff Theory Mindlin Theory Thin shells ignore shear deformation through the thickness of the shell 20 thickness span 20 10 thickness span
- 92. 92 Ι © Dassault Systèmes Ι Confidential Information Ι Misaligned shell elements Shell Element Alignment Shell Elements - Alignment Incorrect stress result representation
- 93. 93 Ι © Dassault Systèmes Ι Confidential Information Ι Shell Elements (midplane) – Von Mises Stress Bottom (orange) Top (gray) Lesson 8: Results
- 94. 94 Ι © Dassault Systèmes Ι Confidential Information Ι Shell elements can greatly decrease the required computational time. Modeling with shell elements is more demanding than with solids. * See results of Exercise 16 Lesson 8: Results Shell vs. Solid Elements
- 95. 95 Ι © Dassault Systèmes Ι Confidential Information Ι Case Study: Joist Hanger Shell elements generated automatically for sheet metal features
- 97. 97 Ι © Dassault Systèmes Ι Confidential Information Ι Top Exercise 17: Shell Mesh Using Outer/Inner Faces Shell Elements (surfaces) – Von Mises Stress Bottom Bottom (orange) Top (gray)
- 98. 98 Ι © Dassault Systèmes Ι Confidential Information Ι 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?
- 99. 99 Ι © Dassault Systèmes Ι Confidential Information Ι Exercise 19: Edge Weld Connector Edge Welds - shell model – weld bead sizes Design the size of the edge weld beads.
- 100. 100 Ι © Dassault Systèmes Ι Confidential Information Ι Exercise 20: Container Handle Weld Self-guided exercise Design double sided fillet welds connecting the container handle to the square plates.
- 103. 103 Ι © Dassault Systèmes Ι Confidential Information Ι Lesson 9 Mixed Meshing Shells & Solids
- 104. 104 Ι © Dassault Systèmes Ι Confidential Information Ι Mixed meshing Solid-shell bonding Shell offset Mesh failure diagnostics Lesson 9: Topics
- 105. 105 Ι © Dassault Systèmes Ι Confidential Information Ι 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.
- 106. 106 Ι © Dassault Systèmes Ι Confidential Information Ι Compatibility problems in mixed solid and shell element meshing Use of mixed mesh in simulation Solid and Shell Elements How many DOF does a solid element have? How many DOF does a shell element have?
- 107. 107 Ι © Dassault Systèmes Ι Confidential Information Ι 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) Bonding between solids and shells Hinge
- 108. 108 Ι © Dassault Systèmes Ι Confidential Information Ι Mid-surface Top surface Bottom surface Ratio Shell offset By default, mesh located at mid-plane Orientation important when defining shells with different thickness
- 109. 109 Ι © Dassault Systèmes Ι Confidential Information Ι Incompatible mesh Mesh control Auto-looping Check geometry Switch mesher Mesh failure diagnostics
- 110. 110 Ι © Dassault Systèmes Ι Confidential Information Ι Lesson 9: Results Why are the stresses highest at the base near the support and bonded contacts?
- 111. 111 Ι © Dassault Systèmes Ι Confidential Information Ι Exercise 21: Mixed Mesh Analysis
- 113. 113 Ι © Dassault Systèmes Ι Confidential Information Ι Lesson 10 Mixed Meshing Solids, Beams & Shells
- 114. 114 Ι © Dassault Systèmes Ι Confidential Information Ι Beam elements Joints Bonding of beams Post-processing of beam elements Lesson 10: Topics
- 116. 116 Ι © Dassault Systèmes Ι Confidential Information Ι joints are connected to two or more beam members. joints are connected to a single member only Joints
- 117. 117 Ι © Dassault Systèmes Ι Confidential Information Ι Bonding of beams Bond joints or entire beam to target entities • Beam profile imprinted on target entities • Accurate results at the interface
- 119. 119 Ι © Dassault Systèmes Ι Confidential Information Ι Stress: Axial, bending, worst-case, torsional, shear Displacement Axial force diagrams Shear & bending moment diagrams Reaction forces & moments Results for beam elements Simply supported with uniform distributed loading
- 125. 125 Ι © Dassault Systèmes Ι Confidential Information Ι 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
- 127. 127 Ι © Dassault Systèmes Ι Confidential Information Ι Lesson 11: Results (Loads input)
- 128. 128 Ι © Dassault Systèmes Ι Confidential Information Ι Design Scenario with geometry input
- 129. 129 Ι © Dassault Systèmes Ι Confidential Information Ι Lesson 11: Results (Geometry input)
- 132. 132 Ι © Dassault Systèmes Ι Confidential Information Ι Static analysis with temperature load Use of various contact conditions Temperature dependent material properties Soft spring and Inertia relief options Lesson 12: Topics
- 133. 133 Ι © Dassault Systèmes Ι Confidential Information Ι Averaging across boundaries ON Averaging across boundaries OFF Lesson 12: Results
- 134. 134 Ι © Dassault Systèmes Ι Confidential Information Ι Axial strain at the sensor locations Lesson 12: Results
- 137. 137 Ι © Dassault Systèmes Ι Confidential Information Ι 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? How to achieve it? Make sure our results are close to some defined accurate solution. (typical parameter is strain energy density) 1. Modify and refine the mesh topology 2. Modify the “order” of elements h-adaptivity p-adaptivity
- 138. 138 Ι © Dassault Systèmes Ι Confidential Information Ι Adaptive Finite Element Analysis h-Adaptivity, p-Adaptivity Refining the mesh (h-Adaptivity) Changing the “order” of elements (p-Adaptivity) 1st order (Draft Quality) 2nd order (High Quality) … 5th order
- 139. 139 Ι © Dassault Systèmes Ι Confidential Information Ι Lesson 13: Results h-Adaptivity - results 98% convergence criteria (2% accuracy) was achieved in 6 iterations
- 140. 140 Ι © Dassault Systèmes Ι Confidential Information Ι Lesson 13: Results p-Adaptivity - results 0.05% convergence criteria was/was not achieved in 4 iterations
- 141. 141 Ι © Dassault Systèmes Ι Confidential Information Ι Summary Max. displacement difference: 0.2% Max. Von Misses stress difference:10% Which method would you use? Lesson 13: Results
- 143. 143 Ι © Dassault Systèmes Ι Confidential Information Ι Surface contact Contact analysis with the large displacement option Evaluate mesh adequacy for modeling bending stresses Limitations of the linear material model Lesson 14: Topics
- 144. 144 Ι © Dassault Systèmes Ι Confidential Information Ι Lesson 14: Results Small displacement contact analysis – Incorrect Displacements
- 145. 145 Ι © Dassault Systèmes Ι Confidential Information Ι Lesson 14: Results Large displacement contact analysis – Correct Displacements