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SolidWorks

2012

SolidWorks Simulation

Dassault Systmes SolidWorks Corporation

175 Wyman Street
Waltham, Massachusetts 02451 USA

In the event that you receive a request from any agency of the
U.S. government to provide Software with rights beyond
those set forth above, you will notify DS SolidWorks of the
scope of the request and DS SolidWorks will have five (5)
business days to, in its sole discretion, accept or reject such
request. Contractor/Manufacturer: Dassault Systmes
SolidWorks Corporation, 175 Wyman Street, Waltham,
Massachusetts 02451 US.

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1995-2011, Dassault Systmes SolidWorks Corporation, a

Dassault Systmes S.A. company, 175 Wyman Street,
Waltham, MA 02451 USA. All rights reserved.
The information and the software discussed in this document
are subject to change without notice and are not
commitments by Dassault Systmes SolidWorks Corporation
(DS SolidWorks).
No material may be reproduced or transmitted in any form or
by any means, electronically or manually, for any purpose
without the express written permission of DS SolidWorks.
The software discussed in this document is furnished under a
license and may be used or copied only in accordance with
the terms of the license. All warranties given by DS
SolidWorks as to the software and documentation are set
forth in the license agreement, and nothing stated in, or
implied by, this document or its contents shall be considered
or deemed a modification or amendment of any terms,
including warranties, in the license agreement.
Patent Notices

SolidWorks 3D mechanical CAD software is protected by

U.S. Patents 5,815,154; 6,219,049; 6,219,055; 6,611,725;
6,844,877; 6,898,560; 6,906,712; 7,079,990; 7,477,262;
7,558,705; 7,571,079; 7,590,497; 7,643,027; 7,672,822;
7,688,318; 7,694,238; 7,853,940 and foreign patents, (e.g.,
EP 1,116,190 and JP 3,517,643).

eDrawings software is protected by U.S. Patent 7,184,044;

U.S. Patent 7,502,027; and Canadian Patent 2,318,706.
U.S. and foreign patents pending.

Trademarks and Product Names for SolidWorks

Products and Services
SolidWorks, 3D PartStream.NET, 3D ContentCentral,
eDrawings, and the eDrawings logo are registered
trademarks and FeatureManager is a jointly owned registered
trademarkof DS SolidWorks.
CircuitWorks, FloXpress, TolAnalyst, and XchangeWorks
are trademarks of DS SolidWorks.
FeatureWorks is a registered trademark of Geometric Ltd.
SolidWorks 2012, SolidWorks Enterprise PDM, SolidWorks
Workgroup PDM, SolidWorks Simulation, SolidWorks Flow
Simulation, eDrawings Professional, and SolidWorks
Sustainability are product names of DS SolidWorks.
Other brand or product names are trademarks or registered
trademarks of their respective holders.
COMMERCIAL COMPUTER SOFTWARE
PROPRIETARY
The Software is a commercial item as that term is defined
at 48 C.F.R. 2.101 (OCT 1995), consisting of commercial
computer software and commercial software
documentation as such terms are used in 48 C.F.R. 12.212
(SEPT 1995) and is provided to the U.S. Government (a) for
acquisition by or on behalf of civilian agencies, consistent
with the policy set forth in 48 C.F.R. 12.212; or (b) for
acquisition by or on behalf of units 3 of the department of
Defense, consistent with the policies set forth in 48 C.F.R.
227.7202-1 (JUN 1995) and 227.7202-4 (JUN 1995).

Document Number: PMT1240-ENG

Copyright Notices for SolidWorks Standard,

Premium, Professional, and Education Products
Portions of this software 1986-2011 Siemens Product
Lifecycle Management Software Inc. All rights reserved.
Portions of this software 1986-2011 Siemens Industry
Software Limited. All rights reserved.
Portions of this software 1998-2011 Geometric Ltd.
Portions of this software 1996-2011 Microsoft
Corporation. All rights reserved.
Portions of this software incorporate PhysX by NVIDIA
2006-2010.
Portions of this software 2001-2011 Luxology, Inc. All
rights reserved, patents pending.
Portions of this software 2007-2011 DriveWorks Ltd.
Copyright 1984-2010 Adobe Systems Inc. and its licensors.
All rights reserved. Protected by U.S. Patents 5,929,866;
5,943,063; 6,289,364; 6,563,502; 6,639,593; 6,754,382;
patents pending.
Adobe, the Adobe logo, Acrobat, the Adobe PDF logo,
Distiller and Reader are registered trademarks or trademarks
of Adobe Systems Inc. in the U.S. and other countries.
For more SolidWorks copyright information, see Help >
About SolidWorks.
Copyright Notices for SolidWorks Simulation
Products
Portions of this software 2008 Solversoft Corporation.
PCGLSS 1992-2010 Computational Applications and
System Integration, Inc. All rights reserved.
Copyright Notices for Enterprise PDM Product
Outside In Viewer Technology, 1992-2010 Oracle
Portions of this software 1996-2011 Microsoft
Corporation. All rights reserved.

Copyright Notices for eDrawings Products

Portions of this software 2000-2011 Tech Soft 3D.
Portions of this software 1995-1998 Jean-Loup Gailly and
Mark Adler.
Portions of this software 1998-2001 3Dconnexion.
Portions of this software 1998-2011 Open Design
Alliance. All rights reserved.
Portions of this software 1995-2010 Spatial Corporation.
This software is based in part on the work of the Independent
JPEG Group.

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Contents

Introduction:

About This Course . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Course Design Philosophy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Using this Book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Laboratory Exercises . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
About the Training Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Windows XP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Conventions Used in this Book . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Use of Color . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
What is SolidWorks Simulation? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
What Is Finite Element Analysis? . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Build Mathematical Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Defeaturing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Idealization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Clean-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Build Finite Element Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Solve Finite Element Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Analyze Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Errors in FEA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Finite Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Element Types Available in SolidWorks Simulation . . . . . . . . . . 10
First Order Solid Tetrahedral Elements . . . . . . . . . . . . . . . . . . . . 11
Second Order Solid Tetrahedral Elements . . . . . . . . . . . . . . . . . . 12
First Order Triangular Shell Elements . . . . . . . . . . . . . . . . . . . . . 13
Second Order Triangular Shell Elements . . . . . . . . . . . . . . . . . . . 14
Beam Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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Choosing Between Solid and Shell Elements. . . . . . . . . . . . . . . . 15

Draft vs. High Solid and Shell Elements . . . . . . . . . . . . . . . . . . . 15
Degrees of Freedom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Calculations in FEA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Interpretation of FEA Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Principal Stresses: P1, P2, and P3. . . . . . . . . . . . . . . . . . . . . . . . . 18
Units of Measurement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Limitations of SolidWorks Simulation . . . . . . . . . . . . . . . . . . . . . . . . 19
Linear Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Small Structural Deformations . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Static Loads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Lesson 1:
The Analysis Process

Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
The Analysis Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Stages in the Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Case Study: Stress in a Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Project Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
SolidWorks Simulation Interface . . . . . . . . . . . . . . . . . . . . . . . . . 26
SolidWorks Simulation Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Plot Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Preprocessing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
New Study. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Assigning Material Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Fixtures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Fixture Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Display/Hide Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
External Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Size and Color of Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Preprocessing Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Meshing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Curvature Based Mesh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Mesh Density . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Element Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Minimum Number of Elements in a Circle . . . . . . . . . . . . . . . . . 44
Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Mesh Quality. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Postprocessing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Result Plots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Editing Plots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Nodal vs. Element Stresses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Show as Tensor Plot Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Modifying Result Plots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Other Plot Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Other Plots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

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Multiple Studies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Creating New Studies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Copy Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Check Convergence and Accuracy . . . . . . . . . . . . . . . . . . . . . . . . 64
Results Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Comparison With Analytical Results . . . . . . . . . . . . . . . . . . . . . . 66
Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Exercise 1: Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Exercise 2: Compressive Spring Stiffness . . . . . . . . . . . . . . . . . . . . . 81
Exercise 3: Container Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Lesson 2:
Mesh Controls, Stress Concentrations and Boundary Conditions
Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Mesh Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Case Study: The L Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Project Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Stages in the Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Run All Studies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Analysis with Local Mesh Refinement. . . . . . . . . . . . . . . . . . . . . 90
Mesh Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Results. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Results Comparison . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Stress Singularities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Case Study: Analysis of Bracket with a Fillet . . . . . . . . . . . . . . . . . . 97
Case Study: Analysis of a Welded Bracket. . . . . . . . . . . . . . . . . . . . 101
Understanding the Effect of Boundary Conditions. . . . . . . . . . . . . . 102
Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Exercise 4: C-bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Exercise 5: Bone Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Exercise 6: Foundation Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Lesson 3:
Assembly Analysis with Contacts
Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Contact Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Case Study: Pliers with Global Contact . . . . . . . . . . . . . . . . . . . . . . 130
Project Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Stages in the Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Applying Materials to Assemblies . . . . . . . . . . . . . . . . . . . . . . . 131
Component Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Component Contact: Options . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Component Contact: Default setting. . . . . . . . . . . . . . . . . . . . . . 134

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Component Contact: Hierarchy and Conflicts . . . . . . . . . . . . . . 134

Viewing Assembly Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Handle Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Required Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Pliers with Local Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Local Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Local Contact Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
No Penetration Local Contact Options . . . . . . . . . . . . . . . . . . . . 143
No Penetration Local Contact: Accuracy . . . . . . . . . . . . . . . . . . 144
No Penetration Local Contact: Remarks . . . . . . . . . . . . . . . . . . 144
Contact Stresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Exercise 7: Two Ring Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

Lesson 4:
Symmetrical and Free Self-Equilibrated Assemblies
Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Shrink Fit Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Case Study: Shrink Fit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Project Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Symmetry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Stages in the Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Defeaturing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Rigid Body Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Shrink Fit Contact Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Plot Results in Local Coordinate System . . . . . . . . . . . . . . . . . . 160
Cylindrical Coordinate Systems . . . . . . . . . . . . . . . . . . . . . . . . . 160
Saving All Plots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Whats Wrong Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Analysis with Soft Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Soft Springs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Inertial Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Exercise 8: Chain Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Exercise 9: Chain Link 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Lesson 5:
Assembly Analysis with Connectors
Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Connecting Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Connector Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Case Study: Vise Grip Pliers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Project Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Stages in the Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Spring Connector Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198

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Spring Connector Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198

Pin/Bolt Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Exercise 10: Lift Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Exercise 11: Analysis with Base (optional) . . . . . . . . . . . . . . . . . . . 216
Exercise 12: Shock Absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
Exercise 13: Spot Welds-Solid Mesh . . . . . . . . . . . . . . . . . . . . . . . . 221

Lesson 6:
Compatible/Incompatible Meshes
Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
Compatible / Incompatible Meshing. . . . . . . . . . . . . . . . . . . . . . . . . 230
Case Study: Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
Project Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
Compatible Mesh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
Incompatible Mesh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
Automatic Switch to Incompatible Mesh . . . . . . . . . . . . . . . . . . 234
Incompatible Bonding Options. . . . . . . . . . . . . . . . . . . . . . . . . . 236
Discussion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
Lesson 7:
Assembly Analysis Mesh Refinement
Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
Mesh Control in an Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
Case Study: Cardan Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
Problem Statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
Part 1: Draft Quality Coarse Mesh Analysis . . . . . . . . . . . . . . . . . . 241
Remote Load. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
Bolt Tight fit and Diameter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
Bolt Pre-load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
Local Contact Sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
No Penetration Local Contact Options . . . . . . . . . . . . . . . . . . . . 250
Rotational and Axial Stiffness . . . . . . . . . . . . . . . . . . . . . . . . . . 256
Knowledge Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
Part 2: High Quality Mesh Analysis . . . . . . . . . . . . . . . . . . . . . . . . . 261
Required Number of Solid Elements in Thin Features. . . . . . . . 262
Aspect Ratio Plot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
Jacobian . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
Exercise 14: Bolt Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
Exercise 15: Awning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
Lesson 8:
Analysis of Thin Components
Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
Thin Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
Case Study: Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278

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Project Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279

Part 1: Mesh with Solid Elements. . . . . . . . . . . . . . . . . . . . . . . . . . . 279
Symmetry Fixtures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
Part 2: Refined Solid Mesh. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
Solid vs. Shell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
Creating Shell Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
Part 3: Shell Elements - Mid-plane Surface . . . . . . . . . . . . . . . . . . . 285
Thin vs. Thick Shells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
Shell Mesh Colors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
Changing Mesh Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
Shell Element Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
Automatic Shell Surface Re-alignment . . . . . . . . . . . . . . . . . . . 292
Applying Symmetry Restraints. . . . . . . . . . . . . . . . . . . . . . . . . . 295
Deformed Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
Results Comparison . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
Computational Effort . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
Case Study: Joist Hanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
Project Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
Exercise 16: Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
Exercise 17: Shell Mesh Using Outer/Inner Faces . . . . . . . . . . . . . . 315
Exercise 18: Spot Welds - Shell mesh . . . . . . . . . . . . . . . . . . . . . . . 319
Exercise 19: Edge Weld Connector . . . . . . . . . . . . . . . . . . . . . . . . . 320
Exercise 20: Container Handle Weld . . . . . . . . . . . . . . . . . . . . . . . . 328

Lesson 9:
Mixed Meshing Shells & Solids
Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
Mixed Meshing Solids and Shells . . . . . . . . . . . . . . . . . . . . . . . . . . 330
Bonding Shells and Solids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
Mixed Mesh: Supported Analysis Types . . . . . . . . . . . . . . . . . . 331
Case Study: Pressure Vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
Project Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
Analyze the Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
Preparing the Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
Material. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
Steel Identification Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
UNS Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
Other Indices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
Bulk and Shear Moduli . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
Bonding Entities with Clearance . . . . . . . . . . . . . . . . . . . . . . . . 339
Shell Face to Shell Face Bonding . . . . . . . . . . . . . . . . . . . . . . . . 339
Shell Edge to Shell Face Bonding . . . . . . . . . . . . . . . . . . . . . . . 339
Shell to Solid Bonded Contact . . . . . . . . . . . . . . . . . . . . . . . . . . 340
Failure Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
Meshing Small Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343

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Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
Exercise 21: Mixed Mesh Analysis . . . . . . . . . . . . . . . . . . . . . . . . . 351

Lesson 10:
Mixed Meshing Solids, Beams & Shells
Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
Mixed Meshing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
Case Study: Particle Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
Project Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
Element Choices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
Beam elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
Stages in the Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
Beam Mesh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
Beam Joints: Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
Beam Joint Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
Section Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368
Connected and Disconnected Joints . . . . . . . . . . . . . . . . . . . . . . 369
Sphere Diameter Defining Beam Joint . . . . . . . . . . . . . . . . . . . . 369
Render Beam Profile. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372
Beam imprint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
Cross-section 1st and 2nd Directions . . . . . . . . . . . . . . . . . . . . . 375
Bending Moment and Shear Force Diagrams. . . . . . . . . . . . . . . 377
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378
Exercise 22: Beam Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379
Slenderness ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380
Exercise 23: Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
Exercise 24: Frame Rigidity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 398
Lesson 11:
Design Study
Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Design Study. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
Case Study: Suspension Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
Project Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
Stages in the Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
Part 1: Multiple Load Cases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
Design Studies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
Design Study Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
Design Study Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
Part 2: Geometry Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
Design Study Graph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
Exercise 25: Design Study . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419

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Lesson 12:
Thermal Stress Analysis
Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425
Thermal Stress Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426
Case Study: Bimetallic Strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426
Project Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426
Material Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427
Importing Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433
Averaging Stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435
Question . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440
Examining Results in Local Coordinate Systems (Optional) . . . . . . 440
Saving Model in its Deformed Shape . . . . . . . . . . . . . . . . . . . . . . . . 442
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 443
Lesson 13:
Adaptive Meshing
Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445
Adaptive Meshing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446
Case Study: Support Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446
Project Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446
Geometry Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 447
h-Adaptivity Study . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450
h-Adaptivity Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 451
h-Adaptive Plots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454
Convergence Graph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454
Review h-adaptive Solution . . . . . . . . . . . . . . . . . . . . . . . . . . . . 455
Strain Energy Error is NOT Stress Error . . . . . . . . . . . . . . . . . . 456
p-Adaptivity Study . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 457
p-Adaptive Solution Method . . . . . . . . . . . . . . . . . . . . . . . . . . . 457
h vs. p Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459
Method Comparison . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 463
h vs. p Elements - Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 464
Which Solution Method is Better? . . . . . . . . . . . . . . . . . . . . . . . 465
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465
Lesson 14:
Large Displacement Analysis
Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 467
Small vs. Large Displacement Analysis . . . . . . . . . . . . . . . . . . . . . . 468
Case Study: Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 469
Project Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 469
Part 1: Small Displacement Linear Analysis . . . . . . . . . . . . . . . . . . 469
Results Discussion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 471
Contact Solution in Small and Large Displacement Analyses . . 471

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Part 2: Large Displacement Nonlinear Analysis. . . . . . . . . . . . . . . . 471

Permanent Deformation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 473
SolidWorks Simulation Premium . . . . . . . . . . . . . . . . . . . . . . . . 474
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 474
Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 474

Appendix A:
Meshing, Solvers, and Tips & Tricks
Meshing Strategies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 476
Geometry Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 476
Defeaturing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 477
Idealization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 478
Clean-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 478
Mesh Quality. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 479
Aspect Ratio Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 479
Jacobian Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 480
Mesh Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 482
Automatic Trials for Solids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 484
Meshing Stages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 484
Failure Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 485
Tips for Meshing Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 486
Tips for Meshing Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . 486
Tips for Using Shell Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 487
Hardware Considerations in Meshing. . . . . . . . . . . . . . . . . . . . . . . . 488
Solvers in SolidWorks Simulation . . . . . . . . . . . . . . . . . . . . . . . . . . 489
Choosing a Solver. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 489
Appendix B:
Customer Help and Assistance
Customer Help and Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 492

ix

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Contents

SolidWorks 2012

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Introduction

Introduction

The goal of this course is to teach you how to use the SolidWorks
Simulation software to help you analyze static structural behavior of
your SolidWorks part and assembly models.

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About This
Course

SolidWorks 2012

The focus of this course is on the fundamental skills and concepts

central to the successful use of SolidWorks Simulation 2011. You
should view the training course manual as a supplement to, and not a
replacement for, the system documentation and on-line help. Once you
have developed a good foundation in basic skills, you can refer to the
on-line help for information on less frequently used command options.

Prerequisites

Students attending this course are expected to have the following:

I
I
I
I

Mechanical design experience.

Experience with the Windows operating system.
Complete the course SolidWorks Essentials.
Completed the on-line SolidWorks Simulation tutorials that are
available under Help. You can access the on-line tutorials by
clicking Help, SolidWorks Simulation, Tutorials.

Course Design
Philosophy

This course is designed around a process- or task-based approach to

training. Rather than focusing on individual features and functions, a
process-based training course emphasizes processes and procedures
you should follow to complete a particular task. By utilizing case
studies to illustrate these processes, you learn the necessary commands,
options, and menus in the context of completing a design task.

Recommended
Length

The minimum recommended length of this course is three days.

Using this Book

This training manual is intended to be used in a classroom environment

under the guidance of an experienced SolidWorks Simulation
instructor. It is not intended to be a self-paced tutorial. The examples
and case studies are designed to be demonstrated live by the
instructor.
There may be slight differences in results in certain lessons due to
service pack upgrades, etc.

Laboratory
Exercises

Laboratory exercises give you the opportunity to apply and practice the
material covered during the lecture/demonstration portion of the
course.

SolidWorks 2012

A complete set of the various files used throughout this course can be
downloaded from the SolidWorks website, www.solidworks.com.
Click on the link for Support, then Training, then Training Files, then
SolidWorks Simulation Training Files. Select the link for the desired
file set. There may be more than one version of each file set available.

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About the Training

Files

Introduction

Direct URL:

www.solidworks.com/trainingfilessimulation

The files are supplied in signed, self-extracting executable packages.

The files are organized by lesson number. The Case Study folder
within each lesson contains the files your instructor uses while
presenting the lessons. The Exercises folder contains any files that are
required for doing the laboratory exercises.

Windows XP

The screen shots in this manual were made using SolidWorks 2011 and
SolidWorks Simulation 2011 running on Windows 7. If you are
running on Windows Vista, or XP, you may notice differences in the
appearance of the menus and windows. These differences do not affect
the performance of the software.

Conventions Used
in this Book

This manual uses the following typographic conventions:

Convention

Meaning

Bold Sans Serif

SolidWorks Simulation commands and

options appear in this style. For example,
Right-click External Loads and select
Force means right-click the External
Loads icon in the SolidWorks Simulation
Study tree and select Force from the shortcut
menu.

Typewriter

Feature names and file names appear in this

style. For example, Restraint-1.

17 Do this step

Double lines precede and follow sections of

the procedures. This provides separation
between the steps of the procedure and large
blocks of explanatory text. The steps
themselves are numbered in sans serif bold.

Introduction

The SolidWorks and SolidWorks Simulation user interface make

extensive use of color to highlight selected geometry and to provide
you with visual feedback. This greatly increases the intuitiveness and
ease of use of the SolidWorks Simulation software. To take maximum
advantage of this, the training manuals are printed in full color.

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Use of Color

SolidWorks 2012

Also, in many cases, we have

Radius 50mm
used additional color in the
illustrations to communicate
concepts, identify features, and
otherwise convey important
information. For example, we
Radius 5mm
might show the fillet areas of a All
Around
Radius 6mm, 4 Places
part in a different color, to
highlight areas for mesh control, even though by default, the
SolidWorks Simulation software would not display the results in that
way.

SolidWorks 2012

Introduction

What is
SolidWorks
Simulation?

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SolidWorks Simulation is a design analysis tool based on a numerical

technique called Finite Element Analysis or FEA. SolidWorks
Simulation belongs to the family of engineering analysis software
products developed by SRAC, now part of SolidWorks Corporation.
Established in 1982, SRAC pioneered the implementation of FEA into
desktop computing. In 1995, SRAC entered the emerging mainstream
FEA software market by partnering with SolidWorks Corporation and
creating COSMOSWorks software, one of the first SolidWorks Gold
Products. COSMOSWorks soon became the top-selling, add-in analysis
software for SolidWorks Corporation. The commercial success of
COSMOSWorks integrated with SolidWorks CAD software resulted in
the acquisition of SRAC in 2001 by Dassault Systemes, the parent
company of SolidWorks Corporation. In 2003, SRAC merged with
SolidWorks Corporation. COSMOSWorks was renamed for 2009 to
SolidWorks Simulation.
SolidWorks is a parametric, solid, feature-based CAD system. As
opposed to many other CAD systems that were originally developed in
a UNIX environment and only later ported to Windows, SolidWorks
has, from the very beginning, been developed specifically for the
Windows operating system. SolidWorks Simulation has also been
specifically developed for the Windows operating system. Full
integration between SolidWorks and SolidWorks Simulation is possible
because both of the programs are native Windows OS applications.
SolidWorks Simulation comes in different bundles, or applications,
designed to best suit the needs of different users. With the exception of
SolidWorks SimulationXpress, which is an integral part of SolidWorks,
all SolidWorks Simulation bundles are add-ins. A brief description of
the capabilities of different bundles is as follows:

SolidWorks SimulationXpress

The static analysis of parts with simple types of loads and supports.

SolidWorks Simulation

The static analysis of parts and assemblies.

SolidWorks Simulation Professional

The static, thermal, buckling, frequency, drop test, optimization and

fatigue analysis of parts and assemblies.

SolidWorks Simulation Premium

All capabilities of SolidWorks Simulation Professional plus nonlinear

and dynamic analyses.

In this volume, we introduce SolidWorks Simulation through a series of

hands-on lessons intermixed with FEA fundamentals. We recommend
that you study the lessons in the order presented in the text. As you go
through the lessons, note that explanations and steps described in detail
in earlier lessons are not repeated later.

Introduction

SolidWorks 2012

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Each subsequent lesson assumes familiarity with software functions

and the FEA background discussed in previous lessons. Each lesson
builds on the skills and experience gained from the previous lessons.
Before we proceed with the lessons, let us construct a foundation for
our skills in SolidWorks Simulation by taking a closer look at what
Finite Element Analysis is and how it works.

What Is Finite
Element
Analysis?

In mathematical terms, FEA, also known as the Finite Element Method,

is a numerical technique of solving field problems described by a set of
partial differential equations. Those types of problems are commonly
found in many engineering disciplines, such as machine design,
acoustics, electromagnetism, soil mechanics, fluid dynamics, and
others. In mechanical engineering, FEA is widely used for solving
structural, vibration, and thermal problems.

FEA is not the only tool available for numerical analysis. Other
numerical methods used in engineering include the Finite Difference
Method, Boundary Element Method, or Finite Volumes Method.
However, due to its versatility and high numerical efficiency, FEA has
come to dominate the software market for engineering analysis, while
other methods have been relegated to niche applications. Using FEA,
we can analyze any shape, use various ways to idealize geometry and
produce results with the desired accuracy. FEA theory, numerical
problem formulation, and solution methods become completely
transparent to users when implemented into modern commercial
software, including SolidWorks Simulation.

A powerful tool for engineering analysis, FEA is used to solve

problems ranging from very simple to very complex. Design engineers
use FEA during the product development process to analyze the
design-in-progress. Time constraints and limited availability of product
data call for many simplifications of the analysis models. At the other
end of scale, specialized analysts implement FEA to solve very
advanced problems, such as vehicle crash dynamics, metal forming, or
analysis of biostructures.

SolidWorks 2012

Introduction

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Regardless of the project complexity or the field of application, the

fundamental steps in any FEA project are always the same, be it for
example a structural, thermal, or acoustic analysis. The starting point
for any analysis is the geometric model. In our case, this is a
SolidWorks model of a part or an assembly. To this model, we assign
material properties, and define loads and restraints. Next, as always the
case when using a tool based on the method of numerical
approximations, we discretize the model intended for analysis.
The discretization process, better known as meshing, splits the
geometry into relatively small and simply-shaped entities, called finite
elements. The elements are called finite to emphasize the fact that
they are not infinitesimally small, but only reasonably small in
comparison to the overall model size.
When working with finite elements, the FEA solver approximates the
wanted solution (for example, deformations or stresses) for the entire
model with the assembly of simple solutions for individual elements.
From the perspective of FEA software, each application of FEA
requires three steps:

Preprocessing

The type of analysis (e.g., static, thermal, frequency), material

properties, loads and restraints are defined and the model is split into
finite elements.

Solution

Computing the desired results.

Postprocessing

Analyzing the results.

We follow the preceding three steps every time we use SolidWorks

Simulation.

From the perspective of FEA methodology, we list the following FEA

steps:
1.
2.
3.
4.

Building the mathematical model.

Building the finite element model.
Solving the finite element model.
Analyzing the results.

Introduction

Analysis with SolidWorks Simulation starts with the geometry

represented by a SolidWorks model of a part or assembly. This
geometry must be meshable into a correct and reasonably small, finite
element mesh. By small, we do not refer to the element size, but the
number of elements in the mesh. This requirement of meshability has
very important implications. We must ensure that the CAD geometry
indeed meshes and that the produced mesh provides the correct
solution of the data of interest, such as displacements, stresses,
temperature distribution, and so on.

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Build
Mathematical
Model

SolidWorks 2012

Often, but not always, this necessity of meshing requires modifications

to the CAD geometry. Such modifications can take the form of
defeaturing, idealization, and/or clean-up, described as follows:

Defeaturing

Defeaturing refers to the process of suppressing or removing geometry

features deemed insignificant for analysis, such as external fillets,
rounds, logos, and so on.

Idealization

Idealization presents a more aggressive exercise that may depart from

solid CAD geometry as, for example, when representing thin walls
with surfaces.

Clean-up

Clean-up is sometimes required because the meshable geometry must

satisfy much higher quality requirements than those commonly
followed in Solid Modeling. For clean-up, we can use CAD qualitycontrol tools to check for problems, like sliver faces or multiple
entities, that the CAD model could tolerate, but would make meshing
difficult or impossible.

It is important to mention that we do not always simplify the CAD

model with the sole objective of making it meshable. Often, we
simplify a model that would mesh correctly as is, but the resulting
mesh would be too large and, consequently, the analysis would run too
slowly. Geometry modifications allow for a simpler mesh and shorter
computing time. Successful meshing depends as much on the quality of
the geometry submitted for meshing as on the sophistication of the
meshing tools implemented in the FEA software.
Having prepared a meshable, but not yet meshed, geometry, we define
material properties, loads, supports and restraints, and provide
information on the type of analysis that we wish to perform.

SolidWorks 2012

Introduction

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This procedure completes the creation of a mathematical model. Note

that the process of creating the mathematical model is not FEAspecific. FEA has not yet entered the picture.
Idealization of geometry
(if necessary)

Type of
Analysis

Material
Properties Supports Loads

MATHEMATICAL
MODEL

CAD geometry

Simplified geometry

FEA Pre-processing

CAD

Build Finite
Element Model

We now split the mathematical model into finite elements through a

process of discretization, better known as meshing. Discretization
visually manifests itself as the meshing of geometry. However, loads
and supports are also discretized and, after the model has been meshed,
the discretized loads and supports are applied to nodes of the finite
element mesh.
Discretization

Numerical solver

MATHEMATICAL
MODEL

FEA model

FEA Pre-processing

FEA Solution

FEA results

FEA Post-processing

Solve Finite
Element Model

After creating the finite element model, we use a solver provided in

SolidWorks Simulation to produce the desired data of interest.

Analyze Results

The analysis of results is often the most difficult step of all. The
analysis provides very detailed results data, which can be presented in
almost any format. Proper interpretation of results requires that we
appreciate the assumptions, simplifications, and errors introduced in
the first three steps: building the mathematical model, building the
finite element model, and solving the finite element model.

Introduction

The process of creating a mathematical model and discretizing it into a

finite element model introduces unavoidable errors. Formulation of a
mathematical model introduces modeling errors, also called
idealization errors. Discretization of the mathematical model
introduces discretization errors, and solution introduces numerical
errors.

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Errors in FEA

SolidWorks 2012

Of these three types of errors, only discretization errors are specific to

FEA. Therefore, only discretization errors can be controlled using FEA
methods. Modeling errors, affecting the mathematical model, are
introduced before FEA is utilized and can only be controlled by using
correct modeling techniques. Solution errors, which are round-off
errors accumulated by solver, are difficult to control, but fortunately are
usually very low.

Finite Elements

As we have already said, the discretization process, better known as

meshing, splits continuous models into finite elements. The type of
elements created in this process depends on the type of geometry
meshed, the type of analysis to be executed, and sometimes on our own
preferences.
SolidWorks Simulation features tetrahedral solid elements for meshing
solid geometry, and triangular shell elements for meshing surface
geometry. Why are we limited to tetrahedral, and triangular shapes?
This is because the automeshers reliably mesh almost any solid or
surface geometry using only those shapes of elements. Elements in
other shapes, such as hexahedral (brick) elements, cannot be created
reliably by the present-day automeshers. This limitation is not specific
to automeshers used in SolidWorks Simulation. A reliable brick
element automesher has not been invented yet.
Before proceeding, we need to clarify an important terminology issue.
What in CAD terminology we call solid geometry, in FEA is called
volumes. Solid elements are used to mesh those volumes. The term
solid has different meanings when it is used as solid geometry in CAD
terminology and when it is used as solid element in FEA terminology.

Element Types
Available in
SolidWorks
Simulation

Five element types are available in SolidWorks Simulation: first order

solid tetrahedral elements, second order solid tetrahedral elements, first
order triangular shell elements, second order triangular shell elements,
and two-node beam elements. The next few paragraphs describe them
in this order.
SolidWorks Simulation terminology refers to first order elements as

Draft Quality elements and second order elements as High Quality

elements.

10

SolidWorks 2012

First order (draft quality) tetrahedral elements model the first order
(linear) displacements field in their volume, along faces and edges. The
linear, or the first order, displacements field gives these elements their
name: first order elements. If you recall from The Mechanics of
Materials, strain is the first derivative of displacement. Therefore,
strain (obtained by derivating displacement) and, consequently, stress
are both constant in first order tetrahedral elements.

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First Order Solid

Tetrahedral
Elements

Introduction

Each first order tetrahedral element has

total of four nodes, one in each corner.
Each node has three degrees of freedom,
meaning that nodal displacements can
be fully described by three translation
components. A more detailed
description of degrees of freedom
follows later in this chapter.

After
deformation

Before
The edges of first order elements are
deformation
straight and the faces are flat. These
edges and faces must remain straight
and flat after the elements experience deformation under an applied
load.

This situation imposes a very severe limitation on the capability of a

mesh constructed with first order elements to model displacements and
stress fields of any real complexity. Moreover, straight edges and flat
faces do not map properly to curvilinear geometry.

The failure of straight edges and flat faces to map to curvilinear

geometry using first order tetrahedral elements is shown in the
following diagram using an elbow geometry.

For demonstration purposes, excessively large (as compared to the

model size) elements are used for this mesh. This mesh would not be
sufficiently refined for any analysis.

11

Introduction

Second order (high quality) solid tetrahedral elements model the

second order (parabolic) displacements field and, consequently, first
order (linear) stress field (note that the derivative of a parabolic
function is a linear function). The second order displacements field
gives these elements their name: second order elements.

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Second Order
Solid Tetrahedral
Elements

SolidWorks 2012

Each second order tetrahedral element has ten nodes (four corner nodes
and six mid-side nodes) and each node has three degrees of freedom.

The edges and faces of second order

solid elements can assume curvilinear
shapes if the elements need to map to
curvilinear geometry and/or during the
deformation process when the elements
deform under a load.

Therefore, these elements map precisely

to curvilinear geometry, as illustrated by
the same elbow geometry.

After
deformation

Before
deformation

Again, for demonstration purposes, excessively large (as compared to

the model size) elements are used for this mesh. This mesh is not
sufficiently refined for analysis, even though it uses second order
elements that require a significantly less-refined mesh compared to that
for first order elements.
For accurate stress results, it is generally recommended to use two
layers of second order elements across the wall thickness.

Because of their much better mapping capabilities and because of their

ability to model the second order displacements field, second order
tetrahedral elements are used for the vast majority of analyses with
SolidWorks Simulation, even though second order elements are more
computationally demanding than first order elements.

12

SolidWorks 2012

Analogous to first order solid elements, first order triangular shell

elements model the linear displacements field and constant strain and
stress along their faces and edges. The edges of first order shell element
are straight and must remain straight while the elements deform.

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First Order
Triangular Shell
Elements

Introduction

Each first order shell element has

three nodes (all in corners) and
each node has six degrees of
freedom, meaning that its
displacements are fully described
by three translation components
and three rotation components.

After
deformation

Before
deformation

If we represent the elbow with a

mid-plane surface and mesh this
surface with first order shell elements, note the imprecise mapping to
curvilinear geometry.

This result resembles the previously demonstrated result of first order

elements mapping imprecisely to curvilinear geometry.

Analogous to first order solid elements shown before, these shell

elements are too large for any real analysis. In the illustration, different
colors are used to differentiate the element top (brown) and bottom
(green). The orientation and colors are arbitrary and can be changed by
flipping the shell elements. They do not refer, in any way, to model
orientation or model geometry.

13

Introduction

Second order (high quality) triangular shell elements model the second
order displacements field and the first order (linear) stress field.

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Second Order
Triangular Shell
Elements

SolidWorks 2012

Each second order shell element

After
has six nodes: three corner nodes
deformation
and three mid-side nodes. The
edges and faces of second order
shell elements can assume
Before
curvilinear shapes in the meshing
deformation
process when the elements need to
map to curvilinear geometry and/or
during the deformation process when the elements deform under a load.
This shell element mesh created with second order shell elements maps
precisely to curvilinear geometry as illustrated again with the elbow
model.

While convenient to show element mapping capabilities, the element

size is too large for analysis, even though second order shell elements
require less refined meshes as compared to first order shell elements.

Beam Elements

Contrary to the first order solid and shell elements, two-node beam
elements model the two out-of-plane deflections as cubic functions and
the axial translations and torsional rotations as linear. The shape of a
two-node beam element is initially straight, but it can assume the shape
of a cubic function after the deformation takes place.
Each two-node beam element
features six degrees of freedom at
each end node: three translations
and three rotations.

The same mesh mapping

considerations that apply to the first
order solid and shell elements apply
to a two-node beam element as well.

14

After
deformation

Before
deformation

SolidWorks 2012

Certain classes of shapes can be modeled using either solid or shell

elements, such as the elbow discussed earlier. The selection of element
type: tetrahedral solid or triangular shell, used for modeling may
depend on the objective of the analysis. More often, however, the
nature of geometry dictates what type of element to use for meshing.
For example, parts produced by casting lend themselves to be meshed
with solid elements, while a sheet metal structure is best meshed with
shell elements.

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Choosing Between
Solid and Shell
Elements

Introduction

A hollow plate, featured in the next chapter, can be meshed with either
solid elements created by meshing solid geometry or with shell
elements created by meshing mid-surface.

Draft vs. High

Solid and Shell
Elements

First order elements, both solids and shells, should be used only for
preliminary studies with specific objectives, such as verifying
directions of loads or restraints, or calculating reaction forces.

The studies ready for the final computations (where the correct setup
has been verified by using the Draft elements, for example) and the
studies where a stress distribution is of any interest (especially in the
through-thickness direction) should be modeled using High quality
elements.

Degrees of
Freedom

The degrees of freedom (DOF) of a node in a finite element mesh

define the ability of the node to perform translation or rotation. The
number of degrees of freedom that a node possesses depends on the
type of element that the node belongs to. Nodes of solid elements have
three degrees of freedom while nodes of shell elements have six
degrees of freedom.

In order to describe transformation of a solid element from the original

to the deformed shape, we need to know only three translational
components of nodal displacement for each node. In the case of shell
elements, we need to know, not only the translational components of
nodal displacements, but also the rotational displacement components.

15

Introduction

SolidWorks 2012

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Consequently, built-in (or rigid) constraints applied to solid elements

require only three degrees of freedom to be constrained. The same
constraints applied to shell element require that all six degrees of
freedom be constrained. Failure to constrain rotational degrees of
freedom may result in unintentional hinge support in place of the
intended rigid support.

Calculations in
FEA

Each degree of freedom of each node in a finite element mesh

constitutes an unknown. In structural analysis, degrees of freedom
assigned to nodes can be thought of as nodal displacements.
Displacements are primary unknowns and are always calculated first.

If solid elements are used, three displacement components, or three

degrees of freedom (three unknowns) per node must be calculated.
Using shell elements, six displacement components, or six degrees of
freedom per node (six unknowns) must be calculated. All other aspects
of the analysis, such as strains and stresses, are calculated based on the
nodal displacements. In fact, some FEA programs offer solutions with
stress calculation as an option, not a requirement.
In a thermal analysis (which determines temperatures, temperature
gradients, and heat flux), the primary unknowns are nodal
temperatures. Since temperature is a scalar value, unlike displacement,
which is a vector, then regardless of what type of elements are used,
there is only one unknown (temperature) to be found for each node in
the thermal analysis model. All other results available in a thermal
analysis are calculated based on those nodal temperatures.

The fact that there is only one unknown to be found for each node
rather than three, or six as is the case in structural analysis, makes
thermal analysis less computationally intensive than structural analysis.

16

SolidWorks 2012

The results of FEA are provided either in the form of displacements,

strains and stresses for a structural analysis or in the form of
temperatures, temperature gradients, and heat flux for thermal analysis.
We now focus on the more intuitive structural analysis. How do we
decide between a passed or a failed design?

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Interpretation of
FEA Results

Introduction

To answer these questions, we need to establish some criteria to

interpret FEA results, be they, for example, the maximum acceptable
deformation, maximum stress, or the lowest acceptable natural
frequency.

While displacement or frequency criteria are quite obvious and easy to

establish, stress criteria are not.

Assume that we conduct a stress analysis in order to ensure that stresses

are within an acceptable range. To assess stress results, we need to
understand the mechanism of potential failure. If the part breaks, what
stress component is responsible for that failure?
Discussion of various failure criteria is beyond the scope of this
manual. Any book in the field of the mechanics of materials provides
information on this topic. Here we limit our discussion to outlining the
differences between von Mises stresses and the principal stresses,
which are both common stress measures used for evaluating structural
safety.

Von Mises Stress

Von Mises stress, also known as Huber

stress, is a stress measure that accounts
for all six stress components of a
general 3D state of stress.

Two components of shear stress and

one component of normal stress act on
each side of an elementary cube. Due to
equilibrium requirements, the general
3D state of stress is characterized by
only six stress components because of
equalities:
xy = yx, yz = zy, xz = zx

The von Mises stress equation can be expressed by stress components

that are defined in a global coordinate system as:
eq =

2
2
2
2
2
2
0.5 ( x y ) + ( y z ) + ( z x ) + 3 xy + yz + zx

17

Introduction

The state of stress can also be described by three principal stress

components: 1, 2, 3 whose directions are normal to faces of an
elementary stress cube.

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Principal Stresses:
P1, P2, and P3

SolidWorks 2012

Von Mises stress is then expressed as:

eq =

2
2
2
0.5 ( 1 2 ) + ( 2 3 ) + ( 3 1 )

Note that von Mises stress is a non-negative, scalar value. Von Mises
stress is a commonly used stress measure because the structural safety
of many engineering materials showing elastoplastic properties, such as
steel, is well described by von Mises stress magnitude.
For those materials, the yield factor of safety or the ultimate factor of
safety can be calculated by dividing the yield stress (also called yield
strength) or the ultimate stress (also called ultimate strength) of the
material by von Mises stress.

In SolidWorks Simulation, principal stresses are denoted as P1, P2, and

P3.
P1 stress which is usually tensile, is used when evaluating stress results
in parts made of brittle material, whose safety is better related to P1
than to von Mises stress. P3 is used to examine compressive stresses
and contact pressure.

18

SolidWorks 2012

Internally, SolidWorks Simulation uses the International System of

Units (SI). As SolidWorks Simulation users, we are spared much
confusion and trouble with systems of units. Data may be entered in
three different systems of units: SI, Metric, and English. Similarly,
results can be displayed in any of those three systems of units. The
available systems of units are summarized in the following table:

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Units of
Measurement

Introduction

International
System of Units
(SI)

Metric
(MKS)

English
(IPS)

Mass

kg

kg

lbm

Length

cm

in

Time

Force

kgf

lbf

Pressure/Stress

N/m^2

Kgf/cm^2

lbf/in^2

Mass density

kg/m3

kg/cm3

lb./in3

Temperature

Limitations of
SolidWorks
Simulation

With any FEA software, we need to take advantage of its strengths as

well as work within its limitations. Analysis with SolidWorks
Simulation is conducted under the following assumptions:
I
I
I

material is linear
structural deformations are small
loads are static

These assumptions are typical of the FEA software used in the design
environment, and the vast majority of FEA projects are run
successfully within these limitations.

For analyses requiring nonlinear material, nonlinear geometry, or

dynamic analysis, tools such as SolidWorks Simulation Premium can
be used. Some dynamic analysis capabilities are also included in
SolidWorks Simulation Professional, which features frequency analysis
and drop test functions.

Note

SolidWorks Simulation also features a geometrically nonlinear solver

to compute large displacement problems. However, because only a
default set of the parameters for the nonlinear solver is available, the
applicability of this SolidWorks Simulation feature is limited. For full
scale nonlinear problems (both the geometry and materials),
SolidWorks Simulation Premium suite must be used.

19

Introduction

In all materials used with SolidWorks Simulation, stress is linearly

proportional to strain.

STRESS

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Linear Material

SolidWorks 2012

Linear
Material

Nonlinear
Material

STRAIN

Using a linear material model, the maximum stress magnitude is not

limited to yield or to ultimate stress as it is in real life.

For example, in a linear model, if stress reaches 100 MPa under a load
of 1,000 N., then stress will reach 1,000 MPa under a load of 10,000 N.
Material yielding is not modeled. Whether or not yield takes place can
only be interpreted based on the stress magnitudes reported in results.

Most analyzed structures experience stresses below yield stress, and the
factor of safety is most often related to the yield stress.

Therefore, the analysis limitations imposed by linear material seldom

impede SolidWorks Simulation users.

Small Structural
Deformations

Any structure experiences deformation under load. In SolidWorks

Simulation, we assume that those deformations are small. What exactly
is a small structural deformation? Often it is explained as a deformation
that is small in relation to the overall size of the structure.

Small structural deformations

Large structural deformations

The preceding figure shows a cantilever beam in bending with small

deformations and large deformations.

20

SolidWorks 2012

Introduction

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If deformations are large, then the SolidWorks Simulation assumptions

generally do not apply, even though SolidWorks Simulation has some
large displacement analysis capabilities, which we will discuss towards
the end of this course.
Other analysis tools, such as SolidWorks Simulation Premium must be
used to analyze this structure.

Note that the magnitude of deformation is not the deciding factor when
classifying deformation as small or large. What really matters is
whether or not the deformation changes the structural stiffness in a
significant way.
Small deformation analysis assumes that the structural stiffness
remains the same throughout the deformation process. Large
deformation analysis accounts for changes of stiffness caused by
deformations.
While the distinction between
small and large deformations is
quite obvious for the beam, it
is not at all obvious for a flat
membrane under pressure.

Pressure

For a flat membrane, initially

the only mechanism resisting
the pressure load is that of
bending stresses.

During the deformation

process, the membrane
acquires membrane stiffness in addition to the original bending
stiffness.

The stiffness of the membrane changes significantly during

deformation. This change in stiffness requires a large deformation
analysis, using tools like SolidWorks Simulation Premium.

Static Loads

All loads, as well as restraints, are assumed not to change with time.
This limitation implies that loads are applied slowly enough to ignore
inertial effects. Dynamic loading conditions cannot be analyzed with
SolidWorks Simulation.

While all loads, in reality, change with time, modeling them as static
loads is most often acceptable for the purpose of design analysis.
Gravity loads, centrifugal forces, pressure, bolt preloads, and so on can
be successfully represented as static loads.

Dynamic analysis is generally required only for fast-changing loads. A

drop test or vibration analysis definitely require that we model dynamic
loads.

21

Introduction

This short review of FEA fundamentals is not, of course, all

inclusive. It is only intended to get us started with the hands-on
lessons. As we progress through the case studies presented in the
following lessons, we will occasionally digress from software-specific
issues in order to discuss relevant FEA fundamentals.

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Summary

SolidWorks 2012

22

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Lesson 1
The Analysis Process

Objectives

Upon successful completion of this lesson, you will be able to:

I

Navigate the SolidWorks Simulation interface.

Execute a linear static analysis using solid elements.

Understand the influence of mesh density on displacement and

stress results.

Employ various methods to present FEA results.

Manage SolidWorks Simulation result files.

Access available help and assistance.

23

Lesson 1

SolidWorks 2012

The Analysis Process

The process of analyzing models consists of the same basic steps

regardless of the type of analysis or model. We must understand these
steps fully to have a meaningful analysis.

Stages in the
Process

Some key stages in the analysis of a model are shown in the following
list:

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The Analysis
Process

Create a study

Each analysis performed on a model is a study. We can have

multiple studies in each model.

Apply material

We apply a material which contains the physical information, such

as yield strength, to the model.

Apply fixtures

Fixtures are added to represent the way the physical model is held.

Apply loads

Loads represent the forces on the model.

Mesh the model

The model is broken into finite elements.

Run the study

The solver calculates the displacement, strain and stress in the

model.

Analyze the results

The results are interpreted.

Case Study:
Stress in a Plate

In this first case study, we will determine the stress in a rectangular

plate, with a hole in it, under a tensile load. We will use this simple
model to familiarize ourselves with all the steps and the majority of the
software functionality typically used in a static analysis of solid
models.
In spite of its simplicity, this is probably the most important lesson in
this course. This lesson goes through all the required steps; however,
after the lesson is complete, you should continue to explore other
software functionality and other modeling assumptions, such as
different material properties, loads, restraints, and so on.

Project
Description

24

The rectangular plate with a

hole is fixed at the shortend face. A 110,000
Newton load is uniformly
distributed along the other
end face.

SolidWorks 2012

Lesson 1
The Analysis Process

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In addition to learning SolidWorks Simulation functions, our objective

is to investigate the impact of different mesh densities on the results.
Using FEA terminology, the objective is to investigate the effect of
different discretization choices on the data of interest, in our case, on
deformation and stress.
Therefore, we perform the analyses using meshes with different
element sizes. Note that repetitive analysis with different meshes does
not represent standard practice in FEA. We repeat the analysis using
different meshes as a learning tool to gain more insight into how FEA
works.

Open a part file.

Open rectangular hollow plate from the Lesson01\Case Studies

folder. Review the dimensions of the model and note down the length,
width, and thickness of the part in millimeters.

Start SolidWorks Simulation.

Click Tools, Add-Ins. Select
SolidWorks Simulation.

Click OK.

25

Lesson 1

SolidWorks 2012

The Analysis Process

SolidWorks Simulation functions are accessed in the same way as core

SolidWorks. To create an FEA model, solve the model, and analyze the
results, we use a graphical interface in the form of icons and folders
located in the SolidWorks Simulation Study tree window.

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SolidWorks
Simulation
Interface

Analysis Library

CommandManager tab

Toolbar

Simulation
Study tree

Simulation Study
Tree

26

Simulation Study
tabs

Once a simulation study is

created, the Simulation Study tree
will appear in the lower part of the
FeatureManager design tree. Its
visibility is controlled by a tab
below the graphics area.

Simulation
Advisor

SolidWorks 2012

Lesson 1
The Analysis Process

The Simulation menu provides a method to access

all the commands for simulation.

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Pull-down
Simulation Menu

Toolbars

The Simulation toolbar contains all the

commands that have toolbar buttons. It
can be customized to show only those
commands you use frequently.

CommandManager

The CommandManager provides a universal toolbar for simulation.

The Simulation tab provides the tools to setup a study and for
analyzing the results.

Context menus

Functions can be selected by rightclicking geometry or items in the

Simulation Study tree.

27

Lesson 1

SolidWorks 2012

The Analysis Process

SolidWorks
Simulation
Options

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Located on the Simulation menu, the Options dialog box enables you to
customize the Simulation software to reflect the standards your
company uses for analysis. There are two categories of options, system
and default.
I

System Options

System options apply to all studies. Included are the settings for the
way the errors are displayed and the location of the default libraries.

Default Options

Default options apply to new studies. As we do not use templates

for simulation studies, this is where the options are set for units,
default plots, etc.

Where to Find It

Menu: Click Options from the Simulation menu

Open Options window.

Click Options on the Simulation menu.

Set default units for SolidWorks Simulation.

Under Default Options, select Units. Make sure that the Units system
is set to SI (MKS) and Length/Displacement and Stress are in mm
and N/mm^2(MPa), respectively.

Set default results.

Under Default options, select the Results folder. In this lesson, the

analysis results will be created and stored in a sub-folder located in the

SolidWorks document directory.

Under Results folder, select SolidWorks document folder.

SolidWorks document folder is the folder where rectangular
hollow plate.SLDPRT file resides on your computer.
Select the Under sub folder check box.

28

SolidWorks 2012

Lesson 1
The Analysis Process

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In the Under sub folder box, enter results. This will automatically
create a sub folder results to store SolidWorks Simulation results.
Under Default Solver, select Automatic.

Note

Solvers will be discussed later in the course.

Plot Settings

Upon completion of any static analysis,

SolidWorks Simulation automatically
creates the following result plots:
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Stress1
Displacement1
Strain1

The plot settings determine which plots

will be automatically created and their
units. To add an additional plot, rightclick Static Study Results and select
the type of plot you wish to define. Each
type of plot can be stored in a userdefined folder.

29

Lesson 1

SolidWorks 2012

The Analysis Process

Set default plots.

Expand the Default plots subfolder located in the Plot folder. This

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section allows you to select default result plots to be generated after

solving the analysis.

We will use the default settings in the Default plots folder for this
lesson.

Specify color chart options.

Under the Plot folder, select Color chart.

Set Number format to scientific (e) and No. of decimal places to 6.

Explore all the chart options in this dialog.
Click OK to close the Options window.

30

SolidWorks 2012

Lesson 1
The Analysis Process

In the following steps, we will prepare the model for analysis. The
preprocessing steps include:

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Preprocessing

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New Study

Create a study
Apply material
Apply fixtures
Apply external forces
Mesh the model

Creation of an FEA model always starts with the

definition of a study.
The study definition is where we enter
information about the kind of analysis we wish
to perform.
Each analysis we do is a separate
study. When a study is defined,
SolidWorks Simulation
automatically creates a study
folder (named in this case,
default analysis) and places
several icons in it.

Some of the icons are folders that

contain other icons.

We use the Parts folder to define

and assign material properties, the External Loads folder to define
loads, the Fixtures folder to define fixtures, and the Mesh icon to
create the finite element mesh.
The Connections folder is not used in this lesson.

There is only one component, named rectangular hollow plate, in

the Parts folder. If an assembly (and not a part) is analyzed, then the
Parts folder contains as many components as there are parts in the
assembly.

Renaming Studies

The name of the study can be changed at any point by click-pauseclicking on the study name (similarly to renaming files and folders in
Windows).

31

Lesson 1

SolidWorks 2012

The Analysis Process

Assigning Material
Properties

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We can assign material to the model in either the SolidWorks or the

SolidWorks Simulation window.
If a material was assigned in the SolidWorks window, the material
definition will be transferred automatically to SolidWorks Simulation.
In this lesson, we assign material to the part in the SolidWorks
Simulation window, not because this is the preferred way, but to
demonstrate this option.
To assign a material:
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Select Material on the Simulation menu, then click Apply material

to all.
Select the component, then click Apply Material
in the
Simulation Main toolbar.
Right-click the body/part/
assembly icon in the
Simulation Study tree and
select Apply/Edit Material.

The first method assigns the same material properties to all components
in the model. The second method assigns material properties to one
particular component and all the multi-bodies associated to the
component. The third method assigns material properties to one
particular body: in this lesson, the rectangular hollow plate.
Because we are not working with an assembly but with a single part
which contains only one body (i.e. this is not a multi body part) any of
the above three ways of material assignment can be used.

Note

Create a study.
Click Study
on the Simulation menu.

Name the study.

Studies can have any name; here we name the

study default analysis. Type default analysis
for the Name.
Select Static for the Type of study.

Click OK.

32

SolidWorks 2012

Lesson 1
The Analysis Process

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10 Assign material properties.

Click Material in the Simulation menu. Click Apply Material to All.

Expand Solidworks Materials and assign AISI 304 from the Steel
folder.

The required material constants are in red. The constants shown in blue
may be required if specific load types are used (for example, the
Temperature load would require the Thermal expansion
coefficient).
Note that you may add a new material library by right clicking any
folder or existing material in the Material dialog window. The new
material can be added by copying the existing material into a new
location and editing its properties.
Click Close.

The rectangular hollow plate icon in the Parts folder now displays
a green check mark and the name of the selected material to indicate
that a material has successfully been assigned.

33

Lesson 1

SolidWorks 2012

The Analysis Process

To do a static analysis, the model must be properly restrained so that it

cannot move. SolidWorks Simulation provides various fixtures that can
be used to restraint the model. Generally, fixtures can be applied to
faces, edges and vertices using various methods.

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Fixtures

Fixture Types

The fixtures and restraints are grouped as Standard and Advanced.

Their properties are summarized below:
Standard Fixtures
Fixture Type

Definition

Fixed Geometry

Also called a rigid support, all translational

and all rotational degrees of freedom are
constrained.
Fixed Geometry does not require any
information on the direction along which
restraints are applied.

Roller/Slider

Use the Roller/Slider restraint to specify that

a planar face can move freely in its plane but
cannot move in the direction normal to its
plane. The face can shrink or expand under
loading.

Fixed Hinge

Use the hinge restraint to specify that a

cylindrical face can move only about its axis.
The radius and the length of the cylindrical
face remain constant under loading.

Advanced Fixtures
Fixture Type

Symmetry

Circular
Symmetry

34

Definition

This option is available for use on flat face;

in-plane displacements are allowed and
rotation in the direction normal to the plane is
allowed.
This option is used to restrain segments
which, if periodically revolved around a
specified axis of revolution, would form a
rotationally symmetrical body.

SolidWorks 2012

Lesson 1
The Analysis Process

Advanced Fixtures
Definition

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Fixture Type

Use Reference
Geometry

On Flat Faces

On Cylindrical
Faces

On Spherical
Faces

Display/Hide
Symbols

This option restrains a face, edge, or vertex

only in desired direction(s), while leaving the
other directions free to move. You can specify
the desired direction(s) of restraint in relation
to the selected reference plane, axis, edge, or
face. The SolidWorks Flyout FeatureManager
is useful for selecting reference geometry
(plane and axis).
This option provides restraints in selected
directions, which are defined by the three
principal directions of the flat face where
restraints are being applied.
This option is similar to On flat face except
that the three principal directions of a
cylindrical reference face define the directions
in a cylindrical coordinate system; this option
is very useful because you can apply a
restraint that allows for rotation about the axis
associated with the cylindrical face.
Similar to On flat faces and On cylindrical
faces; the three principal directions of a
spherical face define the directions of the
applied restraints in a spherical coordinate
system.

Fixture and External Forces symbols can be displayed or hidden by

doing one of the following actions:
I
I

Right-click Fixtures or External Loads and select Hide All or

Show All.
Right-click a Fixture or External Loads symbol for each
restraint individually, and then select Hide or Show.

35

Lesson 1

SolidWorks 2012

The Analysis Process

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11 Define Fixed Restraints.

In the Simulation Study tree, right-click

Fixtures and select Fixed Geometry.

Rotate the model and select the face to apply

restraints. The Flyout FeatureManager is
available in the upper left corner of the
graphics area to make selection easier for
parts, bodies or features.

In the Type box, select Fixed Geometry, and

then click OK
to close the Fixture
PropertyManager.

Having defined fixtures, we have fully restrained the model in space.

Therefore, the model cannot displace without elastic deformation. In
FEA terminology, we say that the model does not have any rigid body
modes.

Renaming

Each boundary condition can be renamed to help us decipher the

meaning later on.

Windows standard click-pause-click technique can be used to rename

fixtures, loads and connectors.

36

SolidWorks 2012

Lesson 1
The Analysis Process

Fixture symbols are displayed on the face

where they have been applied.

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Fixture Symbols

In this case study, we select Fixed Geometry

as the fixture type, meaning that all six
degrees of freedom (three translations and
three rotations) have been restrained.

The fixture symbols are arrows to indicate

translational restraints and discs to indicate rotational restraints in
respective directions. In this lesson, the fixtures are defined by the
directions of the global coordinate system visible in the lower-left
corner of the model window.
If, instead of selecting Fixed Geometry as the
type of fixture, we selected Roller/Slider, then
the rotational degrees of freedom would not be
constrained and the corresponding fixture
symbols would feature only arrows, not discs.

37

Lesson 1

SolidWorks 2012

The Analysis Process

Once the model is restrained, we must apply external loads, or forces,

to the model. SolidWorks Simulation provides various external forces
that can be used to load the model. Generally, forces can be applied to
faces, edges, and vertices using various methods. These external forces
and their properties are summarized below:

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External Loads

Standard External Forces

Force Type

Force

Definition

This option applies a force or moment to a

face, edge, or vertex in the direction defined
by selected reference geometry (plane, edge,
face, or axis).

Note that a moment can only be applied if

shell elements are used. Shell elements have
six degrees of freedom per node (translations
and rotations) and can assume a moment load.
Solid elements have only three degrees of
freedom per node (translations only) and,
therefore, cannot assume a moment load
directly.

Torque

38

If you need to apply a moment to solid

elements, it must be represented by
appropriately distributed forces, or remote
loads.
This option applies torque about a reference
axis using the Right-hand Rule. This option
requires that the axis be defined in
SolidWorks.

SolidWorks 2012

Lesson 1
The Analysis Process

Advanced External Forces

Definition

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Force Type

Pressure

Gravity

Centrifugal Force
Bearing Load

Remote Load/
Mass

Distributed Mass

Applies a pressure to a face. Can be

directional and variable, such as hydrostatic
pressure.
Applies linear accelerations to parts or
assemblies.
Applies an angular velocity and acceleration
to a part or assembly.
Bearing loads are defined between contacting
cylindrical faces.
Remote loads apply loads that would
normally be transferred by connecting
structure.

Distributed masses are applied to selected

faces to simulate the mass of components that
are suppressed or not included in the model.

The presence of an external force is indicated by arrows symbolizing

the load and by the corresponding icon.

12 Rename the fixture.

Use the Windows click-pause-click method to rename the fixture called

Fixture-1 to Fixed side.

13 Define Force.

Rotate the model to reveal the face where

the 110,000 N [24,729 lbf] tensile force
is to be applied and select this face.

39

Lesson 1

SolidWorks 2012

The Analysis Process

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Right-click External Loads and select Force to list the available

options for defining loads. This action opens the Force/Torque
PropertyManager.

In the Type area, select Normal, in the Units dialog make sure that SI is
selected, and in the Force Value box, type 110,000.

Select Reverse direction. This is required to define a tensile force.

Clearing the Reverse direction check box would result in a
compressive force.

When defining a normal force we do not need to use any reference

geometry. Load direction is sufficiently defined by the orientation of
the loaded face when Normal is in effect.

Click OK

14 Rename the force.

Rename this force definition to Tensile force.

40

SolidWorks 2012

Lesson 1
The Analysis Process

The size and color of restraint

and load symbols can be
controlled both locally and
globally.

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Size and Color of

Symbols

The local settings of the

symbols are controlled from the
Symbol settings dialog in the
Fixtures and External Loads
PropertyManagers.

The global definitions for the symbols can be controlled by the

SolidWorks Simulation Options in the Load/Fixture folder.

Display/Hide
Symbols

The model now shows both loads and restraints symbols. To hide or
show the symbols:
I
I

Right-click a particular restraint or load icon in the Fixtures or

External Loads folder and choose Show or Hide.
Right-click the Fixtures or External Loads folder to globally
display or hide loads and restraints and choose Show All or Hide All.

41

Lesson 1

SolidWorks 2012

The Analysis Process

Now that we have assigned the material properties, fixtures, and

external loads, we have fully defined the mathematical model, which
we intend to solve with FEA.

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Preprocessing
Summary

The mathematical model must be discretized into a finite element

model. Before creating the finite element model, let us make a few
observations about the following terms:
I
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Geometry preparation
Material properties
External loads definition
Fixtures definition

Geometry
Preparation

Geometry preparation is a well-defined step with few uncertainties.

Geometry that is simplified for analysis can be checked visually by
comparing it with the original CAD model.

Material Properties

Material properties are most often selected from the material library
and do not account for local defects, surface conditions, and so on.
Generally, material definition has more uncertainties than geometry
preparation.

External Loads
Definition

External loads definition, even though done in a few quick menu

selections, involves many background assumptions because in real life,
load magnitude, distribution, and time dependence are often known
only approximately and must be roughly estimated in FEA with many
simplifying assumptions. Therefore, significant idealization errors can
be made when defining loads. Nonetheless, loads can be expressed in
numbers, which makes loads easier for FEA users to relate to.

Fixtures Definition

Defining restraints is where severe

errors are most often made. A
common error is over-constraining
the model, which results in an overly
stiff structure that underestimates
deformations and stresses.
The relative level of uncertainties in
defining geometry, material, loads,
and fixtures is qualitatively shown.

Idealizations and
Assumptions

42

Geometry Material Loads

Fixtures

Geometry is the easiest to define while fixtures are the most difficult,
but the level of difficulty has no relation to the time required for each
step, so the message in this bar graph may be counterintuitive. In fact,
preparing CAD geometry for FEA may take hours, while defining
material, and applying loads and fixtures involves only a few mouse
clicks.

SolidWorks 2012

Lesson 1
The Analysis Process

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In all examples here, we assume that material properties, external

forces, and supports are known with certainty, and that the way they are
defined in the model represents an acceptable idealization of real
conditions. However, we need to emphasize that it is the responsibility
of the user of the FEA software to determine if all those idealized
assumptions made during the creation of the mathematical model are
indeed acceptable. The best automesher and the fastest solver do not
help if the mathematical model submitted for analysis with FEA is
based on erroneous assumptions.

Meshing

The last step before processing the FEA model is to mesh the geometry.
In this step, the geometry will be divided into finite elements by an
automesher. While the automesher will take care of the tedious part of
the problem, we have input into the process to control the size and
quality of the mesh.

Curvature Based
Mesh

SolidWorks Simulation uses advanced technology to mesh the

geometry into finite elements. The curvature based mesh algorithm
generates a mesh with a variable element size that allows the accurate
resolution of small features in the geometry.

Mesh Density

SolidWorks Simulation will suggest medium mesh

density as the default that SolidWorks Simulation
will use for meshing our model. Mesh density
directly affects the accuracy of results. The smaller
the elements, the lower the discretization errors, but the longer the
meshing and solution times.

Element Sizes

The element size represents the characteristic element size in the mesh
and is defined as the diameter of a sphere circumscribing the element
(on the left in the following figure). This representation is easier to
illustrate with the 2-D analogy of a circle circumscribing a triangle (on
the right in the following figure).

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Because the curvature based mesh algorithm generates a mesh with a

variable element size, the Maximum element size and Minimum
element size define how big and smallare the elements. These
parameters are established automatically, based on the geometric
features of the SolidWorks model. SolidWorks Simulation uses the
units of length specified in the SolidWorks model for the element size.
Remember, however, that we can enter analysis data and analyze
results in any one of three unit systems: SI, Metric and English.

Minimum Number
of Elements in a
Circle

The Min number of elements in a circle

defines how the small features in the
geometry will be resolved. For example, if
the model had a hole, the number of elements
in a circle will define how many elements
will surround that circle. In the image to the
right, we have defined a minimum of 10
elements to surround the hole.

Ratio

The ratio is used to define the transition of the mesh from the Minimum
element size to the Maximum element size.

The Ratio parameter specifies the ratio between element sizes in

consecutive transitional element layers. In our case, the default Ratio is
used.
The following shows the use of this option.
a)

Minimum element
size = 0.1 mm

Maximum element
size = 1mm

Ratio = 2.0

b)

Minimum element
size = 0.1 mm

Maximum element
size = 1mm

Ratio = 1.1

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The Analysis Process

In the majority of analyses with SolidWorks Simulation, the default

mesh settings produce a mesh that provides acceptable discretization
errors while keeping solution times reasonably short.

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Tip

15 Generate the mesh.

Right-click Mesh and select Create Mesh.

Expand Mesh Parameters and select

Curvature based mesh.

The model will be meshed using High

quality elements.

Expand all the sections of the

PropertyManager to see all the available
choices.

16 Set the mesh density.

The default mesh density will have the slider at

mid-scale. Under Mesh Parameters, the
Maximum element size and Minimum element
size of the mesh is shown as 5.72453 mm
[0.2254 in], the Min number of elements in a
circle is 8, and the Element size growth ratio is
1.5. For the initial analysis, we will use the
default settings.

45

Lesson 1

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The mesh can be created with either a High or Draft mesh quality. The
default is to use a High quality mesh. To use a draft quality mesh, you
must select it in the PropertyManager under Advanced options.

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Mesh Quality

The difference between High and Draft quality is that:

I
I

Draft quality mesh uses first order elements.

High quality mesh uses second order elements.

The differences between first and second order elements are discussed
in Element Types Available in SolidWorks Simulation in the
Introduction to FEA chapter.

17 Set mesh quality.

In the Advanced section, clear Draft Quality
Mesh.

We will review the other mesh options as we proceed with the class.
Click OK to generate the mesh.
The mesh appears after mesh
generation is completed.

The Mesh icon in the SolidWorks

Simulation Study tree window now
displays a green check mark to
indicate that meshing has been
successfully completed.

Note

We named this study default analysis with the intention of using the
default mesh size. Later on in this lesson the problem will be solved
again with coarse and fine meshes.

Display/Hide Mesh

Mesh visibility can be controlled by right-clicking Mesh, and then

doing one of the following:
I
I

46

Select Hide Mesh.

Select Show Mesh.

SolidWorks 2012

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18 Run the analysis.

Right-click the study icon, default

analysis, and select Run.

You can monitor or pause the

solution in the solver window while
the analysis is running.

Postprocessing

After the analysis is complete, SolidWorks Simulation automatically

creates the Results folder with the default results plots that we
specified at the beginning of the lesson: Stress1 (-vonMises-),
Displacement1 (-Res disp-), and Strain1 (-Equivalent-).

Result Plots

Each result plot can be displayed by doing

one of the following:
I

Double-click the desired plot icon

(Stress1, for example).

Right-click the desired plot icon

(Stress1, for example) and select Show
under any folder.

While a plot is active (appears in the model window) you can rightclick the plot icon again to examine the plot control options.

19 Show and edit Stress1 (-vonMises-) plot.

Double-click on Stress1 (-vonMises-) under the Results folder to

display the plot.

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Notice that the stress plot is in Mega-pascals (N/mm^2) units and the
legend features scientific numbers with six digits, just as we requested
in the Options at the beginning of the lesson.

We observe that the maximum value of Von Mises stress is 408 MPa,
which significantly exceeds the yield stress of the material, 206 MPa,
indicated by the red marker in following the chart.

Editing Plots

To edit a plot, right-click on the plot and select Edit

definition.

The Display dialog lets you specify a stress

component, units, and the type of plot.

The Advanced Options dialog lets you choose to

plot either Node or Element values which is
discussed below.

The Show as tensor plot option lets users plot the

orientation as well as the magnitudes of the
principle stresses (shown in the discussion below).

The Deformed Shape dialog lets the user specify

the deformation scale for the plot. Automatic
(default), True scale, and User Defined scale
options are available.
Students are encouraged to experiment with these
options.

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SolidWorks 2012

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The Analysis Process

The following figures show the nodal and elemental values of the Von
Mises stress for our model.

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Nodal vs. Element

Stresses

Node Values

Element Values

The stress plot that displays Nodal values appears smooth, while the
stress plot that displays Element values appears rough.
To understand the reasons for these different appearances, we need to
explain the differences between nodal and element stresses.
During the solution process, in each element, stress results are
calculated at certain locations called Gauss points. First order
tetrahedral elements (draft quality) have one Gauss point in their
volume. Second order tetrahedral elements have four Gauss points.
First order shell elements have one Gauss point. Second order shell
elements have three Gauss points.

49

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The Analysis Process

Stresses in Gauss points can be

extrapolated to element nodes. Most
often, one node is shared by several
elements, and each element reports
different stresses at the shared node.
Reported values from all adjacent
elements are then averaged to obtain a
single value. This method of stress
averaging produces averaged (or nodal)
stress results.

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Nodal Values

Element Values

Alternately, the stress values from all Gauss points within each element
can be averaged to report a single elemental stress. Although these
stresses are averaged between Gauss points, they are called nonaveraged stresses (or element stresses) because the averaging is done
internally within the same element only.
Element stresses and nodal stresses are always different, but too large a
difference indicates that the mesh is not sufficiently refined in that
location. See the exercise Exercise 1: Bracket on page 71 for the
practical use of these quantities.

Show as Tensor
Plot Option

This plot type helps visualize the directions as well as the magnitudes
of the principal stresses P1, P2, and P3. Due to the considerable
differences in magnitudes between these stress values, one must zoom
in substantially to see all three arrows.

Modifying Result
Plots

The Results plots can be modified in several ways to suit your needs.
There are three primary functions to control the content, units, display
and annotations of the plots.
I

Edit Definition

Edit Definition controls the component (von Mises, 1st principal

stress, X normal stress) and units to be displayed.

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SolidWorks 2012

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I

Chart Options

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Chart Options control the annotations. Options include which

annotations are shown as well as the color, type of units (scientific,
floating, general) and the number of decimal places shown in the
legend. The position of the legend and titles can also be adjusted.

Settings

Settings are used to control the display of the model.

Where to Find It

Shortcut Menu: Right-click a plot and select either Edit Definition,

Chart Options or Settings

20 Modify the chart.

Right-click Stress1 (-vonMises-) and select Chart Options.

Check Show min annotation and Show max annotation boxes to

show the markers in the plot.

Note that you can also modify the limiting values in the legend, format
of the numbers, and the color options.

If you select the legend, it will be framed. You can then drag the legend
to any location on the plot.
Click OK to save new settings.

Drag chart to new location

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21 Modify settings of stress plot.

Right-click on Stress1 (-vonMises-) and select
Settings.

Explore the Fringe, Boundary, and Deformed

Plot Options in this dialog.

Other Plot
Controls

There are several other plot types available to display specific results of
the analysis.

Introducing: Section
Plot

Sections plots allow a cutting plane to be positioned at any point in the

model and the plotted results shown at the plane location.

Where to Find It

I
I

Menu: Simulation, Result Tools, Section Clipping

Shortcut Menu: Right-click an existing plot and select Section
Clipping

Introducing: Iso
Plots

Iso plots show that part of a model where the plotted parameter is a
certain value or between certain values.

Where to Find It

I
I

Menu: Simulation, Result Tools, Iso Clipping

Shortcut Menu: Right-click an existing plot and select Iso Clipping

Introducing: Probe

A probe allows you to select a point or points on the model and display
the plot parameter in both tabular and plotted form.

Where to Find It

I
I

52

Menu: Simulation, Result Tools, Probe

Shortcut Menu: Right-click a plot and select Probe

SolidWorks 2012

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22 Create section plot.

In many applications it is useful to cut the

model and look at the distribution of the
result quantity in the through-thickness
direction.
Right-click Stress1 (-vonMises-) and
select Section Clipping.

From the SolidWorks fly-out menu, select

Right plane as a Reference entity.

Students are encouraged to explore all the

options and parameters in the Section
dialog. Note that the user can also drag the
triad to easily move the cut plane through the model.

and Clipping On/Off

Use Reverse Clipping Direction
control the cutting direction and to disable the section plot.

to

Click OK to close the Section dialog.

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23 Create Iso plot.

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Suppose that we wish to display portions of the

model where the von Mises stress is between 170
MPa and 275 MPa.
Right-click on Stress1 (-vonMises-) and select
Iso Clipping. This opens the Iso Clipping
PropertyManager.

In the Iso value box, under the Iso1 dialog, enter

275 N/mm^2 [MPa] [39,886 psi].

Check Iso 2 and in the Iso value box, enter 170 N/

mm^2 [MPa] [24,657 psi].
Click OK.

The black arrows on the stress legend indicate the values defined for
the two iso surfaces.
Experiment with the Iso Clipping window options using different
numbers of iso surfaces and different cutting directions.

Use Reverse Clipping Direction

and Clipping On/Off
control the cutting direction and to reset the plot.

54

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SolidWorks 2012

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The Analysis Process

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24 Probe stress results.

Right-click on Stress1 (-vonMises-) and select Probe.

Using the pointer, click the desired locations on the plot. It helps to
zoom in on the area.

The stress results are listed in the Results dialog table and in the plot at
the selected locations.

Select points
in this direction

Under Report Option, you can save the results in a file, plot the pathgraph, or save the locations as sensors. (Sensors are discussed in detail
later on in the class.)

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Lesson 1

SolidWorks 2012

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The Analysis Process

The figure above shows a Von Mises stress path plot for the selected
locations.

25 Define P1: 1st Principal Stress

plot.

Define a new stress plot. Right-click

the Results folder and select Define
Stress Plot.

Select P1: 1st Principl Stress as the stress

component, keep all other default options, and
click OK.

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The Analysis Process

We observe that the maximum value of the 1st principle stress, 416 MPa
[60,304 psi], is very close to the maximum value of the Von Mises
stress, 408 MPa [59,218 psi]. This is because the specified Tensile
load is the only dominant load component resulting in predominantly
tensile stress along the longitudinal direction of the plate.

26 Define displacement plot.

Double-click the Displacement1 (-Res disp-) plot icon.

The post processing features that we practiced in the case of Stress1

(-vonMises-) are applicable to all other result quantities, such as
Displacement.
The displacement shows a maximum resultant displacement of
0.1435 mm [0.00565 in].

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Lesson 1

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The Analysis Process

We record the displacement result with 6 digits only to practice the plot
options and to compare results from studies with different meshes. The
uncertainties and simplifying assumptions used to create the model do
not justify this accuracy.

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Note

27 Superimpose undeformed shape.

Right-click on Displacement1(-Res disp-) and
select Settings.

Select Superimpose model on the deformed

shape. You can also adjust the transparency of the
undeformed image.
Click OK.

28 Animate displacement plot.

To animate the displacement plot, rightclick on Displacement1 (-Res disp-)

and select Animate.

In the Animation PropertyManager you can start

and stop the animation, set the number of frames,
control the speed, and save the animation as an
*.avi file.
Try the options of the animation feature.

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29 Plot strain results.

Double-click the Strain1 (-Equivalent-) plot icon to show the plot.

Note that strain results are dimensionless.

Strain results are shown as non-averaged (element values) by default as

opposed to stress results, which are shown as averaged (node values)
by default.
Examine the strain plot showing Element Values.

To review the averaged strain plot, right-click on Strain1

(-Equivalent-) and select Edit Definition, and then select Node
Values.
To examine the available chart options, right-click Strain1
(-Equivalent-) and select Edit Definition.

All post processing features that we practiced for the stress plot are
available for strain plots as well.

Other Plots

There are several other postprocessing quantities available to view at

the end of the analysis.

Introducing: Factor
of Safety Plot

Factor of Safety Plot show the safety of the design based on the

Where to Find It

Shortcut Menu: Right-click the Results folder and select Define

Factor of Safety Plot

CommandManager: Simulation > Results Advisor > New Plot >
Factor of Safety

Introducing: Fatigue
Check Plot

design strength of the material (typically the yield strength). This plot is
fully introduced in Lesson 7.

Fatigue Check Plot serves as a quick indicator if the fatigue may be of

any concern in the design of the component.

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Lesson 1

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The Analysis Process

Where to Find It

Shortcut Menu: Right-click the Results folder and select Define

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Fatigue Check Plot

Important!

The fatigue check plot is only available if you have Simulation

Professional.

30 Plot Fatigue Check Plot.

Right-click on the Results folder and select Define
Fatigue Check Plot.

Set the Loading type to On/Off Loading to indicate

that the Tensile force may oscillate between 0 and
110,000 N.

Set the Surface Finish Factor to Machined. Keep

the Loading Factor and Size Factor at their default
values of Axial and 0.75.

Under Material keep the Scale this value and

Minimum safety factor fields at their default values
of 1.
Click OK.

The areas in red indicate potential fatigue problems. Note that accurate
calculations using the SolidWorks Simulation Professional fatigue
modulus may be required.

Multiple Studies

We have completed the analysis of rectangular hollow plate with the

default mesh and now wish to see how a change in mesh density affects
the results. For this reason, we will repeat the analysis two more times
using both coarser and finer density meshes.
To repeat the analysis with coarsened mesh, we can create a new mesh
while still in the default analysis study, but this action would
overwrite the old results.

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To preserve the results of the study, we will create a new study, coarse
analysis. Creating a new study can be done in several ways.
Creating New
Studies

New studies can be created in one of two ways:

I

Create a new study from scratch.

Duplicate an existing study. Right-click the tab for the study you
want to duplicate and click Duplicate. This is essentially the same
as copying a study and pasting it into a blank study.

When we duplicate a study, SolidWorks

Simulation displays the Define Study
Name window. This will allow us to
name the duplicated study and choose the
model configuration to use.

Copy Parameters

When we create a new study, we can copy material, fixtures and

external forces from existing studies rather than recreating them in the
new study. To copy parameters, drag the parameter from the Simulation
Study tree to the tab of the new study.

Note

When a study is duplicated, the study settings, Fixtures, External

Forces, Mesh, and the study results will be copied as well.

31 Duplicate the study.

Right-click the default analysis tab and

click Duplicate.

Type coarse analysis for the study

name. The model only has a Default
configuration, so we cannot change it.

32 Create new mesh in coarse analysis study.

In the coarse analysis study, right-click Mesh and select Create
Mesh. A warning window appears.

Remeshing will delete the results for study: coarse analysis.

Click OK to open the Mesh window.

Select Curvature based mesh under Mesh Parameters.

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Move the Mesh Factor slider all the way to the

left. The Maximum element size and Minimum
element size should read 11.4491 mm
[0.4508 in].
Click OK.

The generated mesh is

displayed to the right.

Notice that there is only

one element across the
thickness of the part. In
the default analysis there
were two elements across
the thickness.

Note

The mesh is rather coarse. Later, we will discuss why this sort of mesh
is not acceptable for reliable analysis results.

33 Display mesh details.

Having created the mesh, we can

access the detailed mesh
information by right-clicking Mesh
and selecting Details.
The same detailed information can
of course be displayed for the old
mesh in the default analysis
study.

Many of the items in this list will be

discussed in later lessons.

34 Run the analysis.

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35 View displacement and stress results.

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Record the maximum displacement (0.143 mm / 0.00563 in) and the

maximum von Mises stress (403 Mpa / 58,393 psi).

Note

All plot settings remain the same as the default analysis study
because the plot definitions are copied from that study.

36 Re-run the analysis with fine mesh.

Repeat steps 31 - 34 to generate a new study with fine mesh named
fine analysis.

When re-generating the mesh, move the slider all the way to the right.
The Maximum element size and Minimum element size should read
2.86227 mm [0.1127 in].

The fine mesh generated

using the above settings is
shown to the right.
Notice that we now have
several elements in the
through-thickness
direction. You will later
learn that this mesh is
acceptable for reliable
analysis results.

37 View displacement and stress results.

Record the maximum displacement (0.144 mm / 0.00567 in) and the

maximum von Mises stress (415 Mpa / 60,252 psi).

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Lesson 1

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The Analysis Process

Now we must collect information from all of the studies (default,

coarse and fine analysis) to compare the displacement and
maximum von Mises stress results for the various mesh refinements.
We can determine the maximum displacement and the maximum von
Mises stress results in plots.

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Check
Convergence and
Accuracy

We must also determine the number of elements and the number of

nodes in each mesh. These can be found in the Mesh Details window
of each respective mesh.

Finally, we must determine the number of degrees of freedom (DOF) in

each model. To calculate this number, we could count the number of
unconstrained nodes by subtracting the number of nodes on the
constrained face from the number nodes reported in mesh details. Then
we could multiply this number by three because each node in a solid
element mesh has 3 DOF. An easier method, however, is to right-click
the Results folder in each study and select Solver Messages (see
below).

38 View solver messages.

Right-click on Results and choose
Solver Messages. Note the number

of elements, nodes, and degrees of

freedom.

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The summary of the results produced by the three studies is shown in

the following table:

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Results Summary

Mesh
density

Max.
displacement
[mm]

Max. von
Mises stress
[MPa]

Number
of DOF

Number
of
elements

Number
of nodes

coarse
analysis

.1432014

402.608

7,128

1,173

2,427

default
analysis

.1434608

408.292

44,037

8,677

14,844

fine
analysis

.1435097

415.427

310,977

68,511

104,248

Note that all of the results of this table pertain to the same problem. The
only difference is in the mesh density. You may find small differences
between your own results and those presented in this table. This is due
to service pack upgrades, etc. Having noted that the maximum
displacement increases with mesh refinement, we can conclude that the
model becomes less stiff (or softer) when the number of degrees of
freedom increases. In our case, by selecting second order elements, we
impose the assumption that the displacement field in each element is
described by second order polynomial functions.
With mesh refinement, the displacement field in each element is still
described by second order polynomial functions; however, the larger
number of elements makes it possible to approximate the real
displacement and stress fields more accurately.

We can say that the artificial constraints resulting from element

definition become less imposing with mesh refinement. Displacements
are always the primary unknowns in FEA, and stresses are calculated
based on displacement results. Therefore, stresses also increase with
mesh refinement. If we continued with mesh refinement, we would see
both displacement and stress results converge to a finite value. This
limit is the solution of the mathematical model. Differences between
the solution of the FEA model and the solution of the mathematical
model are due to discretization error. Discretization error diminishes
with mesh refinement.

The process of consecutive mesh refinements that we have completed

is called the convergence process. Its objective is to determine the
impact of our discretization choices (element size) on the data of
interest, which, in this lesson, are the maximum resultant displacements
and the maximum von Mises stress.

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An infinitely long rectangular hollow plate under a tensile load

possesses an analytical solution [1]. We compare FEA results with
analytical results.

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Comparison With
Analytical Results

W, D and T denote plate width (100 mm), hole diameter (40 mm) and
plate thickness (10 mm). P is the tensile load 110,000 N or 24,729 lb.
For comparison with analytical results, it is more convenient to use the
SI system because the SolidWorks model have been defined in mm.

n is the normal stress in the cross section where the hole is located, Kn
is the stress concentration factor, and max is the maximum principal
stress.
P
110000
n = ---------------------------- = ----------------------------------- = 183.33MPa
( W D )xT
( 100 40 )x10
2

K n = 3 3.13 ----- + 3.66 ----- 1.53 ----- = 2.23568

D
W

D
W

D
W

max = K n x n = 183.33 ( 2.23568 ) = 409.87MPa

Review the P1: 1st principal stress plot for study default analysis.
The maximum value reached 415.78 MPa, which corresponds to
approximately 60.3 ksi.
Therefore, the difference is:

NumericalSolutions THEORY
415.78 409.87
difference = -------------------------------------------------------------------------------------- = --------------------------------------- = 1.42
NumericalSolutions
415.78

The difference of 1.42% between the SolidWorks Simulation result and

the analytical solution does not necessarily mean that the SolidWorks
Simulation result is worse and has a 1.42% error.

We must be very careful in how we compare these results. Note that the
analytical solution is valid only for a very thin plate where a plane
stress condition is assumed. SolidWorks Simulation calculates a
solution for a 3D model with substantial thickness (10 mm) and
accounts for realistic stress distribution across the plate thickness.
SolidWorks Simulation also takes into consideration the fact that the
plate has a finite length (200 mm) rather that an infinite one, as the
analytical solution does.

Furthermore, detailed inspection of the stress results show the stress

gradient across the plate thickness, which is not accounted for in the
analytical model. Thus, we can conclude that SolidWorks Simulation
provides more detailed stress information than the analytical solution.

66

SolidWorks 2012

Lesson 1
The Analysis Process

Results may need to be recorded in report form for review, presentation

or archive purposes.

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Reports

Reports can be published in Microsoft Word format. Different sections

can be added to the report from a list of predefined commonly used
topics. The default settings for the Reports can be found in the
Simulation, Options menu.
Predefined sections include:

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Description
Model Information
Units
Loads and Fixtures
Contact Information
Sensor Details
Beams
Conclusion

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Assumptions
Study Properties
Material Properties
Connector Definitions
Mesh Information
Resultant Forces
Study Results
Appendix

To edit the content of a section, select the section in the Included

sections and fill in the appropriate section properties.

Where to Find It

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Menu: Click Reports in the Simulation menu

Simulation Toolbar: Click Report .
CommandManager: Simulation > Report

39 Generate report in Microsoft Word format.

Under SolidWorks Simulation menu item,
select Report.

67

Lesson 1

SolidWorks 2012

The Analysis Process

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40 Add sections.
Under Report sections, select the required report parts. (For example,
you could deselect the option Contact Information, as we do not have

any in this analysis.)

Enter your Header information and click Publish.

41 Examine the report.

Open the report in Microsoft Word and examine the results.

42 Save and Close the file.

68

SolidWorks 2012

Lesson 1
The Analysis Process

We used a simple model of a hollow rectangular plate to introduce the

SolidWorks Simulation interface and, at the same time, to go through
all major steps in the FEA process.

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Summary

We created multiple studies to execute a linear static analysis with three

different meshes.
While preparing models for analysis and examining results obtained
with different meshes, we introduced the concept of modeling error and
discretization error.
This first lesson was intended to provide an understanding of FEA
methodology and the software skills necessary to complete the lessons
that follow.

References

1. Young and Budynas, Roarks Formulas for Stress and Strain, 7th
Edition.

Questions

The pre-processing stage of the FEA includes the following steps:

1._________________________________________________
2._________________________________________________
3._________________________________________________
4._________________________________________________
5._________________________________________________

The density of finite element mesh (does / does not) have

considerable impact on the analysis results.

In general, we would favor (finer / coarser) meshes to obtain

reliable analysis results. Therefore, the time required to solve the
analysis will (increase / decrease), but this is an unavoidable
consequence.
Ultimately, we will try to design optimum meshes providing
reasonable accuracy levels and resulting in acceptable run times.

The primary unknown in finite element analysis is (displacements /

strains / stresses). This quantity is therefore the most accurate.

The accuracy levels of (displacements / strains / stresses) and

(displacements / strains / stresses) are approximately the same, but
significantly worse than that of (displacements / strains / stresses).
Therefore, to obtain good (displacement / strain / stress) results, the
mesh must be reasonably fine.

(Refining / Coarsening) the mesh results in solutions approaching

the analytical solution of a mathematical model.

69

Lesson 1

SolidWorks 2012

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The Analysis Process

70

SolidWorks 2012

Exercise 1
Bracket

Exercise 1:
Bracket

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In this first exercise, you will analyze a simple part with a single
restraint and one external force.
This lab uses the following skills:
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Problem
Statement

Fixtures on page 34.

External Loads on page 38.
Meshing on page 43.
Multiple Studies on page 60.

The aluminum part of an

Bolt holes
assembly will be analyzed for its
maximum stresses and
displacements. The part is
bolted to the rest of the
assembly through the two bolt
holes, as indicated in the figure.
The part is then subjected to a
normal force of 500 N, applied to the counter bored face.

Open a part file.

Open part from the Lesson01\Exercises folder.

Specify SolidWorks Simulation options.

Select Options in the Simulation menu.

Select the Default Options tab, specify SI (MKS) as a default Units for
this analysis. In the Units dialog, set the Length/Displacement and
Pressure/Stress fields to mm and N/mm2 (MPa), respectively.

71

Exercise 1

SolidWorks 2012

Bracket

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The following default results plots are generated after each static study
is completed: nodal von Mises stress and resultant displacement.

Right-click on the Static Study Results folder and select Add New
Plot. Add an additional result plot for the nodal P1: 1st principal
stress be generated as a default result plot.

Specify the subfolder results in the SolidWorks document directory as

a location to store the result files.

Number format.

Select Color chart. Select

Scientific and 2 decimal places.

Define a static study.

Create a new static study named stress analysis.

72

SolidWorks 2012

Exercise 1
Bracket

Apply material properties.

Right-click on the Part folder in the
FeatureManager and select Apply/Edit
Material.

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Specify Aluminum 1060 Alloy from the

solidworks materials library.

73

Exercise 1

SolidWorks 2012

Bracket

Apply Fixtures.
Apply Fixed Geometry to the two bolt holes, as shown in the figure

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below.

This restraint simulates the way this part is attached to the rest of the
assembly.

Fixed Geometry fixtures are used in this exercise to model the bolted
connections mounting the bracket to the other parts of the larger
assembly. Also, the presence of the other parts to which this bracket is
attached is ignored in this exercise.

You will learn in the later lessons that more accurate and elegant
methods and features, such as bolt connectors and virtual wall, exist to
simulate these conditions.

Apply external load.

Apply normal force on the

face indicated in the figure.

Specify a magnitude of
500 N.

74

SolidWorks 2012

Exercise 1
Bracket

Mesh.

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Select Curvature based mesh under Mesh Parameters.

Mesh the model using High quality elements with the default element
sizes.

Run the study.

10 Plot stress results.

We observe that the maximum von Mises stress in the model is

approximately 35.1 MPa, which is above the yield strength of the 1060
Aluminum Alloy (27.5 MPa).

75

Exercise 1

SolidWorks 2012

Bracket

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The distribution of the P1: 1st principal stress indicates a maximum

value of approximately 32.6 MPa. This value corresponds to the
maximum tensile stress in the part (maximum compressive stress
where the value is negative).

11 Probe stress on the fillet.

Later in the course you will learn that the

fixtures may result in stress
intensifications which are not real. For
this reason, we will focus our attention to
the filleted region between the horizontal
and vertical bosses on the part.
Right-click the Stress1 folder and click
Probe.

Select On selected entities, then pick

the seven faces of the fillet between the two bosses.
Click Update.

76

SolidWorks 2012

Exercise 1

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Bracket

Probing the results on selected faces we see that the maximum stress at
this stress concentration region is 30.6 MPa [4,547 psi], which is
slightly above the yield strength of 27.5 MPa [3,989 psi].

12 Plot displacement results.

We observe the maximum resultant displacement of approximately

0.068 mm [0.0027 in].

77

Exercise 1

SolidWorks 2012

Bracket

Are our current results accurate enough? Visual inspection of our finite
element mesh suggests that it may be rather coarse, especially in the
regions where the fillets are present. Furthermore, inspection of the
distribution of the elemental values of the von Mises stress indicates
considerable stress jumps from element-to-element in the higher stress
concentration areas.

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Coarse Mesh and

Element Stress

We will repeat the analysis with finer mesh.

13 Create new static study.

Duplicate the study stress analysis as a new study named stress
analysis - refined.

The folders Fixtures, External Loads, Parts, Mesh, and Results

will be copied into the new study as well.

14 Create fine mesh.

Create High quality mesh. Slide the Mesh Density slider all the way to
the right which will result in an Maximum element size of 2.198 mm
and a Minimum element size of0.733 mm.

78

SolidWorks 2012

Exercise 1
Bracket

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The resulting mesh shows significantly improved mapping of the

model geometry.
15 Run the study.

16 Plot stress results.

We now observe that the maximum von Mises stress increased from
35.1 MPa to 39.1 MPa, which is above the material yield strength of the
27.5 MPa. This translates to a difference of nearly 11%. However, if we
examine the plot, we will see that the maximum stress is at the sharp
corner of the bolt holes. We will discuss this further in the next lesson.

17 Probe stress on the fillet.

Using the identical procedure described in step 11 probe the stress

results on the filleted geometries.

We can observe the maximum von Mises stress on these entities

increased from 30.6 MPa to 30.75 MPa, which is still above the yield
strength but is a neglible difference from the previous study. We can
therefore conclude that the mesh refinement confirmed the validity of
our simulation and our results are converged. It should be noted that in
other situations the difference in the stress results may be significant. In
general, requirements on the good stress results translates into a
necessity to generate finer meshes. In our present case further
refinement does not produce further improvement in the stress results
and we will thus conclude that they are converged.

79

Exercise 1

SolidWorks 2012

Bracket

18 Plot displacement results.

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The plot shows that the maximum displacement resultant increased

from 0.0678 mm to 0.0683 mm; a difference of less than 1 %.

19 Save and Close the file.

Summary

80

In this exercise, we practiced the basic setup of the linear static study as
well as the post processing features available in SolidWorks
Simulation. We observed that the mesh quality has a significant impact
on the results (especially the stress results). While the deviation in the
resultant displacements obtained from the two studies was 1 %, the
deviation for maximum von Mises stresses was nearly 11 % (often the
difference in stresses is much greater). The greater difference in the
maximum stresses is attributed to the following two phenomena:
I

Displacements are the primary unknown in the finite element

analysis and, as such, will always be significantly more accurate
than strains and stresses. A relatively coarse mesh is sufficient for
satisfactory displacement results, while significantly finer mesh is
generally required for satisfactory stress results.

The extreme values of the stresses occur in the vicinity of the

fixture where the stresses often assume unrealistically high values.
This is a subject studied in the next lesson. The stresses at the
filleted regions reported in both studies were closer in their
magnitudes with a negligible difference. Finer meshes are required
in filleted regions as stress results are of importance to us.

SolidWorks 2012

Exercise 2
Compressive Spring Stiffness

Exercise 2:
Compressive
Spring Stiffness

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In this exercise, we will use SolidWorks Simulation to determine the

compressive stiffness of a coil spring.
This exercise reinforces the following skills:
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Procedure

New Study on page 31.

Fixtures on page 34.
External Loads on page 38.
Meshing on page 43.
Result Plots on page 47.

The stiffness of the helical spring can be determined as follows:

Open a part file.

Open spring from Lesson01\Exercises folder.

For convenient application of fixtures and external loads, disks have

been added to both ends of the spring. The distance between the disks
corresponds to the active length of the un-compressed spring.

Note

Set SolidWorks Simulation options.

Set the system of Units to SI (MKS) and the units of Length and
Stress to mm and N/m2 (Pa).

Create study.

Create a Static study named spring stiffness.

Review material properties.

The material properties (Alloy Steel) are transferred from SolidWorks.

Apply Fixed restraint.

Apply a Fixed Geometry fixture to the end face of one disk (item 1).

81

Exercise 2

SolidWorks 2012

Compressive Spring Stiffness

Apply radial restraint.

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Use an advanced fixture to apply a restraint in

the radial direction to the cylindrical face of the
other disk (item 2).
This restraint only allows the spring to be
compressed (or expanded) in its axial direction
and to rotate about the longitudinal axis.
2

Apply compressive force.

Apply a 0.1 N compressive force to the end face of the disk with the
cylindrical face constrained in the radial direction.

Mesh the model and run the analysis.

Select Curvature based mesh under Mesh Parameters.

Use High quality elements with the default Maximum element size
and Minimum element size of 2.787 mm and 0.557 mm, respectively.

82

SolidWorks 2012

Exercise 2
Compressive Spring Stiffness

Plot z displacements.

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Displacement results indicate an axial displacement of 0.426 mm. The

axial displacement is in the z direction.

Coil Spring Axial

Stiffness

The axial stiffness of the spring can be calculated as 234.7 N/m.

(k = f/x).

We use this result to define the spring connector in later lessons using
the equation f= kx, where k=234.7 N/m.

Alternately, we could use an approximate formula for the stiffness of a

helical spring (Mechanical Vibrations by S. S. Rao, 1995).
4
Gd
K Axial = -------------3
8nD

where:

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G is the material shear modulus

d is the diameter of the wire
D is the mean coil diameter
n is the number of active turns

Substituting our values (n = 8.75, d = 1 mm, D = 17 mm, and G =

7.9e10 Pa) into the above formula gives an axial stiffness of
approximately 230 N/m. This result is very close to our actual result of
234.7 N/m.

10 Save and Close the file.

83

Exercise 3

SolidWorks 2012

Container Handle

In this exercise, you will

assess the safety of the waste
container handle.

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Exercise 3:
Container
Handle

This exercise reinforces the

following skills:
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New Study on page 31.

Fixtures on page 34.
External Loads on
page 38.
Meshing on page 43.
Result Plots on page 47.

Base plates

Handle

Problem
Description

The handle is used to attach the hook of the winch when loading the
container on the rails of the transporting truck. The entire container is
manufactured from AISI 304 steel. The handle is welded (double-sided
fillet weld) to the two square base plates located symmetrically on both
sides. The diameter of the handle is 30mm; the thickness of the steel
plates is 5mm. Apply the most suitable fixtures to simulate the
connection between the handle and the steel plates.

Loading
Conditions

In the most extreme loading

situation, when the container is
pulled onto the truck rails, the handle
is loaded by a 3000 N force inclined
at 15 degrees. The force should be
applied on the circular split face indicated in the figure above.
The geometry of the handle
structure with the base plates is
shown in the figure to the right.

Goal

Decide whether the design of this handle is safe. Pay attention to the
most appropriate representation of the fixture.
The part for this exercise is located in the Lesson01\Exercises
folder.

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Lesson 2
Mesh Controls, Stress
Concentrations and
Boundary Conditions

Objectives

Upon successful completion of this lesson, you will be able to:

I

Illustrate the differences between modeling and discretization

errors.

Use Automatic transition option to mesh models.

Use mesh controls.

Describe when the lack of convergence of FEA results may occur.

Understand stress concentrations.

Analyze model in different SolidWorks configurations.

Run multiple studies in a batch mode.

Extract reaction forces.

85

Lesson 2

SolidWorks 2012

Mesh Controls, Stress Concentrations and Boundary Conditions

Meshes are rarely uniform in practical problems. It would be very

inefficient to uniformly reduce the mesh size in a large model because
of a local stress concentration. We would create large number of
elements in areas of uniform or slowly changing stress resulting in an
increase of computational time that in the end tells us little about the
model.

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Mesh Control

Using different methods to control the mesh, we can use a small mesh
in areas of rapid changing stress and a large mesh in areas with little
change.

Case Study:
The L Bracket

In this case study, we will determine the stress in an L bracket, under

load. The L bracket presents the problem of stress at sharp corners and
the effects of fillets and local mesh refinement.

The corner of the bracket is rounded by a small fillet. Since the radius
of the fillet is small compared to the overall size of the model, it may be
suppressed. We will solve the model with and without fillet, discuss the
differences and the applicability of each approach.

We will also investigate the effect of different mesh sizes on the

maximum displacement and stress results. Rather than refining the
mesh uniformly in the entire model, which is called global mesh
refinement, we refine the mesh locally, where high stresses are located.
This is called local mesh refinement.

Project
Description

Stages in the
Process

An L-shaped steel bracket is fixed at the top

and a 900 N load is applied to the lower end
face. We will evaluate the displacements and
stresses in the model.

Suppressed
Fillet

Some key stages in the analysis of this part are shown in the following
list:
I

No fillet

The fillet will be suppressed to simplify the geometry and to

observe the stress at the sharp corner.

Add fillet

The fillet will be unsuppressed to determine the effect of the fillet

on the maximum stress in this part.

86

SolidWorks 2012

Lesson 2
Mesh Controls, Stress Concentrations and Boundary

Conditions
I

Mesh refinement

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As the fillet is small compared to the rest of the model, we will use
different techniques to reduce the mesh size only in the area of the
fillet.

Procedure

In the first part of this case study, we will examine the stress on this part
without the fillet.

Open a part file.

Open L bracket.from Lesson02\Case

Studies folder.

In the SolidWorks ConfigurationManager,

examine the two configurations: fillet and no fillet.
Make the no fillet configuration active.

Set the simulation options.

Click Options from the Simulation

menu. Select the Default Options tab.

Select Units, then select SI (MKS) for the

Unit system. Select mm for Length/
Displacement and N/m^2 (Pascals) for
Pressure/Stress.
Select Color Chart. For Number
format, select Scientific (e) and
6 decimal places.

Define static study.

Create a new study named mesh1.

In the analysis Type list, select Static.

Click OK.

Examine the Simulation Study tree.

The L bracket icon already has a check mark next to the name of the
assigned material because the material definition (AISI 304 steel) has
been transferred from SolidWorks. Also, note that a sharp re-entrant
corner takes the place of the suppressed fillet.

87

Lesson 2

SolidWorks 2012

Mesh Controls, Stress Concentrations and Boundary Conditions

Apply a fixture.
Now apply a Fixed Geometry fixture to the
top face of the L bracket.

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Right-click Fixtures and select Fixed

Geometry.

In the Standard list select Fixed Geometry.

Click OK.

Apply an external load.

Right-click External Loads and select Force.

Select Force.

We want to apply a shearing force and not a normal force, so we must

define the direction of the force. Select Selected direction.

Select the indicated face to apply the force and the Top plane to specify
the direction.
Type 900 N [202.33 lbf] for the force.

Select Reverse direction to make sure the force is pointing as shown.

Click OK.

88

SolidWorks 2012

Lesson 2
Mesh Controls, Stress Concentrations and Boundary

Conditions

Mesh the model.

Select Curvature based mesh under
Mesh Parameters.

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Verify that the meshing option is set to

High quality (Draft Quality Mesh is
cleared), meaning that second order
elements are created.

Mesh the model using the default

Maximum element size and Minimum
element size of 4.812 mm [0.1894 in].

Run All Studies

Multiple studies can be run at the same time. This allows you to setup
multiple studies and then run them after hours.

Where to Find It

CommandManager: Simulation > Run > Run All

Studies

Create a duplicate study.

Study mesh1 is now ready to be analyzed. However, we will create

two more studies and run all three studies at the same time using the
Run All Studies command.

Duplicate study mesh1 into a new study mesh2 (see Creating New
Studies on page 61 on how to duplicate a study).
When creating the duplicate of the study
make sure that the Configuration to use
field says no fillet.
Click OK.

89

Lesson 2

SolidWorks 2012

Mesh Controls, Stress Concentrations and Boundary Conditions

The second part of this case study will

investigate the effect of using smaller elements
in the model on the results. In Lesson 1, we
refined the mesh uniformly throughout the
entire model by controlling the global element
size.

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Analysis with
Local Mesh
Refinement

Stress
concentration

In this part of the case study, we will use a

different technique. Note that a stress
concentration is located near the sharp reentrant corner.

Knowing the location of high stress, we can

refine the mesh locally in that area by applying local mesh controls.

Mesh Control

Mesh controls allow you to control the Maximum element size and
Ratio locally on selected entities independent of the global Maximum
element size and Ratio. As compared to global mesh refinement, this
is a more numerically efficient technique. Small elements are placed
where needed, while portions of the model with no stress concentration
are meshed with larger elements.

Where to Find It

Menu: Simulation, Mesh, Apply Control.

Shortcut Menu: Right-click Mesh in the Simulation Study tree and

select Apply Mesh Control.

Mesh Controls

Mesh controls can also be applied to vertices, faces, or entire

components of assemblies. Once mesh controls have been defined, the

Mesh icon becomes a folder.
Mesh controls can be edited using a shortcut
menu displayed by right-clicking Control-1 and
select Edit Definition in the Mesh folder, or
directly by double-clicking on the Control-1
item.

The mesh, with applied control (also called

mesh bias), features localized refinement
along the edges.
Meshing must be done after controls are
defined.

Mesh control symbols are displayed along

the affected edge.

Mesh Control Symbols

90

SolidWorks 2012

Lesson 2
Mesh Controls, Stress Concentrations and Boundary

Conditions

Mesh control symbols can be displayed or hidden by:

Mesh control
symbols

Right-click Mesh and select Hide All Control Symbols

Right-click Mesh and select Show All Control Symbols

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The visibility of mesh control symbols can also be controlled

individually for each mesh control.

Apply local mesh control

for study mesh2.

Select the edge shown.

Right-click Mesh and select

Apply Mesh Control.
Use the suggested local
Element size of 2.406 mm
and the Ratio of 1.5.

Click OK to close Mesh

controls PropertyManager.

10 Create mesh.
Select Curvature based mesh under Mesh Parameters.

Create High quality mesh with the default settings.

11 Examine the mesh.

Note that smaller elements have been created along the edge where
mesh control has been just applied.

With edge mesh control

No edge mesh control

12 Duplicate study mesh2.

Name the new study mesh3.

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Lesson 2

SolidWorks 2012

Mesh Controls, Stress Concentrations and Boundary Conditions

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13 Apply local mesh control for study mesh3.

In the mesh3 study, edit the definition of Control-1.

In the Element size box, enter 0.508 mm to locally refine the mesh
along the sharp re-entrant edge. Keep the Ratio at its default value of
1.5.

With this mesh control, we will create very small elements along the
sharp re-entrant edge.
Click OK.

14 Mesh study mesh3.

Mesh study mesh3 with High quality elements and the default mesh

parameter. Use the curvature based mesh.

We now have three studies: mesh1, mesh2 and mesh3. The only
difference is mesh refinement along the sharp re-entrant edge.

Study: mesh1

Study: mesh2

Study: mesh3

15 Run all studies.

Select the Simulation tab on the CommandManager.
Select the down arrow under Run Study to flyout the
other choices. Click Run All Studies.
16 Simulation progress log.

Once the analyses are completed,

review the report in the MSG file
located in the result folder.

17 Plot von Mises stresses.

Display the mesh with the plot by right-clicking the corresponding

result plot and selecting Settings.
Under Boundary options, select Mesh.

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Lesson 2
Mesh Controls, Stress Concentrations and Boundary

Conditions

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Click OK.

Study: mesh1

Study:

mesh2

Study: mesh3

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Lesson 2

SolidWorks 2012

Mesh Controls, Stress Concentrations and Boundary Conditions

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18 Plot resultant displacements.

Study: mesh1

Study: mesh2

Study: mesh3

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SolidWorks 2012

Lesson 2
Mesh Controls, Stress Concentrations and Boundary

Conditions

Reporting displacement results with six digits of accuracy is excessive

as uncertainties in loads, restraints, and material properties definition
do not normally justify this level of accuracy.

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Results

We used six digits of accuracy so that we can compare the minute

differences in the displacement results calculated in the three studies
we undertook in this lesson.

Results
Comparison

Results for the maximum resultant displacement and maximum von

Mises stress from mesh1, mesh2 and mesh3 studies are summarized
in the following table:

Study

Max. displ.
[mm]

Increase in
max. displ.
[mm][%]

Max. Von
Mises
stress
[MPa]

Increase in
Von Mises
stress
[MPa][%]

mesh1

0.28741

60.76

mesh2

0.28795

0.00054
(0.2%)

88.38

27.62
(45.5%)

mesh3

0.28856

0.00115
(0.4%)

177.42

116.66
(192.0%)

Each mesh refinement results in an increase in both the maximum

displacement and the maximum stress. The increase in the
displacement results is negligible and becomes less pronounced with
successive runs. From this, we can say that the displacement results
converge.

If we continue this exercise of progressive mesh refinement, either

locally near the sharp re-entrant corner as we did by means of the local
mesh controls, or globally by reducing the global element size as we
did in Lesson 1, we would note that the displacement results converge
to a finite value and that even the first mesh is adequate if we are
examining only displacement results.

Stress
Singularities

Stresses, however, behave quite differently. Each subsequent mesh

refinement produces higher stress results. Instead of converging to a
finite value like the displacement results, the stress results diverge.

95

Lesson 2

SolidWorks 2012

mesh3

mesh2

mesh1

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Mesh Controls, Stress Concentrations and Boundary Conditions

With enough time and patience, we can produce results that show any
stress magnitude. All that is necessary is to make the element size small
enough!
The reason for divergent stress results is not that the finite element
model is incorrect, but that the finite element model is based on the
wrong mathematical model.

According to the theory of elasticity, stress in the sharp re-entrant

corner is infinite; a mathematician would say that stress there is
singular. The finite element model does not produce infinite stress
results due to discretization errors, and these discretization errors mask
the modeling error.
However, stress results in the vicinity of the re-entrant corner are
completely dependent on mesh size; therefore, they are totally
meaningless at this location.

If our objective is to determine the maximum stress at this location,

then the decision to suppress the fillet and analyze a model with a sharp
re-entrant corner is a very serious mistake. The stress in a sharp reentrant corner is singular, or infinite. The fillet, no matter how small it
is, must be included in the model if we seek to find accurate stresses in
or near that fillet.

Suppressed
Configuration

When the active configuration is different from the configuration used

to create the study, the study is suppressed and all items in the study are
shown in grey. To unsuppress the study, the configuration must be
changed to that used to do the study.

Activate SW
Configuration

To change the SolidWorks configuration to the one used for a study, we

can activate the configuration from the Simulation Study tree.

Where to Find It

96

Shortcut Menu: Right-click the study in the Simulation Study tree

and click Activate SW Configuration.

SolidWorks 2012

Lesson 2
Mesh Controls, Stress Concentrations and Boundary

Conditions

Case Study:
Analysis of
Bracket with a
Fillet

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Now that we understand the problem caused by the sharp re-entrant

corner, we must repeat this analysis using a model with the fillet.
Obtaining the correct model requires unsuppressing the fillet.

Change SolidWorks configuration.

In the SolidWorks ConfigurationManager, make

the configuration fillet active.

Examine the Simulation Study tree.

With the fillet configuration active, the mesh1, mesh2 and mesh3

studies are greyed-out. You can access them again only after activating
the SolidWorks configuration corresponding to these studies.

Create new study.

Create a study mesh4 by duplicating the mesh1 study.

We copied the mesh1 study and not the mesh2 or mesh3 studies for
convenience because mesh1 does not have mesh controls defined and
mesh4 does not require mesh controls.

If we use mesh2 or mesh3, we have to edit or delete the mesh

controls in the mesh4 study because the geometry of the model has
changed.

Mesh the model.

Select Curvature based mesh under Mesh

Parameters.

Mesh the model with High quality elements and

the Maximum element size and Minimum
element size of 4.813 mm [0.1895 in].

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Lesson 2

SolidWorks 2012

Mesh Controls, Stress Concentrations and Boundary Conditions

Run the analysis.

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5
6

Plot Displacement results.

The maximum resultant displacement result (0.2845 mm) reported for

the fillet study differs only insignificantly from the earlier
displacement results. This small difference can be attributed to the
change in the model geometry.

Plot von Mises stresses.

The stress results obtained by the model with the fillet indicate that the
maximum von Mises stress is at the fillet location and its magnitude is
88.76 MPa.

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SolidWorks 2012

Lesson 2
Mesh Controls, Stress Concentrations and Boundary

Conditions

Analyze the plots.

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Analyzing the stress distribution uniformity at the fillet location we see

rather spotty behavior and no symmetry. This is another sign of
insufficient mesh resolution for stresses. The displacement results are
accurate in all studies solved in this lesson.

We will therefore apply a new local mesh control on fillet and rerun the
study again.

Apply mesh control on fillet.

To get more accurate results, we will apply a local mesh control on the
fillet face.

Apply mesh controls to the fillet face using 0.762 mm [0.030 in] for
the local Element size, 1.2 for the Ratio.

10 Re-mesh model.
Select Curvature based mesh
under Mesh Parameters.

Mesh the model with High quality

elements and the Maximum
element size and Minimum
element size of 4.813 mm
[0.1895 in].
The resulting mesh can be seen at
right.

This mesh is a little excessive in

its size, but given the small size of
the problem we can afford it.

11 Run the study.

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Lesson 2

SolidWorks 2012

Mesh Controls, Stress Concentrations and Boundary Conditions

12 Plot von Mises stress.

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We observe that the maximum stress increased to 102 MPa. The details
of the stress distribution are uniform and symmetrical. We could
conclude that this stress value is accurate.

13 Extract reaction force.

Right-click on the Results folder and select List Result Force.

Select the face where the bracket is supported and click Update. Make
sure the units are set to SI.
The Reaction force (N) dialog will list the resultant of the reaction on
the selected face (or faces, if more supported faces exist and are
selected) as well as on the entire model.
We can see that the equilibrium is satisfied; the reaction force is equal
to 900 N, which confirms the equilibrium and the correctness of the
solution.

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SolidWorks 2012

Lesson 2
Mesh Controls, Stress Concentrations and Boundary

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Conditions

Note

Moment reactions are not reported since solid elements feature three
translational degrees of freedom only. Nodes of the solid elements do
not carry any moment.

Case Study:
Analysis of a
Welded Bracket

Now that we understand the stress concentration in the fillet, lets

repeat the analysis using a more realistic model where the edges of the
faces are fixed rather than the entire face. This would more closely
represent the face being welded to a plate.

Create a new study.

Create a static study named mesh5 by duplicating the study mesh4.

Edit the Fixture.

Edit the fixture and remove the top face.

Add the four edges surrounding that face
as shown.

This type of restraint would simulate the

part being welded to a surface when only
the edges are firmly attached to the
structure, and not the entire face.

Run the analysis.

101

Lesson 2

SolidWorks 2012

Mesh Controls, Stress Concentrations and Boundary Conditions

Plot the stress results.

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Another stress concentration has appeared at the edges where fixed

geometry was used. Again, a singularity of stress is formed due to the
fixed geometry at the sharp end. Although perhaps a more realistic
finite element model, the stress concentration is an artifact of the
mathematical model.
These types of effects must be understood to properly analyze model
results.

Understanding
the Effect of
Boundary
Conditions

102

Save and Close the file.

Boundary conditions are necessary in order to fix the model in space

and solve the mathematical problem. In real life every part is connected
to another and finally attached to the primary structure or the ground.
We can, however, view the
boundary conditions as a means to
significantly simplify our
simulation. As an illustration,
consider the bracket assembly
shown in the figure to the right,
where the bracket is part of a larger
structure.

SolidWorks 2012

Lesson 2
Mesh Controls, Stress Concentrations and Boundary

Conditions

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Then, before we even begin modeling in SolidWorks Simulation we

have to decide whether to model the entire upper level assembly with
the boundary conditions applied as shown in the figure above, or the
full bracket only, or a part of the bracket (a model identical to what we
had in Lesson 2). See the images below.

The decision is based on what is the objective of the analysis, i.e. what
results do we truly need. The larger the model we chose, the more
realistic it becomes. At the same time the size of the finite element
model increases, resulting in significantly longer solution times.
Boundary conditions therefore serve to express the fact how a specific
part or sub-assembly is grounded or attached to another primary
structure, and help us substantially reduce the size of the problem.
Reduction of the problem comes at a cost, i.e. the stress results at the
location of the boundary conditions may be singular and have to be
ignored in such cases.

Also, we need to understand that the boundary conditions do effect our

solution. In the three cases listed above the final results will be
comparable, but not exactly the same. Therefore the selection, as well
as the location, of the boundary condition must be done so that its effect
on the results and the rest of the model is minimal.

Conclusion

The question may arise: which one study is the correct one?

The second to last study with the fillet and fixed face included in the
model and the mesh control applied produce the most accurate results
and is favored provided one can afford the increased size of the model
due to the additional regions that must be meshed. Then what about the
other studies where stress concentrations are seen?

103

Lesson 2

SolidWorks 2012

Mesh Controls, Stress Concentrations and Boundary Conditions

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These results are obtained by using the incorrect mathematical model.

It does not make sense to debate which of the first three models
produces the most accurate results and, therefore, which one was the
best among the three. All models with sharp re-entrant edges or edges
that are fixed are equally poor if we examine the stress on those edges.
Thus, if we are interested in stress at or near a sharp edge (or a sharp
corner for shell models), this edge must be modeled with a fillet, even
if the fillet is very small. In addition, if the edge of the model is fixed,
we must realize that the appearance of the stress concentration is
artificial. In general, if stresses at these singularities are of no interest,
these studies still produce good results for the overall model.

Summary

In this lesson, we illustrated what can go wrong when FEA is based on

an incorrectly prepared model.

Using local mesh controls rather than the global mesh controls, we
obtained solutions for different meshes and revealed stress singularities
at a sharp re-entrant corner and at fixed geometries.

We used this lesson to further discuss modeling and discretization error,

meshing techniques, and also to illustrate the integration between
SolidWorks and SolidWorks Study tree.

Questions

104

Why do we often eliminate fillets and small rounds if such

suppression can lead to locally inaccurate stress results? Does it
imply that the stress results are inaccurate for the whole model?

Are displacements affected by the suppression of small features

(fillets, rounds) as much as stresses? Why?

SolidWorks 2012

Exercise 4
C-bracket

Exercise 4:
C-bracket

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In this exercise, you will analyze a bracket with two different

configurations to determine the effects of the internal fillets.
This exercise reinforces the following skills:
I
I
I
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Problem
Statement

Mesh Controls on page 90.

Results Comparison on page 95.
Stress Singularities on page 95.
Suppressed Configuration on page 96.

A hanging bracket mounted on the ceiling will

be supporting a sign mounted on the bottom
flange of the bracket. The sign will be mounted
onto the bracket with a flat ribbon like cable. A
900 N [202 lb.] force will be exerted on the
bracket due to the weight of the sign and
ribbon. We will evaluate the displacements
and stresses for the bracket due to this loading.
We are also interested in how modeling the
bracket with and without fillets will effect our
results. The effects of different boundary conditions will also be
investigated.

Part 1: Analysis of
Bracket with no
Fillet

Open a part file.

Open bracket from Lesson02\Exercises folder.

Specify active configuration.

Make the configuration No Fillet active.

Notice that the rounded inside edges become

sharp re-entrant corners. This configuration,
suppresses all inner fillets.

3
4

Define a static study.

Create a Static study named no fillet 1.
Apply material properties.

Apply the material Alloy Steel from the

solidworks material library.

105

Exercise 4

SolidWorks 2012

C-bracket

Apply a fixture.
Apply a Fixed Geometry fixture to the top

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face as indicated.

We will assume that the compressive force of

the screw is large enough to prevent any
sliding or rotation about the screw.

Apply force.
Apply a 900 N [202 lb] normal force to the top

face of the bottom flange. This force is due to

the weight of the sign.

Mesh the model.

Select Curvature based mesh under Mesh

Parameters.

Mesh the model with the default element size.

Use High quality elements.

8
9

Run the analysis.

Plot stress results.

We find that the bracket has a maximum von Mises stress of 132 MPa
[19.2 ksi] and does not yield. However, there is a high stress
concentration at the sharp corners.

106

SolidWorks 2012

Exercise 4
C-bracket

10 Plot displacement results.

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Maximum displacement is 1.25 mm.

11 Create a new study.

Duplicate the existing study and name it no fillet 2.

12 Apply mesh control.

Apply mesh control to each of the three edges on the inner faces of the
bracket. Use the default mesh control size.

13 Mesh the model.

Mesh the model with the default element size. We have created a finer
mesh at the inside edges of the bracket, while the mesh sizes are coarser
at all other locations in the bracket.

14 Run the analysis.

107

Exercise 4

SolidWorks 2012

C-bracket

15 Plot stress results.

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The maximum von Mises stress is now 160 MPa [232 ksi], which is
higher than the von Mises stress value obtained in the previous study
with no mesh control. This shows the diverging stress results and
verifies that the stress in the corners are indeed concentrations. Further
refinement will continue this trend.

16 Create a new study.

Duplicate the no fillet 1 study and name it no fillet 3.
17 Apply mesh control.

Add mesh control to the same three edges. Change the local Element
size to 0.889 mm [0.035 in].

18 Mesh the model.

Mesh the model with the default element size. We have created a finer
mesh at the inside edges of the bracket, while the mesh sizes are coarser
at all other locations in the bracket.

108

SolidWorks 2012

Exercise 4
C-bracket

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19 Run the analysis.

20 Plot stress results.

We find that the maximum von Mises stress is significantly higher than
the value obtained in the previous study with a coarser mesh control.
We see that, although we are refining the mesh, the stress results are not
converging. This is due to the sharp re-entrant corners.

Part 2: Analysis of
Bracket with Fillet

We will now look at a model with fillets and analyze its solution.

Change configuration.

Change the active configuration to Default.

This configuration has the fillets unsuppressed.

Create a new study.

Duplicate the no fillet 1 study and name it
fillet.
Mesh the model.

Mesh the model with the default local Element

size.

109

Exercise 4

SolidWorks 2012

C-bracket

Run the analysis.

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4
5

Plot stress results.

The stress results obtained from the model with the fillet indicate that
the maximum von Mises stress is approximately 127 MPa [18.4 ksi].
Because no sharp edges are present in the model, this value is close to
the real stress magnitudes. Further mesh refinement would improve the
results and eliminate the spotty stress distribution.

Part 3: Analysis of
Bracket with Fillet
and Fixed Hole

In this last study, we will change the way the part is restrained by
editing the one fixture and holding the part by the cylindrical hole
instead of the entire top face.

1
2

Create a new study.

Duplicate the fillet study and name it fillet fixed hole.
Use Fixed Geometry on hole.

Edit the fixture and remove the

top face. Add the hole face.

110

SolidWorks 2012

Exercise 4
C-bracket

Apply mesh control.

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Apply a mesh control with an Element

size of 0.508 mm to the inner cylindrical
surface of the hole.

Mesh control on the fillets.

Apply a mesh control with the default

Element size of 1.9 mm to the three
fillets.

Run the analysis.

The study will mesh and solve.

Add

111

Exercise 4

SolidWorks 2012

C-bracket

Plot the stress results.

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The stress results obtained from the model with the fillet and the fixed
geometry on the hole produce a stress concentration around the edges
of the hole. This is because a singularity of stress appears in this region
due to the perfectly rigid support at those edges. This is similar to the
singularity seen in the fixed edges of the L-Bracket in Lesson 2 and
can be ignored. Change the scale of the legend to obtain a more realistic
plot.

We can see that the stresses on the filleted faces increased from 127
MPa (see previous study) to nearly 145 MPa.

Modify the mesh controls.

Change the Element Size for both mesh controls to 0.1mm for the hole
and 1.1mm for the fillets.

Run the Study.

The study will mesh and solve.

112

SolidWorks 2012

Exercise 4
C-bracket

Examine the stress plot.

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As can be seen the stress near the support increased considerably and
represents the maximum stress in the model. From Lesson 2 we know
that this stress is unreal and will increase as we reduce the size of the
elements.

Probing on selected entities reveals the maximum stress on the filleted

faces as 150 MPa, a slight increase from the 145 MPa obtained from
the previous run. This stress is real and approaching a finite value (we
say it converges).

10 Save and Close the file.

113

Exercise 5

SolidWorks 2012

Bone Wrench

Exercise 5:
Bone Wrench

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In this exercise a bone wrench will be analyzed for its stresses and
deformations when subjected to loads resulting from regular working
conditions.
The analysis will include a report generated automatically.
This exercise reinforces the following skills:
I
I

Problem
Statement

Plot Settings on page 29.

Results Summary on page 65.

One side of the wrench is fixed,

simulating a tight contact with a
nut. The other side is subjected to
a horizontal 150 N force exerted
by an operator when tightening
(loosening) the nut.

Open a part file.

Open bonewrench from the Lesson02\Exercises folder.

Set SolidWorks Simulation options.

Set the Units to SI(MKS), and the units of Length and Stress to mm
and N/mm^2, respectively.
Define a static study.

Create a Static study named bone wrench analysis.

Apply material properties.

Assign Alloy Steel as the material from the solidworks materials

library.

Apply fixtures.

The tight contact between the wrench and the nut will be simulated by
the application of Fixed Geometry fixture on the faces (a total of eight
faces), as shown in the figure.

Note

114

Restrained faces are featured in beige in the SolidWorks model.

SolidWorks 2012

Exercise 5
Bone Wrench

Apply force.

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Apply a force of 150 N [33.7 lbf] exerted by an operator, as shown in

the figure below.

Mesh the model.

Select Curvature based mesh under Mesh Parameters.

Mesh the model using High quality elements. Use the default settings.

Run the analysis.

115

Exercise 5

SolidWorks 2012

Bone Wrench

Plot stress results.

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We observe that the resulting von Mises stress in the model is 244 MPa
[35.4 Ksi], which is well below the material yield strength of the 620
MPa [89.9 Ksi].

10 Plot resultant displacements.

The absolute values of the displacements are very small, with a

maximum value of 0.3 mm.

Note

The next task, extraction of the reaction torque requires a specification

of the local cylindrical coordinates system. This is explained in Lesson
4.

11 Check the reaction moment.

Right-click on Results folder and select
List Result Force.

As shown in the following figure, in the

Plane, Axis or Coordinate system field,
select Axis1. SolidWorks Simulation will
switch to the cylindrical coordinate
system defined by Axis1.
Select all the faces where the model is
restrained (a total of 8 faces).
Click Update.

The Reaction force (N) dialog reads Sum Y: -1391.7 N.

Note

116

This force could be negative or positive depending on which side of the

wrench the force was applied.

SolidWorks 2012

Exercise 5
Bone Wrench

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This is the total value of the reaction force in the second cylindrical
(circumferential) direction. To obtain a reaction moment, we have to
multiply this value by a radius.

12 Compute the moment.

Because the opening is not

circular, we will measure the
outer and inner diameters and
use the average as an
approximation of the opening
diameter.
The average diameter is
17.321 + 15
---------------------------- = 16.16mm .
2

Therefore, the total reaction moment is approximately equal to

16.16
------------- x 1391.7 = 11244.94 Nmm
2

To calculate the loading moment, measure the distance between the

centroid of the applied load and Axis1.

117

Exercise 5

SolidWorks 2012

Bone Wrench

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The measured distance is 75 mm. Therefore, the loading moment is

equal to 75x150 = 11250Nmm , which confirms the equilibrium.
Note

The slight difference in the two values is not caused by the inaccuracy
of SolidWorks Simulation computations. It is merely a consequence of
the approximate calculation of the average diameter of 16.16 mm.

13 Generate report.

14 Save and Close the file.

118

SolidWorks 2012

Exercise 6
Foundation Bracket

Exercise 6:
Foundation
Bracket

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The foundation bracket is used to secure a table

leg to the floor.
In this exercise the foundation bracket will be
analyzed for its stresses and deformations
when subjected to loads resulting from regular
working conditions.
This exercise reinforces the following skills:
I
I
I

Problem
Statement

Mesh Controls on page 90.

Stress Singularities on page 95.
Results Comparison on page 95.

Model courtesy of
Bosch Rexroth

One side of the foundation bracket is bolted to

the floor by a single bolt. The vertical face is
bolted to a table leg with two bolts.

Analyze the stress in the foundation bracket

when the table leg is forced to displace by
0.5 mm in both the plus and minus X direction.

+X

Both of these displacements are rather large and would not occur under
normal conditions.

Note

We will first analyze the stress when the table leg moves in the plus X
direction.

1
2

Open a part file.

Open bracket from the Lesson02\Exercises folder.
Set options.

Select Units, then set the Unit system to use SI units, mm for length
and displacement and N/m^2 (Pascals) for pressure and stress.

Select Color Chart, then set the number format to display Scientific
units at 2 decimal places.
Select Specify color for values above yield for vonMises plot.
Leave the color as the default gray.
Select Results, then select Automatic as the Default solver.

Create a study.

Create a new static study and name it stress analysis x+.

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Foundation Bracket

Apply material.

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Apply the material Chrome Stainless Steel from the SolidWorks

material library.

Add fixtures.

We are going to ignore friction along the direction of the slot and only
constrain the surface that the bolt head and shank contact to zero
displacement.
Add an On Flat Faces fixture to the four faces shown. Set the
Translations to zero for the direction Normal to Face.
Rename the Fixture to Bottom bolt.

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Exercise 6
Foundation Bracket

Apply fixtures.
Apply an On Flat Faces fixture to the four faces where the bolt heads
contact the vertical plate. Rename this fixture to Top bolts-1.

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Foundation Bracket

Apply a displacement.
Apply a 0.5 mm normal displacement to the two faces indicated using
the On Flat Faces fixture. Select the face shown in blue as the

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direction.

Rename this fixture to Top bolts-2.

Mesh the model.

Select Curvature based mesh under Mesh

Parameters.
Mesh using the default element size.

122

Run the study.

SolidWorks 2012

Exercise 6
Foundation Bracket

10 Plot the results.

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The displacement plot shows a maximum displacement of 0.5 mm

which was our input.

11 Examine the stress plot.

The stress plot shows high stress at the lower bolt and at the sharp edge.
We can see that there is significant yielding as indicated by the gray
color and the position of the yield arrow in the color band.
We see that the part will yield around the areas of the bolts, and at the
sharp corner between the back vertical face and the angled face.

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Foundation Bracket

12 Re-mesh.

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Re-mesh the model with a finer mesh. Move

the mesh size slider all the way to the right
and mesh.
We now have two elements in the thickness
direction.

Note

You will learn later in the course that at least two solid elements
through the thickness are required in the bent regions to obtain
acceptable stress results.

13 Run the study.

The choice of Automatic for the solver should cause the FFEPlus
solver to be used.

14 Review the plots.

The stress plot shows essentially the same results as with the coarser
mesh. We still have yielding around the bolts and the sharp corner.

15 Duplicate the study.

Name the new study stress analysis x-.

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Foundation Bracket

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16 Change the direction.

Edit the fixture Top bolts-2 to switch the direction and have the

displacement applied to the two faces on the other side of the slot as we
want to push, not pull, the material in the negative x direction.

17 Run.

Run the study with the fine mesh.

Note

No remeshing is necessary; the geometry was not modified.

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Foundation Bracket

18 Examine the results.

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The stress on the inside faces looks similar to the stress found when the
movement was in the +X direction, however we can now see additional
yielding on the back face.
From these results, we can see that we would need to possibly increase
the thickness of the material to avoid yielding. However, we need to
remember that we purposely subjected the bracket to a very large
displacement, which is not likely to occur frequently.

19 Probe the result.

By probing several points in the yielded region on the back face, we

can see that the stress is about 200 MPa.

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Exercise 6
Foundation Bracket

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20 Probe the face.

In the Probe Results, select On selected entities, then select the

indicated face.
Click Update.

By selecting the face, we now have Summary information that show

the maximum stress is 351 MPa.

21 Conclusion.

Based on the analysis, we might conclude that the bracket is not strong
enough in this configuration. We might consider a change to the design
to avoid yielding, probably by increasing the material thickness to
sustain the applied displacements.
However, as the displacement applied is very large and occurs
exceptionally, and the resulting maximum values of 224 MPa are close
to the yield strength of the material, this bracket design is appropriate.

22 Save and Close the file.

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Foundation Bracket

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Lesson 3
Assembly Analysis
with Contacts

Objectives

Upon successful completion of this lesson, you will be able to:

I

Perform structural analyses of simple assemblies.

Apply and define contact conditions.

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Lesson 3

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Assembly Analysis with Contacts

When we analyze an assembly, we must understand how the

components interact with each other so that our mathematical model
correctly computes the stress and deformation.

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Contact
Analysis

Different conditions must be considered where the parts can pull apart
or penetrate each other and whether or not the surfaces can slide over
each other.

Case Study:
Pliers with
Global Contact

In this lesson, we analyze a simple hand tool. It consists of four

components: two identical arms, a hinge pin, and a piece of flat
stock squeezed by pliers.

We are not interested in

the contact stresses that
develop between the
arms and the piece of
flat stock.

Therefore, we can
simplify the model by
suppressing the flat
stock and replacing it
with the appropriate fixture.

Project
Description

Calculate the stresses that develop in the arms when a 225 N [50.6 lbf]
squeezing force is applied to the end of each arm. The design
strength is set at 138 MPa [20,016 psi], approximately 22% of the
material yield strength.

Stages in the
Process

Some steps in analyzing an assembly.

I

Apply materials

Materials can be applied to all components together or individually.

Add fixtures

Fixtures are added in the same way they are done in parts to restrain
the motion of the model.

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Lesson 3
Assembly Analysis with Contacts
I

Apply component contact conditions

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Component contact conditions dictate how parts or sub-assemblies

in contact or close proximity interact in the absence of local
overrides.

Apply local contact conditions

Local contact conditions override the component contact.

Apply mesh control

The mesh can be refined in areas of stress concentrations or rapidly

changing geometry.

Mesh the model

Run the analysis

Analyze the results

Determine if the results are accurate enough or further refinement

of the analysis is needed.

Procedure

To begin this case study:

Open an assembly file.

Open pliers from Lesson03\Case Studies folder.

Suppress flat.

Suppress the part flat in the SolidWorks FeatureManager design tree.

Create study.

Create a static study named pliers.

Examine the Simulation Study Tree.

There is now a Parts folder with three components

because there are three parts in the assembly to be
analyzed.

Applying Materials
to Assemblies

You can apply the same material to all components of an assembly or to

each component individually.
To apply material to the components:

I
I

To apply the same material to all components, right-click Parts and

select Apply Material to All.
To apply different material to each component, right-click a part
and select Apply/Edit Material.

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Assembly Analysis with Contacts

Apply materials to components.

Apply Plain Carbon Steel material

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properties to all components including the

pin.

Apply fixed restraints.

Define Fixed Geometry fixture on both

jaws.

The applied restraints simulate the

suppressed piece of squeezed flat stock.
This condition assumes that the flat is not
sliding when held by the jaws.

Apply force to handles.

Apply a 225 N [50.6 lbf] force to both

handles. The outer face of each arm has a
split face so that the load is only applied to
part of the face.

In the Force/Torque PropertyManager,

select Normal.

Component
Contact

Whenever we create a study of an assembly, a new

folder named Connections is added to the
Simulation Study tree. We use this folder to define
how the assembly components interact with each
other.

We have defined the fixtures and external loads, but we are not yet
ready to mesh this assembly. We have to account for the contact
between the two arms.

The Component Contact options defines the way components interact

with each other. You can override the component conditions by
defining different conditions locally for selected pairs of features.
Local contact conditions are discussed later in this lesson.

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Lesson 3
Assembly Analysis with Contacts

The available options for the component contact are: Bonded, Allow
penetration and No penetration. These options are explained in the
following figure and table.

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Component
Contact: Options

Part A

Part B

Bonded Contact

I
I
I

Part A

Part B

Allow penetration

Part A

Part B

No penetration

In the Simulation Study tree, right-click Connections and select

Component Contact.
Select Contact/Gap in the Simulation menu and then click Define
Contact for Components.
Select the Simulation tab in the CommandManager, then select
Component Contact from the Connections Advisor pull-down
list.
Component Contact Types

Bonded

This is the default choice. Select this option

when all touching faces are bonded and the
assembly behaves as one part. The only
difference between a part and an assembly
with bonded parts is that in an assembly we
can assign different material properties to
individual components.

Allow penetration

Select this option when the assembly is a

series of unattached components with no
structural connection between them.

No penetration

Select this option when touching components

can come apart, but cannot penetrate each
other.
The coefficient of friction can be specified in
the component contact property manager.

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Assembly Analysis with Contacts

Component
Contact: Default
setting

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Default component contact setting is bonded

contact between all touching faces for the top
level assembly.
Editing default component contact,
Global Contact, shows that it is applied
to the top level assembly.

Component
Contact: Hierarchy
and Conflicts

It is possible to delete and re-define the top level assembly contact

condition. However, multiple top level component contact conditions
would result in a conflict and are not permitted.
Any additional component contact between parts and subassemblies
must not be in conflict and will override the top assembly level
component contact. If the conflict is detected a warning message will
be displayed.

Check for existing interferences.

Click Tools, Interference Detection.

In the Options dialog, select Treat

coincidence as interference and click
Calculate.
Three sets of faces in the assembly are
touching.

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Lesson 3
Assembly Analysis with Contacts

In the parts of this assembly, the manufacturing clearance between the

pin and the arms is ignored. That is why the coincident contact of
cylindrical shape between the pin and the arms was detected.

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Note

Change top level component contact option.

In order to allow the relative movement of the arms while the model
deforms under the load, change the default component contact (Global
Contact) condition to No Penetration.
Expand the Connections folder, edit the Global
Contact item and change it to No Penetration.
Click OK.

10 Mesh the model.

Select Curvature based
mesh under Mesh
Parameters.

Mesh the assembly with

Draft quality elements and
the slider all the way to the
right. This should produce the Maximum element size of 4.912mm,
Minimum element size of 0.982mm, Number of elements in a circle
as 8, and Ratio of 1.6.

Important!

Meshing must always be performed after the contact conditions are

defined.

11 Run the analysis.

12 Switch to exploded view.

Switch to the exploded view.

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Assembly Analysis with Contacts

13 Plot von Mises stresses.

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Display the von Mises stress plot by double-clicking on the Stress1

plot icon.

We want to see if the von Mises stresses in any portion of the model
exceed 138 MPa [20,016 psi], which is our design stress. To determine
whether the von Mises stresses exceed the maximum we can change
the plot options.

14 Change the plot.

While the plot is displayed, right-click Stress1

and select Chart options.

Under Display options, select Defined, and then

enter the minimum stress as 0 and the maximum
stress as 138,000,000.
Click OK.

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Assembly Analysis with Contacts

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15 Change Plot Settings.

Right-click Stress1 and select Settings. Under Fringe options, select
Discrete.

Click OK.

Viewing Assembly
Results

Areas with stresses higher than 138 MPa would appear in red.

Note that an exploded view offers a very convenient way of examining

the analysis results of an assembly, whereas, in normal viewing,
components may obstruct the view.
Another way of reviewing results of an assembly is to hide some
assembly components.

16 Isolate the arm.

Isolate arm<1>.

17 Define stress plot of one arm.

In the Simulation Study tree, right-click the Results folder, and select
Define Stress Plot.
Click OK.

Note

You can also use the existing plot Stress1 after hiding an assembly
component arm.

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Assembly Analysis with Contacts

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18 Max/Min annotations.
In Chart Options, select Show max. annotation and Show min.
annotation.

The maximum stress locations and their magnitudes are indicated for
the displayed arm.

Conclusion

The maximum von Mises stress of approximately 93.0 MPa is

produced by normal operation of the pliers when a 225 N force is
applied to the handles. This load can be (perhaps with some difficulty)
applied by hand and 93.0 MPa can easily be tolerated by the pliers
material (which has a yield stress of almost 220 MPa).
Before concluding that our design is safe, re-meshing the model and
looking for stress convergence would be required.

Handle Contact

We wish to determine the maximum stress that the pliers undergo when
squeezing a 5 mm stock plate. The maximum stress corresponds to the
situation where the handles are blocked.

19 Show the hidden arm and pin.

20 Collapse the assembly.

21 Create UY: Y displacement plot.

To determine the force that brings the ends of the two handles together,
we need to create a displacement plot showing the y component of the
displacements.
Double-click the Displacement1 plot icon to make the plot active.
Right-click the Displacement1 plot icon and select Edit definition.

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Lesson 3
Assembly Analysis with Contacts

Select UY as the Displacement Component, and select mm as the

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Units.

Under Deformed shape, select True scale. This option plots the
deformation in 1:1 scale.
Click OK.

Required Force

We see that under the 225 N force, the end of each handle travels
0.393 mm. Consequently, the distance between the two ends decreases
by twice that amount, 0.786 mm.
Since the original distance is 15.24 mm, the force magnitude must be
increased by a factor of:
15.24 mm / 0.786 mm = 19.39

Therefore, the force required to bring both arms in contact is equal to

19.39 x 225 = 4362 N. This is based on fundamental assumptions of
linear analysis where the structural response is assumed to be
proportional to the applied load.

Pliers with
Local Contact

We will now load the pliers with a force that significantly exceeds
4265 N to ensure that both arms come in contact. The appropriate
definition of the contact will ensure that the handles can come together,
but cannot penetrate each other.

Create new study.

Duplicate the study pliers and name the new study pliers with local

contact.

Edit force.

Edit the force magnitude to 4,500 N. This is an arbitrary magnitude

based on our rough estimation of forces that will definitely bring the
two arms together.

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Assembly Analysis with Contacts

The top level component contact condition remains the same (No
Penetration) as in the previous study. However, now that the force is
considerably larger in order to bring the two arms together, we need to
specify a local contact condition that prevents their penetration (No
penetration top level assembly component contact applies to initially
touching faces only).

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Local Contact

This local contact

condition has
precedence over the
component contact. In
general, the hierarchy of
the contact conditions
can be explained by the
pyramid shown in the
following figure.

High precedence
in contact hierarchy

LOCAL

OTHER
COMPONENT
CONTACTS

Low precedence
in contact hierarchy

TOP LEVEL
COMPONENT CONTACT

Top assembly level contact (only one definition is permitted) is

overridden by other user defined component conditions. All component
contacts are then overridden by local conditions.
The local contact conditions can be defined
by right-clicking on the Connections
folder and selecting Contact Set.

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Lesson 3
Assembly Analysis with Contacts

In addition to Bonded, No Penetration, and

Allow penetration, the local contact features
two more contact types: Virtual wall and
Shrink fit.

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Local Contact
Types

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Assembly Analysis with Contacts

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The table briefly describes the local contact condition types.

Local Contact Types

No
penetration

The features (both initially touching and separated

by a gap) may move away from each other but
preserve the physical requirement that they may not
penetrate each other. Friction coefficient and initial
geometrical offset can be specified in the contact
options.

Bonded

The selected features will become bonded, similarly

to the component level contact types. While
component bonded contact only applies to touching
faces, local condition is capable of bonding features
separated by a gap.

Shrink fit

The program creates a shrink fit condition between

the selected faces. The faces may or may not be
cylindrical. This condition requires that the two
parts exhibit a finite volume interference.

Allow
penetration

The selected pair of features is free to move in any

direction. Free features can penetrate into each
other, a physical impossibility. You should use this
option only when you are absolutely sure that the
specified loading will not cause the features to
penetrate.

Virtual wall

This provides a sliding support in a way similar to

Roller/Sliding restraint, except that a friction
coefficient and wall elasticity can be specified.

Each local contact type features various options described at various

locations throughout the manual.

Note

Define contact set.

To define a contact zone between the

ends of the two handles, we use the
two small split faces on the inside of
the handles to define a contact pair.
Right-click Connections and select
Contact Set.

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Assembly Analysis with Contacts

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In the Contact Set PropertyManager, select No

Penetration.
Click one face to define it as the Set 1, and then
click the other face to define it as Set 2.
Click OK.

Note

The selection of the faces for Set 1 and Set 2

is arbitrary.

No Penetration
Local Contact
Options

The above image shows two properties of the two local condition,
Friction and Gap (clearance).

No Penetration
Local Contact:
Advanced Options

Friction: Any value of the friction coefficient is permitted.

GAP (clearance): In many applications, two entities cannot come

into full contact due to the manufacturing limitations and the
modeling approaches that we use. This feature restricts such two
entities from coming closer than the initial geometrical offset. For a
more detailed explanation, please refer to Lesson 7.

The No Penetration contact also features advanced options accessible

through the simulation study options. These options, generally not
required, are discussed in Lesson 7.

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Assembly Analysis with Contacts

The default algorithm for the local contact is fast and suitable to most
contact solutions. However, if contact stresses are of primary
importance, or if the areas in contact are large and/or the default
solution for contact stresses is spotty or discontinuous, Improve
accuracy for contacting surfaces feature should be activated.

Introducing:
Improve Accuracy
for contacting
surfaces

Improve accuracy for contacting surfaces feature employs advanced

solution algorithm resulting in improved results. While such contact
solution is more accurate it may take significantly more time.

Where to Find It

Shortcut Menu: Right-click <study name>, Properties and under the

Options tab, click the Improve accuracy for contacting surfaces
check box.

No Penetration
Local Contact:
Remarks

Edges and vertices in local No Penetration contact condition can

onlybe selected in the first field (Set 1), while the second field (Set 2)
accepts faces only.

Note

Because the friction forces are small and no initial geometrical offset
exists in this case, neither the Friction nor the Gap (clearance)
properties will be used. Since the contact stresses are of no interest in
this simulation Improve accuracy for contacting surfaces option
will not be utilized.

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No Penetration
Local Contact:
Accuracy

Because the contact conditions have changed, the

warning signs indicate that remeshing and recalculation of the results are necessary.

Mesh the model.

Select Curvature based mesh under Mesh Parameters.

Mesh the model with High quality elements and the same element size
as before.

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Run the analysis.

SolidWorks 2012

Lesson 3
Assembly Analysis with Contacts

Large/Small displacement.

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While the study is running, the following message will appear:

Excessive displacements were calculated in this model. If
your system is properly restrained, consider using the Large
Displacement option to improve the accuracy of the
calculations. Otherwise, continue with the current settings
and review the causes of these displacements.

Click No to complete the analysis as linear.

The large displacement dialog box warns us that the large

displacements of some parts in the assembly were detected. The large
displacement computations are the subject of Lesson 14. At this point,
we will ignore this fact.

Note

Plot von Mises stresses.

After the analysis is complete, create a von Mises stress plot, with
discrete fringes, the mesh showing, and the stresses scaled from 0 to
220 MPa [89,925 psi].

The region in red indicates the yielding material. We can observe that
the maximum reported von Mises stress is approximately 1,806 MPa.
This value is, of course, unrealistic. Yielding of the material indicates
that a linear analysis is no longer valid and that a nonlinear analysis
would be required.

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Assembly Analysis with Contacts

Contact Stresses

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After the handles are blocked, any further increase in force magnitude
has little effect except for increasing the contact stresses where the
handles touch.

Question:

Can we analyze the contact stresses in the current study?

Answer:

No, the element size in the

contact area is much too large
in comparison to the size of
the contact area. This
comparison is best seen in a side view.

The two handles touch only along the edge. For accurate modeling of
contact stresses, we need several elements along the length and width of
the contact zone.

Summary

Save and Close the file.

In this lesson we analyzed the simple assembly model of pliers with

various contact conditions. To simplify the geometry, the flat was
suppressed and its presence was simulated with the help of the fixed
geometry fixtures on the jaws. When the analysis was run, we saw a
maximum von Mises stress of 93 MPa. This stress is below our
specified design strength of 138 MPa. To be sure of our stress results, a
more refined mesh should be run to insure that the stress is converging.

Additionally, we saw that the maximum displacement produced was

0.402mm. We used this result to change our loading application to
investigate what happens if the load was so large that the handles touch.
The contact conditions can be grouped into two distinct categories:
component and local. Both categories were introduces and practiced in
this lesson.

The local contacts take precedence over all of the component

conditions, while all user defined component contacts take precedence
over the top assembly level component condition (essentially serving
as the global contact condition for the entire assembly). While the
component contacts apply to initially touching faces of parts or
assemblies, the local conditions may feature gaps and initial separation.
Various types (namely Bonded, Allow Penetration, No Penetration,
Shrink Fit and Virtual Wall), properties and options of the contacts
were discussed and practiced.

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A linearity principle (linear dependence of the input and output) was

used to scale the magnitudes of the loads in order to close arms of the
pliers.

Finally, the limitations of analysis with linear materials were examined

and contact stresses were introduced.

Questions

As a review, the available component condition types are:

___________________________________________________
___________________________________________________
The available local contact condition types are:
___________________________________________________
___________________________________________________

The (component / local) No Penetration condition applies to the

initially touching faces only, while the (component / local) contact
may feature gaps and initial separation.
To simplify the analysis in this lesson, the flat was suppressed and a
Fixed Geometry fixture was applied on the jaws. Thus, we made
an assumption that the stiffness of the flat is
_____________________.
This assumption can only be made if the stiffness of the plate is
significant, relative to the stiffness of the rest of the assembly.

Can you propose a more accurate solution? (Hint: Browse through

the available connectors types in the SolidWorks Simulation
Connections folder.)

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Assembly Analysis with Contacts

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Exercise 7
Two Ring Assembly

Exercise 7:
Two Ring
Assembly

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Analyze a simple two ring assembly, in which the outer faces of the
rings exert contact pressure on each other if tensile loading is applied.
This exercise will show how models with surface contact conditions
can be set up and analyzed.
This exercise reinforces the following skills:
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Project
Description

Component Contact: Options on page 133.

Viewing Assembly Results on page 137.
No Penetration Local Contact Options on page 143.
Contact Stresses on page 146.

A 3.5 MPa pressure load is applied to face of the plate with the Ubracket. The plate holding the large ring is held fixed. The outer faces
of the rings exert contact pressure on each other.
Partial Restraint

Fixed Restraint

Pressure Loading

Procedure

Open the existing assembly from the Exercises folder.

Open an assembly file.

Open TwoRingsAssem fromthe Lesson03\Exercises folder.

Set SolidWorks Simulation options.

Set the global system of units to SI (MKS), units of Length to mm and

Stress to N/mm^2 (MPa).

Define a static study.

Create a Static study named Pressure Loading.

Apply material properties.

In the SolidWorks Simulation study tree, right-click Parts and select

Apply Material to All.
Select AISI 1020 from the solidworks material library.

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SolidWorks 2012

Two Ring Assembly

Apply fixed restraint.

Apply a Fixed Geometry fixture to the back
face of TwoRingsPart1.

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Constrain TwoRingsPart2 to move in the

direction of the load.
Right-click Fixtures and select Advanced
Fixtures.

Select Use Reference Geometry.

Select Plane2 to specify the direction of the

restraint.
Select the three cylindrical surfaces to apply
boundary condition.

Activate the Displacement components Along

plane Dir 2 and Normal to plane, and set the
values to 0 mm.
Click OK.

Apply pressure.

Apply a 3.5 MPa pressure normal to the surface of

the TwoRingsPart2.

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SolidWorks 2012

Exercise 7
Two Ring Assembly

Define contact set.

Right-click Connections and select
Contact Set.

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In the Contact Set PropertyManager,

select No Penetration as the desired
type of contact.
Click one face to define it as a Set 1,
and then click the other face to define
it as Set 2.

It does not matter which face is selected as Set 1 and Set 2.

Note

Click OK.

Apply mesh control.

Apply mesh control to the indicated surface on

TwoRingsPart2.

In the element size box, enter a value of 2 mm.

Take all other default mesh control settings.

10 Mesh the model.

Select Curvature based mesh under Mesh
Parameters.

Mesh the model with the default element size. Use High quality
elements.

11 Run the analysis.

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Two Ring Assembly

12 Plot stress results.

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We see that the maximum stress in the model is 845 MPa. This is well
above the yield strength of 351 MPa. If these truly were the in service
loading conditions, the design needs to be re-evaluated and a new
material or design should be selected.

13 Plot Displacement Results.

The maximum displacement in this model is 0.44mm.

14 Animate Displacement Results.

15 Save and Close the file.

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Lesson 4
Symmetrical and Free SelfEquilibrated Assemblies

Objectives

Upon successful completion of this lesson, you will be able to:

I

Understand symmetry.

Displaying results using a cylindrical coordinate system.

Locate problems with the help of the Whats Wrong feature.

Use soft springs and inertial relief options to eliminate rigid body
modes.

Presenting analysis results using eDrawings.

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Symmetrical and Free Self-Equilibrated Assemblies

When parts are assembled with a shrink fit, internal forces are
developed in the absence of external forces.

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Shrink Fit Parts

Case Study:
Shrink Fit

We will analyze a wheel assembly where the rim is shrunk fit onto the
hub to determine the stresses caused by the shrink fit.

A shrink fit causes stress within the parts without external forces being
applied to the model. The parts initially have an interference fit.
The directions of stress, strain and deformation are not plotted in
Cartesian coordinates, but rather cylindrical coordinates so that we can
determine radial, axial and circumferential (hoop) stress and
deformation.

Project
Description

A rim with an inside radius of 121 mm [2.382 in.] is pressed on a hub

with an outside radius of 121.45 mm [2.391 in.].
Find the following stress results in both components:
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Symmetry

von Mises stress

Hoop stress
Contact stress

We can take advantage of the

multiple symmetry of this
assembly model and analyze 1/2,
1/4, or even 1/8 of the model.

To reduce the processing time, we

will analyze a 1/8 section of the
model.

Note that an axis, Axis1, has been

defined in the assembly. We will
use it as a reference to produce
plots of hoop stresses and contact
stresses.

Stages in the
Process

Some key stages in the analysis of this part are shown in the following
list:
I

Symmetry

Determine if the model has symmetry that will allow only a portion
of the model to be analyzed.

Defeature

Suppress features that will not have an effect on the analysis.

Stabilize the model

Eliminate rigid body motion.

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Lesson 4
Symmetrical and Free Self-Equilibrated Assemblies
I

Define contact

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Because the parts have an interference fit, we must define the

contact as a shrink fit.

Plot results

With shrink fit analysis, we display the results using cylindrical

coordinates rather than cartesian coordinates.

Open an assembly file.

Open wheel assembly from the Lesson04\Case Studies folder.

Activate the configuration.

Activate the configuration called FEA. It

unsuppresses the feature named cut 1/8
which is used for symmetry in the model.
In addition, to defeature the model, the
round features have been suppressed in
both parts.
I

rim
rounds

hub
round1
round2

Defeaturing

With this modification to the CAD assembly model, we have departed

from the original CAD geometry and are now analyzing geometry
specifically created for the purpose of analysis.
Suppression of the rounds has left some sharp re-entrant edges.

These are permissible only because we do not intend to examine

stresses along these edges or in their vicinity.

Set SolidWorks Simulation options.

Set the global system of units to SI (MKS), the units of Length to mm

and Stress to N/m^2.

Create static study.

Create a static study named shrink fit.

Review material properties.

Notice that the Parts folder holds two icons, corresponding to the hub
and rim components of the assembly, and that the material properties
have been automatically transferred from SolidWorks.

Examine each part individually to confirm that the hub material is

Plain Carbon Steel with a yield stress of 220 MPa [32,000 psi] and the
rim material is Alloy Steel with a yield stress 620 MPa [90,000 psi].

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Symmetrical and Free Self-Equilibrated Assemblies

Define symmetry restraints.

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We use a 1/8 section of the wheel

assembly, but want valid results for the
complete model. Therefore, we need to
simulate the remaining 7/8 of the
assembly model. Applying symmetry
boundary conditions to the radial faces
created by the cut make the 1/8 section
behave as if the wheel was still complete.

Apply Symmetry boundary conditions to all the

faces that were created by the radial cut.
Symmetry boundary conditions on both sides of
the radial cut can be created in one step.

Select faces from both components on both planes

of symmetry: four faces on the hub and two faces
on the rim.
Right-click Fixtures and select Advanced
Fixtures.

Select Symmetry.
Click OK.

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Lesson 4
Symmetrical and Free Self-Equilibrated Assemblies

Rigid Body Mode

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With the symmetry restraints applied, the model can still move in the
axial direction. Thus, one rigid body mode remains unconstrained.
To eliminate this rigid body motion, it is enough to restrain just one
vertex on each of the components (the total of two vertices) in the axial
direction. Note that each part must be constrained individually because
parts can slide in the axial direction, the shrink fit contact is
frictionless.
This is actually an artificial restraint simply for the purpose of
removing rigid body motion, which is not allowed in structural FEA
and causes the solver to terminate.

Alternatively, we can use the soft spring feature which is specified in

the study properties. We will demonstrate this option in the second part
of this lesson.

Eliminate rigid body mode in the model.

Restrain the model by one vertex on each of the

two assembly components.
Select one vertex on the rim and one on the hub
(any vertex), right-click Fixtures and select
Advanced Fixtures.

Select Use reference geometry.

Using the fly-out menu, select Axis1 as the

direction.

Under Translations, specify that the displacement

in the direction along the axis (Axial) is equal to 0.

Now the assembly is fully restrained; it has no

unconstrained rigid body modes. Any other movement of the assembly
must be associated with the deformation.

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Symmetrical and Free Self-Equilibrated Assemblies

Shrink Fit Contact

Condition

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Because the rim diameter is smaller than the wheel diameter, there is an
interference in the SolidWorks assembly. SolidWorks Simulation
eliminates this interference by stretching the rim and squeezing the
wheel if we define the contact conditions between the interfering faces
as Shrink Fit. Shrink Fit is one of the several types of local Contact/
Gap conditions available in SolidWorks Simulation.

Explode the assembly.

The faces that are in contact are hard to select. It is easier to select them
in the exploded view.

Define shrink fit condition.

Define a Shrink Fit, right-click
Connections and select Contact Set.

Select Shrink Fit, from the available

types of contact conditions.

Selected
Faces

Define one contact face as Set 1 and the

other face as Set 2. The order of the
faces is not important.
Click OK.

Note

Under the Friction dialog, we could specify the coefficient of friction.

In this analysis we will assume no friction.

10 Mesh the model.

Select Curvature based mesh under
Mesh Parameters.

Create a High quality mesh with the

default settings.

Note that along the axial direction of the

two faces in contact, eight elements have
been created, which is adequate for this
particular analysis.

If we expected high gradients in the

contact stress distribution, then more
elements along the contacting faces would be required to model contact
stresses.

11 Run the analysis.

Note that the solution takes longer than if the model were treated as
Bonded.

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Lesson 4
Symmetrical and Free Self-Equilibrated Assemblies

12 Plot von Mises Stresses.

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Show the von Mises stress plot.

Under Settings, change the Fringe type to Discrete.

Make sure that the deformed shape is in the True scale.

Right-click the Stress-1 icon in the Results folder and select Chart
Options (alternatively, you can double-click directly on the legend).
Under Display Options select Defined and set the maximum stress
legend to 620,400,000 Pa, which is the yield stress of the rim material.

The von Mises stress results indicate that a portion of the rim
experiences stresses above the material yield stress.

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SolidWorks 2012

Symmetrical and Free Self-Equilibrated Assemblies

Now we will prepare a stress plot showing hoop (circumferential)

stresses. For this we must present stress results in a cylindrical
coordinate system with the z axis aligned with the axis of the wheel
assembly.

Cylindrical
Coordinate
Systems

Any axis defines a cylindrical coordinate system whose first direction

is radial, second is circumferential, and third is axial.

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Plot Results in
Local Coordinate
System

Therefore, Axis1 defines radial, circumferential, and axial directions

associated with the axis position.
Using an axis as a reference redefines the meaning of the stress
components SX, SY, and SZ, which are normally associated with the
directions of the global coordinate system.

If an axis is used as a reference, definitions of SX, SY, and SZ undergo

the following changes:
I

SX becomes the stress

component in the radial
direction.

SY becomes the stress

component in the
circumferential direction.

SZ becomes the stress

component in the axial
direction.

13 Set units and select axis for stress plot

reference.
Right-click on the Results folder and select
Define Stress Plot.

Select the SY stress component.

Set the Units to N/m^2.

Under Advanced Options, select Axis1 as

the reference entity in Plane, Axis,
Coordinate System.

Axis1 now defines a local cylindrical system used to plot the required

stress plot (the definition of this plot is continued in the next step).

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Lesson 4
Symmetrical and Free Self-Equilibrated Assemblies

14 Plot hoop stresses.

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Because we are defining a

stress plot showing hoop
stresses, select the SY
stress component.
The SY stress component
points in the
circumferential direction,
which is the hoop stress.
Make sure that Average

results across
boundaries for parts is

cleared.

Set the Deformed shape

scale to the True scale.

15 Settings.
Under Settings, select Discrete as the Fringe Option.

16 Chart Options.
Under Chart Options, select Defined and set the maximum value of
the stress legend to 620,400,000 Pa [90,000 psi].

Cylindrical System
Icon

When a local cylindrical system is specified in the definition of the

result plots, the familiar triad icon is replaced with a new symbol
denoting a cylindrical system.

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Symmetrical and Free Self-Equilibrated Assemblies

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17 Plot contact stresses.

Use exploded view and display a plot showing the contact stress on
contacting surfaces:
Right-click the Results folder and select Define Stress Plot.

Display an exploded view and select Axis1 as a reference. Set the

Deformed shape scale to True scale.
Plot the SX component of stress with respect to Axis1.

The SX stress component, which corresponds to the direction normal to

the two faces in contact, is the radial direction and, hence, SX is the
contact stress.

18 Plot contact pressure.

Right-click the Results folder and select Define Stress Plot.

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Lesson 4
Symmetrical and Free Self-Equilibrated Assemblies

Under Component, select CP: Contact Pressure.

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Click OK.

19 Probe stress results.

To probe the stress plot for detailed stress results, right-click the plot
icon and select Probe. An undeformed plot is required if we want to
probe for detailed stress results.
Stresses on both surfaces are, of course, equal. The negative sign
denotes stress towards the surface.

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Lesson 4

SolidWorks 2012

Symmetrical and Free Self-Equilibrated Assemblies

Each plot created in a study can be saved individually in any of several

formats available. To view the list of available formats, right-click any
plot icon, select Save as to open the Save as window, and examine the
options in the Save as type menu.

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Saving All Plots

Most likely you will find the eDrawings

format the most useful when
communicating the SolidWorks Simulation
analysis results.

Rather than saving result plots

individually, it is also possible to save them
in one step either in JPEG or eDrawings
format. Right-click the study or the
Results folder to invoke the pop-up menu
and select either Save all plots as JPEG
files or Save all plots as eDrawings.

Using JPEG format, individual files will

be created for each plot that has been
defined in the study. Using eDrawings format, all plots will be stored
in one file. In both cases, files will be located in the SolidWorks
Simulation report folder. (The report folder can be selected in
Simulation, Options, Default Options (New study), under Results.)

Whats Wrong
Feature

Occasionally, when defining SolidWorks Simulation model or

analyzing results you may notice warning symbols
showing
in Simulation Study tree.
To find out what is wrong, right-click the item under a study (in
Simulation Study tree) accompanied by the warning sign and select
Whats wrong to open the Whats Wrong window. This window will
list a description of the problem for that item only.

You can also see a summary of all the problems in a study. Right-click
the Study and select Whats wrong to list all problems in the study.

Analysis with
Soft Springs

Earlier in this lesson, we explained that to prevent rigid body

movement along the axis of the assembly, at least one vertex on both
the rim and the hub must be restrained in the axial direction. Without
these restraints the assembly would have zero stiffness along the axial
direction.

There are two alternative methods to prevent rigid body movements in

the model without restraining the two vertices. These are to use soft
springs or inertial relief.

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Lesson 4
Symmetrical and Free Self-Equilibrated Assemblies

Theoretically, we do not expect the model to sway in the axial direction

due to the action of some external loading (none that would cause such
action exists in our model). All of the loads, which are applied in the
form of the shrink fit contact condition, are inherently balanced. Finite
element method, however, does not recognize this fact and a small
inaccuracy, a numerical error, or mesh asymmetry may cause the model
to displace uncontrollably in axial direction. All such cases can be
stabilized by the Soft Spring option.

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Soft Springs

When this option is activated, the model is surrounded by springs with

stiffness values that are negligible relative to the stiffness of the model
(see the following figure). The finite element model is then stabilized
and restrained against all rigid body motions.

This procedure works as long as the model is self-equilibrated, or the

net magnitude of the external load is so small that the soft springs are
able to compensate for it.

Inertial Relief

Another method to prevent rigid body movements is Inertial Relief.

Rather than adding artificial stiffness to counteract the load imbalance,
as is done using soft springs, this option adds an artificial balancing
load eliminating any load resultant along unrestrained directions.

This option should not be used with the intention to stabilize an

analysis where gravity, centrifugal or some thermal loads are defined.

In our case, both the Use soft springs to stabilize model and the Use
inertial relief solver options can be used.

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Symmetrical and Free Self-Equilibrated Assemblies

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20 Create new study.

Duplicate the existing study shrink fit into a new study called soft
springs.

21 Suppress axial restraint.

Under the soft springs study, right-click Fixture-2 and select
Suppress to release the axial constraint.
22 Select soft spring option to stabilize
model.
Right-click the soft springs study and
select Properties.

Under the Options tab, activate

the Use soft springs to
stabilize model option.

Select the Direct sparse solver.

Click OK.

23 Run the study.

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Lesson 4
Symmetrical and Free Self-Equilibrated Assemblies

24 Plot hoop stresses.

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Plot the distribution of hoop stresses.

Set the Units to N/m2.

Under Settings, select Discrete as the Fringe Option.

Set the maximum value of the stress legend to 620,400,000 Pa.

Comparing the results above with the corresponding plot in the

previous study, we see that they are indeed identical.

25 Save and Close the file.

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Lesson 4

SolidWorks 2012

Symmetrical and Free Self-Equilibrated Assemblies

In this lesson, we calculated the von Mises stress, hoop stress (using
cylindrical coordinates), and contact pressure. The stress magnitude
was above the yield strength of the material for the rim, therefore we
may want to select a different material so that yielding is avoided.

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Summary

Interference between assembly

components is allowed only if a
Shrink fit condition is present in the
assembly.
The results of a study with a Shrink
fit condition are best viewed using a
1:1 scale of deformation.
To see results on contacting faces,
use exploded view.

The results for axi-symmetric parts

are best viewed in cylindrical
coordinate systems.

This observation particularly applies to stress components other than

von Mises stress. Von Mises stress, as a scalar value, is insensitive to
the choice of reference coordinate system.

To prevent the rigid body motions the model must be stabilized in the
axial direction. The most straight forward method is to restrain one
vertex (point) on each model in the axial direction. Alternatively, we
used the Use soft springs to stabilize the model option which
surrounds the model with a layer of soft springs to provide a minimum
stiffness in unrestrained directions.

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SolidWorks 2012

Exercise 8
Chain Link

Exercise 8:
Chain Link

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In this exercise, we will analyze

a link in a chain that is under
load. With chains, the
relationship between load and
elongation is important.

We will analyze the link several

times. We will start with an entire
link and see what problems
develop. Based on the results, we
will explore different solutions to get more accurate result without the
need for long solution times.
This exercise reinforces the following skills:

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Project
Description

Symmetry on page 154.

Rigid Body Mode on page 157.
Soft Springs on page 165.

Our goal is to develop the force to elongation relationship for this

chain. We are not interested in the actual stress in the components as we
are not designing them.
All of the chain parts are made of AISI 304 steel.

Procedure

Follow the steps below:

Open an assembly file.

Open Roller Chain from the Lesson04\Exercises folder.

The Default configuration consists of the sprocket, pivot and several

links.

Change configuration.

Make the configuration Link-full

active. This configuration shows a
single link which is really an inner
link and two halves of the outer link.

Create a study.

Create a static study and name it

Link-full-soft springs.

Apply material.

Apply the material AISI 304 steel to all the parts in the assembly.

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Exercise 8

SolidWorks 2012

Chain Link

Determine contacts.

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There are two types of contacts in this link, No Penetration and

Bonded. All contacts between parts of the same link are Bonded. Parts
that are in contact between an inside and outside link are No
Penetration.
Link Plate
Roller
Bushing

Link Plate
Pin

Inside Link

Outside Link

Because of the number of contacts, we will start with a Global Bonded

contact and then add the No Penetration contacts.

Explode the assembly.

Exploding the assembly will make it easier to see the contact sets.

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SolidWorks 2012

Exercise 8
Chain Link

Add contacts.
Right-click Connections in the Simulation
Study tree and select Contact Set.

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In the Contact dialog select Automatically

find contact sets.
Under Options select Touching faces.

For Components, select the assembly, then

click Find faces.
Twenty four contact sets will be found.

In Results, select all 24 contact sets. Select

No Penetration and click the Create
contact sets button.
Make sure all 24 contact sets are selected
and added.
Click OK.

Delete contacts.

We must now remove the No Penetration contact sets for contacts that
are supposed to be bonded.

Select each contact set in turn and determine if it should be Bonded

(contact between parts in the same link assembly) or No Penetration
(between parts in different link assemblies or any contact with a
Bushing). Delete the No Penetration contact for contacts that should
be bonded.

When done, there will be 16 contact sets that are No Penetration. The
eight contact sets that you delete will be Bonded by the Global
Contact condition.

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Exercise 8

SolidWorks 2012

Chain Link

In image 1, the contact is between the Pin and Link Plate of the same
Inside Link assembly. The No Penetration contact must be deleted as
these two parts are Bonded.

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Example

In image 2, the contact is between the Pin on an Inside Link and the
Bushing from an Outside Link, so this contact does not get deleted as
it should be No Penetration.
1

Collapse the assembly.

10 Apply a force.

Because we are interested in the

force to elongation of the chain
and we are doing a linear analysis,
the actual force we apply is not
important. We could apply the
maximum force for the system,
but it is not necessary.

Subject the link to the total axial force of 400 N (apply 200 N to all four
faces indicated in the figure).

11 Boundary conditions.

This is a self equilibrated problem so theoretically no fixtures are

required. We must however prevent the rigid body movement by
adding soft springs, thus stabilizing the model.
Right-click the study and click Properties.

Select Use soft spring to stabilize model and Direct sparse for the
solver.

Note

172

Since multiple contatcs are defined in the study and the area of contact
is found through several contact iterations, the Direct Sparse solver is
preferred.

SolidWorks 2012

Exercise 8
Chain Link

12 Mesh.

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Select Curvature based mesh

under Mesh Parameters.

Mesh the model using high

quality elements and the default
mesh size.

13 Mesh size.

Examine the mesh details. There

are about 19,400 nodes which is
over 58,200 degrees of freedom.

14 Run the study.

15 Plot the displacements.

Make sure that the plot uses Automatic for the Deformed Shape.

The assembly translates in the x-direction. The animation will reveal

the effect of the soft springs on the unconstrained self-equilibrated
model.

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Chain Link

16 Animate the displacement.

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The model translates.

This translation is caused by several factors:

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The mesh is not completely symmetric.

The model is not fixed in space.

These are rigid body translations and are very small. While they do not
have any impact on the stress results, they significantly effect the
displacements.

17 Plot the stress.

The stress plot should be symmetrical. If it is not, the reason is that the
mesh is too coarse. Stress magnitudes may vary due to mesh size and
stress concentrations.

Lets solve the problem again, but this time we will use symmetry to
keep the model constrained axially.

Second Approach

174

Duplicate the study.

Name the new study Link-full- soft springs and restraint.

SolidWorks 2012

Exercise 8
Chain Link

Edit the force.

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Edit the force so that it is only

applied to one set of faces (400 N
total force pulling the link in a
single direction).

Apply a fixture.
Apply a Roller/Slider fixture to the

two faces where the forces were

removed.

This fixture now restraints any

movement of the faces in the X
direction. They can still move in
the plane of symmetry (Y and Z
directions).

Mesh.

Use the same mesh as in the previous problem which is a high quality
mesh at the default element size.

5
6

Run the study.

Plot the displacement.

We have eliminated translation in the x-direction, however we now are

left with rotation about the x-axis.

Because the model translated vertically, we need to verify the true

extension of the chain link with the plot of the axial displacement.

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Exercise 8

SolidWorks 2012

Chain Link

Magnify the displacements, Animate.

Set the Deformed Shape for the above displacement plot to
Automatic.

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Additional rigid body translations could occur in the vertical direction

where the model is stabilized with the help of the soft springs. Animate
the solution to see whether this phenomenon occurred in your solution.

Note

Axial displacement.

Additional rigid body rotation may have occurred at the unconstrained

edge. The effect of the rigid body rotation can be easily seen in the plot
of axial displacements (UX). Probe on two points on the unconstrained
edge. Notice that there are two different displacement values. Without
any rotation, we would have the same value for displacement. This
result violates our symmetry assumption.

In conclusion, the correct chain link extension cannot be determined by

this analysis as well.

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Exercise 8
Chain Link

To see how a correct axial extension of the chain link is determined,

complete this exercise.

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Note
9

Plot the stress.

Create a plot of von Mises stress.

While displacements from the previous two approaches were affected

by the rigid body displacements and remain undetermined, stress
solution is not affected by this phenomenon (verify that the stress
solution in both solutions is the same). Stress accuracy, however,
depends on highly the mesh quality and can be much improved.

The mesh used in the previous two solutions was rather coarse to
determine accurate stress distribution. To improve the stress results, we
need to create a finer mesh.

Stresses Accuracy

Duplicate the study.

Name the new study Link-full- fine.

Refine the mesh.

Re-mesh the model with high quality elements and the slider set to
Fine.

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Exercise 8

SolidWorks 2012

Chain Link

Examine the mesh.

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The new mesh is now fine enough to get reasonably accurate stress
results, but the number of nodes and degrees of freedom are high. With
over 119,000 nodes, we will have to solve over 359,000 degrees of
freedom. This will result in a much longer solution time.

Do not solve.

While we could run this study, the solution time is too long. Instead we
will examine a different approach to get the small mesh size and
accurate results.

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SolidWorks 2012

Exercise 8
Chain Link

By taking advantage of the symmetry, we do not have to analyze the

entire model, but instead only the smallest symmetrical element of the
model. We must however remember that it is not just the geometry that
must be symmetrical, but also the loads.

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Using Symmetry

If we look for symmetry, we can see that there are three planes of
symmetry in this model.

If we cut the model through all three planes of symmetry, we get the
following result which is one-eighth of the original model.

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Exercise 8

SolidWorks 2012

Chain Link

Change configuration.
Make the configuration Link-symmetry active.

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This configuration has three assembly cuts to reduce the model to oneeighth of its original size.

Create a new study.

Name the new study Link-symmetry.

Apply material.

Copy the material from the previous study.

Define contacts.

Using the same procedure as in step 7 and step 8 on page 171, create
the contacts sets.
You should have five No Penetration contact sets.

Add symmetry fixture.

Right-click Fixtures in the

Simulation Study tree and

select Advanced Fixtures.
Select Symmetry.

Select all the symmetrical

faces (there are 13 faces).

With symmetrical fixtures on

three orthogonal faces, the
model is now fixed in space
so the soft spring stabilization is no longer required.

In the axial direction (X-direction), the symmetry fixture is applied on

the face in the negative X-direction only. The face on the opposite side
is used to apply the force in the next step.

Note

Apply force.

Apply a force of 100 N to the

face indicated.

Question

180

Why do we apply 100 N? We have one-eigth of the model, why not

400/8=50 N?

SolidWorks 2012

Exercise 8
Chain Link

Mesh.

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Select Curvature based mesh under Mesh Parameters.

Mesh the model using high quality elements and the default settings.

Examine the mesh.

We now have a mesh with elements smaller than in the fine mesh we
tried to use earlier, but the total number of nodes is now only 16,783 or
about 50,349 degrees of freedom. This is much less than the 359,000
degrees of freedom we had earlier.

Run the study.

10 Plot the displacement.

The maximum displacement is now 0.00246 mm.

Note that to obtain the chain axial extension, this displacement value
would have to be multiplied by a factor of two (0.00246 x 2 = 4.9e-3
mm). While this result may, under some circumstances, be close to the
real chain extension, it will be soon shown that it is still incorrect.

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SolidWorks 2012

Chain Link

11 Plot the stress.

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We can see a stress concentration where the Pin, Bushing and Link
Plate join. To get a better look at this area we need to explode the
assembly.

12 Explode the assembly.

If we show the mesh, we can see

that the mesh is very coarse in the
area of the highest stresses and
that we have a stress singularity.

Any mesh refinement would

improve the stress distribution but
would not eliminate the stress
singularity.
In a real part, there would be a
fillet and some yielding which
would redistribute the stress into
the neighboring regions of the
elastic material. The
displacement solution would also
improve only marginally.

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Exercise 8
Chain Link

13 Post processing evaluation.

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Examine the displacement plot. We analyzed this assembly using

symmetry and have obtained results.

Look at the displacement plot in the Top view. Make sure the setting is
Automatic so that we see an exaggerated view of the displacement.

Important!

What is wrong with this analysis? There is something that is

fundamentally wrong with this analysis, when you think you
understand the reason that this analysis is wrong, discuss it with your
instructor.

14 Save and Close the file.

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Exercise 9

SolidWorks 2012

Chain Link 2

Exercise 9:
Chain Link 2

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In the previous exercise, we ran an analysis that initially appeared to

give us a correct answer, but in fact had a problem because the
symmetry conditions were violated.

When we look closely at the displacement plot, faces 1 and 2 are

perpendicular because of the symmetry fixture. Face 3 is were we
applied the force and while it is required to be parallel to the face 1, it is
not.
1

In this exercise, we will solve the same problem using a different

technique that will give us the correct result. Rather than applying a
force, which allows the face to tilt, we will apply displacement to the
face and then determine the force from the solution.

Open an assembly file.

Open the Roller chain assembly from the last exercise.

Duplicate the study.

Duplicate the study named Link-symmetry and name it Linksymmetry displacement.

Remove the force.

Suppress the 100 N force.

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SolidWorks 2012

Exercise 9
Chain Link 2

Add a displacement.
Right-click Fixtures in the Simulation Study tree and click Advanced
Fixtures.

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Select On Flat Faces.

Select the same face that used to have the force applied.

Enter a distance of 2.45e-3 mm for the displacement in the Normal to

Face direction.

The face will now stay parallel with its original orientation; the
symmetry of the model will therefore be satisfied.

The displacement of 2.45e-3 mm, an incorrect solution from the

previous exercise, is chosen because it is relatively close to the correct
solution. A principle of linear dependence will be used to scale the
displacement to its correct value.

Note

Run the study.

Run the study using the same refined mesh as in the previous exercise.

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Exercise 9

SolidWorks 2012

Chain Link 2

Display the displacement plot.

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If we examine the plot closely, we can see that all the correct faces are
now orthogonal.
1

Extract the force.

Right-click the Results folder and click List Result Force.

The force in the X direction is 119.24 N which is close to the loading

force used in the last part of the previous exercise (100 N).

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SolidWorks 2012

Exercise 9
Chain Link 2

Having used the symmetry, the results now need to be converted for the
full link chain model. To obtain the axial force corresponding to the full
link, the above resultant force must be multiplied by a factor of four,
i.e. 4 x 119.24 N = 476.96 N. To obtain the axial extension for the full
link, the above prescribed displacement must be multiplied by a factor
of two, i.e. 2 x 2.45e-3 mm = 4.9e-3 mm.

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Results for full link

chain

We now have the two points (these results [4.9e-3 mm, 476.96 N]
along with 0 mm, 0 N) with which we can establish the force to
elongation plot.

To conclude this exercise, it remains to answer what is the correct

extension of the full chain link when subjected to a load of 400 N.
Using the principle of linear dependence the answer is:

What is the
extension for 400 N
force?

u(F=400 N)= 4.9e-3 x 400/476.96 = 4.109e-3 mm.

A point with coordinates of [4.109e-3 mm, 400 N] also lies on the same
force to elongation plot.
Force displacement graphs are common characteristics of the chains.
The graphs always begin at a point [0 mm, 0 N] and feature a constant
slope until a point where the material exhibits significant yielding and
the force displacement relationship is no longer constant. The ultimate
strength of the chain is then defined at a force causing the chain to
break.

Note

Save and Close the file.

187

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Exercise 9

Chain Link 2

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Lesson 5
Assembly Analysis
with Connectors

Objectives

Upon successful completion of this lesson, you will be able to:

I

Use spring connectors.

Use pin connectors.

Use spot weld connectors.

Apply restraints in a local coordinate system.

Analyze results in a local coordinate system.

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Lesson 5

SolidWorks 2012

Assembly Analysis with Connectors

Mate definitions in the SolidWorks assembly do not translate into

contact definitions in SolidWorks Simulation. Therefore, from the point
of view of SolidWorks Simulation, the components of the assemblies
are un-attached until we define the proper contact conditions or
connectors describing interactions between the assembly components.

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Connecting
Components

We use mathematical connectors instead of actual models of the

connectors to speed the analysis process as the mesh and contacts are
reduced and solution can be found more quickly.

The main purpose of this lesson is to examine various other connectors

available in SolidWorks Simulation.

Connectors

When analyzing assemblies with connectors, we frequently do not need

to analyze the connectors itself, only the parts around the connectors.
Replacing the connector model with SolidWorks Simulation connector
speeds the analysis process as there is nothing to mesh and solve.
SolidWorks Simulation provides the following types of connectors:
I
I
I
I

Connector Types

Rigid
Spring
Pin
Elastic support

I
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Bolt
Link
Spot Welds
Bearing

The following table lists the available connector options:

Connector Type

Definition

Rigid

Defines a rigid link between the selected faces. The connected faces do
not deform.

Spring

Connects avertex or a face on a component (or solid body) to a face or a

vertex on another component (or solid body) by distributed springs with
the specified normal and shear stiffness. The stiffness values may be
entered as distributed or total values.
The two faces must be either planar and parallel to each other, or
cylindrical and coaxial.
You can specify a pre-load for the spring connector.
The following types are available:
Compression Extension
Compression only
Extension only

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Lesson 5
Assembly Analysis with Connectors

Definition

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Connector Type
Pin

Connects cylindrical faces of two components. The following two

options are available in the pin definition:
1. With retainer ring (No Translation). Specifies a pin that prevents
relative axial translation between the two cylindrical faces.
2. With key (No Rotation). Specifies a pin that prevents relative
rotation between the two cylindrical faces.
The stiffness values corresponding to the axial and rotational
directions may be specified as well. The pin material and strength
data can be specified to perform a pass/no pass pin check.

Elastic support

Defines an elastic foundation between the selected faces of a part or

assembly and the ground. The faces do not have to be planar.
A distributed stiffness at a point on the face represents the stiffness
density associated with an infinitely small area around the point.

The tangential and normal stiffness components are assumed constant

and directed in the directions tangential and normal to the face at every
point. This connector can be found in the fixture menu.

Bolt

Defines a bolt connector between two components, multiple components

or between a component and the ground.
Bolts both with and without nuts are supported. Material specifications
directly from the material libraries and various preload options are
available.
To see the definitions of the bolt connectors see Lesson 7 and Exercise
14: Bolt Connectors on page 271

Spot weld

Defines a connector simulating spot weld between two solid faces or two
shell faces.

Edge weld

Defines a connector simulating edge weld bead between two shell

features, or one shell and one solid feature.

Fillet and Groove welds, both single and double sided are available.

Link

Ties any two locations on the model by a rigid bar that is hinged at both
ends.
The distance between the two locations remains unchanged during
deformation.
Link does not restrict rotations at both ends.

Bearing

Simulates the interaction between a shaft and a support through a

bearing.

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Lesson 5

SolidWorks 2012

Assembly Analysis with Connectors

The vise grip pliers require the

use of several connectors and
various contact sets to be
analyzed.

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Case Study:
Vise Grip Pliers

Pins and springs will be used

to simulate the physical parts
and contact sets will be
defined between the various
parts.

Project
Description

The vise grip pliers are

clamping a piece of bar
stock. The pliers are set so
that they are not in the
locked position. A 225 N
force is applied to the
handles.
All components are made
of Cast Carbon Steel.

Determine the maximum

stress in the assembly and
if any of the parts exceeds
the yield strength.

Stages in the
Process

The following are the major steps in this analysis:

I

Create an analysis configuration.

Not all the parts need to be analyzed. Suppress the parts and detail
that are not necessary.

Apply materials.

Either apply the materials in SolidWorks or through SolidWorks

Simulation.

Apply fixtures.

The model must be restrained to represent the way it is held in the

physical world.

Determine contact conditions.

Using interference detection, we can determine contact points

between the parts. Contact sets are then created to represent these in
the analysis problem.

Apply connectors.

The actual connectors are not part of the analysis so they will be
represented by pin connectors.

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Lesson 5
Assembly Analysis with Connectors
I

Apply external forces.

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Apply the loads that represent a hand squeezing the vise grip pliers.
I

Mesh.

There are multiple parts and each must mesh with the correct
contact conditions to satisfy the contact with adjacent parts.

Run the analysis.

Run the analysis and analyze the results to determine further action.

Procedure

Follow the steps below to analyze the vise grip pliers:

Open an assembly file.

Open wrench from the Lesson05\Case Studies folder.

Change configuration.
Make the For analysis configuration active. In this configuration, the
release lever and pincap parts have been suppressed. A simplified
configuration of the screw is also used which removes the small

chamfers and holes as they do not affect the study.

Set the simulation options.

Click Options from the Simulation menu. Select the Default Options
tab.
Select Units, then select SI (MKS) for the Unit system. Select mm for
Length/Displacement and N/m^2 (Pascals) for Pressure/Stress.
Select Color Chart. For Number format, select Scientific (e) and 2
decimal places.

Create a study.

Create a static study named vise grip analysis.

Apply material.

Apply the material Cast Carbon Steel from the SolidWorks

Materials database to all the parts.

Simulate bar stock.

We are not interested in the stress in the piece

of bar stock, so it has been suppressed. To
simulate it, add Fixed Geometry fixtures to the
two flat faces of the jaw.

Check interference.

To determine where the different components

are in contact, we can use the SolidWorks
interference detection. Click Tools,
Interference Detection in the menu.

Select the assembly file and Treat coincidence as interference.

Three contacts are detected.

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Assembly Analysis with Connectors

Evaluate the contacts.

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Examine the model to determine the effects of each contact.

I

Interference1 is a line contact between the screw and the end of

the center link. We will add a contact set for bonded contact

between these two components because as long as the force is

applied, these two components remain in contact.
Interference2 is between the screw and the barrel of Arm1 where
the threads engage. This contact will be handled with a help of the
top level assembly component contact (Global Contact).
Interference3 is between two different components of Arm1 that
do not move relative to one another. This contact will also be
handled with a help of the top level assembly component contact
(Global Contact).

Interference1

Interference3

Interference2

Close Interference Detection.

194

Set the top level assembly contact.

Confirm that the top level assembly contact (Global Contact) under
the Component Contacts folder is set to Bonded.

SolidWorks 2012

Lesson 5
Assembly Analysis with Connectors

10 Explode.

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Explode the assembly to make it easier to select the faces and edges.
11 Add Contact.
Add a Bonded contact set between the edge of the center link and the
end face of the screw.

Bonded

Introducing: Pin
Connectors

Pin connectors ensure that two cylindrical faces remain coaxial during
the deformation process. The two faces are not allowed to deform and
will remain cylindrical during deformation.
The following options are available with pin connectors:
I

With retainer ring (No translation): If checked, the two

cylindrical faces will not be allowed to translate axially relative to

each other.

With key (No rotation): If checked, this option eliminates axial

rotation of the two cylindrical faces relative to each other.

Include mass: The mass of the pin can be included in frequency

analysis or if acceleration loads are applied in static stress analysis.

Axial and Rotational stiffness: If any of the two relative

displacements are unrestricted (axial translation or rotation), linear

stiffness values in those two particular directions can be specified.

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Assembly Analysis with Connectors

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If the geometrical and material parameters of the pin are known, it can
be conveniently tested at the end of the analysis. The following
parameters are needed:
I

Tensile stress area: cross chord area of the pin.

Pin strength: Design strength for the material of the pin (typically

the yield strength).

Safety Factor: Pin Design Safety Factor.

Alternatively, pin strength can be populated automatically by

specifying the material in the material dialog window.

Note

Depending on the type of connector used, certain contact conditions

have to be defined between connected components (such as
No penetration contact between two bolted parts).
We will need three pins to connect the components.
Pin 2

Pin 1

Pin 3

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Lesson 5
Assembly Analysis with Connectors

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12 Add pins.

In the Simulation Study tree, right-click Connections and select Pin.

Select the inside face of the hole in the CenterLink part and the face of
the shaft in the secondGrip part.
Select With retaining ring and clear With key.

Check the box for Strength Data, input 1.2 mm^2 for Tensile Stress
Area, 3.516e8 N/m^2 for the Pin Strength and 2 for the Safety
Factor.
Click Select material and select AISI 1020 steel.
Clicks OK.

13 Add additional pins.

Repeat the above procedure to add the two additional pins with the
same properties.

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Lesson 5

SolidWorks 2012

Assembly Analysis with Connectors

Spring connectors are used to replace tension,

compression or tension and compression
springs.

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Introducing: Spring
Connector

Spring Connector
Types

Under Type, we can specify whether the spring is active

in both compression and tension, compression only, or
tension only.
The options Flat parallel faces, Concentric
cylindrical faces, and Two locations specify the
characteristics of the spring end entities.

Spring Connector
Options

Under Options we can specify the Normal and

Tangential spring stiffness values. Both quantities
can be expressed as Total (N/m or lb/in), or
Distributed in the units of (N/m)/m2 or (lb/in)/
in2, for example.
Both the Compression preload and Tension
preload can be input.

Where to Find It

I
I
I

Use in Instructions

198

Menu: Simulation, Loads/Fixtures, Connectors

Shortcut Menu: Right-click Connections, Springs
CommandManager: Simulation > Connections Advisor > Spring

Select Springs from the Type list in the PropertyManager.

SolidWorks 2012

Lesson 5
Assembly Analysis with Connectors

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14 Add a spring connector.

While we do not have a spring modeled into the

assembly, we will add a connector spring to apply
the appropriate force.
Right-click Connections and select Spring.

Select Two locations. We have split faces on the

appropriate features of each part to create vertices
on which to connect the spring.
Type 250 N/m for the Axial Stiffness. Select
Tension preload force and type 5 N.

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Assembly Analysis with Connectors

15 Apply external loads.

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We will have to add two opposing forces, one to the Arm1 and the
other to Arm2. As modeled, each of these components has an
appropriate face on which to apply the loads.

Apply a 225 N force, normal to the Top plane to each of the surfaces
shown.

Note

Make sure that the force applied to the top handle is 225N as a Total
force.

16 Mesh.

Select Curvature based mesh under Mesh Parameters.

Mesh the model using High quality elements and the default settings.

17 Run.

Run the study.

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Lesson 5
Assembly Analysis with Connectors

18 Plot the stress.

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We observe stresses well above the yield strength. To locate the high
stress regions more in depth stress post processing analysis is required.

19 Chart Options.

We would like to see if any components yield. We can change the chart
options to make the top of the scale equal to the yield stress of the Cast
Carbon Steel material. Anything that yields will then be shown in red.
Right-click the plot Stress1 and click Chart Option.

Select Defined and type the yield stress for Cast Carbon Steel
(248,168,000 Pa) as the maximum limit of the legend.

20 Examine the plot.

There are several areas with stresses above yield. Some of these are
sharp corners/singularities. We will focus on the area where yielding
might occur at the line contact on the center link.

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Assembly Analysis with Connectors

21 Isolate the part.

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To get a better look at this one part, we will isolate it. Hide the stress
plot. Right-click on the center link part and select Isolate.
Create a new stress plot to visualize the stresses in the center link.

We can see that the problem is the area where we have defined line
contact between the center link and the screw. This concentration
(stress singularity), i.e. unreal distribution of stresses, was subject of
Lesson 2. While it is not possible to eliminate it with the current
geometry, we could minimize its impact on the rest of the stress
distribution by refining the mesh.

22 Show all parts.

Click Exit Isolate to show all the parts.

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Lesson 5
Assembly Analysis with Connectors

The pins and bolts can be quickly designed, knowing the basic loads:
shear and axial forces, bending moment, and torque. The figure below
shows the directions of these loads.

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Pin/Bolt Force

Shear force

Bending moment

Torque

Axial force

Note

The x, y, and z components are reported in the global coordinate

system. The sign of the axial force indicates tensile or compressive
force.

List Pin/Bolt/Bearing
Force

The pin, bolt and bearing forces are calculated and displayed in tabular
form.
The dialog lets you save data as a *.csv or *.txt file, which can be
opened and edited in Excel or Notepad. Exported information can be
used very effectively for the pin/bolt design. Provided the strength data
was entered for each pin, the software will analyze each pin
automatically.

Where to Find It

I
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Menu: Simulation, Result Tools, Pin/Bolt Force

Shortcut Menu: Right-click the Results folder and click List Pin/
Bolt/Bearing Force

CommandManager: Simulation > Results Advisor > List Pin/

Bolt/Bearing Force

203

Lesson 5

SolidWorks 2012

Assembly Analysis with Connectors

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23 Extract the pin force.

Now that we have simplified the

analysis by suppressing the pins, we
have to extract the pin forces.

Right-click on the Results folder

and select List Pin/Bolt/Bearing
Force.

The Pin/Bolt Force dialog lists all important force loads on pin
connectors.

We can examine the forces on each pin or the maximum values and
which connector they are on. The red background indicates that the pin
is failing with the safety factor of 2.

24 Save and Close the file.

204

SolidWorks 2012

Lesson 5
Assembly Analysis with Connectors

The focus of this lesson was to provide a summary of the available

connector types and demonstrate the use of some of them.

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Summary

In the vise grip model we analyzed an assembly and used spring and
pin connectors to simplify the model by eliminating the spring and pin.
Of course, this approach is acceptable only if the spring and pins
themselves are of no interest in the analysis.

We saw that due to the geometry of the center link, a stress

concentration caused unrealistic stress results along the sharp edge. To
better investigate this region, we would want to refine the mesh
significantly. We could then attempt to compare the stress results to the
yield strenght of the material.

We also successfully evaluated the pin connectors and showed that the
pins were failing with respect to our input factor of safety. To remedy
this, we would need to either select a new pin material or make the pins
larger.
Practice problems using additional types of connectors are found in the
exercises following this lesson.

205

Lesson 5

SolidWorks 2012

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Assembly Analysis with Connectors

206

SolidWorks 2012

Exercise 10
Lift Assembly

Exercise 10:
Lift Assembly

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Analyze a lift assembly, in which a weight is supported by four arms.

This exercise will introduce another fixture called a hinge.
This exercise reinforces the following skills:
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Problem
Statement

Component Contact on page 132.

Local Contact on page 140.
Rotational and Axial Stiffness on page 256.

A scissor lift used to lift a 1,800 N.

weight is operated by an external
hydraulic cylinder connected to a
slider traveling on a base.

1800
N

The load is assumed to be evenly

distributed between the two rollers
which, in turn, evenly split the load
between the arms. This way each
arm is loaded with a 450 N. force.

Find the displacements and stresses in the lift components at the

collapsed position of the lift arms. We are not interested in contact
stresses in the pin joints, nor the stresses in the base.

Open an assembly file.

Open lift from Lesson05\Exercises folder.

Familiarize yourself with the collapsed and extended configurations

of this assembly. The goal of this analysis is to analyze the assembly in
the collapsed configuration.

Activate the configuration collapsed.

The weight, hydraulic cylinder, connecting pins, and many other details
are not modeled, and the SolidWorks assembly lift depicts the scissor
lift in a somewhat idealized way.

Base

Slider

Set SolidWorks Simulation options.

Set the global system of units to SI (MKS) and the units of Length and
Stress to mm and Pa (N/m^2), respectively.

207

Exercise 10

SolidWorks 2012

Lift Assembly

Create study.
Create a Static study named collapsed-without base.

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4
5

Assign material properties.

Specify Plain Carbon Steel for all of the components.

Check for assembly interferences.

There are only two parts in the assembly with touching faces.

Since we are not interested in the deformations and stresses in the base,
we will suppress this part to simplify our mesh. At the same time,
however, we must correctly represent the contact condition with the
corresponding friction forces. This can be achieved by using a Virtual
wall contact condition type, introduced in Lesson 7.

Note

Exclude the base part from the analysis.

Update all components.

Because the base part was suppressed

after the study collapsed-without base
was defined, we have to update the study
components.

Right-click on the study collapsed-without base and select Update

All Components.

Note

208

Alternatively, you can use Exclude from Analysis command which

does not require suppression of the part in SolidWorks.

SolidWorks 2012

Exercise 10
Lift Assembly

Define Virtual wall.

Specify the bottom face on the slider as a Set 1 and the base plane as
a Set 2.

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Specify the Friction Coefficient of 0.1. Under Wall Type, select

Flexible.

Specify the values of 1.6537E+013 (N/m)/m2 [60.92e6 lb/in/in2] and

6.2216E+012 (N/m)/m2 [22.92e6 lb/in/in] as Axial stiffness and
Tangential stiffness, respectively.
Click OK to save the virtual wall settings.

209

Exercise 10

SolidWorks 2012

Lift Assembly

The connection between the lift arms and the base has to be simulated
as hinges.

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Hinge Restraint

The Hinge type of restraint suppresses radial and axial translations,

which are defined in the local cylindrical coordinate system associated
with the cylindrical surface.

Exactly the same restraint can be defined using the On Cylindrical

Face type of restraint where we restrain the radial and axial
displacement components.

10 Define hinge restraint.

Right-click the Fixtures folder
and then select Fixed Hinge.

Select the two cylindrical faces

initially connected to the base.
Click OK.

Note

Using the Fixed Hinge restraint, we assume that the base is rather stiff
and does not deform. If the elastic behavior of the base must be
accounted for, it would have to be included in the analysis.

11 Define Pin connectors.

Define two rigid Pin connectors between the four arms, and two rigid
Pin connectors between the arm and slider.

For all the pins, allow the relative rotation and restrain the relative
translation between the connected components.

210

SolidWorks 2012

Exercise 10
Lift Assembly

12 Define restraint on slider cylindrical face.

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To model the support offered by the hydraulic cylinder restrain the

cylindrical face on the slider in the global x- direction (in the direction
of the piston).

Hint

Utilize Use reference geometry restraint type to define this boundary

or condition.

Note

By applying restraints to the entire cylindrical face we ignore the

realistic distribution of stresses between the cylinder pin and the lug.
This modeling simplification is acceptable because we do not intend to
investigate the contact stresses in the lug.
The model is now fully constrained even though the assembly
components are not touching each other.

211

Exercise 10

SolidWorks 2012

Lift Assembly

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13 Apply 450 N force on link components.

Apply a downward force of 450 N to each of the four cylindrical
openings at the free ends of the four link components. The total weight

distributed equally between all four locations is thus 1,800 N.

Bearing Load

Applying the load to the entire cylindrical hole is an acceptable

simplification because we do not intend to analyze contact stresses
developing between the arms and roller pins.

Note that there is a more accurate way to apply load to a cylindrical

hole that still does not require contact stress analysis. It is called a
Bearing Load.
A load defined as a bearing load is applied to a portion of the
cylindrical face (this requires splitting the face), and its variation is
described by a cosine function to simulate the contact pressure
distribution.

14 Create mesh.

Mesh the model with

High quality elements
and the default settings.

15 Run the analysis.

212

SolidWorks 2012

Exercise 10
Lift Assembly

16 Plot von Mises stress and resultant displacement.

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We observe that the model is not yielding and the resultant

displacements are rather small (the deformed shape is shown in the
magnified scale).

213

Exercise 10

SolidWorks 2012

Lift Assembly

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17 List slider lug hole

reaction force.

The reaction force in

the x-direction, which
is the direction of the
hydraulic cylinder, is
approximately
6,350 N.

18 List contact and friction

forces.

List contact and friction

forces on the bottom face
of the slider.

The Normal force (ycomponent) is equal to

900 N, which amounts to
half of the total load (the
second half is carried by
the two hinge restraints).

The Friction force (xcomponent) is equal to 45

N.

Is the friction force

correct?

214

Can you verify whether the result for the friction force, 45 N, is
correct? Why?

SolidWorks 2012

Exercise 10
Lift Assembly

19 Analyze deformation of slider.

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Define a new displacement plot of the slider in highly magnified scale.

(You may hide all of the remaining components in SolidWorks to view
the deformed shape more clearly).
In the Deformed Shape dialog, un check the Show colors option.

We can see that the

middle part of the slider
detaches from the base;
the contact is provided
only by very small areas
on both sides.
Also note that, to
accurately model the
contact stresses, a highly
refined mesh would be
required.

20 Save and Close the file.

215

Exercise 11

SolidWorks 2012

Analysis with Base (optional)

The results from the previous study can be verified by running the same
analysis with the base included in the finite element model.

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Exercise 11:
Analysis with
Base (optional)

Run the simulation again with the base included in the model and
compare the solutions to verify that the virtual wall contact condition
accurately models the real situation.
This exercise reinforces the following skills:
I
I

216

Connectors on page 190.

Pin Connectors on page 195.

SolidWorks 2012

Exercise 12
Shock Absorber

Exercise 12:
Shock Absorber

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In this exercise, we will analyze a

shock absorber. Results from
Exercise 2: Compressive Spring
Stiffness on page 81will be used in
the application of a spring
connection.
This exercise reinforces the
following skills:
I

Problem
Statement

Spring Connector on page 198.

The miniature shock absorber consists of a tube, a plunger, clamp, and

a helical spring. We will investigate the stresses that develop in the
plunger collar when the assembly is compressed with a 3 N force. We
have already calculated the stiffness of the spring to be 255.7 N/m in
Exercise 2: Compressive Spring Stiffness on page 81. This result will be
used to set up a spring connector in this exercise.
Stresses in the helical spring are not of interest, therefore we will
remove the spring from the model and replace it with an equivalent
spring connector.

Determine the maximum stress on the shock absorber components and

the displacement under a 3 N load.

Procedure

Follow the steps below:

Open an assembly file.

Open shock from the Lesson05\Exercises folder.

Suppress the helical spring (part file Front Spring).

Set SolidWorks Simulation options.

Set the global system of units to SI (MKS) and the units of Length and
Stress to mm and N/m^2, respectively.
Create study.

Create a static study named shock assembly.

Assign material.
Assign Alloy Steel to all the components.

217

Exercise 12

SolidWorks 2012

Shock Absorber

Apply fixtures.
Apply a Fixed Geometry fixture to the

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cylindrical face of the eye belonging to the

Shock Tube (item 1).

This fixture fully restrains the Shock Tube

component.

Restrain Shock Plunger.

Apply an Advanced Fixture in the radial and

circumferential directions to the cylindrical

face of the eye (item 2) belonging to the part
Shock Plunger.

Use On cylindrical face as the type of fixture.

With these three constraints, the assembly model is left with one degree
of rigid body motion. The Shock Plunger can slide in and out of the
tube because the Shock Plunger and Shock Tube are disconnected.
We connect these two parts with a spring connector.

Note

Define spring connector.

Right-click Connections and select Spring.

Under Type, select Compression Extension with Flat parallel faces.

As shown, specify the selected face on the Shock Tube as the Planar
Face of Component1 and the face on the Shock Plunger as the
Parallel Face of Component2.

Note

218

Which face is selected as 1 and 2 is not important.

SolidWorks 2012

Exercise 12
Shock Absorber

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Under Options, select Total stiffness and enter

255.7 N/m in the Normal direction. The Shock
Tube and Shock Plunger are now connected.
Click OK.

Apply force to shock plunger.

Apply a 3 N load to the split face on the

cylindrical face of the Shock Plunger ear in
the direction of the rod.
The load is applied normal to Plane1.

Apply mesh control.

Apply mesh control to the fillet face on

the Shock Plunger where a higher
stress concentration can be expected.
Specify a local Element size of 0.5
mm and the default Ratio of 1.5.

10 Mesh the model.

Select Standard mesh under Mesh Parameters.

Mesh the model with the default settings.

11 Run the analysis.

Run the analysis and note that the solver issues a warning about large
displacements.
Click No. The analysis will then complete.

219

Exercise 12

SolidWorks 2012

Shock Absorber

In this case, we ignore the warning because the large displacements

caused by the spring connector are translations only. The rotations of
the assembly components are restricted and the deformations are very
small.

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Large
Displacement
Warning

You may run the solution with and without the Large Displacement
Contact/Connector flag activated to verify that both runs produce the
same results.
Large displacement analysis is a subject of Lesson 14.

12 Plot von Mises stresses.

We note that the maximum

stresses of 2.44MPa are well
below the yield strength of the
Alloy Steel (620 MPa).

For more accurate stress results,

we could further refine the
mesh around the fillet, but that
is not the main purpose of this
project.

13 Plot displacements.

Plot the distribution of the UZ: Z

Displacement in the True Scale.

We observe the maximum

displacement of 11.7 mm, which is
in accordance with the linear
spring equation (uz = F/k = 3/255.7
= 0.0117 m = 11.7 mm).

14 Save and Close the file.

220

SolidWorks 2012

Exercise 13
Spot Welds-Solid Mesh

Exercise 13:
Spot WeldsSolid Mesh

Spot Welds

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A tube is fabricated out of two

sheets of galvanized steel that
are joined by spot welds on
each side.
We will use FEA to
investigate torsional stiffness
of the assembly by finding the
torque required to twist the
tube.

The twist angle of 1o that we

will use is arbitrary. We are
not attempting to duplicate
Spot Welds
any real life test conditions.
We intend to use the results of this numerical test to compare different
spot welds configurations. The two-piece design is the first
configuration we test.
This exercise reinforces the following skills:
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Project
Description

Spot weld on page 191.

Cylindrical Coordinate Systems on page 160.
Soft Springs on page 165

The tube is fabricated out of two sheets of galvanized steel 1 mm

[0.04 in] thick. The two pieces are joined by 10 spot welds on each
side. The spot welds are spaced 25.4 mm [1.0 in] apart and the diameter
of each spot weld is 3.175 mm [0.125 in].
Determine the torque required to twist the tube by 1o.

Open an assembly file.

Open tube solid located in the

Lesson05\Exercises folder.

Examine two configurations:

complete tube and half tube.
The assembly consists of two
identical parts, tube 30.
Examine part model tube 30
and note a split line added to
locate the positions of spot
welds.

Split Line

Assembly configuration.

Make the configuration complete tube active.

221

Exercise 13

SolidWorks 2012

Spot Welds-Solid Mesh

Set SolidWorks Simulation Options.

Set the system of Units to SI (MKS), the units of Length to mm, and
Stress to N/m^2.

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Create study.

Create a study named tube solid.

Review Material properties.

Verify that the material definition, Galvanized Steel, has been

transferred from SolidWorks to SolidWorks Simulation.

Treat tubes as solids.

Expand the Parts folder. Right-click the tube features and select Treat
as Solid.

Spot welds are defined by the two faces which are connected by the
weld. Additionally the weld location needs to be specified on either one
of these two faces.

Introducing: Spot
Welds

To specify the spot weld location you can use an assembly reference
point (not a part reference point) or a vertex.

Where to Find It

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Shortcut Menu: Right-click Connections folder and select Spot

Welds.
CommandManager: Simulation > Connections Advisor > Spot
Welds.

Define Spot Welds.

Right-click the Connections folder and select Spot Welds.

Select Spot Weld First Face, as shown in the figure.

Then select the connected face on the other part (see the figure) as the
spot weld second face. Then select Spot Weld Locations and select
the ten vertices shown.
In the Spot weld diameter, enter 3.175 mm [0.125 in].

This way, all spot weld locations on one side are defined in a single
restraint.

222

SolidWorks 2012

Exercise 13
Spot Welds-Solid Mesh

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Click OK.
Select 10
vertices

Repeat the process for the other

side.

Similarly, apply spot welds at all the

other 10 locations on the other side
of the tube.

223

Exercise 13

SolidWorks 2012

Spot Welds-Solid Mesh

Apply Torque

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We are going to apply torque to this assembly using two fixtures. On

one end the geometry will be prevented from moving in the axial and
circumferential directions. On the other end, we will apply a fixed
movement of 1 degree.

Apply fixtures.

Select the Use reference geometry fixture under advanced and select
the assembly axis as reference geometry. This way, the directions of
restraints are aligned with the cylindrical coordinate system defined by
this axis. The first component is radial translation, the second is
circumferential rotation (expressed in radians), and the third is axial
translation.
Select the two faces on one side of the tube and restrain the
Circumferential displacement component (enter 0 rad).
Click OK.

224

SolidWorks 2012

Exercise 13
Spot Welds-Solid Mesh

10 Prescribe rotation at the other end.

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Analogous to the previous condition, apply a 1deg (0.0174 rad)

Circumferential displacement to the two faces on the opposite end.

11 Use soft springs to stabilize the model.

The prescribed displacements defined on both ends of the tube do not

restrain the assembly in the axial direction. The model can move in the
axial direction as a rigid body without experiencing any deformation.
To stabilize the model, activate the Use soft spring to stabilize
model option.

Contact Between
Parts

Before meshing the model we have to make an important modeling

decision, that is, how do the two parts interact. We are going to assume
that the two halves of the tube interact with each other only through
spot welds rather than through the flange faces.

Assuming that there is no interaction other than specified through the

spot welds conveniently simplifies the model because we do not have
to solve contact conditions. However, it is a reasonable assumption
considering that thin spot welded sheets often come apart in-between
spot welds.
As a result of this decision, we model the contact condition between
touching faces of the two halves as Allow Penetration.

225

Exercise 13

SolidWorks 2012

Spot Welds-Solid Mesh

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12 Define Contact.

Define a new component contact of type Allow Penetration.

13 Apply mesh control.

To avoid excessive
element turn angle, apply
a mesh control with the
Element size of 3.0 mm
[0.118 in] and the Ratio
equal to 1.5, to all four
rounds and flanges.

Element Turn
Angle

Turn angle 45o means that one element face wraps over a 45o arc.
Generally an element turn angle of 45o or less is preferred.

The figures below show the mesh with and without the mesh control
definitions.

No Mesh Control
Element Turn Angle 90 deg

Spot Welds Stress

Concentrations

Mesh Control Applied

Element Turn Angle 30 deg

Note that the mesh has only one element across the wall thickness.
Generally two layers of second order elements are recommended. One
layer is acceptable for the analysis of deformations but may produce
high stress error in detailed stress results.

We accept one layer of elements because we intend to use this model

for the analysis of deformations, not stresses. Besides, models with
Spot welds connectors are not suitable for detailed stress analysis.
Spot welds connector models point to point connections, which
mathematically results in infinite stresses near the spot weld.

226

SolidWorks 2012

Exercise 13
Spot Welds-Solid Mesh

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Models with Spot welds are suitable for analysis of deformations and
global stresses, which is our intention in this model.
Also, the model geometry would be better meshed with shell elements
than with solid elements. We use solid elements to practice Spot welds
connectors with solid geometries. Later in the course we will solve the
same model using shells.

14 Mesh the model.

Select Curvature based mesh under Mesh Parameters.

Create a High quality mesh with the Mesh Density slider set to Fine.

15 Run the analysis.

16 Plot von Mises stresses.

Von Mises stress results indicate high stress near spot welds. As we
said before, any stress results near spot welds are unreliable.

227

Exercise 13

SolidWorks 2012

Spot Welds-Solid Mesh

To calculate the resulting torque, we first list the y-component of the

reaction force in the cylindrical coordinate system and multiply it by
the radius (see Exercise 3 for an additional example).

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Resulting Torque
Extraction

17 List reaction force in cylindrical system.

List the y-component of the reaction force in the cylindrical coordinate

system defined by Axis1 (see the following figure).
The circumferential component of the reaction force is 8314.8 N.
Calculate resulting torque.

The average radius is 0.1265 m [4.98 in]. Therefore the resulting torque
T is:
T = 8314.8 N x 0.1265 m = 1051.82 N-m

18 Save and Close the file.

Note

228

Exercise 18: Spot Welds - Shell mesh on page 319 shows how this
problem can be solved using shell elements, a distinct modeling
technique applicable to thin, sheet like structures.

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Lesson 6
Compatible/Incompatible
Meshes

Objectives

Upon successful completion of this lesson, you will be able to:

I

Understand mesh compatibility in solid element meshes with

various contact conditions.

Understand advanced incompatible mesh bonding (Mortar

bonding) algorithm.

229

Lesson 6

SolidWorks 2012

Compatible/Incompatible Meshes

Compatible /
Incompatible
Meshing

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In the following example, we will learn the difference between

compatible and incompatible meshing. A compatible mesh is one
where the nodes of meshes of adjacent parts or bodies are merged to
insure bonding. An incompatible mesh results if this condition cannot
be met.
We will use solid mesh part with unmerged bodies for this purpose.

Case Study:
Rotor

In this case study, we will analyze a simplified four bladed rotor part.
The blades and rotor disk are separate, unmerged, bodies. The rotor
disk is a thick part and the blades are relatively thin which presents a
problem in the way the mesh must be created in the area where the two
type bodies join.

Project
Description

The rotor will be subjected to a rotation of 1 rad/sec, causing stress in

the blades. Both the rotor disk and blades are made from Alloy Steel.

Determine the maximum stress and deflection in the four-bladed rotor.

Procedure

To begin this analysis:

Open a part file.

Open rotor2a from the Lesson06\Case Studies folder.

Define a new study.

Create a new static study named rotor2a-compatible.

Apply mesh control.

Apply mesh control with the Element size of 2.3 mm and the default
Ratio to all four blade bodies.

230

SolidWorks 2012

Lesson 6
Compatible/Incompatible Meshes

Compatible Mesh

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When a compatible mesh is created, the parts or bodies in the assembly

are meshed so that a smooth mesh transition between any two parts is
achieved. The nodes along the interface are then imprinted one upon
another. If bonded contact is requested, the nodes are then merged to
ensure the bonding. If compatible meshing fails at some interface, the
software will attempt to generate incompatible mesh for the two parts
involved.

Set global compatible bonding.

Edit the top assembly level component contact

(Global Contact).
Make sure that Bonded is selected under the
Contact Type dialog.

Under Options, select Compatible mesh.

Mesh part.

Select Curvature based mesh under Mesh

Parameters.

Mesh this multi body part with High quality mesh

and the default settings.
The resulting mesh can be seen below.

Note that the mesh in the blade is rather dense and the nodes are nicely
aligned along the blade/solid interface. In fact, the nodes along this
interface are merged to ensure the prescribed bonding.

Hide one blade solid body.

Hide one of the blade bodies, as shown in the figure below. Display the
mesh.

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Compatible/Incompatible Meshes

Examine the mesh.

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A node-to node
correspondence is also forced
along the entire blade/solid
interface. The nodes are
subsequently merged to ensure
the required bonding.

While merging the nodes is the

most accurate way to ensure
the bonding between two
touching bodies in a part, or
two parts in an assembly, it
poses additional constraints on
the mesher. All bodies and
parts must be meshed together,
causing the operation to become more complex and take longer.

Show the blade.

Show the blade that was hidden.

Material.

Assign Alloy Steel to all components.

10 Fixture.

Apply a Fixed Geometry restraint on the top

face of the rotor.

11 External Load.
Apply 1 rad/s Centrifugal load. Use Axis1 for

the reference.

12 Run the analysis.

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Compatible/Incompatible Meshes

13 Displacement results.

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The displacement plot shows a symmetrical pattern of the deformation

with a maximum resultant displacement of 4.2 e-7 m.

14 Von Mises stress results.

Stress distribution shows singularities in the vicinity of the blades.

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Compatible/Incompatible Meshes

When the nodes of adjacent meshes cannot be merged, we have an

incompatible mesh. We can select an incompatible mesh which tells the
mesher to mesh every body/part independently and ensure the bonding
via the constraint equations (additional mathematical expressions).

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Incompatible Mesh

15 Define a new study.

Duplicate study rotor2a-compatible as a new study rotor2aincompatible.
16 Set global incompatible bonding.

Edit the setting of the top level assembly component

contact (Global Contact) and change the Options to
Incompatible.

17 Mesh part.
Select Curvature based mesh under Mesh
Parameters.

Mesh the part with the default settings.

Automatic Switch
to Incompatible
Mesh

If a compatible mesh is requested and meshing

fails due to the complexity of the contacts, remeshing model with the incompatible mesh often
solves the problem.

Introducing:
Automatic Switch
to Incompatible
Mesh

The option Remesh failed parts with incompatible mesh

automatically re-meshes parts where compatible meshing was not
successful.

Where to Find It

234

Shortcut Menu: Right-click Mesh, Create Mesh and under

Advanced select Remesh failed parts with incompatible mesh.

SolidWorks 2012

Lesson 6
Compatible/Incompatible Meshes

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18 Examine the mesh.

The solid bodies of the rotor and the blades are meshed independently
and the nodes along the interface are not aligned. The bonding is
ensured by means of the additional constraint equations.

19 Run the study.

20 Displacement results.

The results are the same when compared to those obtained in the study
with the compatible mesh.

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Compatible/Incompatible Meshes

SolidWorks Simulation features several bonding algorithms when

handling the bonds between bodies with an incompatible mesh. These
options can be accessed in the study properties. In this section, we will
discuss these options and their advantages and disadvantages.

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Incompatible
Bonding Options

Simplified Bonding

When Simplified is selected, the traditional (node base) bonding

algorithm is used. The source body is represented using its nodes, while
the target is represented through the element faces (target must always
be a face). However, depending on the density of the source mesh, not
all target element faces may participate. This may lead to a generation
of patched contact.

In the figure above we try to demonstrate a traditional, node based

incompatible bond between an edge (source) and a face (target). Only
the elements where a node uniquely lies on their faces will participate
in the contact. This leads to a patched description of the contact which
may lead to less accurate results.

More Accurate
(Mortar) Bonding

When the More accurate (slower) option is used, source entities use
full description of the geometry including edges (faces) between the
nodes. This leads to a complete and accurate description of both the
source and the target.

In the figure above the entire edge (continuos description) of the source
as well as the faces of the touching target elements form the contact set;
This description is more accurate but requires longer solution times.
In general, when incompatible contact is used the size of the elements
defining the source and the target should be compatible and the More
accurate (slower) option should be used.

Automatic

236

When the Automatic option is selected, the software will decide which
is the most appropriate bonding type with respect to the model and
solution times. It is suggested to leave this option as the default
bonding type.

SolidWorks 2012

Lesson 6
Compatible/Incompatible Meshes

21 Simplified bonding.

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In the study Properties activate the Simplified bonding option.

22 Run the study.

23 Displacement results.

The results are significantly different to those obtained in the study

with the compatible mesh, automatic bonding.

24 Save and Close the file.

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Compatible/Incompatible Meshes

The interface on two of the blades is not properly bonded due to the
simplified bonding algorithm. There are two reasons for this. First of
all, the mesh sizes are very different between the two bodies.
Additionally, the simplified bonding algorithm failed to accurately
bond the two bodies. To obtain the correct solution, More accurate
(Mortar) bonding must be used. By default Automatic bonding treats
this contact correctly.

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Discussion

Summary

In this lesson we showed the difference between the compatible and

incompatible meshing approach for solid element meshes.

Compatible mesh is somewhat more accurate along the interface

because a node to node correspondence between the meshes is forced
or the two corresponding nodes are directly merged. However it puts
additional strain on the mesher and the meshing process may take
longer to complete.

Incompatible meshing procedure generates mesh for each part

independently which then reduces the time necessary for completion.
The contact condition is then ensured by the additional constraint
equations (Bonded contact). If possible, incompatible bonded contacts
should feature elements of comparable sizes.

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Lesson 7
Assembly Analysis
Mesh Refinement

Objectives

Upon successful completion of this lesson, you will be able to:

I

Analyze more complex solid mesh assemblies with various contact

conditions and connectors.

Use initial clearance in definitions of local No penetration contact

conditions.

Auto-generate the local contact definitions.

Define bolt connectors.

Analyze and judge the quality of solid finite element mesh.

Use the Remote Load feature to simplify the analysis.

Use and define Design Check plot.

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Assembly Analysis Mesh Refinement

In Lesson 2 we learned how to apply mesh control when analyzing a

part. In this lesson, we will apply mesh control when analyzing an
assembly.

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Mesh Control in
an Assembly

Once we have run the analysis, we will create a Design Check Plot to
display the Factor of Safety of the model.

Case Study:
Cardan Joint

In this case study we will analyze an assembly of a cardan joint. We

will determine the various contacts in the assembly and apply different
mesh controls to different contact conditions.

We will apply external forces to the assembly that bypass existing

components using remote loads. This allows us to analyze the assembly
faster as several components will not have to be meshed and solved.
We will use a draft (first order) mesh to get an initial solution and then
compare this with the results obtained with a high quality (second
order) mesh.
To determine the suitability of our design, we will create a Design
Check plot to display the factor of safety of this assembly.

Problem
Statement

The differential assembly is used to transmit a

torque from the vertical direction to the
inclined direction. The assembly is bolted to
the base plate at the four locations on the
back side of the bracket using M6 ANSI
B18.6.7M countersink bolts. The base plate is
then bolted to a secondary structure using two
M8 counterbore bolts. The torque is generated
by applying a 2.5 N horizontal force to the
handle. (In the top view, this force is
perpendicular to the handle arm.)
The shaft is rigidly connected to the
bottom yoke (Yoke_female) and passing
through the bottom opening on the
bracket. It is assumed that, due to
improper manufacturing and elevated
temperature from the friction in the shaft/
bracket contact, this interface becomes
temporarily blocked and the shaft
consequently transfers all the torque to the
bracket. (Further increase in the torque
would loosen this connection and the joint
assembly would begin to rotate.)

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Furthermore, the geometry of the shaft ensures that the Yoke_female

and the RevBracket do not come any closer than the initial clearance
of 3.469 mm (see the figure above).

The goal of the analysis is to obtain the distribution of stresses and

strains in the components of the Cardan joint and the internal forces in
the bolts required for their subsequent design. The deformations and
stresses in the shaft, Rev Bracket, and the full-crank-assy are of no
interest at this time.

Part 1: Draft
Quality Coarse
Mesh Analysis

In the first part of the lesson we will define all of the appropriate
contact conditions with the help of SolidWorks Simulation Find
Contact Sets feature.

Procedure

Follow the steps below:

Open an assembly file.

Open Cardan joint from the Lesson07\Case Studies folder.

Set SolidWorks Simulation options.

Set the global system of units to SI (MKS), units of Length to mm and
Stress to N/mm2 (MPa).

Store the results in the SolidWorks document folder in the results

subfolder.

Activate configuration Without_crank.

This step suppresses the crank-shaft, crank-arm, crank-knob and
the Shaft.

Define static study.

Define a new Static study. Name it stress analysis.

Assign material.

Right-click on the Parts folder and select Apply material to All.

Assign Alloy Steel material from the Solidworks Materials library to

all parts in this assembly.

Modify material of the RevBracket and of the base-plate.

Under the Parts folder, right-click on RevBracket-1 part and click
Apply/Edit Material. Assign Aluminum 1060 Alloy to this part.

Repeat this step and assign Aluminum 1060 Alloy to the base-plate.

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Assembly Analysis Mesh Refinement

The Remote Load option allows the user to simplify certain

assemblies prior to meshing, often helping reduce the size of the mesh.

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Remote Load
Where to Find It

Menu: Simulation, Loads/Fixtures, Remote Load/Mass

Shortcut Menu: Right-click External Loads and select Remote

Load/Mass

CommandManager: Simulation > External Loads > Remote

Load/Mass

Remote Load
Example

Examine a pot supported by

three outriggers. A load is
applied to the tip of each
outrigger.When analyzing an
assembly, such as this pot
with outrigger, we may not
be interested in the
deformations and stresses of
the outriggers and we wish to
concentrate solely on the
analysis of the pot.

Taking advantage of the

Remote Load option, we avoid modeling the outriggers and still are
able to apply loads to the pot as if the outriggers were present.

Instead of analyzing the assembly, we analyze the pot as a part. Using

the Remote Load menu, we apply a load to the split faces marking the
area where the outriggers are attached to the pot.

The point of application of the Remote Load must be defined in the

coordinate system selected in the Remote Load/Mass menu.

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There are three ways in which Remote Load can be defined:

Load (Direct transfer) is applicable if the omitted component (the

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outrigger) can be assumed to be much more flexible than the

analyzed part (the pot). The load that would have been applied to
the outrigger is applied to the split faces of the pot and is expressed
by means of equivalent loads and moments.

Load/Mass (Rigid connection) is applicable if the omitted

component is very rigid and can be assumed to displace as a rigid

body. In this case the faces where the loads are applied are
connected by invisible rigid bars to the point of load application.

This option also allows you to specify a remotely located, isolated

mass. This feature is useful when the gravity (or another constant
acceleration load) is included or when performing a frequency
analysis.

Displacement (Rigid connection), the third option in the Remote

Load definition, is also applicable when the omitted component is

very rigid and can be assumed to displace as a rigid body; however,

the load needs to be applied as a prescribed displacement. In this
case, the faces where the loads are applied are also connected by
invisible rigid bars to the point of the load application.

Define remote load.

Because we are not interested in the stresses and the deformations of

the crank arm, shaft, and knob, we will simplify the analysis by
using a remote load feature.
Right-click External Loads and select Remote Load/Mass.

Setup the remote load.

Select Load (Direct transfer) under the Type, and select the faces on
the Yoke_male knob where the torque will be transmitted.

Under the Reference Coordinate System dialog, specify User

defined and select Coordinate System 1 from the SolidWorks fly-out
menu. The remote location of the force will be specified in this local
coordinate system.

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In the Location dialog, enter the following coordinates:

X-Location: 57.15 mm, Y-Location: 24.6 mm, and Z-Location: 0
mm.

For the Force, specify -2.5 N in Z-Direction. The components of the

force are also specified in the local coordinate system Coordinate
System 1.
Click OK.

By selecting Load (Direct transfer), we are accounting for the

possibility of having looser connections between the crank subassembly and the Yoke_male part, and for the fact that the crank
shaft, arm and knob are manufactured from material that is softer
than Alloy Steel.

Note

Add Bolt Connectors.

Right-click the Connections folder and select Bolt.

Under Type select Countersink with Nut.

Under Conical Face select one of the bolt head faces.

The Circular Edge of the Bolt Nut Hole field will populate the correct
edge feature automatically.

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Since the bolt connection

was defined using the Hole
series feature in
SolidWorks, the
specification of the M6 bolt
is automatically transferred
in SolidWorks Simulation.
Notice that Bolt Shank
Diameter and Nut
Diameter parameters read
6.6 mm and 9.9 mm,
respectively. If different,
these values can be
modified to your real
design values.

Bolt Tight fit and

Diameter

The Tight fit option controls not only whether the bolt shank is in direct
contact with the hole, but also whether the walls of the bolt hole may
deform or not.
I

If the stiffness of the bolt material is significantly smaller than the

stiffness of the material of the bolted components, the presence of a
rather soft bolt shank will not have a substantial effect on the
deformation of the hole walls. In such a case, the Tight fit option
should be cleared.

If the stiffness of the materials are comparable, or the stiffness of

the bolt material is greater than the stiffness of the material of the
bolted parts, the Tight fit option should be activated.

If the diameter of the bolt is smaller than the diameter of the bolt
hole, the Tight fit option should always be cleared. In this case, the
stiffness characteristics of the materials are not important.

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Assembly Analysis Mesh Refinement

Bolt pre-load can be defined directly by entering an axial force or

indirectly as torque. When the torque value (T) is entered, SolidWorks
Simulation calculates the axial bolt force, which is the corresponding
bolt pre-load, using the following formula:

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Bolt Pre-load

T
F = -----------KxD

where D is the diameter of the bolt, and K is the friction factor (also
commonly known as the torque coefficient).

The exact formula for the friction factor K is rather complicated and
can be found in Mechanical Engineering Design by J.E. Shigley
(1986). However, the value of K=0.2 is a very good approximation for
most practical cases.

10 Add material and fit.

Check the Tight Fit

check box and select the

Shank Contact Faces

(see the figure).

11 Bolt material.
Under Material, select
Library. Click Select
material and specify
Alloy Steel from the
Solidworks Materials

library.

Click Apply and Close

the Material window.

12 Add preload.
Under Preload select Torque.

In the Torque box, enter 30 N-m. Specify the

Friction factor (K) of 0.2.

Click OK to complete the definition of this bolt

connector.

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13 Hole Series.

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Because the bolted connections

were defined using SolidWorks
Hole series feature,
SolidWorks Simulation will
display the following message:
Do you want to add bolt
connectors to all holes in
the Hole Series? Click Yes
to propagate bolts to all
holes. Click No to add a
bolt to only the selected
hole.

Click Yes in the above dialog

box window to automatically
generate the remaining three
bolts connecting the
RevBracket and the baseplate.

Connectors created based on

the hole series are automatically grouped in a
separate folder. Editing one connector from such
group will automatically modify the definition of the
others. It is possible to dissolve or restore the connector series at any
point.

Note

The Tight Fit option is not copied to the rest of the holes. It must be
added manually.

14 Bolt base-plate to the ground.

Add another connector.

In the Type list select Bolt.

Under Type select Foundation Bolt.

Under Circular Edge of the Bolt Nut Hole select the edge of the hole
where the bolt head would rest.

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Under Target Plane select PLANE2 SolidWorks feature.

The Nut Diameter as well as the Bolt Shank Diameters will be prepopulated based on the specifications of the bolted connection in
SolidWorks and can be modified if desired. In our case we will use the
values of 13.5 mm and 9 mm, respectively.
Select Tight Fit and select the only cylindrical face as Shank Contact

Faces.

Specify Alloy Steel for the Material and a Torque preload of 30 N-m
with the Friction factor (K) of 0.2.

15 Hole series.

Again, you will be asked if you would like to copy the bolt to the other
holes in the series. Click Yes to add the other bolt.

Note

248

Again, you will have to apply the Tight Fit option manually.

SolidWorks 2012

Lesson 7
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16 Locate all contacts in the assembly.

From the Tools menu, select Interference Detection. Under the
Options dialog, activate the Treat coincidence as interference field.

Click Calculate.

Browse through and analyze the identified contact interfaces.

Due to the significant number of the contacts the contact sets will be
generated automatically.

17 Explode the view.

Explode the view for easier definition of the contact conditions.

18 Delete Global Contact.

To make sure that no two parts will be accidentally bonded, Global

Contact will be deleted.

This is a good habit if analyzing complex assemblies. Any mistakenly

omitted contact condition would likely result in a problem during the
solution phase or visually erroneous displacement result.
Delete the top assembly component contact (Global Contact).

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Assembly Analysis Mesh Refinement

We have deleted Global Contact to ensure that no two faces remain

accidentally bonded. In most assemblies, one type of contact (in our
case Allow Penetration) condition does not satisfy all interfaces, so we
must adjust the contact condition at each contact set that does not meet
the global condition.

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Local Contact Sets

Automatically Find
Contact Sets

Automatically Find Contact Sets helps to automate the process of

Where to Find It

Menu: Simulation, Contact/Gaps, Contact Sets

Shortcut Menu: Right-click Connections and select Contact Sets

CommandManager: Simulation > Connections Advisor

defining contacts within an assembly.

>Contact Set

Use in Instructions

Under Contact select Automatically find contact sets

No Penetration
Local Contact
Options

No penetration contact was introduced in Lesson 3 where all basic

No Penetration
Local Contact:
Advanced Options

The advanced options of the No Penetration contact are accessible

through the simulation study options. To activate them, Show
advanced options for contact set definitions option must be
activated in the simulation Default Options, under Mesh.

250

options were described. In this section advanced options will be

discussed.

SolidWorks 2012

Lesson 7
Assembly Analysis Mesh Refinement

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The Advanced dialog in the No

Penetration type of the Contact
Set definition offers the following
types of options:
I

Node to node: Entities must be initially touching and no significant

sliding or change in the contact region shape may occur. This
option may not be used when the Large displacements option (see
Lesson 14 ) is active.

Node to surface: No restriction on the initial configuration is

imposed, i.e. the entities participating in contact do not need to be
touching at the beginning of the analysis and sliding is permitted.
Because the directions of the friction and normal forces are updated
during the analysis, this option is valid for the Large displacements
calculations.
This type of contact is able to
describe complex contact
configurations and behavior, but it
requires substantially more
Set 1
computational effort.Typically, we
would use this type of contact when
Set 2
edge-to-face configuration is
expected and if contact stresses are not of primary importance.

Surface to surface: This type of

Set 1
No penetration condition is the
most general and accurate one.
Entities participating in the
Set 2
contact are represented by the
subsurfaces of the finite element
mesh. As in the case of the Node to surface type, no restriction is
imposed on the initial configuration and sliding is allowed. The
directions of the contact and friction forces are updated during the
analysis and this option is valid for the Large displacement
computations. Typically, we would use this type of contact when a
face-to-face configuration is expected or if accurate resolution of
the contact stresses is required.

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Assembly Analysis Mesh Refinement

Advanced options of the No Penetration contacts helps to set the

accuracy/time required to compute the contact solution. To access the
options below, Show advanced options for contact set definitions
option must be activated in the simulation Default Options.

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No Penetration
Contacts: Advanced
Options

If these advanced options are not used, the default no penetration

contact type will be Surface to Surface.

Where to Find It

Menu: Simulation, Contact/Gaps, Contact Sets

Shortcut Menu: Right-click Connections and select Contact Sets

CommandManager: Simulation > Connections Advisor

>Contact Set

Use in Instructions

Under Advanced choose from Node to node, Node to surface or

Surface to Surface.

19 Activate Advanced options of the No Penetration contact.

Edit the simulation Default Options. Under Mesh folder activate the
Show advanced options for contact set definitions option.

Right-click on the Connections folder and select Contact Sets.

20 Define local contact sets.

We will take advantage of the automatic contact generation feature in

SolidWorks Simulation.
Right-click on the Connections folder and select Contact Sets.

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Under Contact select Automatically find

contact sets.
Under the Options dialog, select Touching

faces.

In Components, select the top level assembly.

Click Find contact sets.

All detected contact sets are listed in the

Results dialog. You can browse through and
view each by clicking on it.

Select all found contact sets under the Results

dialog.
Under Type and Options, select No
penetration.

Under Properties activate Friction and

specify the Friction Coefficient of 0.05.

Select
All

Under Advanced select Surface to surface.

Click OK twice. All the contact sets will be
generated and listed under the Connections
folder.

Note

Node to surface and Node to node, No penetration advanced

contact options could also be used. Node to node option (global,

component or local) would, however, force the compatible mesh, while

Node to surface option (local only) could result in less accurate
contact stresses.

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Assembly Analysis Mesh Refinement

As specified in the statement of the problem, the geometry of the Shaft

ensures that the Yoke_female and the RevBracket do not come any
closer than the initial manufacturing distance of 3.469 mm. We will
simulate this constraint with the help of the No penetration contact
condition with Gap (clearance) settings.

Gap (clearance)

This feature enforces the contact offset equal

only to the initial geometrical distance between
the participating entities. The options of this
feature enables the user to select whether the
initial geometrical offset should be applied to
all of the selected entities within a specific
contact set or only to those with the initial
separation distance smaller than the user
defined value.

Gap Example

Let us demonstrate this feature on the following example:

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No Penetration
Local Contact
Options

If the Always ignore clearance option is activated in the Gap

(clearance) dialog, no node along the specified source edges will

be allowed to come closer than their respective initial geometrical

separations of 3 mm and 7 mm. All the points along the source
edges will, however, be permitted to separate further.

254

If Ignore clearance if < 4 mm is specified, for example, the 3 mm

contact will behave as described above, while the 7 mm contact will
be allowed to fully close (if the appropriate load is specified).

SolidWorks 2012

Lesson 7
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21 Define Yoke_female vs. RevBracket contact.

Define a No penetration, Node to surface contact set with the edge of
the contact face between the shaft and the Yoke_Female as the first
component and the face on the RevBracket as the second component.

Select Gap (clearance) and select Always ignore clearance.

Under Advanced select Node to surface.

Click OK.

Note

We specified a Node to surface contact since our first entity is an

edge. The Surface to surface option would not be appropriate in this
case.

Also, edge is used to simplify the solution. Full contact face between
the shaft and the Yoke_Female could be used as well.

The above contact condition ensures that the two entities will not come
any closer than the initial manufacturing distance of 3.469 mm, but
allows them to separate.

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The last restraint must ensure that the cylindrical openings on the
Yoke_female and RevBracket remain aligned and that these two
openings remain connected for the transmission of the torque (they are
physically connected by a shaft). Without this condition, the
differential is free to rotate and our solution may fail or be inaccurate.
Instead of using a model of the shaft, we will use a pin connector.
In addition to providing the alignment between the holes, the pin
connector must be able to account for both rotational and axial
stiffness.

Rotational and
Axial Stiffness

Assuming a cylindrical shape with a constant cross-section, the

rotational stiffness can be calculated using the formula:
JG
KROT = ------L

4
r
-------where J = 2

is the polar moment of inertia for the circle with radius r,

G is a shear modulus of the material, and L is the length of the shaft

connecting our two points (effective length of the shaft). Substituting
our values into the above equation, we obtain KR = 18,403 N-m/rad.

The axial stiffness of a cylindrical shaft with a constant cross-section

can be calculated using the formula:
KAXIA = EA
-------L

where E is the Youngs modulus and A = r is the cross-sectional area

of the circle with radius r. Substituting our values into the above
equation we obtain KA = 4.3135e9 N/m.

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22 Define Yoke_female and RevBracket connector.

Specify a Pin connector between the cylindrical openings of the
Yoke_female and that of a RevBracket (see the figure below).

For Connection Type, make sure that both With retainer ring (No
translation) and With key (No rotation) are cleared.

In the Advanced Option dialog, enter 4.3135e9 N/m for the Axial
Stiffness and 18,403 N-m/rad for the Rotational Stiffness.
Click OK.

Axial Stiffness
Rotational Stiffness

The base-plate bolted to the ground using the foundation bolts is free
to lift up at certain locations such as between the bolts and along the
edges. To correctly simulate this behavior without the inclusion of the
additional component to model the ground, a Virtual wall, local No
Penetration feature can be conveniently used.

Virtual Wall, Axial

and Tangential
Stiffness

Two wall types are available: Rigid and Flexible

Rigid type assumes infinite stiffness and can be
used to simulate very stiff foundation plates. If
Flexible type is requested, effective foundation
stiffness values in Axial and Tangential directions
must be specified. This approach allows users to
simulate composite foundation walls without it
being necessary to include them in the model.
Both types support Friction Coefficient and the
Gap (Clearance) contact features.

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Assembly Analysis Mesh Refinement

To determine how to calculate the Axial and

Tangential stiffness values for the virtual
wall, it is convenient to use the Knowledge
Base, which is an excellent compilation of
numerous articles with images.

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Knowledge Base

Expand the Analysis Research tab

and
enter virtual wall stiffness in the Search
Knowledge Base field. The article, which is
the result of the search, gives full
explanation and a simple formula which can
be used for both single layered as well as composite foundation walls.

Where to Find It

Menu: Simulation, Research

Note

Internet connection and subscription are required to access the

Knowledge Base database.

23 Virtual Wall.

Right-click on the Connections folder and select Contact Set.

For Type, select Virtual Wall.

Select the bottom face on the base-plate as the Set 1 and PLANE2 as
Set 2.
Under Wall Type select Rigid. This option is required for the
Foundation bolt connector.

Enter 0 for the Friction Coefficient. (With Foundation bolts defined,

friction has little effect on the results of the analysis.)
Click OK.

Friction Coefficient

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Assembly Analysis Mesh Refinement

All of the necessary contact conditions have now been defined.

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Our main concerns are the components of the differential; namely,

Yoke_male, Yoke_female, Spider, and the Pins. We will use a finer
mesh for these parts. To speed up the calculation in this lesson coarse
mesh will be used instead.

24 Mesh the assembly.

Select Curvature based mesh under Mesh Parameters.

Mesh the assembly with Draft quality elements. Move the Mesh
density slider to the left for a coarse mesh with Maximum element
size of 23.630mm, Minimum element size of 4.726mm, Number of
elements in a circle as 8, and Ratio of 1.6.
The resulting mesh is shown in the figure below.

25 Set properties of study.

Specify Direct Sparse solver for this analysis.

Note

The Direct Sparse solver is specifically chosen because we have a

larger number of contacts and connectors, but the size of the model is
still rather small. We expect this solver to be more efficient than an
FFEPlus iterative solver. In general, however, with the increasing size
of the problem, the FFEPlus iterative solver becomes more efficient
and would be our choice instead. For more information on solvers, see
Appendix A.

26 Run the study.

The study may run for several minutes and then complete successfully.

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27 Display and animate stress results.

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Display and animate the distribution of the von Mises stresses in the
model.

We observe that the stresses in RevBracket are rather high, above the
yield strength of Aluminum 1060 Alloy (27 MPa). The stress peak is
located at the bolt location where the stiff bolt connection condition is
applied.

28 Isolate components.
Isolate Yoke_male, Yoke_female, spider and the three PIN

components.

29 Analyze stress results on isolated components.

Under the Chart Options make sure that Show Min/Max range on
shown parts only option box is checked.

For better viewing explode the assembly.

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The stress values dropped to approximately 0.58 MPa, a value

significantly smaller when compared to the yield strength of the
material (620 MPa). It is apparent than the stress magnitudes in the
components of our interest will be rather small.

However, note that our mesh is rather coarse and that Draft quality
elements were used. For reliable stress results, we would have to refine
the mesh and use High quality elements.

30 List Bolt forces.

Right-click on the Results folder and select List Pin/Bolt/Bearing

Force.

Select All bolts from the list.

Examine the results.

Click Close.

Part 2: High
Quality Mesh
Analysis

In the second part of this lesson, we analyze the quality of the current
mesh, generate a new High quality mesh, and post-process the results
of the refined study.
First, let us have a look at the quality of our current mesh.

31 Analyze details of current coarse Draft mesh.

Right-click on the Mesh folder and select Details.
Mesh Details lists the basic

information about our current

mesh. Scroll all the way
down and note the three rows
that provide information
about the Aspect Ratio. (For
the detailed information on
the Aspect Ratio, consult
Appendix A.)

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Both the Maximum Aspect Ratio

of 22.44 and the Percentage of
elements with Aspect Ratio < 3

of 86.9 are acceptable.

The overall judgement about our

mesh can be achieved by simple
visual inspection. Two Draft
quality elements per thickness of
the Yokes walls, as well as in
through-thickness direction in the
pins, are not enough for reliable
stress and strain results.

Required Number
of Solid Elements
in Thin Features

In general, we would require at least four Draft (two to three High)

quality elements in the through-thickness directions when stresses or
strains are of any concern and substantial bending or high curvature in
the geometry is present. A fairly coarse mesh of the RevBracket and
the base-plate is not a major concern. We would, however, still
require a minimum of one (High quality) or two (Draft quality)
elements through the thickness. The contact interfaces do not
necessarily need to be refined any further, especially if in High quality
elements, unless contact stresses are of any importance.

Note

A requirement on the minimum number of solid elements in the

through the thickness direction can be relaxed if no significant
curvature exists and no substantial bending or torsion (compression in
nonlinear analysis) is expected.

Aspect Ratio Plot

The distribution of the Aspect Ratio in the mesh can also be displayed
graphically. This plot allows for the detection of the location of the
sliver elements with high Aspect Ratio values.

The value of the Aspect Ratio should be kept below 50 in the regions
where stresses are of crucial importance. In all other instances the value
should be limited by approximately 1000.
It is typically straight forward to rectify the high Aspect Ratio problem
by applying local mesh controls to the regions in the vicinity of such
badly shaped elements.

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32 Aspect Ratio plot.

Right-click on the Mesh icon and select Create Mesh Plot. Select
Aspect ratio and click OK.

Edit the legend and select Show max annotation feature.

Note that the maximum value indicated in the plot is indeed 22.44.

Annotation for the maximum Aspect ratio value shows the location
where the elements are rather sliver - bent in the sliver part of the yoke.
If the stress and strain values were of importance to us we could use
local mesh control to refine the mesh at this location.

33 Define new study.

Duplicate the study stress analysis as a new Static study named

stress analysis refined.

34 Mesh the model.

Select Curvature based mesh under Mesh Parameters.

Mesh the assembly with High quality elements. Move the Mesh
density slider to the right for a fine mesh with Maximum element size
of 5.908mm, Minimum element size of 1.182mm, Number of
elements in a circle as 8, and Ratio of 1.6.

Note

A message appears warning you that the results will be deleted. Click
OK to proceed.

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35 Examine the mesh.

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The mesh now has the recommended

numbers of elements in throughthickness directions for all components.
The resulting mesh can be seen in the
figure.

36 Display the mesh details.

We note that the Maximum

Aspect Ratio decreased to an
acceptable value of 10.6 and
that the Percentage of elements
with Aspect Ratio < 3 increased
to 96.6.
Meshes with these parameters
can be regarded as very good.

Notice that the number of Total

nodes has increased 17 times
to 50,152.

Jacobian

We have already discussed the Aspect Ratio as a measure of the mesh

quality. Aspect Ratio plot was also demonstrated in step 32 on
page 263.

Another mesh quality measure, which identifies highly curved and

skewed elements is Jacobian. SolidWorks Simulation has an automatic
check of this quantity during the solution phase and the user typically
does not need to pay attention to it. However, the closer the value of the
Jacobian to 1, the better. Its value also should never be close to 0 or
negative; this may be a sign of a serious localized mesh problem. The
Jacobian is only available for high quality elements.

37 Plot distribution of Jacobian.

Right-click the Mesh folder and select Create
Mesh Plot.

Specify Jacobian and click OK.

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Assembly Analysis Mesh Refinement

The maximum Jacobian value for our mesh is 8.21 which is very
acceptable.

Due to the time required, this study has been calculated and its results
can be found in the completed - High Elements subfolder of the
Lesson 7 directory.

38 Save and Close the file.

39 Open an assembly file.

Open Cardan joint from the completed- High Elements subfolder.

40 Display stress results.

We can again observe high stress concentrations in the vicinity of the

bolts.

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41 Isolate components.
Isolate Yoke_male, Yoke_female, spider and the three PIN

components.

42 Display von Mises stress results.

Under the Chart Options make sure that Show Min/Max range on
shown parts only option box is checked.

We can observe a raise in the maximum von Mises stress magnitude

from 0.58 MPa to approximately 1.44 MPa. This raise, while
insignificant for the design of the components in this assembly (both
values are well below the yield strength of the material 620 MPa),
represents a significant relative increase of nearly 60%. Also, the
location of the maximum stress has changed.
This example demonstrates that good quality mesh is a necessity if
stress are of importance to us.

We would, therefore, conclude that this assembly is designed with the

sufficient factor of safety.
Exit Isolate.

Factor of safety plot

A Factor of Safety Plot can be used to conveniently plot the

distribution of the factor of safety in the assembly. The procedure to
create a design check plot is a wizard that uses sequential steps to
define the plot parameters.

Where to Find It

Shortcut Menu: Right-click Results folder and select Define

Factor of Safety Plot.

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43 Plot a factor of safety distribution.

Right-click on the Results folder and select
Define Factor of Safety Plot.

As nearly all standards (except the ASME

Boiler and Pressure Vessel Code, for
example) require the use of von Mises stress
for the calculation of the factor of safety,
choose Max von Mises stress in the first
window.

Note

The inequality
shown in the dialog window is not the
definition of the factor of safety and the user should not be confused by
this expression. It is a definition of the von Mises yield criterion used
by the software to identify material points that experience yielding
(with factor of safety < 1). Users should ignore this expression at this
time. It will become clearer as the user becomes more proficient with
the software and theory.
Click Next.

44 Specify material constant.

The second step is to specify the material

constant that will be used as a comparison
against the von Mises stress selected in the
previous step.

Select Set stress limit to Yield strength as

most of the standards specify the material yield
stress and the Material involved as 1060 Alloy.

Note

Remember that our computations are valid

within the scope of the linear elasticity
traditionally limited by the yield stress point on
the material stress-strain curve.

Also note that the bottom of the dialog in the

figure on the previous page lists the materials
used in the assembly along with their
corresponding yield strength information. The
units can be set at the top of the same dialog window.
Click Next.

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45 Specify factor of safety.

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The third step allows the user to specify the

quantity to plot. Select Factor of safety
distribution.
Click OK to generate the plot.

46 Analyze the plot.

Change the maximum value of the legend to 100.

We can see that the lowest value of the factor of safety, 0.05, is very
small due to the stress concentration. It is a good habit to set the lowest
value to the design value of the factor of safety, 3.5 for example.

47 Edit the plot.

Change the lower limit of the legend to 3.5.

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We can see that the image did not change significantly. The red regions
indicate the parts in the model which do not pass the design factor of
safety criterion.

48 Iso Clipping.

Define an iso clipping of this plot that shows the regions where the
factor of safety is below 3.5.

This plot indicates the regions that we should be concerned about

failure. Turn off the iso clipping when you are finished.

49 Isolate components.
Isolate Yoke_male, Yoke_female,
spider and the three PIN components

and re-plot the factor of safety plot.

We can observe that the minimum
value of the factor of safety in the
chart, 284, is very conservative.

50 Save and Close the file.

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Assembly Analysis Mesh Refinement

In this lesson, we analyzed an advanced solid mesh assembly with

various contact conditions and connectors. The creation of the local
contact sets was shown and practiced.

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Summary

The pin connector with specified rotational stiffness was used to

simulate a real shaft. The remote load feature was used to remotely
apply the load without a need to model the linking parts.

We analyzed the quality of the finite element mesh and discussed the
optimum size of elements with respect to the characteristic dimensions
of the model.

Finally, a new postprocessing feature, Design Factor of Safety, was

introduced. In this lesson, we used this feature to plot the distribution of
the factor of safety and discussed various options available in the
definition of this plot type. We saw that the yoke and spider parts were
safe from failure, while the mounting bracket show a factor of safety
less than 3.5. Before making conclusions, we should investigate a finer
mesh on the bracket to see our stress results converging. We could then
make a determination on whether or not we need to change materials or
design to satisfy the 3.5 factor of safety.

Questions

270

The minimum number of solid elements in the through the

thickness direction is_____ if in Draft quality or_____ if in High
quality.

SolidWorks 2012

Exercise 14
Bolt Connectors

In this exercise, we will use bolt connectors to replace the physical

bolts and eye bolt. With the absence of the eye bolt, the external load is
applied as a remote load.

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Exercise 14:
Bolt
Connectors

This exercise reinforces the following skills:

I
I

Problem
Statement

Pin Connectors on page 195.

List Pin/Bolt/Bearing Force on page 203.

A bar is attached to a base plate with two loose fitting bolts: bolt
diameter is 12 mm, hole diameter is 12.2 mm.
Eye bolt

Base Plate

Bolts

Bar

The base plate is supported along both sides. The eye bolt is loaded in
vertical and horizontal directions with 1,100 N [247 lb] forces, as
indicated in the figure below. It is assumed that the eye is rather stiff
and provides a nearly rigid connection between the forces and the strip.
Both the bar and the base plate are manufactured from steel AISI
1020.
Fixed Support

Vertical Load
1,100 N.

Fixed Support

Horizontal Load
1,100 N

Determine the maximum stress and deformation for the components.

Also determine the forces in the bolts.

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Exercise 14

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Bolt Connectors

Open an assembly file.

Open bolt joints from
Lesson07\Exercises

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folder.

The bolts, nuts and washers

have been suppressed. This is
because in this exercise we
will use bolt connectors. To
account for the missing eyebolt, we will apply the horizontal load as a
remote load on the cantilever beam.

Set SolidWorks Simulation options.

Set the global system of units to SI (MKS) and the units of Length and
Stress to mm and N/m^2, respectively.
Create Study.

Create a static study named two bolts - torque preload.

Apply material.

Apply AISI 1020 steel as the material for both parts.

Create Bolt Connectors.

Create two Standard bolt

Edges defining
bolt heads

connections with nut.

Use 24 mm for the diameter

of the head and nut, and
12 mm for the diameter of
the bolt.
Make sure that the Tight Fit
option is not checked- the
bolts are loose fitting.

Use Alloy Steel for the Material.

Apply the Torque preload of 160 N-m [1416 lb-in] with the Friction
factor of 0.2.

You can verify with hand calculations that the corresponding axial bolt
preload force is 66,666N [16,860 lb]. Consequently, bolt tensile stress
equals 590 MPa [96,160 psi] which is 95% of the yield strength of
Alloy Steel.

Note

272

Show Exploded View.

SolidWorks 2012

Exercise 14
Bolt Connectors

Define Contact conditions.

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For correct modeling of bolted connections

we need to define a contact condition
between the two assembly components.

Because we expect a horizontal slide along

the interface, a local No penetration, Node
to surface or Surface to surface contact
condition is required.

Define a No penetration, Node to surface contact set between the

two components, as indicated in the figure.

Apply remote load.

As mentioned in the beginning of this problem, we assume that the eye

bolt is rather rigid. Thus, use the Load/Mass Rigid connection option.

Select both the bottom and the top contact

faces as Faces, Edges or Vertices for
Remote Load/Mass. This reflects the reality
in which most of the loads are transmitted
through the friction forces between the bolt
head/nut and the bar.
Apply horizontal and vertical
forces, both at a magnitude of 1,100
N, as indicated in the figure.
Use local Coordinate System1 to
specify the location of the force (0,
0, 51 mm) and the magnitude
(1100 N, 0, 1100 N).

Apply fixture.
Apply a Fixed Geometry fixture to
the two side faces on the base plate.

10 Mesh assembly.
Select Curvature based mesh under
Mesh Parameters.

Create High quality mesh with the default settings.

11 Run the analysis.

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Bolt Connectors

12 Review Results.

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Review the area where the highest stresses are located and notice that
the size of the hot spot is smaller than that of the element size.
Therefore, stresses in this area are reported with a large error. Mesh
refinement would be required to obtain more accurate maximum stress
results.

13 Plot details of deformation.

Analyze the details of the

deformation in magnified scale.

It can be seen that the bar and

the base plate separate from
each other.

14 Review bolt forces.

The axial bolt forces in Bolt Connector-1 and Bolt Connector-2 are
66,667 N and 69,057 N.

As compared to the bolt preload of 66,666 N, the effect of the external

load is very small. A negligible change in bolt axial load is desirable if
we want to avoid bolt loosening.

15 Save and Close the file.

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SolidWorks 2012

Exercise 15
Awning

In this exercise, you will analyze a

retractable awning.

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Exercise 15:
Awning

This exercise reinforces the

following skills:
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I

Problem
Description

Pin Connectors on page 195.

Remote Load on page 242.

The retractable awning in the photograph is

used to shield a vegetable stand from
weather. The total area that the awning covers
is 2m^2.
Six springs are attached to the awning and
keep it in the extended position. Each spring
has a spring constant of 875N/m. In the
extended position, the springs have a tension
pre-load of 45 N.
Assume that the awning is rigidly connected
to the base with a 150 N-m pre-loaded bolt.

All parts in the assembly are made of AISI 1020 steel. Consider the
pins that connect the pieces together to be rigid.

Goal

Calculate the maximum stresses and displacement in one side of the

awning assembly when it is loaded with 152mm of snow (with density
of 80 kg/m^3). With the snow on top, a 186 N horizontal load from the
fabric roll and snow weight is generated.

Tip

The awning roll is attached in the global coordinate system at

(-1259.84mm, 50.8mm, 3.175mm).

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Exercise 15

Awning

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Lesson 8
Analysis of Thin Components

Objectives

Upon successful completion of this lesson, you will be able to:

I

Create a mid-plane shell element mesh.

Create a shell mesh from selected surfaces.

Perform structural analyses and analyze results using shell elements

on parts.

Evaluate mesh adequacy to model stress concentrations.

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Analysis of Thin Components

To this point, we have used solid tetrahedral elements to mesh our

models. These work fine when the model does not have a thin cross
section, but when one dimension is much smaller than the other two,
such as in sheet metal parts, solid meshes can take a long time to solve.

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Thin
Components

To mesh a model properly with solid elements, we would need to place

at least two layers of tetrahedral elements across the thickness. Such a
mesh calls for a very small element size to fit across the thin section of
the model. These small elements are unnecessary in the other
directions, so the mesher creates a lot more elements than are necessary
for an accurate solution in those direction. Consequently, the large
number of elements requires far more time to be created by the mesher
and also requires a lot more time to evaluate the solution.

Case Study:
Pulley

Shell mesh can be generated on faces of solid bodies or on surfaces. In

such situations, all of the model boundary conditions and loads must be
applied on the edges of the solid bodies or directly on the surfaces.
If sheet metal features are used in the assembly, shell mesh is
automatically generated on the midplane. Furthermore, all restraints
and loads are correctly determined using the solid geometry directly.
This lesson contains two case studies. The first shows how to model
using shell elements when surface is used, the second then
demonstrates the analysis with the sheet metal part. It is strongly
recommended that both case studies and the following exercises are
completed to fully understand shell modeling in SolidWorks
Simulation software.

In this lesson, we analyze a stamped steel pulley used as an idler in an

automotive belt drive.
Because one dimension of the pulley geometry, its thickness, is much
smaller that the other dimensions, meshing this geometry with solid
elements will create a very fine mesh. We will first use solid elements
to see the problem, then we will use shell elements and compare the
results.

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Lesson 8
Analysis of Thin Components

Project
Description

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A belt exerts a vertical resultant force of 500 N on the pulley. From this
we can calculate that the belt force is equal to 353.55 N based on
equilibrium.
Determine the deformations and stresses that develop in the pulley.

Part 1: Mesh
with Solid
Elements

We will first analyze the pulley using solid elements, just as we have in
previous lessons.
We can take advantage of the symmetry of the geometry, loads, and
restraints by analyzing one half of the pulley while simulating the
missing half with symmetry boundary conditions.

In this case, the pulley is simple enough to analyze without using

symmetry. Idealizations, such as using shell elements in place of solids
and using one half of the model in place of the whole model, are
utilized here only as a learning example.

Procedure

Follow the steps below to analyze the pulley with a solid mesh:

Open a part file.

Open pulley located in the Lesson08\Case Studies folder.

Split lines define a face extending over a 90 section of the pulley. This
area is where we apply a belt load as pressure exerted on the pulley.

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Make symmetry cut.

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Activate the configuration called FEA.

3

Create new study.

Create a new static study named

pulley solids.

Set SolidWorks Simulation options.

Set the global system of units to

SI (MKS) and the units of Length and
Stress to mm and N/mm2 (MPa),
respectively.

Store the results files in the results folder in the SolidWorks document
folder.

Apply fixed restraint.

Select the face on the outside semi-cylindrical face

and apply a Fixed Geometry restraint.

Symmetry Fixtures

Symmetry fixtures simulate the half of the pulley that is missing from
the model. The fixture will prevent any displacement across the plane
of symmetry but can allow displacements on the plane of symmetry.

Alternatively, rather that applying a Symmetry fixture to a face, we can

apply the same condition manually to either one of the two edges of
this face. The restraint will still be transferred to the edge of the surface
that is meshed with shell elements. See the discussion in the second
part of this lesson for more information on symmetry restraints.

280

Apply symmetry restraint.

Faces with symmetry

Select the two faces in the plane of

symmetry, and apply a Symmetry
fixture.

boundary conditions

SolidWorks 2012

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Analysis of Thin Components

Define pressure load.

Right-click External
Loads and select Pressure,
and then select Normal to
selected face.

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Select the face upon which

the pressure load needs to be
applied, and define a
pressure load equal to 0.2
MPa (200,000 Pa).
Click OK to save the
definition.

Notice that we do not load the model by the forces in the belt. Rather,
we apply a pressure value simulating the presence of the belt.

Note

Also, you may ask how we know that this 200,000 Pa pressure results
in the desired 500 N reaction force in the vertical direction. A linear
static analysis with an arbitrary magnitude of the pressure was run
ahead of time. Based on the reaction force magnitude obtained in this
study, we were able to scale the pressure to 200,000 Pa to obtain the
500 N vertical reaction. We already used a similar proportionality in
Lesson 3.

Create mesh.
Select Curvature based mesh under Mesh Parameters.

Mesh the model with High quality elements and the default settings.

Examine the mesh.

There is only one element

across the thickness of the
model. From the mesh details,
we can see that there are 9,582
elements and 19,378 nodes.

10 Run the analysis.

Note

You can merge these two steps, mesh and run, if you select Run
(solve) the analysis in the Options dialog of the Mesh command.

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11 Plot von Mises stresses.

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The maximum stresses on the outside and inside faces of the solid
pulley are approximately 65.7 MPa and 81.3 MPa.

Note, however, that this mesh

features one element through
the thickness while two layers
of high quality elements are
recommended as a minimum.

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Part 2: Refined
Solid Mesh

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Now we will refine the mesh so that we have two layers of elements
across the thickness of the material and then compare the results with
the previous analysis.

Create new study.

Duplicate the pulley solids study and name the new study pulley
solids dense.

Mesh the model.

Select Curvature based mesh

under Mesh Parameters.

Mesh the model with a Maximum

element size and a Minimum
element size of 1.1 mm.
Additionally, use 8 as the
Minimum number of elements
in a circle and 1.5 as the Ratio.

This element size ensures that

two layers of elements are placed
across the wall thickness, which
is 2 mm.

This mesh will take considerably

longer to create, on the order of 15 times longer.

Examine the mesh.

This time we have 208,370 elements and 336,174 nodes (987,978

DOF).

Run the analysis.

Because of the large size of this mesh, we need to change to the

iterative solver. Right-click the study and select Properties. Select the
FFEPlus solver.
Run the study.

Even using the iterative solver, this solution will take much longer to
run.

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Plot von Mises stresses.

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Create a von Mises stress plot.

The maximum von Mises stresses on the outside and inside faces are
62.7 MPa and 87.0 MPa. The dense solid element mesh reports a more
regular shape of the stress concentration.

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Solid vs. Shell

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Using the solid mesh required a very long mesh and solution time to get
an answer that we could be confident with in this relatively simple
model. If the wall thickness had been even thinner, the solution could
take several hours, which would be unacceptable for a part of this
simplicity.
Now that we have done a solid mesh, we will construct a shell mesh
using two distinct modeling techniques:
I
I

Shell mesh using mid-surfaces

Shell mesh using outside/inside faces of solid bodies

Creating Shell
Elements

Shell elements can be created on surfaces, faces of solid bodies or for

sheet metals parts. In the following study, we will create mid-plane
surface to act as our shell sheets.

Part 3: Shell
Elements - Midplane Surface

The pulley does not feature any mid-plane surface. We must therefore
first create surfaces that will be used as our shell sheets.

Create mid-plane surface.

Click Insert, Surfaces, Mid-surface from the menu.

Select surfaces.

Select the face on the

outside as Face 1 and
the matching face on
the inside as Face 2.

Select Knit surfaces to

make sure the
command will create a
single surface.
Continue selecting
faces until entire
midplane is created.
Click OK.

Tip

Click Find Face Pairs to find the faces automatically.

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The mid-surface location for the shell mesh is the most desirable. In
some situations, however, extraction of the midplane is too difficult or
not convenient. In such cases the shell mesh can be placed on either the
outside or inside face of the solid geometry. Because shell elements are
suitable for thin structures, the difference in results due to the different
position of the shell is rather small. Students should complete Exercise
17: Shell Mesh Using Outer/Inner Faces on page 315 to verify the
above in the case of the pulley model

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Note

Create study pulley shells -midplane.

For now, let us skip the definition of loads and fixtures and go directly
to the mesh creation.

Introducing:
Exclude from
Analysis

In parts and assemblies, there may be more components than we are

interested in analyzing or we may want to limit the scope of the
analysis to only certain components. Exclude from analysis essentially
suppresses the component from the analysis.

Where to Find It

Shortcut Menu: Right-click a part, body or surface in the

Simulation Study tree and click Exclude from Analysis.

Exclude Solid body.

We have a solid body and a surface body, but we only want to analyze
the surface body. To do this we must exclude the solid body that is not
to be analyzed.
In the Simulation Study tree, expand the pulley folder and right-click
the solid body, then click Exclude from Analysis.

Note

286

Notice that when we exclude the solid body, it is also hidden in the
graphics window. Since we are using shell elements that are defined by
surface geometry, we only want to select the surface geometry to apply
our loads and restraints.

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Thin vs. Thick

Shells

Thin shell element technology assumes that the cross-section

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perpendicular to the midplane remains straight and also

perpendicular to the midplane at the end of the deformation
(Kirchhoff theory). As a consequence, this shell element ignores the
shear deformation and stress in the through-thickness direction.
Thin, membrane-like structures with the span to thickness ratio
larger than 20 can be accurately modeled using this element.

Thick shell element technology assumes that the cross-section

perpendicular to the midplane remains straight after the

deformation takes place, but it is no longer perpendicular to the
deformed midplane (Mindlin theory). As a consequence, this
element assumes constant distribution of the shear deformation in
the through-thickness direction. Thicker shells where shear effects
become noticeable can be accurately modeled using this element.
THIN

THICK

BEFORE
DEFORMATION

MIDPLANE

AFTER
DEFORMATION

In both cases the distribution of the normal bending stresses can be

seen as linear.

LINEAR DISTRIBUTION OF IN-PLANE STRESS IN

BOTH THIN AND THICK SHELL

Define the shell.

Select the midplane surface body. Right-click

either selected body and click Edit Definition.

Select Thin and set the thickness to 2 mm.

Click OK.

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Mesh control.

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Apply a mesh control on the rounded face

(see the figure) with the Element size of 1.5
mm. Keep the Ratio at its default value of
1.5.

Create mesh.

Select Curvature based mesh under Mesh Parameters.

Create a High quality mesh with the default settings.

The resulting mesh can be seen in the following figures.

Examine the mesh.

The Mesh colors section indicates that the shell bottom faces are

marked with an orange color. The shell top faces assume the part color,
gray in this case. This fact is very important in the postprocessing
phase.
Furthermore, we see that the inside and outside are colored uniformly
(i.e. gray and orange colors do not alternate on any side). Such aligned
shell mesh is required for correct postprocessing.

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Shell elements have a top and bottom side. To indicate the side, the
mesh is color coded with the top and bottom being shown in different
colors.

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Shell Mesh Colors

To obtain proper results, all the mesh elements must be aligned

properly with the tops on one side and bottoms on the other.
Menu: Simulation, Options, System Options, General.

Where to Find It

Changing Mesh
Orientation

In some cases, however, we may wish to change the mesh orientation

or the shell mesh may not to be aligned at the end of the meshing phase.
In such cases, the mesh need to be aligned manually. We can practice
flipping the top and bottom of the shell mesh with our current mesh.

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Flip the mesh on one face.

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Left-click on the face indicated in the

figure.

Right-click on Mesh and select Flip shell

elements.

The result of this operation can be seen below.

We can see that the colors are not uniform and the shell mesh is
misaligned. While the finite element computations would be correct
with such misaligned mesh, the postprocessing would show
meaningless results along the lines of misalignment.

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Before proceeding further, we need to explain why shell element

alignment is important. Shell elements can model bending; therefore,
most often, different stress results are reported at the top and bottom of
shell elements.

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Shell Element
Alignment

Using the postprocessing options

for shell elements, we can choose
to display the stresses on the top
or bottom. Additionally, stress
distribution in the throughthickness direction can be
divided into two components:
bending and membrane. All
four options are demonstrated in
the figure to the right.

Let us depart for a moment from the

pulley and examine a rectangular
cantilever beam meshed with
misaligned shell elements.

Say we want to display the P1

stress (maximum principal stress)
at the top of the beam.
Because the shell element
orientation in the model is
inconsistent, the stress plot is in
error.

Now, instead of the P1 stress, we

plot the von Mises stress.

The fact that the plot is erroneous

again becomes obvious along the
line of misalignment.

This error is because stresses are

averaged before the von Mises
stress is calculated. Averaging
between the results on the top and the results on the bottom of the shell
elements across the misalignment line results in nearly zero stress.
Having explained the importance of shell element alignment, we now
return to the pulley lesson.

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This option automatically aligns the surface of the generated shell

mesh.

Where to Find It

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Automatic Shell
Surface Realignment

Menu: Simulation, Options, Default Options

10 Align mesh.

Flip the mesh so that the bottom of the shell mesh faces the inside of
the pulley model. Make sure that the mesh remains aligned, i.e. colors
on both the inside and outside must remain uniform.
The resulting mesh can be seen in the following figure.

Note

292

Provided that the mesh is aligned, there is no need to flip the mesh. In
our case, we flipped the entire mesh so that the bottom of the shell
mesh coincides with the inside of the pulley. The postprocessing then
becomes more intuitive.

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11 Add a pressure load.

Apply a pressure of 0.2 MPa (200,000 Pa) to

the surface of the pulley where the belt would

make contact.

12 Add fixtures.
Add a Fixed Geometry fixture to the

surface where the pulley contacts the shaft.

Note

Fixed Geometry is used because shell elements have both translational

and rotational degrees of freedom. Immovable would only constrain the
translations.

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13 Apply symmetry restraint.

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In the case of the shell mesh using surfaces mesh type, the symmetry
condition must be specified manually.

Apply Fixtures, Advanced Fixtures, Use reference geometry type.

Select all the edges located on the symmetry plane.

Tip

Right-click on a particular edge and click Select tangency.

Select Right plane as your reference entity.

Enter 0 mm in the Normal to Plane field under Translations.

Enter 0 rad in both Along Plane Dir 1 and Along Plane Dir2 fields
under Rotations.
Click OK to save this fixture.

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To illustrate a rule for applying symmetry boundary conditions,

consider a point on the plane of symmetry. Any displacement that
moves the point out of this plane must be restricted. Furthermore, any
rotation that inclines the plane of the cut from the plane of symmetry
must be restricted as well.

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Applying
Symmetry
Restraints

The following table summarizes symmetry boundary conditions in the

three principal planes.
Symmetry Boundary Conditions
Plane of Symmetry

xy

yz

xz

x translation

free

constrained

free

y translation

free

free

constrained

z translation

constrained

free

free

x rotation

constrained

free

constrained

y rotation

constrained

constrained

free

z rotation

free

constrained

constrained

14 Define material.

Make sure the material AISI 1020 is applied to the mid-surfaces.

15 Run the analysis.

This analysis will run very quickly.

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16 Plot von Mises stresses.

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Display the distribution of the von Mises stress.

Edit the definition of the plot to make sure that the
results correspond to the top face of the shell mesh.
Analogously, define a new plot for the distribution
of the von Mises stresses on the bottom of the shell
mesh.

Top

Bottom

We observe that the maximum von Mises stresses on the top and
bottom of the shell mesh are 64.5 MPa and 80.6 MPa, respectively. The
comparison of all of the results is shown at the end of the next section.

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17 List reaction forces.

Right-click the Results folder and select List Result Force.

Select the supported face.

Set the Units to SI and hit the Update button.

The Reaction force (N) and Reaction moment (N-m) dialogs show
the reaction resultants for the selected face in the global cartesian
coordinate system.

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18 Examine the results.

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We observe, for example, that the global y and x components of the

reaction force resultant are approximately 250 N and 116 N,
respectively.
The reaction moments resultants about the x axis is -0.73 N-m.
Note that 250 N vertical resultant force for half of the pulley
corresponds to the 500 N vertical reaction for the entire model.

The moment reactions reflect the fact that the pulley or the load is
asymmetrical with respect to the xy and xz planes. As expected, the
resultant reaction moment about the global z and y axes are nearly zero,
i.e. the pulley as well as the load are symmetrical with respect to the yz
plane.

Deformed Results

Deformed Plot displays toggles between the deformed and undeformed

geometry of the SolidWorks model.

Where to Find It

CommandManager: Simulation >Deformed Results to toggle

between deformed and undeformed plots.

19 Animate deformation plot.

To verify that the symmetry boundary conditions are correct, animate

the deformed geometry plot.
Double-click the Displacement plot to make it active.
Make sure Deformed Result
CommandManager.

Show the undeformed shape

over the deformed geometry.
Right-click the
Displacement1 plot and
select Settings. Select

Superimpose model on the

deformed shape. Adjust the
Translucent slider to see both

shapes.

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20 Animate the plot.

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Observe that the edge where the symmetry boundary conditions were
applied remains in its original plane (remains flat) while the pulley is
deforming.

The best way to report such results is to save the animation file in AVI
format.

21 Save and Close the file.

Shell Mesh Using

Outside Face

In Exercise 17: Shell Mesh Using Outer/Inner Faces on page 315 you
will solve the shell problem using the outside faces of the pulley and
compare the results with the three pulley studies in this lesson. It is
recommended that you complete this exercise to fully understand shell
modeling in SolidWorks Simulation.

Results
Comparison

The following table compares the displacement and stress results from
the four studies that we solved in this lesson.
Displacement
[mm]

von Mises
Stress [MPa]

D.O.F.

pulley shells midplane

0.306

80.6 (bottom)

31,236

pulley shells outer faces

pulley solids

0.316

81.3

55,449

pulley solids
dense

0.318

87.0

987,978

Study

Note

The values for the pulley shells - outer faces study will be
computed in Exercise 17: Shell Mesh Using Outer/Inner Faces on
page 315. Once you complete the exercise, fill in the remaining values
in the table.

Computational
Effort

The summary table also lists the number of degrees of freedom in each
model. While the model is open, locate the file with the OUT extension
in the SolidWorks Simulation database to view this information. The
number of degrees of freedom can be used as a measure of
computational effort required to obtain the solution. Lower
computational effort is directly related to the time and cost required to
run a study.

Note that the models produce practically identical displacement results.

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Compare the number of DOF for the pulley solids and pulley solids
dense studies to see that the dense model is 18 times larger. The stress
results of both solid models are within 5%, demonstrating that the
model with two layers of elements is not really necessary in this case.

The reason for the 8% maximum difference in the stress results

between shell and solid models is that shell elements can not account
for the shift of the neutral bending layer towards the inside of the pulley
curvature.

We must then conclude that solid elements provide more accurate

results when analyzing models with highly curved walls in bending.

Case Study:
Joist Hanger

Working with shell elements simplifies significantly for the sheet metal
features.
In this case study, we will analyze a sheet metal part used to support
floor joists in buildings. Each floor joist is supported at each end by a
joist hanger, so we can use symmetry to analyze one hanger with only
half of the beam.

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Project
Description

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The back face of the joist

hanger is nailed to a wooden
header. Each joist is
supported by a joist hanger at
each end and nailed in
position.
Calculate the maximum
stress and displacement on
the joist hanger and joist.

Open an assembly file.

Open Floor Joist for Analysis located in the Lesson08\Case

Studies folder.
This assembly has one joist hanger with only half of the beam.

Create a study.

Create a new static study named floor joist.

Set SolidWorks Simulation options.

Set the global system of units to SI (MKS) and the units of Length and
Stress to mm and N/m2 (Pa), respectively.

Store the results files in the results folder in the SolidWorks document
folder.

Add material.

Add the material Galvanized Steel to the joist hanger.

Add material.

Add new custom material for the wooden beam. Wood is not isotropic
(the same material properties in all directions) but rather orthotropic
(material properties are different in each perpendicular direction), so
we will have to define a custom material and some custom properties.

Note

In reality, wood is a rather complex material for which orthotropic

description is not exactly correct. Modeling wood as orthotropic
material is therefore a common engineering simplification giving
acceptable results.

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Select Linear Elastic Orthotropic for the Model Type. We can now
define the material constants in three perpendicular directions oriented
with respect to the selected reference geometry.

Select the Front plane as reference geometry. In this case, this

selection makes the global coordinate x, y, z axes coincide with the x, y,
z axes in the Material dialog window. Global x coincides with the
width, y with the height and z with the length of the beam.

Enter the following values for Elastic Modulus, Poisons ratio, Shear
modulus, and Mass density. Enter 50 N/mm^2 for the Yield
strength.

Click OK.

Make sure that correct material data is entered in correct units of N/

Note

mm^2 (MPa).

Set global contact.

Edit the top level assembly component contact (Global Contact) and
change it to No Penetration.

Note

302

The component contact handles this situation because the faces of the
solid components are touching. In general, contacts in meshes with
gaps must be specified with the help of the local contact conditions.

SolidWorks 2012

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Add fixtures.

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The hanger is nailed to the header beam. Add

Fixed Geometry restraints to the eight
cylindrical holes on the back face of the hangers.
Because we have a sheet metal part, be sure to
select the faces and not the edges of the holes.
The fixture will automatically map to the shell
edge.

Add symmetry boundary condition.

Add a Symmetry fixture on the end of the beam.

Effect of the nails

At this point a decision on the stiffness of the joint must be made. The
side nails between the beam in the joist certainly add some stiffness to
the joint. However, because the beam is placed in the joist before the
nails are applied, nearly all of the load in the vertical direction is
transferred into the joist through the bottom load bearing face. Nails
then add some stiffness reducing the actual deflection of the wooden
beam: this is, however, not the subject of this lesson. Our objective is to
assess the performance of the joist; transferring all the load then
provides more realistic and also conservative solution.

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Add external loads.

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Add a 500 N force to the top face of the beam. Because we are
analyzing only half of the beam, the total load on the beam then
represents 1,000 N.

10 Mesh.

Select Curvature based mesh under Mesh

Parameters.

Mesh with the element size created with the

slider all the way to the right. Use a Draft quality
mesh.
The beam will have solid elements and the
hanger will mesh with shell elements because it
is a sheet metal part.

Note

304

Notice that the surface generation in SolidWorks is not necessary; sheet

metal parts are shell meshed automatically.

SolidWorks 2012

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Analysis of Thin Components

11 Run.

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Run the study. Specify Direct Sparse solver.

Note

Since component contatcs are defined in the study and the area of
contact is found through several contact iterations, the Direct Sparse
solver is preferred.

12 Plot results.

We can observe that the maximum stress of 222 MPa is above the yield
strength of the joist material (204 MPa). To understand the stress
distribution correctly we will analyze the joist alone.

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13 Stress plot.

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We can observe that four support openings are exhibiting the stress
peaks. As was shown in Lesson 2, these values are somewhat unreal
and potential yielding with finer mesh can be ignored. More detailed
analysis may be required.

The high stress on the flat load bearing face is of some concern; its
value (92.61 MPa) is however, still below the yield. Also, applications
of the nails (which were excluded from this analysis) would help
somewhat to redistribute the load more evenly, thus reducing the stress
a little.

Note

Either side of the shell can be selected since a sheet metal has been
selected.

14 Save and Close the file.

306

SolidWorks 2012

Lesson 8
Analysis of Thin Components

The pulley case study introduces us to shell elements and familiarizes

us with concepts such as shell element thickness and orientation.

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Summary

The shell mesh using mid-surfaces modeling technique was introduced

and used to build the finite element model.

In modeling thin objects, shell mesh can also be placed on the outside
or inside faces of the solid bodies. The difference between the midsurfaces and either the outside or inside faces of the thin solid bodies is
in general small. If the difference reaches significant levels, shell
modeling then becomes inadequate and solid elements should be used
(i.e. the parts are too chunky for shell elements). Students should
complete Exercise 17: Shell Mesh Using Outer/Inner Faces on
page 315 to verify that both approaches yield comparable results for
structures with small thickness.
Symmetry boundary conditions were used in both modeling
techniques. Manual application of this restraint was introduced and
practiced as well.

The concept of mesh adequacy was also addressed, and the results and
modeling differences between shell and solid element models were
discussed. It was concluded that solid elements may produce results
that are slightly more accurate than those produced by shell elements,
provided the solid mesh is sufficiently fine. This can, however, lead to a
substantial increase in the problem size which may become intractable.

It was also shown that shell mesh may be generated on the faces of the
solid bodies or surfaces. Sheet metal parts are mesh with shell elements
automatically.

Tip

To model a sheet metal part as solid, i.e. to mesh it with solid elements
instead, right-click the surface feature in the FeatureManager design
tree and click Treat as Solid. In general this is, however, not desirable.

307

Lesson 8

SolidWorks 2012

Analysis of Thin Components

When a model contains sheet metal features, the corresponding

shell mesh will be formed automatically on the (outside face/
midplane/ inside face) of the sheet metal. The thickness of the shell
features (must/may not) be specified manually.

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Questions

When creating shell mesh manually, ideally it should be defined on

the (outside face/ midplane /inside face). Placing them on the
(outside face/ midplane /inside face), results in acceptable
difference of (0.0001%/a couple of percent/ tens of percent). If the
error is significantly larger, shell elements are not suitable for such
structure and solid elements should be used instead.

Shell elements can be used to mesh thin sheet like components. The
characteristic span length vs. thickness ratios indicating when to
use solid, thin, or thick shells are.
solid elements:

L
--t

<

L
t

thick shells:

---

thin shells:

---

L
t

The figure below shows a flat plate with a thickness t=5mm, and
planar dimensions of a=200mm and b=75. The bold and dashed
lines indicate simply supported (hinged) and free edges,
respectively. The best element type fit for this structure is solids/
thick shells/ thin shells.
Simply supported edge

b=75mm

Free edge

a=200mm

308

To accurately model the stress and strain gradients when using solid
mesh, a minimum of_____Draft quality or _____ High quality
solid elements should be required in the through the thickness
direction.
If a sufficient number of elements is generated, (solid / thick shell /
thin shell) elements will always provide the most accurate solution.
We sacrifice a little accuracy by using shell elements to mesh thin
features because______.

SolidWorks 2012

Exercise 16
Bracket

Exercise 16:
Bracket

Analyze a sheet metal bracket. The analysis will use shell elements.

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This exercise reinforces the following skills:

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Project
Description

Creating Shell Elements on page 285.

Shell Element Alignment on page 291.

A sheet metal bracket has been designed to support a side load of 450 N
[101 lb] applied in the x-direction of the global coordinate system.
We consider two design configurations:

I
I

One without any welds

One with welds connecting the miter flanges

Compute and compare the maximum displacements and maximum von

Mises stresses for these two configurations.

Open a part file.

Open horseshoe located in the Lesson08\Exercises folder.

Examine the two configurations:
I

no welds

with welds

In the with welds configuration, a total of eight extrusions have been

added to connect the mitre flanges.

no welds

Part 1: Analysis of
Bracket With No
Welds

with welds

The first analysis will be without the welds that would stiffen the part.

Activate the no welds configuration.

Create study.

Create a static study named no welds analysis.

Define material properties.

Assign Galvanized Steel to the part.

309

Exercise 16

SolidWorks 2012

Bracket

Create mesh.
Select Curvature based mesh
under Mesh Parameters.

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Specify High quality elements and

the default settings.

Shell mesh should be consistently aligned to ensure correct stress

averaging along the boundaries separating faces.

Note

Fix the edges.

Select the end faces on both sides of the bracket

and apply a Fixed Geometry restraint.

Apply 450 N force.

Apply a 450 N forces to the top

face of the bracket, as indicated

in the figure.

Moment Load

The Force definition window also allows you to apply a load in the
form of moment.
This option is possible because shell elements have six degrees of
freedom (three translational and three rotational) and, thus, can be
loaded with either a force or a moment.

310

Run the analysis.

SolidWorks 2012

Exercise 16
Bracket

Plot von Mises stresses on both faces.

The stress plot indicates that the outside face is yielding at the sharp reentrant edges of the sheet metal bracket. As you recall however from
Lesson 2, the numerical values of these stress results are meaningless,
as they are singular at these locations.

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Outside Face

Inside Face

311

Exercise 16

SolidWorks 2012

Bracket

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The stress results are

meaningful at a certain
distance from the source of
the singularity. See Lesson
2 on page 85 for the detailed
discussion of this
phenomenon.

10 Plot displacement results.

We observe the maximum resultant displacement of approximately

1 mm [0.04 in].

Part 2: Analysis
With Welds

We will run the analysis again to see how much stiffer the part is when
the flanges are welded together.

Activate the with welds configuration.

Create new study.

Create a study named with welds analysis using the same study
options as in the previous analysis.

Copy external loads and fixtures.

Even though the study no weld analysis is inactive, you can copy

external loads, fixtures and material.

312

SolidWorks 2012

Exercise 16
Bracket

Mesh the model and align shell elements.

Select Curvature based mesh under Mesh Parameters.

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Use High quality elements with the default settings.

5
6

Run the analysis.

Plot von Mises stresses.

The maximum von Mises stress results are not easily comparable
because of stress singularity in the model without welds.

Outside Face

Inside Face

313

Exercise 16

SolidWorks 2012

Bracket

Plot resultant displacements.

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Comparison of the resultant displacements between the model without

welds and the model with welds shows a reduction of the maximum
displacement from 1 mm [0.04 in.] to 0.04 mm [0.0017 in].

314

Save and Close the file.

SolidWorks 2012

Exercise 17
Shell Mesh Using Outer/Inner Faces

Exercise 17:
Shell Mesh
Using Outer/
Inner Faces

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The mid-surface location for the shell mesh is the most desirable. In
some situation however, extraction of the midplane is too difficult or
not convenient. In such cases the shell mesh can be placed on either the
outside or inside face of the solid geometry. Because shell elements are
suitable for these structures, the difference in results due to different
position of the shell is rather small.
This exercise reinforces the following skills:

Creating Shell Elements on page 285.

We will set up a new study with the shell mesh created on the outside
faces of the solid model and compare the results with those obtained in
the previous lesson. We must apply the external loads, fixtures and
materials again because we are using different position for the shell
mesh. The setup steps are only outlined below as they are the same as
in the previous example.

Open the part file.

Open Pulley used in the Lesson 8 case study.

Define new study.

Define a new Static study named pulley shells - outside face.

Hide and exclude mid-surface.

Hide and Exclude from Analysis the surface feature used in the lesson

case study.

Make sure that the solid body is shown.

Define shells.

Right-click on the SolidBody in the pulley folder and select Define

Shell By Selected Faces.

Select all faces on the outside of the pulley.

Specify Thin shell with the Thickness of 2 mm.

Apply material.

Apply the material AISI 1020 steel to the offset surfaces.

315

Exercise 17

SolidWorks 2012

Shell Mesh Using Outer/Inner Faces

Apply fixed restraint.

Apply a Fixed Geometry

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fixture to the outside semicylindrical face, as indicated

in the figure.

All boundary conditions and loads must be applied on the face where
the shell mesh feature was defined; in our case the outside face.

Important!

Apply symmetry
restraint.

Manually create a
symmetry fixture on the
outside top edges of the
pulley, as indicated in the
figure.

Review the case study used in the lesson for the specification of the
symmetry boundary condition on surface feature.

Hint

Apply pressure.

Apply a pressure of 0.2 MPa

(200,000Pa).

Note that the pressure must be

applied on the outside face
where the shell feature was
defined.

316

SolidWorks 2012

Exercise 17
Shell Mesh Using Outer/Inner Faces

Apply mesh control.

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Apply a mesh control with a

Element size of 1.5 mm to the
rounded face, as indicated in the
figure. Keep the Ratio at the
default value of 1.5.

10 Mesh the model.

Select Standard mesh and mesh
the model with High quality
elements and the global Element
size of 4.5 mm and a Tolerance
of 0.225 mm.

Make sure that the shell mesh is

aligned. To be consistent with the
first part of this lesson, orient the mesh so that the bottom of the shell
mesh coincides with the inside of the solid pulley.

11 Run the analysis.

12 Plot von Mises stress.

Plot the von Mises stresses on both the bottom and the top of the shell
mesh.

317

Exercise 17

SolidWorks 2012

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Shell Mesh Using Outer/Inner Faces

13 Examine the plots.

We can see that the maximum von Mises stresses on the top and
bottom are 83.7 MPa and 67.46 MPa, respectively. These values are
very close to the results obtained in the lesson, where the mesh was
located exactly at the midplane.

In many applications, the midplane extraction is not a trivial process.

Given the fact that shell mesh is applicable to thin sheet-like structures,
the above modeling error is rather small and commonly acceptable.

14 Save and Close the file.

318

SolidWorks 2012

Exercise 18
Spot Welds - Shell mesh

Exercise 18:
Spot Welds Shell mesh

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We will now return to Exercise 13: on page 221 where we practiced

the use of the spot welds. We will now compare the results of that
exercise with the results of a study using shell elements. This study will
also show the use of spot welds for shell sheets that are not in direct
contact.

Open an assembly file.

Open tube solid located in the Lesson08\Exercises folder.

For the result comparison purposes this assembly contains the results of
Exercise 13: on page 221, where this problem was solved using the
solid elements.

Create new study.

Duplicate the study tube solid and name it tube shells.

Treat tubes as sheet metal.

Right-click on both bodies in the Parts folder and select Treat as

Sheet Metal.This will define them as shells and their thickness will
automatically transfer from SolidWorks.

4
5

Assign materials.
Make sure that Galvanized steel is assigned to both sheets.
Re-Mesh the assembly.

Select Curvature based mesh under Mesh Parameters.

Create High quality mesh with the default settings.

Apply soft springs and specify direct sparse solver.

Run the analysis.

List reaction force and calculate torque.

Using the identical procedure as in Exercise 13: on page 221, list the

circumferential component of the resultant reaction force and compute

the resultant torque.

Compare your answer with the results obtained in Exercise 13: on

page 221.

Save and Close the file.

319

Exercise 19

SolidWorks 2012

Edge Weld Connector

Exercise 19:
Edge Weld
Connector

Single sided
fillet weld

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A segment of piping system,

welded at several locations, is
to be tested on the extreme
loads: 3.5 mm vertical and 1o
degree torsional
displacements applied at the
end of the segment.

We will use FEA and the edge

weld connector to simulate
this problem. The size of the
edge weld beads will also be
designed.

Single sided
groove weld

Double sided
3.5mm vertical and
fillet weld
1 degree rotational
prescribed displacements

This exercise reinforces the following skills:

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Project
Description

Edge weld on page 191.

Cylindrical Coordinate Systems on page 160.

A segment of the piping system manufactured from 5mm thick AISI

1020 steel sheets is anchored to a solid steel wall. The other side of this
segment, modeled as free, is loaded with a 3.5 mm vertical and 1o
rotational displacements applied at the free edge. These loads are
known as the most extreme conditions to which the system can be
exposed at this location. The components are connected using fillet and
groove welds, as indicated in the above figure.
Determine the optimum size of the weld beads at all three locations.

Open an assembly file.

Open Pipes located in the Lesson08\Exercises folder.

Set SolidWorks Simulation Options.

Set the system of Units to SI (MKS), the units of Length to mm, and
Stress to N/m^2.
Create study.

Create a study named extreme loading.

Review Material properties.

Verify that the material definition, AISI 1020 Steel, has been
transferred from SolidWorks to SolidWorks Simulation.

320

SolidWorks 2012

Exercise 19
Edge Weld Connector

Edge welds can be defined between two shell bodies, or one shell and
one solid body. The terminated part must always be represented by
shell body. The edge weld beads are defined by the two faces which are
connected and the edge on the terminated part representing the location
of the bead. Electrode type, weld strength and the estimated weld size
must be specified manually or taken from the library.

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Introducing: Edge
Weld

Where to Find It

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Shortcut Menu: Right-click Connections, Edge Weld.

CommandManager: Simulation > Connections Advisor > Edge
Weld.

Define shells.

Define Thin shells for the pipe and the supporting sheet. Specify
Thickness of 5 mm.

Define Edge Weld.

First, we will defined the edge weld bead between the first section of
the pipe and the solid component representing the stiff steel wall.
Right-click the Connections folder and select Edge Weld.
Under Weld Type select the Fillet, Single-Sided.

For Face for Set 1, select the face of the terminated component, as
shown in the figure below.

For Face for Set 2, select the face of the second component (in this
case face of the solid component).
For Intersecting Edges, select the weld bead location on the first
terminated component.

Specify the weld to be on side 1 under Weld Orientation. This will

place the weld on the top surface of the shell

Note

If we specified the weld to be on side 2, it would be on the bottom

surface of the shell. Be sure to check the mesh to make sure the top and
bottom are defined correctly.

321

Exercise 19

SolidWorks 2012

Edge Weld Connector

Under Weld Sizing, Select the American Standard.

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Select E60 for the Electrode and enter 4 mm for the Estimated weld
size. Enter the Safety Factor as 1.
The Weld strength field is populated automatically based on the
selected electrode.
Click OK.

For the custom electrode properties select Custom Steel or Custom

Aluminum under Electrode.

Note

Repeat the process for the remaining two edge welds.

Similarly, create one Fillet, Double-Sided and one Groove, SingleSided edge welds as indicated in the figure below.

Use the same properties as specified in the previous step.

For the groove weld, specify the location on side 1.

322

SolidWorks 2012

Exercise 19

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Edge Weld Connector

Fillet, Double-Sided
edge weld

Groove, Single-Sided

Apply fixtures.

Apply Fixed Geometry fixtures to the four

faces of the rigid steel wall and to the
bottom edge of the supporting sheet, as
indicated in the figure.

Prescribe displacements.

Using Use Reference Geometry fixture type

prescribe 3.5 mm vertical displacement to the end
edge, as indicated in the figure.

323

Exercise 19

SolidWorks 2012

Edge Weld Connector

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Using Use Reference

Geometry fixture type
prescribe 1o (0.0175 rad)
rotational displacement to
the edge of the pipe. Use the
cylindrical face as a
reference and make sure
that the direction of the
rotation is the same as
shown in the figure.

10 Mesh.

Mesh the assembly with the High quality mesh of the default size.

11 Check shell orientation.

We specified the welds on side one (top of the shell). We need to make
sure the shell is aligned properly. If necessary, flip the shells to be
aligned as shown in the figure below.

12 Run.
Run the simulation.

324

SolidWorks 2012

Exercise 19
Edge Weld Connector

13 Resulting displacements.

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Create the plot of the resultant displacements.

Note

The following post processing options for the edge weld are only
available for Simulation Professional.

14 Post process the edge welds.

Right-click the Results folder and select List Weld Results.

Under Selection dialog select SI for the Unit and All edge welds for
the Type.

The table above shows all of the resulting weld forces for all welds in
the model along with the computed minimum weld sizes.

Notice that the edge weld between the pipe and the supporting sheet is
plotted green, while the remaining two are red. This result indicates
that the estimated weld size (4 mm) entered in step 6 on page 321 is
sufficient for the middle weld, while the other two need attention.

325

Exercise 19

SolidWorks 2012

Edge Weld Connector

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15 Edge weld connector 1.

Under Type select Edge Weld Connector-1.

Note that the maximum of the Weld size (mm.) row indicates the
required weld size of 9.76 mm, which is significantly larger than the
estimated weld size of 4 mm. The weld is therefore plotted in red.
The yellow sphere and the red arrow in the above figure indicate the
origin and the orientation of the weld bead.

Click the Plot button to see the variation of the required weld size as a
function of the weld bead.

Click OK to close the Edge Weld Results dialog.

326

SolidWorks 2012

Exercise 19
Edge Weld Connector

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16 Weld Check Plot.

Right-click the Results folder and select Define Weld Check Plot.

Click OK.

The dialog window provides easy overview of the welds while the
transparent plot indicates all welds in the assembly. Again, welds beads
in red color need attention because their estimated size was not
sufficient.

Tip

The European Standard for evaluating welds is also available. It is

recommended to investigate the results available when using this
standard. Additional information about weld sizing is also located in
the Help menu.

17 Save and Close the file.

327

Exercise 20

SolidWorks 2012

Container Handle Weld

In Container Handle on
page 84, we assessed the design
of the waste container handle.
In this exercise you will size the
double-sided fillet welds
connecting the container handle
to the two square base plates.

Double-sided
Fillet welds

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Exercise 20:
Container
Handle Weld

All necessary information

Base plates
required for this task can be
obtained from the text of the assignment in Exercise 3: on page 84.
The base plates, welded to the container webs, can be assumed as
rigidly fixed.
This exercise reinforces the following skills:

I
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I
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Procedure

328

Create mid-plane surface. on page 285.

Exclude from Analysis on page 286.
Thin vs. Thick Shells on page 287.
Define the shell. on page 287.
Edge weld on page 191.

The assembly for this study is located in the Exercises folder. Choose
the most suitable location of the shell feature.

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Lesson 9
Mixed Meshing
Shells & Solids

Objectives

Upon successful completion of this lesson, you will be able to:

I

Construct good quality mesh with the appropriate mesh controls.

Set up various shell to shell and shell to solid contacts in mixed

mesh assembly.

329

Lesson 9

SolidWorks 2012

Mixed Meshing Shells & Solids

There are many cases where a model has both thick and thin sections.
In these cases, the mesh needs to be a combination of both solid and
shell elements.

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Mixed Meshing
Solids and
Shells

In this lesson we will use the mixed mesh capabilities of SolidWorks

Simulation to construct a mesh where solid elements coexist with
shell elements in the same study. However, we will see that it takes
extra efforts to ensure mixed mesh connectivity.

You will recall from the first lesson that nodes of a solid element have
three degrees of freedom, meaning that node displacement is fully
described by three translational components. You will further recall that
nodes of a shell element have six degrees of freedom. Displacement of
a shell element node is described by three translational components and
three rotational components.
y

ROT Y

ROT X

ROT Z

DEGREES OF FREEDOM OF
A NODE OF A SOLID ELEMENT

DEGREES OF FREEDOM OF
A NODE OF A SHELL ELEMENT

We usually show these displacement components (or degrees of

freedom) as aligned with global coordinate system. However, degrees
of freedom may be presented in any coordinate system.

Because nodes of solid elements do not have rotational degrees of

freedom as compared to nodes of shell elements, an attempt to connect
shell and solid elements results in an unintentional hinge along the
common edge.

330

SolidWorks 2012

Lesson 9
Mixed Meshing Shells & Solids

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The rotational degrees of

freedom of shell element
nodes have nothing to hold
on to at the interface with
solid element nodes.
Therefore, these rotations
remain unconstrained,
forming a hinge along the
connecting edge.

Hinge

With a hinge joint present,

we have a discontinuous
displacement field
(discontinuity of rotations)
and possible rigid body nodes in the model.

Shell Elements

Solid Elements

The incompatibility between shell and solid elements that lead to

unintentional hinges is not specific to SolidWorks Simulation. It occurs
in any FEA software every time we try to connect elements of different
type having nodes with different numbers of degrees of freedom.

Bonding Shells
and Solids

As a consequence of the element type incompatibility, the shell and

solid portions of the mesh remain completely detached. The software
enforces auto-bonding between a face or an edge of shell and a solid
through multi-point constraints internally when the mesh is not
compatible. In some special cases, it is best practice to define proper
local bonded contact sets along all connecting edges and faces.

Mixed Mesh:
Supported
Analysis Types

Mixed meshing is available for static, frequency, buckling, thermal,

nonlinear and linear dynamic studies.

Case Study:
Pressure Vessel

This case study will involve the analysis of a pressure vessel. It consists
of some thin wall elements such as the vessels shell. It also has thick
walled elements such as the flanges.

In this case study, we will prepare the shown pressure vessel for the
analysis (mesh, loads, contacts and supports) and solve a simplified
static analysis. No conclusions on the design safety and similar topics
will be made. This is the subject of Lesson 11 in SolidWorks Simulation
Professional training manual, where ASME Boiler and Pressure Vessel
Code governing the design of pressure vessels is discussed and utilized.

331

Lesson 9

SolidWorks 2012

Mixed Meshing Shells & Solids

A pressure vessel manufactured

from low alloy carbon steel SA
515, grade 60 shown in the figure
is to be analyzed. The vessel is
orientated vertically and
supported on four lugs (see the
figure) with slotted holes
allowing the vessel to expand
freely in the radial direction
(detailed lug subassemblies are
not needed for this analysis and
are not included in the model).
The maximum operating
pressure load for the vessel is
165 psi at a temperature of 700
F. Besides pressure no other
loads are considered in this
analysis.

Top head

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Project
Description

Manhole nozzle

Vessel
Section 1

Small
nozzle

Steam inlet

Vessel
Section 2

Lug

Bottom head

Analyze the
Assembly

Before proceeding, we need to analyze each subassembly and decide

upon the appropriate mesh type.
I

Pressure vessel body, top

and bottom heads: The

thickness of the vessel body

manufactured from 0.5 in
carbon steel is very small
compared to the outside
vessel diameter of 56 in.
Therefore shell elements
will be used for these
components.

332

SolidWorks 2012

Lesson 9
Mixed Meshing Shells & Solids

Nozzles: The Steam inlet nozzle shown in the above figure is

manufactured from the same grade carbon steel piping with a 1 in

wall thickness and the outside diameter of 24 in. The Manhole
nozzle is manufactured from typical piping with wall thickness of
0.1875 in and a 20 in diameter. The lug support reinforcements as
well as pipings have a thickness of 0.25 inches which is very small
relative to the diameter of the lug pipings. Shell elements will
therefore be used for the modeling of all nozzles and their
reinforcements.
Nozzle flanges and the Manhole cover: Nozzle flanges are not
very thin and may be exposed to significant bending moments
(especially the manhole nozzle flanges). The Manhole cover is
also relatively thick and is bolted to the flange. Solid elements will
therefore be used to study the accurate stress results at these
locations.

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Procedure

Due to the time required to set up the study some of the study
components as well as contacts have already been defined in study
partially completed. We will make use of them during the study
setup procedure.

Open an assembly file.

Open Pressure Vessel located in the Lesson09\Case Studies

folder.

The model already contains study partially completed with many

steps partially completed. Continue working with this study.

Verify the default units.

Verify that the English (IPS) are set as the default unit system. Make
sure that in is used for Length/Displacement and psi for Pressure/
Stress.
Explode.

Explode the assembly to make it easier to see the individual

components.

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Mixed Meshing Shells & Solids

Before beginning the analysis, we decided which features we wanted to

be meshed as shell elements and which would be solid elements.
SolidWorks Simulation can generate shell mesh on either surfaces or
faces of the solid bodies. To place the shell mesh on the mid-surface, a
preferred location for the shell mesh, additional surface features must
be generated in each part file; this procedure can be time consuming.
Alternatively, we can place the shell mesh on the outside/inside faces of
the solid bodies. We can then offset the shell so that it is recognized on
the mid-surface of the body. This approach will be favored in the
present case because it eliminates the need to generate additional midsurfaces.

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Preparing the
Model

In the following steps, we will define the thickness for the shell
elements.

Introducing: Shell
Offset

If it is inconvenient to create the mid-surface within

the solid body for the definition of the shells, you
can choose to create the shell on the surface of the
solid body and then offset the shell so that the
software recognizes it as a mid-surface.

In the Shell Definition property manager, you

specify the location of the shell by selecting a
surface as the reference geometry. You then specify if you have
selected a mid-surface, top surface, or bottom surface. If a top surface
is selected, the shell will be located at a distance of half the thickness
below the selected surface. Likewise, if the shell is defined as a bottom
surface, the shell will be located at a distance of half the thickness
above the selected surface. Additionally, if your shell should exist at
some other distance away from that surface, you can select Specify
Ratio.

Important!

334

You must be careful when specifying top, bottom, or offset because the
mesh will ultimately define the shell location based on what is the shell
top or bottom.

SolidWorks 2012

Lesson 9
Mixed Meshing Shells & Solids

Vessel body shell.

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Right-click on the
corresponding solid
bodies in the Simulation
study tree and select
Define Shells By
Selected Faces.

Then, select the outside

faces and specify Thin
shell formulation with a
Thickness of 0.5 in.

Select the Bottom

surface as the Offset.
When we mesh the model,
we must insure that this
surface is in fact the
bottom.

The rest of the shell features was already defined beforehand.

Note

Both head shells consist of a

2:1 elliptical and 2 in straight
sections, as recommended in
the ASME Boiler and
Pressure Vessel Code. Make
sure that both faces are
selected in the definitions of
the vessel head shells.

The remaining components in

the manhole area, Manhole
cover and the Manhole nozzle flange will be meshed using solid
elements, as decided in the beginning of this lesson.

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Mixed Meshing Shells & Solids

The data for SA 515, grade 60 carbon steel material can be obtained
directly from the ASME Boiler and Pressure Vessel Code, Section II,
Part D- Properties and is summarized in the table below.

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Material

Ultimate Tensile strength

(room temperature)

60,000 psi

Yield tensile strength

(room temperature)

32,000 psi

Mean coefficient of thermal

expansion (70 F - 700 F)

7.6e-6 /F

Thermal conductivity (700 F)

5.56e-4 Btu/(s-in-F)

Youngs modulus (700 F)

25.3e6 psi

Poissons ratio

0.33

Specific heat

0.09 Btu/(lb-F)

Alternatively the material data can also be found from other sources
(see the discussion below).

Steel Identification
Systems

Some steel types may be identified using different systems (or

standards), each with different nomenclature. We use SA 515, grade 60
specification typical in the ASME Boiler and Pressure Vessel Code.
Section II, Part D- Properties lists basic material constants as functions
of temperature and provide alternate information on the alloy
identification. For SA 515, grade 60- the code lists an alternative
identification UNS # K02401.

UNS Index

The Unified Numbering System (UNS) was created by a joint effort of

Society of Automotive Engineers (SAE) and ASTM. Its goal is to
provide a unique identifying system for metals and alloys.

Other Indices

Many indices for steel identification exist. For example, American

Society for Testing and Materials (ASTM), American Iron and Steel
Institute (AISI), Deutsches Institut fr Normung (DIN), Euronorm and
many others. Ask your instructor about the standards common in your
geographical region.

Introducing:
Analysis Research

We can also use SolidWorks Simulation Research to find the

corresponding material data. Analysis Research can search both the
analysis data base and Matweb. Once Research is selected, a new
Analysis Research tab
will appear in the Task Pane.

Where to Find It

336

Menu: Simulation, Research . Select the Analysis Research tab

.

SolidWorks 2012

Lesson 9
Mixed Meshing Shells & Solids

Search for material properties.

In the Simulation menu, click Research. In
the Analysis Research dialog, enter
K02401 in the Search Matweb field and
click OK.

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The search results return the information for

ASTM A284 Steel, grade C which is an
alternative identification for UNS # K02401
carbon steel.

The following are the material data obtained from the Matweb
database:

Note

Ultimate tensile strength

60,200 psi

Yield tensile strength

29,700 psi

Bulk modulus K

20,300 ksi

Shear modulus G

11,600 ksi

Density

0.284 lb/in3

We will use the data from the ASME Boiler and Pressure Vessel Code
for our simulation. (The yield strength listed above is slightly smaller
than the value listed in the ASME Boiler and Pressure Vessel Code.)
However, each engineer is responsible for collecting their own reliable
material data.

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Bulk and Shear

Moduli

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We are familiar with the elastic modulus E (Youngs modulus) and the
Poissons ratio as constants required to characterize linear elastic
material. Bulk (K) and shear (G) moduli are alternative material
constants and are related to E and as follows:
9KG
E = -----------------3K + G

3K 2G
= --------------------6K + 2G

These relations hold for the traditional 3-dimensional isotropic analysis

only. If other special analysis dimensions are used, modified equations
have to be used.

Note

Out of all four linear elastic material constants (E, , G and K) a

combination of any two is unique. The remaining two constants can be
evaluated using the above relations.

Substituting the data for the bulk and shear moduli for our material we
obtain 29,232 ksi and 0.26 for the Youngs modulus and Poissons
ratio, respectively. Again, for our simulation we will use the material
data provided by the ASME Boiler and Pressure Vessel Code.

Create custom material.

Right-click the Parts folder and select Apply Material to All.

In the Material window create a new category Lesson 9 materials,

and add a new material SA 515, grade 60. Enter the material properties
provided my the ASME Boiler and Pressure Vessel Code shown in the
figure below.

Click Apply and Close.

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Lesson 9
Mixed Meshing Shells & Solids

Entities with clearance between them must be always bonded using

local Bonded contact set.

Shell Face to Shell

Face Bonding

Face to face bonded contact between two shells is always incompatible

and will be automatically enforced if the faces are planar and touching.
The user needs to manually define bonding for touching non-planar
faces that are meshed with shell elements. Compatible meshing with
global bonding will be effective for two shells that directly share an
area created using split lines.

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Bonding Entities
with Clearance

Manhole nozzle reinforcement

vs. Vessel section 1 contact.
Create a local Bonded contact
between the two outer top edges on
the Manhole nozzle
reinforcement and the Vessel
section1 shell.

Note

Use the large face of the vessel as Set 2. Also, since a clearance exists
between these shell features, incompatible meshing is default for this
interface.

Shell Edge to Shell

Face Bonding

Whenever the shell edge coincides with the split line on the shell face,
no local bonding is required. The top level assembly component
(Global Contact) compatible bonding condition ensures that the
interfacial nodes are merged. Additionally, auto-bonding will be
enforced if the shell edge and solid face/shell face are part of a local
component contact definition. The criteria for bonding are determined
by taking the shell thickness into consideration.If there is a clearance
between the edge source and the face target, local bonding must be
defined.

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Vessel section 1 to Manhole

nozzle contact.
Define a local Bonded contact
between the outer edge on the
vessel opening and the Manhole
nozzle shell.

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Shell to Solid
Bonded Contact

340

Manhole nozzle
reinforcement to Manhole
nozzle contact.
Specify local Bonded contact
between the edge of the
Manhole nozzle
reinforcement and the
Manhole nozzle.

The majority of the interfaces featured in our model represent shell to

solid contact type. If there is a clearence between the shell and solid, it
is best practice that local bonded contact is created. Also, a shell entity
(face or edge) must be Set 1, while faces on the solid components must
be Set 2.

SolidWorks 2012

Lesson 9
Mixed Meshing Shells & Solids

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10 Manhole nozzle flange to

Manhole nozzle contact.
Specify local Bonded contact.

Use the nozzle shell face as

Set 1 and the solid face of the
flange as Set 2.

Note

The remainder of the bonded

contacts in this study was
already defined beforehand.

11 Manhole cover to Manhole nozzle flange connection.

Since we practiced the definition of the bolted connections in the

previous lessons, all of the bolted connections have already been
defined in this study.

12 Manhole cover to Manhole

nozzle flange contact.
Define No penetration, Surface to
surface contact between the
Manhole cover and the top face of
the Manhole nozzle flange as

shown in the figure. Make sure that

Gap (clearance), Always ignore
clearance option is selected.

Note

The gap (clearance) contact

option must be used because the
gasket between the Manhole
cover and the Manhole nozzle
flange is not modeled, creating
an empty space.

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13 Lug supports.

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Lugs are connected to the

pressure vessel using
slotted bolt connections
(not modeled) allowing for
the radial displacements of
the pressure vessel wall.
This way no unnecessary
stresses due to the supports
are generated in the vessel.

Use Right assembly plane as reference and restrain the two in plane
translations on the two lug supports parallel to the Right plane (Lug
<1> and Lug <3>).

14 Constrain other lugs.

Constrain the other two lugs in the same way with the Front plane as
the reference.

15 Create mesh.

To begin the meshing phase let us mesh the model with Draft quality
elements. Use the Standard mesh with the Global size of 2.711 in.
The creation of the mesh fails and a message is shown:
Mesh creation failed for the following 1 parts:
Manhole cover-1

You can start Failure Diagnostics by right clicking the mesh

icon in the Feature Manager and selecting Failure Diagnostics
from the menu.

This can happen often if no local mesh controls are used in complex
assemblies.
Click Mesh Failure Diagnostic in the window.

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Lesson 9
Mixed Meshing Shells & Solids

When meshing fails, it can sometimes be difficult to determine the

cause. The Failure Diagnostics tool is used to help locate the problem.

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Failure
Diagnostics
Where to Find It

Shortcut Menu: Right-click Mesh folder and click Failure

Diagnostics

Meshing Small
Features

In most cases when a difficult meshing problem occurs a small feature

(or proximity of small features) exists in the assembly (or part). To
successfully mesh such regions, correct local mesh controls must be
applied.

16 Analyze mesh failure.

The Failure Diagnostics indicates that the

mesh has failed on one of the faces of the

Manhole cover part.

Select the face to see where the mesh has failed.

We can see that the mesh has failed on the face

with the bolt holes. Elements cannot be jammed
in between the bolt holes and the lip on the
manhole cover.

The failure diagnostics gives us some options on

how to deal with this failure. We will try to apply
a mesh control to this face.

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Mixed Meshing Shells & Solids

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17 Apply Mesh Control.

With the Face-1 selected in the Failure
Diagnostics, select Mesh Control.

Enter an Element Size of 1.5 in and click OK in

the Mesh Control PropertyManager.
The model should immediately mesh.

Important!

When using the Failure Diagnostics, only the failed parts are remeshed. This can save a significant amount of time since the computer
does not have to re-mesh all of the geometry.

18 Apply mesh controls to the remaining components.

Mesh controls would have to be applied on other remaining

components of interest (nozzles, flanges, and nozzle to vessel
junctions).

All the remaining components mesh controls have been defined

beforehand.

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Mixed Meshing Shells & Solids

19 Examine the mesh.

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This step completes the definition of the mixed mesh and all the
appropriate contact conditions. Notice that the resulting mesh is
incompatible even though, under the global bonding menu, compatible
mesh was requested.
As no two faces or edges touch, mesh compatibility is not possible.
Lesson 6 explains that the compatibility settings applies to initially
touching faces only. Further more, solid to shell interfaces are always
meshed incompatibly.

20 Check shell alignment.

Remember when we defined the shell, we said that it was located on the
bottom of the face. If we notice the mesh, the shell bottom is
represented as an orange color. If we had defined the shells on the top,
we would have to flip the shell elements so that the tops were shown on
the outside of the vessel.

21 Explode.

Explode the assembly to make it easier to select components and faces.

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Mixed Meshing Shells & Solids

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22 Hide the mesh.

23 Internal pressure in vessel and the
nozzles.
Apply a 165 psi Pressure load on all

vessel and nozzle shells.

Note

Make sure the pressure arrows point outwards to simulate internal

pressure.

24 Internal pressure on
Manhole cover.
Apply a 165 psi Pressure on

the raised face of the

Manhole cover.

25 Study properties.
Select the Direct Sparse solver.

Note

Since multiple contatcs are defined in the study and the area of contact
is found through several contact iterations, the Direct Sparse solver is
preferred.

26 Run the study.

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Mixed Meshing Shells & Solids

27 Resulting displacements.

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We can observe the maximum displacements of approximately 0.19 in

[4.95 mm], a fairly small amount given the vessel diameter of 56 in.

28 Von Mises stresses.

The maximum stress of approximately 62.4 ksi [430.4 MPa] occurs in

the support lug location.

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Mixed Meshing Shells & Solids

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Zoom in and analyze the location

of this maximum.
The stresses are localized along
the bonded interface. Due to the
incompatible bonding interface,
large size and draft quality of the
mesh, the stresses reach
unrealistically large values along
these bonded edges. The ASME
Boiler and Pressure Vessel Code
treats these localized stress
concentrations in a special way.
This area is the subject of Lesson
11 of SolidWorks Simulation Professional training manual.

In this study we are interested in the resultant contact force that would
be used for the design of the weld rather than stress values, which are
highly localized in this region.

29 Save and Close the file.

Note

348

As was mentioned at the beginning of this lesson, no conclusions on the

vessel design will be made. An example of the vessel analysis with
regards to the ASME Boiler and Pressure Vessel Code is shown in
Lesson 11 of the SolidWorks Simulation Professional training manual.

SolidWorks 2012

Lesson 9
Mixed Meshing Shells & Solids

In this lesson we practiced a design of the mixed finite element mesh

with a combination of the solid and shell elements.

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Summary

The pressure vessel assembly featured multiple shell to shell and shell
to solid bonded interfaces. Due to the nature of the shell modeling
clearances (gaps) were created between various components. This is
overcome by generating incompatible meshes where nodes along
bonded interfaces are not merged, but rather constrained by the
additional equations. It was shown that local bonded contact is
necessary to properly bond mixed interfaces and interfaces with
clearances.

An example of the procedure for the mesh design and a failure

diagnostics was shown. Very small features, or rather small proximity
of the features in the model may cause meshing problems. Proper mesh
controls applied on such features are necessary.
No conclusions were made on the design of the pressure vessel. To
make conclusions on the design, we would need to refer to the ASME
Boiler and Pressure Vessel Code that deals with the stress
concentrations. This area is the subject of Lesson 11 of SolidWorks
Simulation Professional training manual.

Questions

After generating all bonded contacts and successfully meshing a

complex assembly you attempt to solve the analysis. The solver
displays the following error message:

Frequently some of the bonded contacts are defined incorrectly or

not at all as it is easy to unintentionally forget to define some of the
contacts. Lack of proper fixtures or bonded contacts makes models
unstable, resulting in the solver displaying the above message.
Propose a solution how to locate missing/incorrect restraints or
bonded contacts.

A bonded contact between the shell and solid components (does /

does not) require a local bonded contact condition.

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Lesson 9

SolidWorks 2012

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Mixed Meshing Shells & Solids

350

SolidWorks 2012

Exercise 21
Mixed Mesh Analysis

Exercise 21:
Mixed Mesh
Analysis

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In this exercise, we will analyze a pump impeller that requires a mixed

mesh due to the differences in thickness between the blades and the
hub.
This exercise reinforces the following skills:
I
I
I
I

Project
Description

Mixed Meshing Solids and Shells on page 330.

Bonding Shells and Solids on page 331.
Define the shell. on page 287.
Shell to Solid Bonded Contact on page 340.

A water pump impeller operates

at 2000 rpm. Analyze the
impeller to determine the
deformation of the blades and the
stress magnitudes.
The centrifugal force in this case
doesnt have a significant impact
on the results of this analysis and
will be neglected.

Open a part file.

Open Impeller01 from the

Lesson09\Exercises folder.

Create study.

Create a Static study named

centrifugal 01.

Apply Fixtures.

We assume that a solid circular

shaft is rigidly connected to the
impeller. Therefore, to simulate a
presence of the shaft, apply
FIxed Geometry boundary
condition to the cylindrical face
shown in the figure.

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Exercise 21

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Mixed Mesh Analysis

Apply force load.

Apply a 8.9 N Normal force

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on each of the blades. Make

sure the force load points in
the correct direction (see the
figure).

The pressure resultant force was computed using SolidWorks Flow

Simulation software for this problem.

Note

Shell surfaces.

Define 16 shell features

representing the blades of the
impeller. Specify Thin shell
formulation with a Thickness of
1 mm.

Apply Material.

Assign Chrome Stainless Steel

to all the components.

Apply Mesh control.

For more accurate resolution of

the bonded contact between the
shell features and the solid body
of the impeller, specify a local
mesh control on the blade edges.
Use the Element size of 2.5 mm
with the Ratio equal to 1.2.

Blades to the impeller body

bonding.
Specify local Bonded contact

between the blade edges and the

body of the impeller. Use the 16
lower edges on the blades as Set 1
and the top face on the body of the
impeller as Set 2.

Note

352

The global bonded contact setting is not important. As explained in

SolidWorks 2012

Exercise 21
Mixed Mesh Analysis

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Lesson 9, shell edge and solid parts bonding require local contact
conditions.
9

Create Mesh.

You may now create a Draft quality

Curvature based mesh with the
default settings.

10 Study properties.
Select the Direct Sparse solver.
11 Run analysis.

12 Radial displacement.

To view radial displacement results, construct a plot showing UX

component displacement. Use the Axis1 of the model as a reference
so UX becomes the radial component of displacement.

We can observe a radial displacement of -9.34e-4 mm at the tips of the

blades.

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Exercise 21

SolidWorks 2012

Mixed Mesh Analysis

13 Von Mises stress.

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To plot von Mises stress we dont need to use any reference geometry
because von Mises stress is a scalar stress measure.
To better picture stress results around the support, use a section view.

We can observe a very small von Mises stress value of 4.01 MPa
depicted in the figure below. The stresses along the blade bonded to the
impeller are localized; the actual stress magnitude along the bonded
edges would be different due to the presence of the weld.

While stresses are rather small, displacements results are important due
to the pump manufacturing clearances and effectiveness.

To obtain accurate results, finer mesh and high quality elements need to
be used. Such detailed analysis on the entire model may take a
significant amount of time, circular periodicity of the model can be
used to simplify the problem.

354

SolidWorks 2012

Exercise 21
Mixed Mesh Analysis

Any model which can be generated by revolving its part about an axis
is said to be rotationaly periodic. All such components can be
conveniently analyzed with the help of the cyclic symmetry boundary
condition.

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Circular Symmetry

14 Activate configuration periodicity.

15 Study.

Define a new Static study named periodicity.

16 Exclude surface bodies

Exclude all surface bodies except SurfaceBody 4.

17 Simulate shaft.
Apply Fixed Geometry restraint on the remainder of the cylindrical

face.

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Exercise 21

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Mixed Mesh Analysis

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18 Simulate circular
periodicity.
Apply Circular Symmetry

fixture on the pair of faces

exposed by the cut. Use
Axis1 as a reference Axis.

Note

You must select a pair of two

faces where one can be
created by the rotation of the
first face about the reference
axis (in this case Axis1, for
example).

Specify the same Circular Symmetry conditions for the remaining two
pairs of impeller faces exposed by the cut.

19 Shell feature.

Define one shell feature in contact with the solid part isolated by a cut.
Specify Thin shell formulation with a Thickness of 1 mm.
Exclude the unused blades from the analysis.

20 Apply load.
Apply an 8.9 N Normal force to the shell feature. Make sure the

orientation of the force is the same as in the analysis of the entire

model.

21 Material.
Assign Chrome Stainless Steel to both solid and shell features.

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Exercise 21
Mixed Mesh Analysis

22 Mesh control.

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Apply a local mesh control along the lower

blade edge in contact with the impeller face.
Use 2 mm for the Element size and 1.2 for
the Ratio.

23 Blade to impeller bonding.

Similarly, create Bonded contact between the

lower edge on the blade and the top face of the

impeller.

24 Create mesh.
Select Curvature based mesh under Mesh
Parameters.

Mesh the model with the High quality

elements and the default settings.

25 Study properties.
Select the Direct Sparse solver.
26 Run analysis.

Notice how quickly the study completes even

when High quality elements are used.

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Exercise 21

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Mixed Mesh Analysis

27 Radial displacement.

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We can observe that the radial displacement, at the indicated tip of the
blade, changed to -9.20e-4 mm, which indicates a slight decrease
compared to the radial displacements obtained from the full model. The
difference is due to the high quality elements and finer mesh settings.
You may try to generate a draft quality coarser mesh with the same
parameters that were used in the analysis of the entire model to verify
that results agree well.

28 Von Mises stress.

We also observe that the location as well as the maximum of the von
Mises stress changed.

29 Save and close the file.

358

SolidWorks 2012

Exercise 21
Mixed Mesh Analysis

In this model, we analyzed the stresses and displacements on the

impeller. Typically, an impeller like this is loaded cyclically (i.e.
dynamically). To continue this analysis, one would want to solve for
the natural frequencies of the systems to verify that any locaing
frequencies will not affect the dynamic response. This could be done
using SolidWorks Simulation Professional. Additionally, a dynamic
study could be utilized to solve the full dynamic solution. This could be
done with SolidWorks Simulation Premium.

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Summary

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SolidWorks 2012

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Mixed Mesh Analysis

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Lesson 10
Mixed Meshing
Solids, Beams & Shells

Objectives

Upon successful completion of this lesson, you will be able to:

I

Construct a mesh with beam, shell and solid elements.

Edit beam joints to add/remove beams from a joint (Exercise 23)

Set up various shell to beam and shell to solid contacts in mixed

mesh assembly.

Display the results obtained with beam elements.

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Lesson 10

SolidWorks 2012

Mixed Meshing Solids, Beams & Shells

To this point, we have used two types

of elements to mesh our models. For
most thick bodies we used solid
elements. When the structure became
thin in one direction, such as a sheet
metal part, we used shell elements to
avoid creating a very large number of
elements. When the part becomes thin
in two directions we use beam
elements.

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Mixed Meshing

In some structures, we may have a

combination of geometry that is best
analyzed with beams for weldments,
solid elements for thick components
and shell elements for thin
components.

Model courtesy of Tamoz, spol. s r. o.

Case Study:
Particle
Separator

In this case study, we will analyze the base of the particle separator.
The base consists of a weldment with various gussets. The particle
separator uses a combination of geometry that will require use of beam
elements for the weldment base and shell elements for the various
plates and the body of the separator. The weldment lends itself to
analysis with beam elements, while the cross gussets are thin sections
that are best analyzed with shell elements.

Project
Description

The loads on the support frame consist of the weight of the particle
separator structure itself that will be applied using gravity. An
additional load of 150 N will be applied to the front of the structure in
the downward direction to simulate the presence of an additional
component that will be attached to the separator. Finally, on the intake
of the particle separator, loads of 75 N and 45 N will be applied to
simulate additional loading that the separator might experience during
installation.

Element Choices

The frame can be analyzed using both solid and shell elements, but
both would result in an excessive number of elements. Also, the
construction of the mesh along with the corresponding contact
conditions may take some time. In this lesson, we will use beam
elements for the weldment structure which will allow us to greatly
simplify the model with a minimum sacrifice on the side of the
accuracy.

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Lesson 10
Mixed Meshing Solids, Beams & Shells

Beam elements

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Beams are another class of structural elements where all of the crosssectional characteristics are accounted for during the derivation of the
element stiffness matrix. As a beneficial consequence, these crosssectional characteristics do not need to be reflected in the finite element
mesh, thus, greatly simplifying the model preparation and analysis.

In general, the beam element has two nodes with six degrees of
freedom in each node. For more information, consult the Introduction
chapter of this manual.

Stages in the
Process

Create beam elements

When weldments are analyzed, beam elements will be created

automatically.

Calculate joints

The existing joints between elements are created.

Merge joints that are too close

The joints are reviewed to determine if joints are too close to each
other. Joints can then be merged to get a better mesh.

Specify joint types

The number of degrees of freedom at each joint is specified.

Apply fixtures and loads

The exterior constraints and forces are applied.

Mesh the model

A beam mesh is created.

Run the analysis

The study is run in the same way as any other mesh.

Plot and analyze the results

Examine the analysis results and determine further action.

Open an assembly file.

Open particle separator 450 located in the Lesson10\
Case Studies folder.

Examine the assembly to familiarize yourself with the components.

Set SolidWorks Simulation options.

Set the global system of units to SI (MKS) and the units of Length and
Stress to mm and N/m^2, respectively.

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Mixed Meshing Solids, Beams & Shells

Naming convention.

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For clarity, we will identify some of the

parts by the names we will use in the
following steps.

Separator body

Static study.

Continue working in the static stress

study. Some features in this study have
been completed beforehand to save time.

Mounting bracket

Cross Gusset

Feet

Examine the parts folder.

There are four types of parts/bodies in
the folder.

The three cross gussets, located where

the diagonal braces cross, are modeled
as solid bodies. They will be meshed as
shell elements on the outer face of the
solid bodies.
The four feet on the end of each leg are
modeled as solids and will use a solid
mesh.

The remaining parts on the frame are all

weldment parts and will be meshed as
beam elements.

Shell

Solid

Beam

Shell

All components of the particle body are

modeled as solids, but will be meshed
with shells.
Four mounting brackets are modeled as
solid components.

364

Solid

SolidWorks 2012

Lesson 10
Mixed Meshing Solids, Beams & Shells

Cross gusset plates.

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Define shells for the three Cross Gusset

plates. Use the outside faces of the solid
bodies, and specify Thin shells with the
Thickness of 5 mm.

Shells

Shell definitions and bonding for the separator body.

All shells and bonding conditions for the separator body have been
defined beforehand.

Solid parts.

The eight parts named Feet are thick solids. We will not do anything
with them in the tree and they will mesh as solids.

The four Mounting Brackets are solid bodies. The bonding with the
separator body has already been defined.

Exclude unused surfaces.

The three surfaces in the Cyclone
Particle Separator subassembly are

used for the design of the particle

separator body only. They will be
therefore excluded from the meshing
phase and the simulation.
Exclude from Analysis the three

indicated surfaces.

Beam Mesh

To mesh any extruded or revolved

solid feature with beam elements,
right-click on the feature and select
Treat as Beam. The icon in the
parts folder
will then indicate
the beam mesh.

Similarly, to mesh any beam feature (for

example weldments) as solid, right-click
on the feature and selected Treat as Solid.

10 Weldment parts.

All the remaining parts are part of the weldment that we will mesh
using beam elements.
Select all the remaining parts, then right-click and select Treat
selected bodies as beams.

365

Lesson 10

SolidWorks 2012

Mixed Meshing Solids, Beams & Shells

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11 Examine the Parts folder.

The Parts folder should look as below:

Solid bodies

Solid bodies of the separator

body modeled as shells

Surfaces Excluded from

analysis

Beams

Solid bodies of the cross gussets

modeled as shells

Solid bodies

12 Apply material.

Apply the material AISI 1020 Steel to all the parts and bodies.

366

SolidWorks 2012

Lesson 10
Mixed Meshing Solids, Beams & Shells

All of the beam cross-sectional

characteristics are already included as
parameters during the derivation of the
beam element stiffness matrix. The
resulting mesh is, therefore, made out
of lines connected by joints. The
example of such lines representing the
beams in our model is shown in the
figure.

Joint 1

Joint 2

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Beam Joints:
Locations

The joints define the straight or curved

segments that will be meshed with
beam elements. While the detection of
the joints is automated in SolidWorks
Simulation, the relative position of
some joints may be too close and we
may wish to merge them, i.e. merge two
segments into one. In the figure, the
joints 1 and 2 are relatively close and
might be merged.

Sometimes the automatically generated joints must be modified

manually.

Beam Joint Types

Each beam end point features six degrees of

freedom that may be restrained or released to
reflect various structural connection
configurations. SolidWorks Simulation offers
the following options to connect the end point
of the beam element to the joint:
I

Rigid - All six degrees of freedom are

tied to the joint. This connection type

transfers all force as well as all of the
moments from the beam element to the
joint (and vice versa).

Hinge - Only three degrees of freedom are tied to the joint. The

connection is not able to transmit the moments from the beam to the
joint (and vice versa).

Slide - The end can translate freely and does not transfer forces to

the joint.
Manual - A custom designed connection type can be generated.

367

Lesson 10

SolidWorks 2012

Mixed Meshing Solids, Beams & Shells

All beam properties are computed

automatically from the solid geometry. The
beam section properties calculated by the
program can be overwritten with userdefined values in the Section Properties
dialog.

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Section Properties

Torsional Constant, K- Torsional

stiffness constant is calculated by the

program. The values for commonly used
beam cross-sections are available in
literature (see Formulas for Stress and
Strain, Roark and Young, Chapter 9,
Table 20, for example).

Distance for Maximum Shear, CTOR- Distance from the center

of the section to the point of maximum torsional shear .

Where to Find It

Shear Factor in direction 1- Shear factor to account for non-

uniform shear stress in direction 1 of the beam coordinate system

Shear Factor in direction 2- Shear factor to account for nonuniform shear stress in direction 2of the beam coordinate system

I
I

Shortcut Menu: Right-click a beam element in the Simulation

Study Tree and click Edit Definition.
To see the shear center line of a beam, right-click Joint group and
select Edit. Under Results, select Display shear center.

13 Edit joints.

Once we designated a body to be treated as

a beam, a new item appeared in the
Simulation Design Tree called Joint
group.
Right-click the Joint group and click
Edit.
For Selected Beams, select All.

Click Calculate.

The joints computed with the default

settings can be seen in the figure.

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SolidWorks 2012

Lesson 10
Mixed Meshing Solids, Beams & Shells

The beam joints are show as yellow or magenta

spheres.

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Connected and
Disconnected
Joints

joints are connected to two or more beam

members.
joints are connected to a single member
only and are therefore disconnected from the
other beams. Such nodes may need to be
manually connected to the adjacent beams
elements or bonded to other parts.

Sphere Diameter
Defining Beam
Joint

By default, the software creates a joint between two beams touching

end-toend (clearence is zero). It is, however, possible to modify the
diameter of a hypothetical sphere defining the joint. All beam ends
within such hypothetical sphere will form a new joint.

Treat as Joint for

Clearance

I
I

equal to zero: Creates a joint when beam ends are touching.

less than:Beams ends within such clearance will be included in
one joint definition. Keep modified joint on update must be

checked to retain the newly computed joints.

Where to Find It

Shortcut Menu: Right-click Joint Group in the Simulation Study

tree and select Edit. Under Selected Beams select Treat as joint
for clearance option.

14 Bond diagonals to gussets.

Add a Bonded contact between

each set of two diagonal braces

and the cross gusset.

Note

Make sure that you select the outside face of the cross gusset solid body
used for the shell definition (step 6).

15 Explode the assembly view.

The exploded view will make it easier to create the contact sets
between the sheet metal corner gussets and the frame elements.

369

Lesson 10

SolidWorks 2012

Mixed Meshing Solids, Beams & Shells

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16 Bond Mounting Brackets to frame.

Use bottom face of each Mounting Bracket to bond it to the top

beams of the frame, as shown in the figure below.

17 Collapse the assembly.

18 Add fixtures.
Add Fixed Geometry Fixtures to bottoms

of four feet.

Applying Loads

The beams button

allows us to apply the loads directly on the
structural members. It is also possible to apply loads directly onto the
joints
or on faces, edges, or vertices
of extruded bodies.

19 Apply External Loads.

Apply a 150 N vertical load applied on the

indicated beam to simulate the additional

weight of the component that may be added to
the structure at a later time.

Note

370

The distributed load is applied on the horizontal beam where no

diagonal braces are present.

SolidWorks 2012

Lesson 10
Mixed Meshing Solids, Beams & Shells

75 N

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Apply 75 N and 45 N forces located

at the back face of the inlet.
These loads can be generated during
the assembly phase.

45 N

Note

The forces must be applied on the faces used to define the shell
features, as shown in the figure.

20 Gravity load.

Specify gravity load in the global positive Z direction.

21 Apply mesh control

to beams
Click on Beams under
Selected Entities and

select the four

horizontal beams.
Select Element size
and enter a value of 5
mm.

371

Lesson 10

SolidWorks 2012

Mixed Meshing Solids, Beams & Shells

22 Mesh.

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Mesh the assembly using High quality

elements. Use the Standard mesh with the
element Global Size of 25 mm.

23 Examine the mesh.

You can see the three different mesh

element types.

You can see the three different mesh element types.

Render Beam
Profile

It is possible to display the mesh and

results for beams as cylinders
(simplified representation) or the
actual beam profiles. Displaying the
mesh or results on the beam profiles
may take longer for models with a
large number of beams.

Where to Find It

I
I

Menu: Simulation, Options, Default Options, select Mesh and

activate Render beam profile.
Shortcut Menu: Right-click Mesh and select Render beam
profile.

24 Align the mesh.

Make sure that the shell top and bottom are aligned and consistent. This
step is important for the correct postprocessing.

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Lesson 10

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Mixed Meshing Solids, Beams & Shells

Note

The default shell mesh alignment shown on the left image may vary.
Align the mesh as shown in the right image.

Beam imprint

When the beam joint is bonded to a solid or shell face, the mesher
creates an imprint of the actual beam cross-section on the touching
face. This generates a more realistic representation of the joint leading
to better results at the beam-solid/shell interface. Additional elements
are created in the area of the imprint and the beam joint is connected to
all the elements inside the imprinted area. In case the beam's crosssection is not entirely on the touching face, the imprint is created based
on the partial touching cross-section.

25 Run.
Run the study.

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Lesson 10

SolidWorks 2012

Mixed Meshing Solids, Beams & Shells

26 Displacement Plot.

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Examine the displacement plot. The

maximum displacement of 0.149 mm
at the inlet location is rather small.

27 Stress plot.

The initial stress plot will show the

Von Mises stresses in the solids and
shell.

The maximum reaches approximately

11.93 MPa and is located in the
Mounting Bracket where the
vertical load is applied.
Because this stress maximum is
located at the junction of the bracket
and shell, detail analysis of this
connection may be required.
Also, review of the stresses on both
the top and the bottom faces of the
shell elements is needed.

Note

374

This plot only shows the stress distribution on the solids and shells. We
will next see the stress distribution in the beams.

SolidWorks 2012

Lesson 10
Mixed Meshing Solids, Beams & Shells

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28 Redefine the stress plot.

Right-click the plot Stress1 and
click Edit Definition.

Select Beams to show the stress

in the beam elements.
From the list, select Axial.

The maximum tensile stress of

0.91 MPa is in one of the
diagonal braces whereas a
compressive stress of -1.53 MPa
is induced two of the legs.

Note

Again, this plot only shows the stress distribution in the beams.

Cross-section 1st
and 2nd Directions

To post-process the bending component of the normal stress, 1st and

2nd directions must be specified.

1st direction is defined along the longest side of the cross-section, and
2nd direction is perpendicular to it.

375

Lesson 10

SolidWorks 2012

Mixed Meshing Solids, Beams & Shells

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29 Additional stress plots.

Define two new stress plots to show the bending in directions 1 and 2.
Render beam profile should be selected.

Maximum bending stresses are 4.97 MPa and 5.37 MPa at the indicated
locations.

30 Highest axial and bending.

Edit any of the plots and

select Axial and bending.
This will show the combined
stress from axial and bending
in both directions. The
absolute maximum combined
stress in any of the beam
elements is 7.02 MPa.

376

SolidWorks 2012

Lesson 10
Mixed Meshing Solids, Beams & Shells

More experienced users may produce a plot of the bending moment and
shear force diagrams. They can be used to study how the internal
bending moments and shear forces vary along the beam, or for the
subsequent design of more complex composite beam members.

Where to Find It

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Bending Moment
and Shear Force
Diagrams

Shortcut Menu: Right-click Results folder and select Define

Beam Diagrams.

31 Show Bending moment

diagram.
In the Beam Diagrams dialog,
under Display select Moment in
Dir1. Specify the units of N-m.

Under Selected Beams click

Select and select the beam shown
in the figure.

32 List Beam Stress.

Right-click on the Results folder

and select List Beam Forces.

Under List select Stresses, set

the units to SI and click OK.

The List Stresses dialog window

shows a complete list of maximum (minimum) normal and shear
stresses for all beam elements.

33 Save and Close the file.

377

Lesson 10

SolidWorks 2012

Mixed Meshing Solids, Beams & Shells

In this lesson, we analyzed a support frame model. Since all the

structural members were thin and long, we used beam elements. Their
use can greatly simplify the analysis and make the computations
significantly faster.

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Summary

The model preparation consists of beam element and joint definition

steps, both of which are automated in SolidWorks Simulation.
Sometimes manual editing of the automatically generated joints may be
required . If any two joints are generated too close, relative to the
position of the remaining joints, they may be merged.
Because beam elements feature six degrees of freedom at each end,
various possibilities for the joint / beam element connection exist.

We usually show these displacement components (or degrees of

freedom) as aligned with global coordinate system. However, degrees
of freedom may be presented in any coordinate system.

Because nodes of solid elements do not have rotational degrees of

freedom as compared to nodes of shell elements, an attempt to connect
shell and solid elements results in an unintentional hinge along the
common edge.
To make final conclusions on the analysis, it could be important to
review the stresses at the joint locations. Due to the limitations of the
bonding between beam/shell and solid, the software does not produce
an accurate result at the interface. A model with only solids could be
run to better investigate the stresses at these locations.

378

SolidWorks 2012

Exercise 22
Beam Elements

Exercise 22:
Beam Elements

Defective weld

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The simplified model of a

conveyor frame (shown
in the figure) is
manufactured from Plain
Carbon Steel with all the
joints welded.

Moment
Foundation

During the inspection, it

was found that the weld at
the indicated joint
became defective and was
not capable of
transmitting the
moments.

In this exercise you will analyze the frame when subjected to the
extreme operating loading conditions (combination of an isolated force
and a moment).
All six legs of the frame are bolted to the ground but only the two
inclined legs can actually transmit the moments to the floor.
This exercise reinforces the following skills:
I
I
I
I
I

Procedure

Mixed Meshing on page 362.

Beam elements on page 363.
Beam Joint Types on page 367.
Bending Moment and Shear Force Diagrams on page 377.
Applying Loads on page 370.

Follow the steps below:

Open a part file.

Open Conveyor Frame located in the Lesson10\Exercises folder.

Set SolidWorks Simulation options.

Set the global system of units to SI (MKS) and the units of Length and
Stress to mm and N/m^2, respectively.
Create new study.

Create a new static study named frame.

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Exercise 22

SolidWorks 2012

Beam Elements

Beam elements.

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Expand the folder Conveyor Frame

and you can see that all the solid bodies
of the weldment have a beam icon .

Right-click the Cut List folder and

select Delete. All the beams are now in
the Conveyor Frame folder.

The sixteen beam elements were

automatically generated because the part
file was a weldment.
There is also an additional folder called
Joint group
.

Slenderness ratio

Beam elements are typically

used to represent long,
slender components. For the
beam formulation to produce
acceptable results, the length
of the beam should be 10
times larger than the largest
dimension of its cross
section.

The software automatically

detects the ratio and warns the user about the beams having a
slenderness ratio of less than 10.

Specify material.

Assign Plain Carbon Steel for all beam elements.

380

SolidWorks 2012

Exercise 22
Beam Elements

Review the calculated joints.

Right-click on the Joint group folder and
select Edit. The automatically calculated

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joints will show on the screen.

If needed, the joints may be modified and re-calculated. In this exercise

this step is not required.

Mesh the model.

Mesh the model with the default element size.

381

Exercise 22

SolidWorks 2012

Beam Elements

Define faulty weld joint.

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The faulty weld in the indicated joint eliminates the possibility to

transfer moments between the beam element and the joint. The moment
ties can be released by specifying the pin connection type.

Under the Conveyor Frame folder, right-click on the beam element

corresponding to the inclined member with the faulty weld and select
Edit definition.

Create a hinge.

The two end points are graphically shown as red and blue circles.

Select Hinge for the upper connection between the joint and the beam.
Click OK to confirm the settings.

382

SolidWorks 2012

Exercise 22
Beam Elements

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10 Restrain the vertical legs.

Apply an Immovable fixture to the bottom joints on all four vertical

legs.

11 Restrain the inclined

legs.
Apply a Fixed Geometry

restraint to the bottom

joints on the two inclined
legs.

12 Apply loads on top

beams.
Right click the External
Loads folder and select
Force.

Under Selection click

Beams
then select the
two beams shown.

Apply 67,000 N [15,062

lb] force in the Normal to
Plane direction (with
reference to the Top
plane). Select Reverse
direction.
Click OK.

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Exercise 22

SolidWorks 2012

Beam Elements

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13 Define loads on corner

joint.

To apply a force or
moment directly into the
joint click the Selection
(Joints) button in the
Force menu (see the
figure).

Apply a 45,000 N
[10,116 lb] force and a
2,260 N-m [20,000 lb-in]
moment to the corner
joint. The force and the
moment are oriented in
the Normal to Plane and
Along Plane Dir1

directions with reference

to the Front plane, respectively.

14 Run the analysis.

Notice how quickly the study completes. If solid or shell elements were
used instead, the computations would take considerably longer.

15 Plot resulting displacements.

Define a RES: Resultant displacement plot.

Zoom closer to the section where both inclined members connect to the
top of the frame. Notice that the member with the faulty weld rotated at
the joint location, while the other member remains perpendicular
irrespective of the structural deformations. This indicates that the faulty
weld connection does not transmit moments, indeed.

384

SolidWorks 2012

Exercise 22
Beam Elements

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16 Plot axial normal stress.

Define an Axial stress plot.

The Axial stress plot indicates a component of normal stress evenly

distributed across the cross-section of the beam element caused by
normal (axial) force. We observe a maximum tensile value of
approximately 13.4 MPa (1.94 ksi).

17 Plot normal stress due to bending.

Define Bending in local direction1 and Bending in local direction2

stress plots.

Direction 1

385

Exercise 22

SolidWorks 2012

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Beam Elements

Direction 2

These plots indicate the maximum and minimum values of the normal
stress (extreme fibers location) caused by the bending moments. We
can observe a significantly greater value (than in the Axial stress plot)
of -569 MPa [-82.5 ksi] (negative sign indicates compression).

A total normal stress experienced by a cross-section is equal to the sum

of the axial and bending components: the hightest axial and bending
stress plot.

18 Plot the extremes of the total normal stress.

Define an Axial and bending stress plot.

This plot adds the Axial and the Bending in local direction1 normal
stresses. It is the plot of the most extreme normal stress experienced by
the beam cross-sections.
We can see that the maximum tensile stress of 446 MPa [64.7 ksi]
significantly exceeds the yield strength of Plain Carbon Steel 220.6
MPa (32 ksi).

386

SolidWorks 2012

Exercise 22
Beam Elements

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19 Plot bending moment diagrams.

Right-click the Results folder and select
Define Beam Diagrams.

Under Display select Moment in Dir 1 and the

units of N-m.
Under Selected Beams,
click Select and pick the
inclined beam with the
faulty weld.

Click OK to plot the diagram.

We can see a linear variation of the bending moment in the elemental

direction 1. Note that the moment at the faulty joint is zero.

The large negative value of -3850 N-m then corresponds to the moment
along the elemental direction 1 transmitted to the floor.

387

Exercise 22

SolidWorks 2012

Beam Elements

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20 List beam stresses.

Right-click on the Results folder and select List Beam Forces.

Under List select Stresses, set the units to SI and click OK.

The List Forces dialog window shows a complete list of maximum

(minimum) normal and shear stresses for all beam elements.

21 Save and Close the file.

388

SolidWorks 2012

Exercise 23
Cabinet

Exercise 23:
Cabinet

Analyze a cabinet with an applied load.

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This exercise reinforces the following skills:

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Project
Description

Beam elements on page 363.

Beam Joints: Locations on page 367.
Connected and Disconnected Joints on
page 369.
Applying Loads on page 370.

A cabinet manufactured from

Aluminum 5052 H32 is loaded by an
isolated 4,450 N [1000 lb] force and
two 4,450 N [1,000 lb] loads distributed
along the two corner beams of the
cabinet, as shown in the figure. All
other loads and masses (such as shelf
loads, etc.) are not included in this
analysis to keep the model simple. The
bottom of the cabinet, along with the
pedestal, are bolted to the floor.
Compute the factor of safety of the
model.

1
2

Open an assembly file.

Open Cabinet Assy located in the Lesson10\Exercises folder.
Create study.

Create a Static study named stress analysis.

Define shell thicknesses.

Using the inside faces, define shell features for the skins of the cabinet.
Specify Thin shell formulation with the Thickness of 2.54mm [0.1in].

389

Exercise 23

SolidWorks 2012

Cabinet

Define beam joints.

Right-click on the Joint group folder
and select Edit.

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At each of the eight corners, there

should be either one or two joints,
connecting all of the beams that
converge on that corner. See the
figure.

Note

Joints identified as yellow spheres are attached to a single member.

Violet color identifies the joints which connect at least two beam
members.

The joints can be merged by entering a

user-defined value through Treat as joint
for clearence.

Select less than and enter a value of 0.1 m.

Click Calculate to update the joint
definitions.

Click OK to complete the definition of the

joints.

390

SolidWorks 2012

Exercise 23
Cabinet

Optionally, the joints can also be merged by adding or removing a

beam member. Right-click each joint to examine the components that
form the joint.

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Tip

In the Select Joint Members window, click the components in the

graphics window to add or remove them from the joint.

To save the new joint definition, close the Select Joint Members
window. Make sure Keep modified joint on update is selected and
click Calculate.
Repeat the procedure for all the joints that need to be merged.

Assign materials.

Specify Aluminum 5052-H32 for all Solids, Shells and Beams.

391

Exercise 23

SolidWorks 2012

Cabinet

Bond skins to the cabinet frame.

Specify Bonded contact condition between the frame beams and the

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skin shell on the left hand side, as shown in the figure.

Click OK.

To select Beams for the Set 1, click the Beams

Note

under Type.

Repeat the definitions of the bonded contacts between the beams and
the skin shells for the right, back, and top sides of the cabinet.

Bond frame bottom beams to the frame bottom plates.

The two solid frame bottom plates must be bonded to the two frame
beams.

Frame Plates

These contacts have been defined in the Completed contacts study.

Copy all the contacts from the Completed contacts study into our
current study, stress analysis.

392

SolidWorks 2012

Exercise 23
Cabinet

Contact between Base and the frame.

The frame side plates and the Base are bolted to the floor. For

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simplicity we will model this contact as bonded. Bond the circular

edges of the bolt holes on the frame side to the top face of the base.

Fix the Base.

Apply a Fixed Geometry fixture to the

cylindrical faces of the four holes in the
Base.

10 Frame plates vs. base contact.

Specify No penetration, Node to
Surface contact between the bottom

faces of the frame plates and the

base, as shown in the figure.

Note

We use the Node to Surface formulation here because the parts are
initially touching and we expect little or no sliding between the two
bodies.

393

Exercise 23

SolidWorks 2012

Cabinet

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11 Concentrated joint load.

Apply a 4450 N [1000 lb]

concentrated vertical force

to the top corner beam
joint, as shown in the
figure.
Make sure to select

Selected direction to

define the force on the

joints.

Note

394

In mixed mesh analysis the Force can be applied to the faces, edges or
vertices of the solid components or shells, beam joints and along the
length of the beam components.

SolidWorks 2012

Exercise 23
Cabinet

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12 Distributed beam load.

Apply 4450 N [1000 lb]

distributed vertical load

on the two beams
indicated in the figure.

13 Create mesh.
Create a High quality Curvature based mesh

with the following

parameters: Maximum element size =

111.37mm, Minimum element size = 5mm,
Min number of elements in a circle = 16, and
Element size growth ratio = 1.6. .

Make sure that the shell tops and bottoms are

consistent.

14 Mesh details.

Show the mesh details.

Combined mesh with beams,

shells and solids resulted in
approximately 39,200 nodes.

15 Run the study stress

analysis.

395

Exercise 23

SolidWorks 2012

Cabinet

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16 Plot von Mises stress.

It can be seen that the maximum von Mises stress in solid and shell
feature, 142.68 MPa, is at a sharp corner. This is an area of singular
stress and can be ignored. There is also some high stress in the vicinity
of the holes that are bonded to the bottom plate(you can verify that both
the Top and the Bottom indicate identical maximum value).

396

SolidWorks 2012

Exercise 23
Cabinet

17 Plot beam stresses.

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Edit the definition of the stress plot and select Beams. Select Axial
and Bending as the Beam Stress. Select the Render beam profile
option.

The highest axial and bending stress plot in beam elements indicate a
maximum stress of 43 MPa. We can therefore conclude that the factor
of safety in strength is approximately 195 MPa/43 MPa = 4.5 (195 MPa
is the yield strength of the Aluminum 5052 H32). This result indicates
that the cabinet frame is designed with sufficient factor of safety.

18 Plot resultant displacements.

The maximum displacement of the cabinet is approximately 1.31 mm.

19 Save and Close the file.

397

Exercise 24

SolidWorks 2012

Frame Rigidity

In this exercise, you will calculate

the torsional rigidity (i.e. applied
torque divided by radial
displacement) of a car frame.

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Exercise 24:
Frame Rigidity

This exercise reinforces the

following skills:
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Problem
Description

Cylindrical Coordinate
Systems on page 160.
Beam elements on page 363.
Beam Joints: Locations on
page 367.

There are many ways to measure the torsional rigidity of a frame. In

one experiment, the front and rear wheels are mounted on beams. The
suspension components are assumed to be fixed so that all of the load
applied is transferred to the frame itself. The rear of the vehicle is held
stationary (fixed) while a load is applied to the beam with the front
wheels to simulate the torque as shown in the figure below.

Force

398

courtesy of:
Stephen Maxfield, University of Wisconsin

Force

SolidWorks 2012

Exercise 24
Frame Rigidity

Remember, all of the components aside from the frame are assumed to
be rigid. This means that the full loading must be transferred to the
frame itself. Since we will assume the response of the frame is linear,
any loading magnitude will be sufficient to calculate the torsional
rigidity.

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Loading
Conditions

Goal

With the proper boundary and loading conditions, calculate the

torsional rigidity:
TorqueLoad
TorsionalRigidity = -------------------------------------------------AngularDeflection

Remember, the angular deflection result is given as the angle of

deflection (in radians) times the radial distance away from the axis.
The part for this exercise is located in the Lesson01\Exercises
folder.

399

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Exercise 24

Frame Rigidity

400

SolidWorks 2012

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Lesson 11
Design Study

Objectives

Upon successful completion of this lesson, you will be able to:

I

Understand and use the Design Study to analyze trends when

specific parameters are varied.

Find optimum value of some design parameters.

401

Lesson 11

SolidWorks 2012

Design Study

Design studies can be conveniently used to analyze an assembly in

which the loads, geometry or material constants are to be treated as
design variables. Results, such as displacements or stresses, can then be
graphed as functions of the design variables. Design studies are used to
run multiple studies with the intent of determining trends that can be
used to make important design decisions, or to fully optimize the
design.

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Design Study

Note that the automatic optimization feature of the Design Study is

available in the SolidWorks Simulation Professional module.

Case Study:
Suspension
Design

The vehicle suspension

assembly can be subjected to
a multitude of loading
variations during its operating
conditions. We will use a
design scenario to test the
assembly under several
different conditions so that
we optimize the size of the
parts.

Project
Description

Analyze the suspension assembly when subjected to the following four

conditions:
1.
2.
3.
4.

stationary vehicle
vehicle moving at constant acceleration on a smooth road
vehicle moving on a bumpy road
vehicle moving at a constant speed on a smooth road and turning on
a banked road
All of the suspension components are manufactured from Alloy Steel.

The goal of the analysis is also to adjust the thickness of the lower arm
to a value that will result in a Factor of Safety of 1.3 or better.

Stages in the
Process

The basic steps of a design scenario are:

I

Specify the parameters.

Determine which parameters will be varied in each scenario.

Create a table defining the values of the variables for the design
studies.
Analyze the results.
Review the available output to determine the necessary changes.

402

SolidWorks 2012

Lesson 11
Design Study

Part 1: Multiple
Load Cases

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For the first design study, four sets of loads will be applied to the axle
of the suspension. There will be both a vertical and lateral load.

Open an assembly file.

Open suspension located in the Lesson11\Case Studies folder.

Set SolidWorks Simulation options.

Set the global system of units to SI (MKS) and the units of Length and
Stress to mm and N/mm^2(MPa), respectively.

Create new study.

Create a new Static study named Multiple loads.

The spring is missing from the assembly. We will simulate the spring
using connectors.

Note

Assign the material.

Specify Alloy Steel to all the components.

This material has a yield strength of 620 MPa.

Define Fixed Hinge fixtures.

Define five Fixed Hinge fixtures as indicated in the figure.

403

Lesson 11

SolidWorks 2012

Design Study

Define a spring connector.

Define a Spring connector between the two Flat parallel faces of the
Front Shock Clamp and the Shock Plunger, as shown in the figure

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below.

Specify the Total, Normal stiffness of 105,000 N/m [600 lb/in].

Pin connectors.

All of the pin definitions have been defined beforehand. Copy all pin
definitions from the study partially completed to this study multiple
loads.

Design Studies

Design studies can be conveniently used to analyze an assembly in

which the loads, geometry or material constants are to be treated as
design variables. Results, such as displacements or stresses, can then be
graphed as functions of the design variables.
A design study is defined in two steps:
1. A list of the parameters (design variables) must be specified.
2. A design study is created in which scenarios (combinations) of the
parameters along with their numerical values are specified.

Where to Find It

Menu: Insert, Design Study, Add.

CommandManager: Evaluate > Design Study.
Parameters, or design variables, are quantities which can be varied in
the design study to investigate the behavior of the assembly. They are
also used in the Optimization module to optimize the design with the
specified set of the design constraints. (Optimization module is part of
the SolidWorks Simulation Professional module.) A multitude of the
parameter types is available: loads, geometrical features, material
constants, and others.
I
I

Parameters

Where to Find It

I
I

Note

404

Menu: Insert, Design Study, Parameters.

CommandManager: Evaluate > Design Study > Parameters.

In some cases, such as when a load or a material constant is used as a

parameter, a definition of the load or of the material constant must be
linked to the corresponding parameter. This intermediate step will be
practiced in this lesson.

SolidWorks 2012

Lesson 11
Design Study

Define the Vertical and Lateral forces.

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Apply force on the cylindrical face, as indicated in the figure. Use the
assembly Front plane as a reference.

Add a parameter..

In the Normal to Plane field,

select Link value (see the
figure above).

In the Select Parameters

dialog window, select Edit/
define to create a parameter
for this direction of the force.

10 Specify load parameters.

The design study will consist of multiple loading conditions

corresponding to various vehicle travel scenarios.
The Parameters window opens automatically.

405

Lesson 11

SolidWorks 2012

Design Study

Type Vertical as Name and select Simulation under Category.

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Under Value, enter 225. The Units field displays N automatically as

the Force/Torque is being defined in SI units.
Define the second parameter named Lateral with 0 N as the Value.

Click OK to close the Parameters dialog window.

Note

Two Force parameters have been defined in this step: Vertical and
Lateral.

11 Link values.
From the Select Parameters
window, select Vertical to

link this parameter to the

corresponding component of
the force.

Click OK to close the Select

Parameters dialog window.

Notice that the user defined

value of 225 N is shown in the appropriate field with a distinct
background color.

406

SolidWorks 2012

Lesson 11
Design Study

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12 Link the other load.

Link the Along Plane Dir 2 force component to
the parameter Lateral.

Both load components are now linked to the

parameters controlling their magnitudes.

Click OK to exit the Force/Torque definition.

13 Refine mesh at higher curvature regions.

Apply mesh controls at the two fillets on the Shock Plunger. and the
eight fillets of the lower arm, as shown in the images below. Use an
Element size of 0.76 mm and a Ratio of 1.5.

14 Mesh the assembly.

Create a High quality mesh with the default settings using the
Curvature based mesh.
15 Run static study Multiple loads.

Run the analysis and note that the solver issues a warning about large
displacements.
Click No. The analysis will then complete.

While running static study is not required at this stage, it is

recommended in order to verify the study setup.

16 Create a design study.

Click the Design Study

icon on the Evaluate tab of the

CommandManager.

407

Lesson 11

SolidWorks 2012

Design Study

Alternatively, select Design Study from the Insert menu.

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Rename the Design Study 1 to Multiple Loads - Design Study.

The Design Study interface opens up on the bottom of the screen. It

offers two view styles:

Variable View, where parameters can be entered in other than table

form.

Table View, where a discrete set of values for each variable is

shown.

17 Select Variables and enter their values.

In the Variable View, under Variables, select the parameter Lateral.

From the pull down list specify Discrete Values and enter the values 0
N, 60 N, 72 N and 115 N, separated by commas, as shown in the figure
below.

Switch to the Table View and include the second parameter named
Vertical. Enter the values of -225 N, 185 N, 385 N and 900 N in the
table.

Make sure that all four scenarios are checked. Unchecking a specific
scenario excludes this combination of the design parameters from the
design study.
Uncheck the Optimization check box.

Note

408

Check box for Optimization is available only in the SolidWorks

Simulation Professional module.

SolidWorks 2012

Lesson 11
Design Study

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Each Scenario represents a load case corresponding to the specific

vehicle travel conditions:
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Design Study
Results

Scenario 1 corresponds to the loading when a vehicle is stationary

[-225 N Vertical, 0 N Lateral].
Scenario 2 to a vehicle moving at constant acceleration on a smooth
road [185 N Vertical, 60 N Lateral].
Scenario 3 to a vehicle moving on a bumpy road [385 N Vertical,
72 N Lateral].
Scenario 4 to a vehicle moving at constant speed on a smooth
curving and banking road [900 N Vertical, 115 N Lateral].

The Design Study automatically generates and runs multiple studies

corresponding to each Scenario (parameter combination). Full results
from all scenarios are saved. As the amount of data can become
excessive, attention should be paid to the size of the model and the
number of the scenarios. All results are reported at specified sensors.

18 Sensors for the global results.

Result quantities are defined through the sensors. For the global results,
monitoring the extremes for the entire model, Model Max sensors will
be specified.
In the FeatureManager add a Simulation Data
sensor for VON:von Mises Stress. Under
Properties select N/mm^2 (MPa) and Model Max.

Similarly, add a Model Max sensor for the URES:

Resultant Displacement. Select mm for the Units.

19 Sensors for the local results.

Additional sensors must be specified at locations where results need to

be reported and graphed. In our case, we will compare hub
displacements from each design scenario.

409

Lesson 11

SolidWorks 2012

Design Study

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In the FeatureManager add a Simulation

Data sensor for VON:von Mises Stress.
Under Properties select N/mm^2 (MPa)
and Max over Selected Entities. Delete
suspension.SLDASM and select the
vertex indicated in the figure.

Similarly, add a Max over Selected

Entities sensor for the URES: Resultant
Displacement. Select mm for the Units.

20 Result quantities.

Selected sensors defining the

global and local results must be
included in the design study.

Under Constraints, select all specified sensors. For all select Monitor
Only and specify study Multiple Loads.

Note

Study selected in the above pull down menu associates our design
study Multiple Loads - Design Study with the static study Multiple
Loads.

Design Study
Options

The design study can be run using two different options, Fast results
and High quality.
I

Where to Find It

410

Fast results: Scenarios, algorithmically selected from the active

scenarios are calculated only. The results for the remaining (not
calculated) active scenarios are obtained using the interpolation. It
is possible to additionally calculate the interpolated scenarios in
order to obtain their precise solution. This option is typically used
with larger number of scenarios where considerable time would be
required otherwise.
High quality: In this option all active scenarios are calculated. If
the number of the scenarios is significant, this option may lead to a
significant computation time.
In the Design Study click the Design Study Options button

SolidWorks 2012

Lesson 11
Design Study

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21 Design Study options.

Click on the Design Study
Options button .

Make sure that High quality option

is selected.

22 Run Design Study.

Click the Run button.

Note

Make sure that the Optimization check box is unchecked.

23 Analyze global extreme results.

Global results are shown in the Design Study dialog when the study
completes.
Results sliders

We can see that the last study (Scenario 4) reports the largest
magnitude for the von Mises stresses 654.35 MPa. The resulting
displacements reaching the value of 25.7 mm is also the largest in
Scenario 4. Thus, we can conclude that the last study, Scenario 4
(corresponding to the loading when the vehicle travels at a constant
speed on a smooth, curved and banked road), represents the most
extreme case and the shock assembly will be designed to withstand this
loading.

411

Lesson 11

SolidWorks 2012

Design Study

24 Plot stress results.

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The complete results for all scenarios are saved on the disk and can be
accessed through the results sliders or by selecting the desired column,
as shown in the above figure.

Expand the Results and Graphs folder of the Multiple Loads Design Study study and Show the VON: von Mises Stress plot.

We see that the von Mises stress in the Scenario 4 exceeds the yield
strength of Alloy Steel 620 MPa.

The four design scenarios could be easily specified as four unique

studies. The advantage of the design study becomes more apparent if
the number of scenarios (in this example, load cases) increases.

Part 2:
Geometry
Modification

Because Scenario 4 was identified as the worst load combination, the

assembly geometry will now be modified with the help of design
scenarios. A safety factor of 2 on von Mises stresses and the maximum
resultant displacement of the hub component equal to 23 mm will be
required.

25 Switch to static study.

Switch to Multiple loads static study.

Note

412

Note the additional folder Parameters. in the static

study FeatureManager. This folder becomes
accessible after the initial parameters definition (steps
9 to 12).

SolidWorks 2012

Lesson 11
Design Study

26 Define geometrical parameter.

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Define an additional geometrical parameter that will be used in this

study.
Go to the View pull-down menu and select All Annotations.

Right-click on the Parameters folder and select Edit/Define.

In the Parameters dialog window, enter Arm_thickness as Name and

select Model dimensions as Category.

Click on the 3 mm dimension (in Extrude2) identifying the thickness

of the lower arm.
The dimension D2@[email protected] will then be shown in the
Model dimension field.
Click OK to close the Parameters window.

27 Modify the load.

Edit the force definition and unlink the values of

the force components from the parameters.

Enter a value of 115 N [25.9 lb] in the Along

plane Dir2 field and 900 N [202 lb] in the Normal
to plane field. This corresponds to the worst
loading case in which the vehicle travels at a
constant speed on a smooth, curved and banked road (Scenario 4 in the
previous design study).
Click OK.

28 Define new Design Study.

Follow the steps 16 to 20 and define a design study with a single
parameter Arm_length reaching the following values:
1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5, 6, 6.5, 7, 7.5 and 8 mm.

413

Lesson 11

SolidWorks 2012

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Design Study

Use identical sensors for both the global and local results.

29 Design Study options.

Set the design study quality to Fast Results.

Note

The Fast results option calculates only algorithmically selected active

scenarios. In our case, only three out of the seven activated scenarios
will be solved.

30 Run design scenario.

Note

Make sure that the Optimization check box is unchecked.

31 Review global extremes of the results.

Use the slider to view the results from the last Scenario in the column
titled Current.

We observe that the maximum value of the von Mises stresses was
reduced to 453.7 MPa. This is still not within our factor of safety. We
would want to investigate the design to see what is causing the high
stresses.
The maximum resultant displacement has reduced to 23.57 mm.

Note

Notice that only three activated scenarios, with results in black font,
were calculated. The remaining activated sets with the numbers in gray
font show results obtained using the interpolation. If precise results for
the interpolated scenario are required, calculation need to be requested.

32 Calculated interpolated scenario.

In the Results View tab right-click on the Scenario 2 column and select
Run. The scenarios will then be computed.

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Lesson 11

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Design Study

The result numbers for this scenario will then change font color from
gray to black, indicating the fact that the scenario is now calculated.

Because in this study we want to see all scenarios calculated, the study
will be recalculated with High Quality settings.

33 Change properties and re-calculate.

Change the study quality to High Quality.

Click the Run button to compute all 14 activated scenarios.

34 Display von Mises plot.

Show the von Mises stress plot for the last scenario (Scenario 14) when
the thickness of the lower arm was 8 mm.

We can see that the maximum von Mises stress has decreased to
472.8 MPa. Notice, also, that the location of the maximum stress
shifted to the fillet on the plunger. Varying model dimensions caused
the stresses to redistribute as the stiffness of the components change
relative to each other.

Design Study
Graph

Design Scenario results can be shown in a graph form to identify the

trends more easily. Multiple results can be shown in the same graph by
selecting the different locations established when setting up the
scenarios.

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Lesson 11

SolidWorks 2012

Design Study
I

Shortcut Menu: Right-click the Results and Graphs folder and

select Define Design History Graph
Simulation toolbar: Click Define Graph

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Where to Find It

35 Graph the global extreme for von Mises

stresses.
Right-click on the Results and Graphs folder
and select Define Design History Graph.

Under the Y-Axis select Constraint, and the

sensor monitoring the model maximum for stresses
(in our case this sensor was named Stress1).
Under Extra Location leave the field blank. This
way the global results will be graphed.
Click OK to show the graph.

The above graph shows the variation of the global extreme value of the
von Mises stress with the thickness of the lower arm.

We observe that any increase in the thickness of the lower arm above 4
mm does not deliver any substantial decrease in the global von Mises
stress magnitude (the maximum value location shifted from the lower
arm to the Plunger). We can, therefore, conclude that the thickness of
4 mm is optimal.
At Arm_thickness = 4 mm, the global extreme of von Mises stress
reached approximately 487 MPa, which is 78.5% of the Alloy Steel
yield strength (620 MPa [90 ksi]). Any further increase in the arm
thickness does not significantly reduce the maximum stress. If we need
to achieve a larger factor of safety, other design modifications must be
investigated.

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Lesson 11
Design Study

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36 Save and Close the file.

Note

Alternatively, we could analyze the variety of material combinations

used for different parts in this assembly. Using the identical procedure
that was practiced in this lesson, we would first define the parameters
for the material properties (such as Youngs modulus or Yield
strength). Then, we would define a design study in which the
combinations as well as the numerical values of the material
parameters would be specified.

Summary

This lesson introduced and practiced the design study that allows the
user to study various trends in the design when specific design
parameters are defined. This feature has many practical applications,
some of which were practiced in this lesson. Namely, it was used to
study load cases simulating various travel conditions of a small vehicle
and to find an optimum value of the thickness of one of the suspension
components.
The design study is defined in two steps:

First, a list of the parameters (design variables) must be specified. A

multitude of parameter types is available: loads, geometrical features,
material constants, and others.
Second, a design study in which scenarios (combinations) of the
parameters along with their numerical values are created.

It is apparent that if an optimum combination of a larger number of

design parameters is desired, the process may be rather lengthy and
cumbersome. In such case, a full automatic Optimization feature of the
design study, available in the SolidWorks Simulation Professional
module, should be used.

In our model, we saw that with an arm thickness of 4mm, we fall below
the yield strength of the material. This is the thinnest we can make the
arm without doing any permanent damage.

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Lesson 11

Design Study

418

SolidWorks 2012

SolidWorks 2012

Exercise 25
Design Study

In this exercise, a design scenario will be created to determine the

distance between two supports that minimizes the deflection in the
plate.

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Exercise 25:
Design Study

This exercise reinforces the following skills:

I
I
I
I

Project
Description

Design Study on page 402.

Design Studies on page 404.
Design Study Results on page 409.
Design Study Graph on page 416.

A rectangular platform made of

Nylon 6/10 plastic material, is
supported by two steel rods
protruding through the platform
width.

The rods are suspended by short

links, which themselves are pinsupported. The distance
between the pins attached to the
platform may change when the platform experiences deformation.

This type of support makes it possible to use linear analysis for the
study of deflections and stresses of the platform.
The platform assembly is
subjected to an acceleration of
100 G.

We can assume that the steel

rods are rigid and that we are
not interested in the contact
stresses between the pins and
the platform. These
assumptions allow us to exclude
the rods from the analysis
model.

Support

Pin

Rod

Link

Since the rods are represented by properly applied supports, the

analysis is conducted using the SolidWorks part file platform, rather
than the assembly file platform assembly.
Find the distance between the two steel pins that minimizes the
platform deflection.

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Exercise 25

SolidWorks 2012

Design Study

Open a part file.

Open platform located in the Lesson11\Exercises folder.

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1
2

Show feature dimensions.

In the FeatureManager design tree, right-click Annotations and select

Show Feature Dimensions.
In this exercise, we take advantage of platform double symmetry to
analyze one quarter of the model.

Note

Make symmetry cut.

Unsuppress the feature called double symmetry.

Create a study.

Create a static study named 100G.

Define parameters.

In the Insert menu, select Design Study, Parameters. (Alternatively,

you can click Parameters on the Evaluate tab).
Define a distance parameter.

Select the 400 mm dimension that defines the distance between the two
hinges.

Material.

Specify Nylon 6/10 material from the Plastics folder.

420

SolidWorks 2012

Exercise 25
Design Study

Fixtures.

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Apply symmetry boundary conditions to the two faces created by the

cut.

Define restraint to
simulate rod support.
Apply a Fixed Hinge

fixture to the cylindrical

face as indicated in the
figure.

Apply gravity load.

To apply a gravity load, right-click External Loads and select

Gravity.

Select the Front plane as the reference to define the direction of

gravitational acceleration. Make sure the Unit field is set to SI.

Enter 981 m/s^2 (this value is one hundred times the gravitational
acceleration) in the direction normal to the Front plane in negative Z
direction.
Click OK.

Note

Mass density is a required material property when using gravity

loading.

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Exercise 25

SolidWorks 2012

Design Study

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10 Mesh the model.

Create a High quality mesh with the default settings using the
Curvature based mesh.
11 Define design study.

Define a design study with 10 scenarios for the following values for the
parameter distance: 475, 425, 375, 325, 275, 225, 175, 125, 75, and
25 mm.

12 Results specification.

Monitor the global maximums for the stress and the resultant
displacement, and the local results for the same quantities at the two
vertices indicated in the figure below.

13 Run design study.

Use High Quality.
14 Results.

Examine the global maximums for the von Mises stress and the
resultant displacement, and review the local stresses and resultant
displacements for the Vertex1 and Vertex2.

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Exercise 25
Design Study

15 Graph results at global max and Vertex1 locations.

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Define design history graphs for the variation of the von Mises stress
and the resultant displacement.

We observe that both the von Mises stresses and the resultant
displacements are minimized when the distance between the two
supporting rods is 275 mm. (Set 5). The corresponding values are
4.7 MPa and 0.36 mm.

16 Save and Close the file.

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Exercise 25

SolidWorks 2012

Design Study

At the beginning of this exercise, we stated that the platform was

suspended by floating links. The links themselves are pin-supported
and rotate about supporting pins. For this reason, the distance between
the rods may change when the platform experiences deformations
under the prescribed load.

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Limitations of
Linear Analysis

Consequently, in the assumption of small displacements, a platform

suspended by floating links does not develop any tensile stresses. It
resists the load only with bending stresses.
Link can rotate about this pin

If the links are rigidly supported and the rods are unable to move closer
together, tensile stresses develop in addition to bending stresses.

These tensile stresses, also called membrane stresses, are the result of
deformation and significantly increase the platform stiffness.

Question:

What does this have to do with linear analysis?

Answer:

Linear analysis assumes that the structure stiffness does not change
with deformation, and the solution is based on the original stiffness
calculated before any deformations occurred.
Therefore, linear analysis cannot account for additional stiffness
created by membrane stresses that develop during the deformation
process.

Even if we intended to model rigid hinges, the results would still have
pertained to floating hinges and the platform stiffness would have been
underestimated.
To differentiate between floating and rigid hinges we use nonlinear
geometry analysis, which is available in SolidWorks Simulation
Premium.

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Lesson 12
Thermal Stress Analysis

Objectives

Upon successful completion of this lesson, you will be able to:

I

Perform a static analysis with a temperature load.

Define temperature dependent material properties.

Use sensors to retrieve results at desired locations.

Use soft springs option in thermal stress analysis.

Save the deformed shape of the model.

Examine results in local coordinate systems.

425

Lesson 12

SolidWorks 2012

Thermal Stress Analysis

The heating or cooling of bimetallic parts create internal stresses due to

the difference in expansion coefficients in different materials. In this
lesson we will determine the stress and deformation that results from
heating a bimetallic part.

Case Study:
Bimetallic Strip

Due to the difference in the coefficients of the thermal expansion of

aluminum (200 W/m K) and nickel (43 W/m K), the bimetal will
deform with temperature changes. In this case study, the stress will be
zero at room temperature.

Project
Description

An aluminum strip, glued with a

nickel strip into a bimetal
assembly, is at room temperature
25C (77F). Without any
constraints on its deformation, the
bimetal strip is then heated to
280C (536F).

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Thermal Stress
Analysis

Aluminum

Nickel

Determine the deformations that

arise due to the different thermal
expansions of aluminum and nickel, and the minimum required
strength of the bonding glue material.

Also required is that the numerical simulation be followed by an

experiment. Six tensometers, oriented along the longitudinal direction,
will be attached to the surface of the tested model (three on the top of
each part) as shown in the figure to measure the surface deformation.
To allow for the correlation between the numerical and experimental
data, sensors will be defined in the same locations in the finite element
model.
The deformed assembly will then be saved as a SolidWorks model for
further design applications.

Procedure

Proceed as indicated in the following steps.

Open an assembly file.

Open bimetal located in the Lesson12\Case Studies folder.

Create study.

Create a static study named bonded.

The Ni and Al properties are automatically transferred from the

SolidWorks assembly.

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SolidWorks 2012

Lesson 12
Thermal Stress Analysis

Material Properties

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Because the model is exposed to an elevated temperature, the material

constants have to be modified accordingly. The following two tables
show the dependence of the material constants on the temperature.
Variation of SIGYLD [Pa] on temperature

Room

100C

204C

260C

316C

Inconel 702
Nickel Alloy

406.9e6

356e6

326e6

2014 - T6
Aluminum Alloy

378.6e6

330.5e6

210e6

119.8e6

44.4e6

Variation of EX [Pa] on temperature

Room

100C

204C

260C

316C

Inconel 702
Nickel Alloy

229.9e9

223.4e9

205e9

2014 - T6
Aluminum Alloy

71.9e9

70.6e9

64.1e9

50.8e9

50.5e9

Create custom material properties for Ni strip.

Right-click on the body ni-2 (under the folder Parts) and select Apply/
Edit Material.

The material dialog window displays default Ni material constants at

room temperature. Because the materials in the default library can not
be edited, we will copy the Ni material into a new custom library
named Lesson 12 materials.

Right-click on Custom Materials folder and

select New Category.
Name the new catergory Lesson 12

materials.

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Lesson 12

SolidWorks 2012

Thermal Stress Analysis

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Copy and Paste Nickel from SolidWorks

Materials, Other Metals, into our newly
created category Lesson 12 materials.

Edit Nickel, select the Tables & Curves tab

and Elastic Modulus in X vs Temperature
under Type.
Select oC and N/m^2 under the Table data
section.

Enter data.

Enter the available data points from the table above defining the
dependence of the Youngs modulus on temperature for Inconel 702
Nickel Alloy.

To add a new line in the Table data definition, double-click on the last
row.

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SolidWorks 2012

Lesson 12
Thermal Stress Analysis

Enter data from Excel.

In some cases, the number of data

points can be excessive. In
SolidWorks Simulation, the data
can be conveniently copied from
other programs such as Excel.

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Continue editing Nickel and under Type, select Yield Strength vs

Temperature, set the Units to oC and N/m^2 (Pa).
Open the Excel file

materialdata.xls located

in the lesson directory, and

navigate to the sheet with
the Inconel 702 Nickel
Alloy data. Right-click on
the corresponding data and
select Copy.

Paste (CTRL-V) the data

into the Table data area of
the Material dialog window.

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Lesson 12

SolidWorks 2012

Thermal Stress Analysis

Make the properties temperature dependant.

Select the Properties tab. Under the Value column, click on the
corresponding cells for Elastic modulus and Yield strength, and
select Temperature dependent.

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Notice that the cells for Elastic modulus and Yield strength under the
Value column show Temperature Dependent.

Click Apply and Save to confirm the definition of the Inconel 702
Nickel Alloy properties and save the database.

We will assume that the thermal expansion coefficient remains constant

in a given temperature range.

Note

Assign material to Al strip.

Follow the procedure above and assign the temperature dependent

material constants (Yield Strength and Elastic Modulus) for 2014-T6
Aluminum Alloy. The data can be again found in the
materialdata.xls Excel file located in the lesson directory.

Global Contact.

The default top level assembly contact (Global Contact) condition is

set to Bonded. As we analyze glued components, bonded contact is
appropriate.

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SolidWorks 2012

Lesson 12
Thermal Stress Analysis

Define sensors on Al strip.

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In the FeatureManager design tree, right-click

the Sensors folder and select Add Sensor.
For Sensor Type, select Simulation Data.

For Data Quantity, select Workflow

Sensitive.

Select the three sketch points on top of the Al strip, then select OK.

Aluminum
Sensors

Nickel
Sensors

Rename this set of sensors to Al_sensors.

10 Define sensors on Ni strip.

Follow the procedure above to define three sensors on the Ni strip.

Name this set of sensors Ni_sensors.

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Lesson 12

SolidWorks 2012

Thermal Stress Analysis

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11 Apply temperature load.

Right-click External Loads and select Temperature. Use the

SolidWorks fly-out menu to select both components.

Enter a temperature of 280C. This definition states that the

temperature of both assembly components is uniformly elevated/
lowered to 280C from the reference temperature at zero strain.
Click OK.

12 Define zero strain

temperature.
Right-click the bonded

study folder and select

Properties.
Select the Flow/

Thermal Effects tab.

In the Thermal options

area, select Input
temperature (this is the
default choice). The
input temperature is the
280C that we defined
earlier.

Enter 25C as the Reference temperature at zero strain. This

temperature corresponds to the room temperature, and we assume that
no strain exists in the model at this temperature, due to the structural
loads and boundary constraints.

432

SolidWorks 2012

Lesson 12
Thermal Stress Analysis

Temperature loads can be also imported from the SolidWorks

Simulation thermal study or directly from the CFD (Computational
Fluid Dynamics) simulation in SolidWorks Flow Simulation.

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Importing
Temperatures

For the stress analysis it is also possible to import the distributions of

the fluid pressures from SolidWorks Flow Simulation.

13 Stabilize the model.

Because the strips deformation should be unconstrained, we cannot

apply an external boundary condition. Since the model is in the state of
thermodynamic equilibrium and is not subjected to any external force
loads, we can use the soft spring option to stabilize the model.
Select the Options tab.

Select Use soft spring to

stabilize model.
Click OK.

14 Mesh the model.

Create a High quality mesh with

the default settings using the

Curvature based mesh.

This element size creates two

layers of elements through the
thickness of each part.

15 Run the analysis.

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Lesson 12

SolidWorks 2012

Thermal Stress Analysis

16 Plot displacements.

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Plot the resultant displacements (in 1:1 deformation scale).

The maximum displacement at the tip of the bimetallic strip is 0.59 mm
[0.023 in].

17 Plot von Mises stress results.

Examine the results. There appears to be very high stress at the junction
of the two materials.

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SolidWorks 2012

Lesson 12
Thermal Stress Analysis

This stress plot can be misleading. As we learned in Lesson 1, the von

Mises stresses are obtained by averaging the stress values extrapolated
to the nodes from all the adjacent elements. In this case, the stresses at
the interface are averaged between two distinct parts. To obtain the
correct distribution of the von Mises stresses, we have to disable the
averaging across the part boundaries.

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Averaging Stress

18 Edit the plot.

Right-click on the stress plot and select Edit

Definition.

In Advanced Options, clear Average results

across boundary for parts.

The new von Mises plot above shows the correct distribution. We can
see that with the averaging across the boundaries option disabled, the
maximum value jumped to approximately 264 MPa [38.2 ksi] in some
interface regions.

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Lesson 12

SolidWorks 2012

Thermal Stress Analysis

19 Stress on individual parts.

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To view the maximums in each of the two parts separately, isolate the
components in SolidWorks and plot the distribution of the von Mises
stress for the displayed part only.

Display the extreme values for the shown parts. In Chart Options,
select Show min annotations, Show max annotations, and Show
Min/Max range on shown parts only options.

Aluminum part

Nickel part

436

SolidWorks 2012

Lesson 12
Thermal Stress Analysis

20 Examine the plots.

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We can see that the maximum von Mises stresses in the Aluminum and
Nickel Alloy parts are 121 and 264 MPa respectively. The stress in the
Aluminum part is well above the corresponding yield strength at 280C
(93 MPa) whereas the Nickel part is below (335 MPa at 280C ). This
indicates that one of the parts is yielding.

The accurate solution to the above problem can, therefore, be obtained

using a nonlinear modulus of SolidWorks Simulation Premium, where
full stress-strain curves for the given alloys would have to be specified.
We will ignore the fact that one of the parts is yielding and continue
with the lesson. In the next part, we would like to analyze the interface
layer and find the minimum required strength of the bonding material.

21 Show strain results at the sensor locations.

Define a new strain plot for the ESPX: X Normal strain component.

Right-click on the newly defined strain plot and select List selected.

Select From sensors under Options and Al sensors under Results.

These are the probes for the Aluminum strip.
The normal strain values will be listed in the table and shown on the
model.

Note that the buttons under Report Options let you graph the results at
the sensor locations or save them in.cvs file for further processing.
Also, it is possible to include the results at all sensor locations in the
study report.

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Lesson 12

SolidWorks 2012

Thermal Stress Analysis

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22 Plot distribution of normal stress SX.

Define a new stress plot for the SX: X Normal stress component. In
exploded view, analyze the through-thickness variation of the SX

normal stress.

Important

Similarly to the von Mises stress plot, deactivate Average results

across boundary for parts option.

23 Graph stress through the thickness.

Use the Probe feature to path plot the variation of the SX stress through
the thickness.

Ni (interface)

Al (top)

Ni (bottom)

Al (interface)

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SolidWorks 2012

Lesson 12
Thermal Stress Analysis

The results and the graph above indicate the following variation of SX.

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Interpret the Results

We observe that at the interface the normal stresses change abruptly

from -96 MPa (compression) in Aluminum to 147 MPa (tension) in
Nickel. Furthermore, we can observe three neutral axes (planes) where
the normal stresses are at zero. Two of these axes (planes) are clearly
indicated in the figure. The third axis coincides with the interface
plane, where the normal stresses change abruptly from -96 MPa
(compression) in Aluminum to 147 MPa (tension) in Nickel. All three
locations are accompanied by the local extremes of shear stress that
may delaminate the glued strips (see the figure above).
Since our main goal is to obtain the required strength of the bonding
material, we will focus on the interface location. The bonding material
must be capable of resisting the shear stress at the Aluminum/Nickel
interface.

Reviewing the Interpretation of FEA Results on page 17 of the

Introduction reveals that we must plot the xy component of the stress.
This corresponds to the TXY: Shear stress in the Y dir on YZ plane
component.

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Lesson 12

SolidWorks 2012

Thermal Stress Analysis

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24 Plot interface shear stress.

Define a new plot of TXY: Shear stress in the Y dir on YZ plane
stress. Display the plot in the exploded view and, under Settings,
Fringe Options select Discrete.

We can observe that the interface shear stress on the side of Aluminum
and Nickel are identical, i.e. the equilibrium is satisfied. The discrete
plot conveniently shows that the maximum value of shear stress
(ignoring the localized stress concentrations at the tip of the straight
section) equals approximately 13 MPa. This would be the minimum
required strength of the glue in shear for this application.

Question

We concluded that the minimum required strength of the glue is

approximately 10 MPa. Inspection of the xy plot above shows that the
bent part should experience much larger shear stress. Why?
For the answer review the following section.

Examining
Results in Local
Coordinate
Systems
(Optional)

440

xy

in the previous figure is referencing the global coordinate system.

In the bent section, the global x, y and z axes are no longer aligned with
the interface geometry. In other words, the xy distribution in the bent
section no longer represents the interface shear stress.
For the correct representation of the interface shear stress in the bent
section, we have to switch to the appropriate coordinate system aligned
with the geometry.

SolidWorks 2012

Lesson 12
Thermal Stress Analysis

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25 Interface shear stress at the bent location.

Create a Discrete xy plot with Axis1 used as a reference. Axis1

defines a local cylindrical coordinate system aligned with the geometry

of the bent section.

Shear Stress in
Cylindrical
Coordinates

In the cylindrical coordinate system, the r, , and z sequence of

coordinate axes corresponds to the x, y, and z sequence in the Cartesian
coordinate system. By specifying xy in the plot definition dialog with
Axis1 specified as a reference, we request a plot of r , which is the
interface shear stress.
The above plot of the interface shear stress shows that the bent section
experiences similar shear. The indicated value is approximately 11
MPa. As this is greater than the value of 10 MPa obtained from the
straight section, we conclude that this is the minimum required shear
strength of the bonding material.

Since the bonding material will also have to resist the normal stress we
would have to verify the interface normal stress in the proper
coordinate systems. It can be checked that this stress is significantly
smaller in this case (approximately 5MPa) and will not govern.

441

Lesson 12

SolidWorks 2012

Thermal Stress Analysis

Saving Model in
its Deformed
Shape

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We end this lesson by saving the deformed shape as a new SolidWorks

model so that it can be used as an assembly component to check for
interference, and so on.

Create new body from deformed shape.

Right-click on the Results folder and select Create Body from
Deformed Shape.

Click the Save as New Part button and enter

Deformed bimetal as the Part name.
Click OK.

Open the new body in the SolidWorks

environment.
In the options area of the SolidWorks File, Open
window and select the saved Deformed bimetal.sldprt file.

Click OK.

The deformed geometry model appears as an imported feature in the

SolidWorks FeatureManager. The deformed shape can now be
examined with the standard SolidWorks tools.

442

Save and Close the file.

SolidWorks 2012

Lesson 12
Thermal Stress Analysis

A simple bimetal assembly was analyzed when subjected to the

elevated temperature. To eliminate the effect of absent external
supports, the Use soft springs to stabilize model option was used.

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Summary

At elevated temperatures, the values of some of the material properties

may vary considerably. In this lesson, we practiced the definition of the
temperature dependent yield strength and Youngs modulus.
The main goal of the lesson was to obtain the minimum required bond
strength of the interface glue. To obtain this value, a complex
distribution of the normal stress SX was studied, and the definition of
the neutral axes (planes) was introduced. Furthermore, the
corresponding component of the shear stress was plotted.
In the bent section, the curved geometry required the introduction of
the local cylindrical coordinate system. The interface shear stress was
then plotted with respect to this local coordinate system.

Since the experimental verification of the numerical results was

required a set of sensors was defined to extract the deformation results
at the specified tensometer locations.

Lastly, exporting of the deformed geometry as a VRML file was shown

and discussed.

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SolidWorks 2012

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Thermal Stress Analysis

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Lesson 13
Adaptive Meshing

Objectives

Upon successful completion of this lesson, you will be able to:

I

Use and understand the h-adaptive solution method.

Use and understand the p-adaptive solution method.

Compare results obtained using h-adaptive and p-adaptive solution

method.

Use symmetry boundary conditions.

Use the Graph tool.

445

Lesson 13

SolidWorks 2012

Adaptive Meshing

Through the previous lessons, we have manually refined the mesh to

improve the accuracy of our results. In this process, we have examined
the model and then the results to determine the refinements necessary
to get accurate results. Two new solution methods called h-adaptive
and p-adaptive will be used in this lesson that will automate the
process.

Case Study:
Support
Bracket

A cantilever bracket will be

analyzed using the different
meshing techniques.

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Adaptive
Meshing

Symmetry boundary conditions

will be used to reduce the
analysis to only half the model,
resulting in a faster solution.
First we will create a mesh
using the same method used in
previous lessons. This will be
the standard solution. The
results of the standard study
will serve as a basis for
comparison between the three
different solution methods used
in this lesson:

1. Standard solution
2. h-adaptive solution
3. p-adaptive solution

Project
Description

A cantilever bracket is
supported along the face at the
back side.

A load of 22,000 N [4,946 lb] is

uniformly distributed to the
split face that surrounds the
cylindrical hole.
Determine the location and
maximum magnitude of von
Mises stresses.

446

Load

Support

SolidWorks 2012

Lesson 13
Adaptive Meshing

Procedure

Proceed as indicated in the following steps.

Open a part file.
Open support bracket located in the Lesson13\Case Studies

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folder.

Activate symmetry configuration.

Activate the configuration called symmetry.

Geometry
Preparation

The bracket geometry has been defeatured to make meshing easier; the
external cosmetic fillets have been suppressed. While these details do
not complicate this model to the point of preventing us from meshing
or solving it, we use the model with suppressed features to emphasize
the fact that defeaturing is often necessary for more complex models.

Symmetry

Due to the symmetry of the bracket geometry, loads, and supports, we

can simplify the finite element model by analyzing only one half of its
geometry.

Define a study.

Define a static study named standard.

This study will provide results that will serve as reference when
comparing different solution methods. The study name standard
reflects the fact that we use a regular solution method where mesh
does not change during the solution process. This is how we have
solved all previous lessons in this training manual.

The material properties (AISI 304) were defined earlier in SolidWorks

and have been transferred automatically to SolidWorks Simulation.

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Lesson 13

SolidWorks 2012

Adaptive Meshing

Apply load as a force.

Apply 11,000 N [2,473 lb.] force

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to the split face around the hole.

Note that only one half of the
force magnitude must be applied
because the model represents only
one half of the geometry.

Apply Fixed Geometry

fixture to the back face.

Apply Symmetry Boundary

Conditions.
Apply Symmetry boundary

conditions on the faces

exposed by the cut.

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SolidWorks 2012

Lesson 13
Adaptive Meshing

Mesh the standard study.

Create a High quality mesh with the

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default element size using the

Curvature based mesh.

Since no local mesh control was

defined, the element size is uniform.

Run the analysis.

Run the solution for the standard

study.

To verify that the symmetry boundary

conditions work as expected, animate one of the results plots. While the
model deforms, verify that the faces with symmetry boundary
conditions applied to them remain flat and there is no movement of
these faces in the direction normal to the plane of symmetry.

h-Adaptive Solution
Method

Before we explain the h-adaptive solution method, recall that any

solution obtained using the Finite Element Analysis depends on how
the analyzed model has been meshed.
We may re-phrase the above observation to say that the FEA data of
interest depends on the choice of discretization. Thus, changing the
mesh parameters (global or local mesh controls) will affect the FEA
results. This is because different meshes (different choices of
discretization) will cause different discretization errors.

Discretization errors can be estimated by making systematic changes to

the mesh and studying the impact of these changes in the area of
interest. This process is called convergence process.
One way to make systematic changes to the mesh is to modify the
element size through mesh refinement. Because h denotes the
characteristic element size, the convergence process through mesh
refinement is called h convergence process. In this process, the size
of the elements is gradually reduced.

We have already conducted the h convergence process in Lesson 1 and

Lesson 2.

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Lesson 13

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Adaptive Meshing

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In Lesson 1, we refined the model uniformly, meaning the entire model

was meshed with the same element size. That size was reduced in
different studies. In Lesson 2, we used mesh controls to refine the mesh
only in areas where we deemed it necessary.
The convergence process we conducted in Lesson 1 and Lesson 2
required us to define several studies with different meshes, run the
analysis, and summarize the results. These were informative but rather
tedious exercises.

Using the h-adaptive solution method we will automate the

h convergence process.

h-Adaptivity
Study

We will analyze the same bracket, with the same material fixtures and
loads using an h-adaptive solution.

Create new study for h-adaptive solution.

Duplicate the study standard into a new study and name it

h adaptive.

Set h-adaptive solution parameters.

Right-click h-adaptive study and select Properties.

Select the Adaptive tab.

Note

The Adaptive solution tab is available only for static analysis and solid
mesh elements.

Under the Adaptive

method option, select hadaptive.

Under the h-Adaptive

options, accept the default
value for Target accuracy.
Also, accept the slider
location at the center for
Accuracy bias.
In the Maximum no. of
loops box, enter 5.

Select the Mesh

coarsening check box.
Click OK.

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SolidWorks 2012

Lesson 13
Adaptive Meshing

What is going to happen when we solve the study with the above
settings?

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h-Adaptivity
Options

SolidWorks Simulation will solve the same model several times, each
time using more refined meshes. The mesh refinements will be
performed automatically, no user intervention is required.

How many mesh refinements will be performed?

Considering that we have set the Maximum number of loops to 5,

SolidWorks Simulation will solve for the original mesh and then
perform several other mesh refinements. Looping will terminate when
Target accuracy is obtained or if the Maximum number of loops is
reached. Maximum number of loops of 5 means that the solution
may consist of a maximum of six steps: the original mesh and five
refinements.
Target accuracy is the accuracy of strain energy norm (RMS strain

energy) in the model. We set it at 98% which means that looping stops
if the difference in the strain energy norm between the two consecutive
loops drops below 2%.

Target Accuracy

The Target accuracy is based on the total strain energy in the model.
This is a global measure of the discretization error. As such, it is largely
insensitive to localized errors, even if those errors are high.

Accuracy Bias

To account for the local errors, looping is also controlled by an

Accuracy bias.You can move the Accuracy bias slider to the left
(Local) to instruct the program to concentrate on getting accurate peak
stress results, meaning that local areas with high strain energy errors
will receive preferential treatment (mesh will be highly refined in
those areas). Or, you can move the slider to the right (Global) to
instruct the program to compute overall accurate results with respect to
lower strain energy errors. We do not have explicit control over the
magnitude of local strain energy error.
From Lesson 2 you will recall that stress singularity occur at the
locations of concentrated forces and sharp re-entrant corners. The
stresses at these locations diverge to infinity as smaller mesh elements
are used.

Therefore, for models with such singularity, it is recommended to move

the Accuracy bias slider to the right (Global). This way high, but
localized, strain energy errors will be ignored; the solver will not adjust
mesh refinement pattern to reduce these errors.

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Lesson 13

SolidWorks 2012

Adaptive Meshing

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Local Accuracy bias usually produces results faster than Global

Accuracy bias.
De-refined

Refined

De-refined

Original mesh

Mesh after completion of

h-adaptive solution

When h-adaptive solution is used, you can start with a coarser original
mesh size. This mesh is a starting point and SolidWorks Simulation
refines it as needed during the solution process. Additionally during the
mesh refining process, the mesh may be de-refined if Mesh
coarsening is selected, as it has been in our study.

The mesh may become coarser in some locations if the h-adaptive

solver decides that the initial user defined mesh is too fine, meaning
it is excessively refined giving low stress gradients in these locations.

The mesh is not refined uniformly but only where needed to keep strain
energy errors low. We may say that mesh adapts to the stress patterns.
This gives the adaptive name to h-adaptive solution method.

Create mesh for h-adaptive study.

Mesh the model with the mesh density
slider set to Coarse. Make sure High
quality elements are used.

This mesh is not acceptable for standard

solution techniques because there are
not enough elements to capture the
complex stress gradients around the
fillets.

Run the h-adaptive study.

Run the solution for the h-adaptive study. The solution progresses in
steps corresponding to the number of mesh refinements.

To help re-visualize the stress results, the regions where the material
yields will be plotted in a distinct color.

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SolidWorks 2012

Lesson 13
Adaptive Meshing

Set distinct color for yielding regions.

Select Option from the Simulation menu. Select the Default Options
tab. Select Color Chart under Plot.

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Select Specify color for values

above yield for von Mises plot

feature. The default color is gray.

Click OK.

Plot von Mises Stress.

Define a new von Mises stress plot. Under Settings, select Mesh for
the Boundary options.

The stress plot shows the maximum von Mises stress of 227 MPa
[33 ksi], which slightly exceed the yield strength of AISI 304 steel.
Note that the yielding regions are shown in a distinct color.

Displaying mesh superimposed on the plot confirms that the mesh has
indeed been refined where stress concentrations are located and derefined in quiet portions of the model.

453

Lesson 13

SolidWorks 2012

Adaptive Meshing

h-Adaptive Plots

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Any plot (stress, displacement, strain, and so on) in the results folders
of the h-adaptive study displays the final result, or the last performed
step of the h-adaptive solution process. In addition to displaying the
final plot results, we can also access the history of the iterative solution.

Convergence
Graph

To visually see how well the solution is converging, we can use a

convergence graph.

Where to Find It

Shortcut Menu: Right-click on the Results folder and select Define

Adaptive Convergence Graph.
Menu: Simulation, Results Tools, Convergence Graph.

Create convergence graph.

Right-click on the Results folder and select
Define Adaptive Convergence Graph.

Under Options, select Maximum von Misses

stress. Clear Target Accuracy.
Click OK.

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SolidWorks 2012

Lesson 13
Adaptive Meshing

Review h-adaptive
Solution

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Let us review the graph and make a few observations about the hadaptive solution.
I

I
I

The h-adaptive iterations went through all five steps: the first using
the original mesh and the next four steps with automatically refined
meshes.
In each loop the mesh is refined further.
The maximum number of loops (5) has been reached. Because no
convergence confirmation message was displayed at the end of the
process the required strain energy error of 2% was not achieved.
The stress units in the graph are N/m^2, regardless of what units are
used in the model.

We now wish to continue with the iterative procedure to reduce the

strain energy error below the requested 2%.

Continue running the analysis.

Run the study h-adaptive again.

The last results and mesh from the previous iterations are now the
initial configuration for new h-adaptive iterations.

Note

At one point we get the following message:

Analysis has satisfied the current h-Adaptive accuracy of

98.0334 percent. You may increase target accuracy to re-run.

The convergence criteria has now been met.

Plot von Mises stress.

The maximum stress increases from 227 to 229.3 MPa [33 ksi to 33.25
ksi]. The difference in stresses is therefore minimal in this case.

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Lesson 13

SolidWorks 2012

Adaptive Meshing

10 Create convergence graph for Maximum von Mises stress.

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Counting the number of data points we see that the h-adaptivity

iterations had to go through seven loops to achieve the desired accuracy
of 2%.

Strain Energy
Error is NOT
Stress Error

The 2% strain energy error we specified in the properties of the hadaptive study is not the stress error.

If we are interested in von Mises stress, why cant we specify the error
in terms of von Mises stress? In other words, why dont we use von
Mises stress rather than the total strain energy as a convergence
criterion?

The reason why the total strain energy is used as a convergence

criterion is because the total strain energy (total means in the entire
model) always shows monotonic convergence without local plateaus,
which might lead to premature termination of the convergence process.
Also, recall the local stress singularities phenomenon analyzed in
Lesson 2. In this case the stress diverges and convergence could not be
achieved.
Review displacement results of study h-adaptive before proceeding.

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SolidWorks 2012

Lesson 13
Adaptive Meshing

Having obtained a solution with the h-adaptive solution method we

now solve the same model using the p-adaptive solution method.

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p-Adaptivity
Study

P-adaptive solution requires the use of a different type of finite

element called p-element. Before we begin, we need to explain what pelements are and what they do.

p-Adaptive
Solution Method

In Lesson 1, we said that SolidWorks Simulation uses three types of

elements: tetrahedral solids, triangular shells, and beams. Each can be
defined as either a:
I
I

First order element (draft quality).

Second order element (high quality).

First order elements model a linear (or first order) displacement and
constant stress distribution, while second order elements model a
parabolic (second order) displacement and linear stress distribution.

We now have to amend the above paragraphs. Besides first and second
order solid tetrahedral elements, SolidWorks Simulation also has
higher order tetrahedral solid elements (up to the 5th order) meaning
that a polynomial of the 5th order can be used to model a displacement
field inside the element, along its faces and edges. These elements are
available when the p-adaptive solution method is used.

The order of elements used in the p-adaptive solutions is not predefined, but can be upgraded automatically during the iterative solution
process without our intervention. These elements with upgradeable
order are called p-elements.

457

Lesson 13

SolidWorks 2012

Adaptive Meshing

Create p element study.

Duplicate the study h adaptive into a new study named p adaptive.

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1
2

Define p-element method and its options.

To utilize p-elements in the analysis, right-click the p elements study

folder and select Properties.
Select the Adaptive tab, then select the p-adaptive. This option is
available only for static analysis and only when using solid elements.

Set Starting p-order to 2, which means that all elements are first
defined as second order elements.

Set Maximum p-order to 5. The p-adaptive solution runs in iterations,

called loops, and with each new loop, the order of elements increases.
The highest order available is the 5th order, but the actual highest order
we use can be lower and is defined by Maximum p-order.
Set Maximum no. of loops to 4.

Under p-adaptive options, in the change is text box, enter 0.05.

Click OK.

Looping continues until the change in Total Strain Energy between the
two consecutive iterations is less than 0.05%, as specified in the
p-adaptive options. If this requirement is not satisfied, then looping
stops when the elements reach the highest available order, which in our
case is the 5th order. Note that it takes four iterative loops to reach a 5th
order element. Investigate other choices in the p-adaptive options area.

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Lesson 13
Adaptive Meshing

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Why are we specifying this high accuracy requirement (0.05%) for the
total strain energy error? Actually, we do not expect that the solution
will satisfy this requirement. We want to force the solver to complete
all four steps so we can analyze graphs consisting of four, rather than
two or three points.

The p-adaptive solution process is conceptually similar to the already

performed h-adaptive iterative process of mesh refinement. Both add
degrees of freedom to the model, one by mesh refinement, the other by
element order upgrade.
The difference between h-adaptive and p-adaptive solution methods
is that, in h-adaptive, mesh changes while element order stays the
same, while in p-adaptive, mesh stays the same but element order
changes.

h vs. p Elements

Let us pause to explain some terminology:

Question:

Why are upgradeable elements called p-elements?

Answer:

The iterative process that we are currently discussing does not involve
mesh refinement. While the mesh remains unchanged, the element
order changes from the initial 2nd order all the way to 5th order (or less
if the convergence criterion is satisfied sooner).

The element order is defined by the order of polynomial functions that

describe the displacement field in the element. Because the polynomial
(p) order experiences change, the process is called the p convergence
process, and the upgradeable elements we use are called p-elements.

Question:

Why is the p convergence process called a p-adaptive solution, and

what exactly does adaptive mean?

Answer:

Adaptive means that not all p-elements are necessarily upgraded during
the solution process.

Indeed, as you see in the p-adaptive options area, Update elements

with relative Strain Energy error of _% or more means that only
those elements not satisfying the above criterion are upgraded. We say,
therefore, that element upgrading is adaptive, or driven by the results
of consecutive iterations.
This is in close analogy to h-adaptive solution (performed earlier in
this lesson), where the mesh was refined during consecutive loops.

We are now sufficiently familiarized with p-elements to proceed with

p-adaptive solution.

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Lesson 13

SolidWorks 2012

Adaptive Meshing

Create mesh.
Right-click Mesh and select Create Mesh.

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Under Advanced, select At nodes for Jacobian points.

Mesh the model and run the

analysis.
Create a High quality mesh using the
Curvature based mesh intended for

p-elements with the mesh density

slider set to Coarse.

Considering that a p-adaptive

solution is used, we can manage with
a coarser mesh.
Select Run (solve) the analysis to
combine the mesh and run steps into
one.

This mesh would not be acceptable for use in the standard study
because there are not enough elements to capture the complex stress
field, especially near the rounds. Using higher order p-elements,
however, is equivalent to refining an h-element mesh, so that even this
coarse mesh delivers accurate results.

Note

Run.

When the analysis runs, the solution progresses in steps corresponding

to the number of element-order upgrades.

Display von Mises stress plot.

Now that we have solved the study with p-elements, we display a von
Mises stress plot.

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Adaptive Meshing

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To set the plot settings, right-click the stress plot and select Settings.
Select Discrete for the Fringe options and select Mesh for the
Boundary options.

The resulting stress plot shows a maximum von Mises stress of

207 MPa [30.0ksi], which is just above the yield stress of AISI 304.

Note

Any plot (stress, displacement, strain, and so on) in the results folders
of the p elements study displays the final result, or the last step of the
p-adaptive solution process. In addition to displaying the final plot
results, we can also access the history of the iterative solution.

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Lesson 13

SolidWorks 2012

Adaptive Meshing

Create a convergence graph.

Right-click the Results folder and select Define
Adaptive Convergence Graph.

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Because we are primarily interested in the

maximum von Mises stress, select Maximum von
Mises stress in the Options.

Click OK.

Review the graph.

Let us review the graph and make a few observations about the padaptive solution.:
I

462

The p-adaptive iterations went through all four steps: the first
using the second order elements, and the next three with higher
order element up to the 5th order.
The 0.05% strain energy error we specified in the properties of the
p-adaptive study is NOT stress error.
The maximum strain energy error of 0.05% has not been achieved
and we would have to continue with the iterations further to reduce
the error. (The maximum element order is limited by 5, however.)

The stress units in the graph are N/m2. SI units are internally used
by SolidWorks Simulation for calculations, regardless of what units
are used in the model.

Save and Close the file.

SolidWorks 2012

Lesson 13
Adaptive Meshing

Now, let us summarize the results of all three studies executed in this
lesson. Recall that information on the number of degrees of freedom is
taken from the OUT file corresponding to the given study in the
SolidWorks Simulation data base.

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Method
Comparison

Solution type

Max. resultant
displacement

Max. von
Mises stress
[psi]

# D.O.F.

Standard

0.427 mm
[0.0168 in]

207.5 MPa
[30,094 psi]

37479

h-adaptive

0.428 mm
[0.0168 in]

229.3 MPa
[33,254 psi]

75225

p-Adaptive

0.428 mm
[0.0168 in]

207.9 MPa
[30,150 psi]

42801

Displacement results are practically the same. Stress results are within
9%. Considering that a highly concentrated stress is rather difficult to
model with any solution technique, this accuracy is satisfactory.
Standard solution appears to be the most economical; it had the shortest
solution time.

Having completed the exercise with three solution methods, we note

that h-adaptive and p-adaptive solution methods are very close,
conceptually. Upgrading the element order in the p convergence
process adds degrees of freedom to the model, which is a direct analogy
to adding degrees of freedom by mesh refinement in the h convergence
process.
This explains why we can use a coarse mesh for both h-adaptive and
p-adaptive solution. The degrees of freedom that are missing in the
initial mesh are added in the process of iterative solution either by mesh
refinement or by element order upgrade, and produce an analogous
effect to using a standard solution technique with properly refined
mesh.

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Adaptive Meshing

The following table summarizes the differences between h-adaptive

and p-adaptive solutions.

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h vs. p
Elements Summary

Solution type

h-adaptive

464

p-adaptive

Element
order

2nd order, does not

change during the
solution.

Changes during the

solution process from 2nd
to max. 5th to satisfy the
accuracy requirements.

Mesh
adaptivity

Mesh is changed by
refinement (both element
size and location of
refinement) and adapts to
the pattern of stress
distribution found in the
model. High stress
gradients are meshed with
more refined mesh.

Mesh does not change.

Global
error
control

Total Strain Energy

(called Target accuracy)

Total Strain Energy, or

RMS Resultant
Displacement, or
RMS von Mises stress

Local
error
control

Local strain energy

(called Accuracy bias)

Local strain energy

Maximum
number of
loops

Unlimited:
The study can re-run
repeatedly until the
desired accuracy level is
reached.

Four:
The first one with 2nd
order elements, the last
one with 5th order
elements but, mesh can
be refined then re-run.

Element order adapts to

the pattern of stress
distribution found in the
model. High stress
gradients are meshed with
higher element order.

SolidWorks 2012

Lesson 13
Adaptive Meshing
I
I

The standard solution using h elements?

The h-adaptive solution using h elements?
The p-adaptive solution using p elements?

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Which Solution
Method is Better?

Generally, with the standard solution method using second order

elements, we obtain a reasonably accurate solution within a reasonably
short time.

Experience indicates that the standard solution method utilizing second

order elements offers the best combination of accuracy and
computational efficiency.
For this reason, the automesher in SolidWorks Simulation is tuned to
meet the requirements of an h-element mesh intended for the standard
solution method.

Both h-adaptive and p-adaptive methods involve iterative solutions

that stop either when the accuracy requirement has been satisfied or
when the maximum allowed number of iterations has been reached. In
this lesson, we requested a very low error to make sure that the solver
goes through the maximum number of iterations. This way we obtained
solutions with low, but not explicitly known, error.
Try running h-adaptive and p-adaptive studies again with relaxed
accuracy requirements so that the solver does not use up all available
loops.
If the convergence graph shows:

less than six iterations have been performed for h-adaptive solution
or...
I less than four iterations have been performed for p-adaptive
solution,
I

then this means that the solution has stopped because your accuracy
requirements have been satisfied and not because the maximum
number of loops has been reached.

Summary

Both h-adaptive and p-adaptive solution methods are significantly

more time-consuming. Therefore, these solution methods are reserved
for special cases where the solution must have narrowly specified
accuracy.

The adaptive solution methods are also great learning tools, leading to a
better understanding of element order, the convergence process, and
discretization error. For this reason, you are encouraged to repeat some
of the lessons presented in this course using the adaptive solution
technique of your choice.

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Lesson 13

Adaptive Meshing

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Lesson 14
Large Displacement Analysis

Objectives

Upon successful completion of this lesson, you will be able to:

I

Understand the difference between geometrically nonlinear (large

displacement and geometrically linear (small displacement)
analyses.

Perform geometrically nonlinear (large displacement) analysis.

Assess limitations of the linear material model.

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Large Displacement Analysis

As explained in the beginning of this course, SolidWorks Simulation

computations are limited to the small displacement class of problems
(geometrically linear analysis). In this lesson, we will show that this
limitation is actually not present and SolidWorks Simulation is capable
of solving large displacement, nonlinear problems as well.

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Small vs. Large

Displacement
Analysis

In small displacement analysis, it is assumed that the shape of the

model before and after the deformation took place is nearly identical.

Consider a cantilever beam loaded by a pressure, as shown in figure a

below. First, let us assume that our load is small in relation to the
stiffness of the beam, resulting in deformations that are barely
noticeable (figure b). The stiffness of the deformed beam, [ K 1 ] , which
is a function of geometry and the material, will be nearly identical to
the original stiffness of the undeformed beam, [ K ] .
We can conclude that [ K ] [ K 1 ] , and that the linear elastic solution
[ K ] { u } = { F } is valid as long as the above assumption is acceptable.
a.

b.

c.

If the same beam is loaded with a significantly larger pressure, its

deformation will become large. Because of the significant change in the
geometry, the stiffness of the this beam, [ K 2 ] , is considerably different,
and the linear elastic solution is no longer acceptable.
Cases b and c are commonly referred to as small displacement and
large displacement problems, respectively.

Large displacement problems are of a nonlinear nature. They are

significantly more complicated because they require a gradual increase
of the load in small increments and elaborate iterational schemes to
converge the solution to the equilibrium. They are very sensitive to the
selection of the various analysis parameters and their solution requires
some experience.

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Lesson 14
Large Displacement Analysis

Case Study:
Clamp

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A u-shaped clamp will have a force applied to one side while the other
side remains fixed. For small applied forces, the clamp will still retain
its u-shape. If the force is larger, the ends of the clamp will get closer
together or touch which will require a large displacement analysis.
We will analyze the clamp using both small and large displacement
methods and compare the results.

Project
Description

A clamp is bent with a

14,000 N [3,147 lb.] force
applied to one arm while
the other arm rests on a
rigid support (such as a
steel block or concrete
foundation).

It is known that this load

deforms the clamp
significantly and brings
both of the arms in contact.

Determine whether this load causes the arms to touch and if the clamp
remains permanently bent after removal of the load.

Part 1: Small
Displacement
Linear Analysis

First, we will attempt to solve this problem as linear, with the

assumption of small displacements.

1
2

Open an assembly file.

Open clamp located in the Lesson14\Case Studies folder.
Define study.

Define a Static study named small displacements.

Review material properties.

The material properties of Alloy Steel are automatically transferred

from SolidWorks.

Apply restraint.

Locate the two faces created by the split

lines on the outside of the arms.
Apply Fixed Geometry restraint to one
face.

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Large Displacement Analysis

Apply force.
Apply a 14,000 N force normal to the other

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face.

Define surface contact set.

Define a No penetration, Node to Surface

contact set between the two small faces at the end

of the clamp arms.

Mesh assembly.

Mesh the assembly with High quality elements

and the default settings using the Curvature
based mesh.

Specify Direct Sparse solver.

Direct sparse solver is considerably faster for this type and size of
problem.

Run the analysis.

SolidWorks Simulation solver detects the large displacements in the

model and issues a warning.

Excessive displacements were calculated in this model. If

your system is properly restrained, consider using the Large
Displacement option to improve the accuracy of the
calculations. Otherwise, continue with the current settings
and review the causes of these displacements.

Click No to complete the analysis as linear with small displacements.

10 Plot resultant displacements.

Create a URES: Resultant displacement plot in True deformation

scale.

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Large Displacement Analysis

11 Examine the model.

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A quick review of displacement results reveals that

the loaded arm has overextended the fixed arm.
Obviously, this result is incorrect.

Results
Discussion

The ignored warning of the solver along with the incorrect

displacement results are sufficient reasons to invalidate the produced
results. Therefore, we do not have to analyze the stresses.

Contact Solution
in Small and Large
Displacement
Analyses

In small displacement analysis, the normals to the contact areas do not

change directions during the loading. This implies that the direction of
the normal and friction forces remains fixed as well.

Contrarily, in the large displacement analysis, the directions of the

normal and friction forces are updated during the deformation process.
Because of the potential significant displacements and sliding in the
contact regions during the large displacement analysis, the Node-tonode (No penetration) contact option should not be used.
For more information on the contact solution in a geometrically
nonlinear analysis, consult the SolidWorks Simulation Premium:
Nonlinear training manual.

Part 2: Large
Displacement
Nonlinear
Analysis

To obtain the correct solution, we must use large displacement

formulation.

Create new study.

Duplicate the study named small displacements into a new study

named large displacements.

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Large Displacement Analysis

Set study properties.

Right-click study large displacements
and select Properties. Select the Options
tab and then select Large displacement.

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Click OK.

Run the analysis.

Note that the solution takes significantly longer due to the extra time
required to increment the load in steps, as discussed earlier.

Plot resultant displacements.

Plot the distribution of URES: Resultant displacements.

Examine the model.

We can observe that the detail of the

displacements at the tip location is what we would
expect, i.e. the tip edges of the contact surfaces are
nearly touching.

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Large Displacement Analysis

Plot von Mises stresses.

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Stress results are also consistent with what we expect to see in a

bending problem such as this.

Analyze the results.

There is no high stress shows in the contact region because the mesh
size is too large to capture these localized contact stresses.

Observing that contact area is very small (in fact, the solution presents
it as a line contact) we conclude that our choice Node to surface
option in No penetration contact set definition is correct.
While stress results obtained using the large-displacement contact
option are generally correct, a closer examination reveals some
problems.
Additionally, the stresses are well above the yield strength of the
material, however this lesson is for demonstration purposes only.

Permanent
Deformation

Save and Close the file.

It is evident that significant portions of the clamp experience stresses

above the yield stress. Therefore, after the load is removed, the clamp
will not return to its original shape.

This is as far as we can take this problem using a linear material model
(the large displacement analysis is geometrically nonlinear, but the
material model is linear elastic).

To determine the shape and residual stresses in a permanently deformed

clamp after the load has been removed, the analysis must include a
nonlinear material model. This option is available in SolidWorks
Simulation Nonlinear modulus which is part of the SolidWorks
Simulation Premium suite.

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Large Displacement Analysis

The presence of a geometrically nonlinear solver (large displacement

option) in SolidWorks Simulation provides the user with the very
powerful feature to solve problems out of the scope of the
geometrically linear static study. However, the solution of these
problems in general requires the correct setup of various parameters
and solver options. Because a large displacement option of SolidWorks
Simulation uses a predefined set of parameters, its solution success is
limited.

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SolidWorks
Simulation
Premium

All of the features and options of the advanced nonlinear solver are
available in SolidWorks Simulation Nonlinear modulus which is part of
the SolidWorks Simulation Premium suite. Furthermore, multiple
advanced material models are available in SolidWorks Simulation
Premium only. Users who wish to take their SolidWorks Simulation
expertise to the next level are encouraged to inquire about SolidWorks
Simulation Premium suite and to take a SolidWorks Simulation
Premium: Nonlinear training course.

Summary

In this lesson, we ventured into the next level of FEA analysis and
discussed and practiced the basic characteristics of the geometrically
nonlinear (large displacement) analysis. The limitations of the
geometrically linear (small displacement) analysis were discussed as
well.

We first attempted to solve the problem using a small displacement

formulation, but erroneous displacement results indicated the need to
consider this analysis as a large displacement problem.

In the large displacement problem, the load was applied in steps and the
model stiffness was updated during the deformation process. This
process took longer to solve, but was required to obtain accurate
results.
Stress results indicated that the clamp will remain permanently
deformed after the load has been removed, but for a quantitative
analysis of this deformation a nonlinear material analysis would be
required.

Finally, the significance of a SolidWorks Simulation Premium suite

upgrade for users interested in nonlinear FEA was discussed.

Questions

474

SolidWorks Simulation suite computations (are / are not) limited to

small displacement analyses only.

SolidWorks Simulation suite computations (are / are not) limited to

models that experience stresses below the material yield strength.

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Appendix A
Meshing, Solvers, and
Tips & Tricks

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Meshing, Solvers, and Tips & Tricks

Meshing, more precisely called discretization, is what converts a

mathematical model into a finite element model ready for solution.

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Meshing
Strategies

As a finite element method, meshing accomplishes two tasks. First, it

replaces a continuous model with a discrete one. Meshing, therefore,
reduces the problem to one with a finite number of unknowns suitable
for solution with an approximate numerical technique. Second, it
represents the desired solution (e.g., displacements or temperatures)
with an assembly of simple polynomial functions defined individually
for elements. See the Introduction to FEA section of the manual for a
description of this process.

For the user, meshing is a necessary step towards the problem solution.
Many new FEA users expect meshing to be a fully automated process
requiring little, in any, input from the user. With experience comes the
realization that meshing is often a demanding task.

The history of development of commercial FEA software witnessed

many attempts to make meshing invisible to FEA users, but this has not
been a successful approach.

While the meshing process has been simplified and automated, it is still
not a hands-off task that runs in the background. As FEA users, we
require a means to interact with the meshing process.
SolidWorks Simulation finds the fine balance by isolating us from
those issues that are purely meshing-specific, but providing us control
over meshing when needed.

Geometry
Preparation

Ideally, we use SolidWorks geometry, toggle to SolidWorks

Simulation, where we define the type of analysis and material, apply
external loads and fixtures, and then we mesh the geometry and obtain
the solution.

This approach works well for simple models. More complex geometry
requires preparation before it can be meshed. In the process of
geometry preparation for FEA, we depart from manufacturing-specific,
CAD geometry and construct geometry intended specifically for
analysis. We call this geometry FEA geometry.

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We differentiate between CAD geometry and FEA geometry based on

their different requirements:
CAD Geometry

Must contain all information

necessary for manufacturing

FEA Geometry

Must be meshable

Must allow for creation of a mesh

that will correctly model the data
of interest
Must allow for creation of a mesh
solvable within a reasonable time

Often CAD geometry does not satisfy the requirements of FEA

geometry. CAD geometry serves as a starting point in the process of FE
model preparation, but is only seldom used for FEA without
modifications.
We now describe several actions performed on manufacturing-specific,
CAD geometry in order to convert it into FEA-specific geometry.

Defeaturing

CAD geometry contains all the

features necessary to make a part.
Many of those features are
unimportant for analysis and should be
suppressed prior to meshing.

At best, leaving such features results

in an unnecessarily complicated mesh
and a long solution time. At worst, it
may prevent the mesher from completing its task.

Of course, determining which features to exclude and which to include

in the FE model requires careful engineering judgment. The small size
of a feature as compared to the overall size of the model does not
always justify its exclusion. For example, very small internal fillets
should be retained in the model if the objective of the analysis is to find
stresses in the area of the round.

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Idealization modifies CAD geometry more substantially than

defeaturing. Idealization may, for example, involve converting 3D,
solid-CAD geometry into surface geometry suitable for subsequent
meshing with shell elements.

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Idealization

SolidWorks Simulation can automatically create shell elements if the

geometry was modeled as sheet metal in SolidWorks. If the part was
modeled as a solid body, however, surfaces must be created in the
SolidWorks model so that shell elements can be created.

CAD geometry meshed

with solid elements

Idealized geometry meshed

with shell elements

Note that idealization creates an abstract geometry (zero thickness

surface) suitable exclusively for analysis.

Clean-up

Clean-up refers to issues of

geometry quality that must be dealt
with to enable correct meshing.

Clean up

Geometry that is adequate for

manufacturing purposes may
contain features that either do not
mesh or force the mesher to create a
large number of elements or create
distorted elements. Examples
include very short edges and/or faces. Those small features must be
removed or the automesher tries to mesh them.

Mesh creation may also fail because of quality issues, including

multiple entities, floating solids, and other quality problems.

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To avoid creating elements with tangent edges (see Mesh Quality later
in this appendix), geometry faces may have to be merged.

Before merging

Mesh Quality

After merging

Creating a solid-element mesh can be likened to a process of filling up

a volume with tetrahedral elements, while creating a shell-element
mesh can be likened to filling up a surface with triangles.
Recall from the Introduction to FEA section of this manual, that in the
vast majority of problems, the second-order, tetrahedral elements and
second-order, triangular elements map to curvilinear geometry and are
much easier to work with when meshing and analyzing.

This observation exemplifies the fact that elements experience

distortion during meshing, which brings us to the issue of mesh quality.
While elements are almost always distorted in the process of mapping
to geometry, excessive distortion leads to element degeneration.
Mesh degeneration can often be prevented by controlling the default
element size or applying local mesh or component controls. We have
practiced mesh controls in many lessons. Now we discuss the most
important forms of element distortion.

Aspect Ratio
Check

Numerical accuracy is best achieved by a

mesh with uniform, perfect, tetrahedral
or triangular elements whose edges are
equal in length. For a general geometry, it
is not possible to create a mesh of
perfect, tetrahedral elements. Due to
small edges, curved geometry, thin
features, and sharp corners, some of the
generated elements can have some edges
much longer than others. When the edges
of an element become much different in
length, the accuracy of the results
deteriorates.

ASPECT RATIO
inscribed / circumscribed circles

AR

large radius
small radius

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The aspect ratio of a

perfect, tetrahedral
element is used as the
basis for calculating
aspect ratios of other
elements. The aspect
Correct element shape
Excessively distorted
ratio of an element is
elements
defined as the ratio
between the longest edge and the shortest normal dropped from a
vertex to the opposite face normalized with respect to a perfect
tetrahedral. By definition, the aspect ratio of a perfect tetrahedral
element is 1.0. The aspect-ratio check is automatically used by the
program to check the quality of the mesh and assumes straight edges
connecting the four corner nodes.

As part of the aspect-ratio check, SolidWorks Simulation performs an

edge-length check, a radius of inscribed and circumscribed radius
check and a length of normals check.
ASPECT RATIO
edge length checks

AR

ASPECT RATIO
edges/face normal ratio

long edge length

short edge length

long edge

short edge

AR

longest normal
shortest normal

This aspect-ratio measure does not

recognize flat elements as bad.

Jacobian Check

Second-order elements map to curved geometry much more accurately

than linear elements of the same size. The mid-side nodes of the
boundary edges of an element are placed on the actual geometry of the
model. In sharp or curved boundaries, placing the mid-side nodes on
the actual geometry can result in generating distorted elements with
edges overlapping each other.
The Jacobian of an extremely distorted element becomes negative. An
element with a negative Jacobian causes the analysis program to stop.

The Jacobian check is based on a number of points located within each

element. SolidWorks Simulation gives you a choice to base the
Jacobian check on 4, 16, or 29 Gaussian points or At Nodes.

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The Jacobian ratio of 1.0 is given to a parabolic, tetrahedral element

with all mid-side nodes located exactly at the middle of the straight
edges. The Jacobian ratio increases as the curvatures of the edges
increase. The Jacobian ratio at a point inside the element provides a
measure of the degree of distortion of the element at that location.
SolidWorks Simulation calculates the Jacobian ratio at the selected
number of Gaussian points for each tetrahedral element.
JACOBIAN CHECK

Correct element

Self-intersecting element

It is generally the case that a Jacobian ratio of 40 or less is acceptable.

SolidWorks Simulation adjusts the locations of the mid-side nodes of
distorted elements automatically to ensure that all elements pass the
Jacobian check.

Even if this check of mesh quality does not issue warnings, avoiding
elements that are too concave is generally good practice. This can be
accomplished by using mesh controls or adjusting the global element
size.

Note

SolidWorks Simulation tries to

place two elements over a 90 arc.
This, combined with global
elements that are too large, may
lead to very small elements placed
next to large elements.

Too rapid a transition

in element size

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If arc is larger than 90, one

element is placed over the arc
leading to the creation of elements
with concave faces.

Concave elements

Applying mesh controls (here to the

round face) allows for the creation
of a correct mesh.

Correct mesh

Mesh Controls

We have practiced the use of mesh controls in many lessons. For easy
reference, we review them now.
Generally, mesh controls can be applied to faces, edges, vertices, and
assembly components.
Mesh control applied to:

Faces

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Edges

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The definition of mesh controls applied to a part consists of specifying

the following:
I
I

Element size on the selected entity

Ratio of element size between the layers

Element size ratio between layers = 1.5

Element size ratio between layers = 1.1

The definition of mesh controls applied to a component consists of

specifying the Component significance, which instructs the mesher,
based on the position of the slider, to use a different element size for
each selected component.

The left end of the slider corresponds to using the default globalelement size of the assembly. The right end of the slider corresponds to
using the default element size if the component is meshed
independently.

Low component significance

High component significance

If the option Use the same element size is selected, then all selected
components are meshed with the same element size as specified in
Mesh Control window.

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Many meshing problems can be solved by

using a smaller element size. Using a smaller
element size, of course, results in longer
solution times.

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Automatic Trials
for Solids

To find the largest element size that still meshes, we can use Automatic
trials for solids, specified in the advanced meshing options.
Automatic looping instructs the mesher to automatically mesh the
model again using a smaller, global element size. You control the
maximum number of trials allowed and the ratio by which the global
element size and tolerance are reduced each time.

Meshing Stages

Meshing proceeds in three steps:

I
I
I

Evaluating the geometry

Processing the boundary
Creating the mesh

Meshing problems may arise at any step.

During the first step, evaluating the geometry, SolidWorks Simulation

checks the geometry imported from SolidWorks. Geometry import is
completely transparent to the user.

The actual meshing of a solid component consists of two phases. When

processing the boundary, the mesher places nodes on the boundary.
This phase is called surface meshing. If this phase is successful, the
third phase, creating the mesh, starts as the volume is filled with
tetrahedral elements.
If meshing fails when evaluating the geometry, the most likely cause is
a geometry error. To verify if geometry error is the cause, export the
geometry as an IGES to see if the error message, Failed to process
trimmed surface entity is displayed. If this message appears, send the
part to SolidWorks support for diagnosis of the geometry problem.

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When meshing fails, SolidWorks Simulation displays a message and

stops unless the automatic mesh looping is active. A failure diagnostics
tool is provided to help you locate and resolve solid-meshing problems.

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Failure
Diagnostics

The Failure Diagnostics PropertyManager lists the components, faces,

and edges that fail. It also highlights the failed entities in the model
window.
To review the entities that prevented successful meshing, right-click
Mesh and select Failure Diagnostics.

The offending entities are listed in Failure Diagnostics window and

highlighted in the graphics window and the study tree.

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Check for underdefined sketches.

Use SolidWorks Utilities to find sliver faces, knife edges, and so on.

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Tips for Meshing

Parts

For meshing failures on faces, create a shell study and select only the
failed face. Then try various element sizes until that face meshes.

If the mesh failure diagnostics do not provide enough information to

determine the exact location of the problem, successively cut portions
off the model to isolate the region of failure, or roll back the
SolidWorks models until the model meshes.

Tips for Meshing

Assemblies

Select Tools, Interference Detection to determine where parts

interfere and where faces touch (coincident). Remember that
interference is allowed only if the shrink fit contact condition is
defined.

Do not model line contact (such as a cylinder tangent to a plate) or

point contact (such as the top of a cone touching a plate) between
assembly components. The area of contact should be > 0.

Note that when SolidWorks Simulation meshes an assembly,

imprints are made on all touching faces, allowing the nodes from
both components to align.

If bonded contact conditions have been defined, then the same node is
shared by both components. If node to node or surface conditions have
been defined, two coincident nodes are created and joined by gap
elements. Gap elements remain invisible to the user.
Note that the color of the imprint in the following illustration has been
modified in a graphics program to make it clearly visible.

Imprint

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Beware of imprints that cause sliver faces, thin annular faces, or faces
with multiple lobes connected by thin sections.

Thin section

Tips for Using

Shell Elements

Sliver face

Shell meshing uses only the surface meshing phase; no volume filling
occurs.

Although the use of shell elements results in a simpler model that

solves faster than a corresponding solid-element model, preparation of
a shell-element mesh is more time consuming as compared to a solidelement mesh.
Meshing in mid-planes often results in disjointed meshes.

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If surface geometry is to be meshed, split lines may be used where

surfaces meet to ensure alignment of the nodes and, consequently, mesh
compatibility. However, incompatible mesh with misaligned nodes is
also allowed!

No split lines

Split lines added

Hardware
Considerations
in Meshing

Incompatible mesh

Compatible mesh

Meshing is the most critical step on the way to obtaining a solution.

The maximum mesh size, meaning the smallest, element size that can
be used, depends on the amount of random access memory.
While the simple rule the more the better applies, we recommend
2 GB for working with real-life, complex models.

488

SolidWorks 2012

Appendix A
Meshing, Solvers, and Tips & Tricks

Having successfully meshed the model we are only one step away from
obtaining a solution.

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Solvers in
SolidWorks
Simulation

Generally, if a model can be meshed, it will solve; solving is a less

critical step than meshing.

However, several problems can arise. The solver may find problems
with model definition, such as no definition of material or loads. The
kinds of issues that prevent solution depend, of course, on the type of
analysis (static, frequency, and so on).

The solver may also detect rigid body motions due to insufficient
restraints. Rigid body motions can be dealt with using solver options,
such as Use soft spring to stabilize model or Use inertial relief.
Available solver options depend on the type of analysis.
Static analysis

Frequency analysis

Buckling analysis

Soft springs

Soft springs

Soft springs

In-plane effects

In-plane effects

Inertial relief

The meshed model is presented to the solver in the form of a large

number of linear algebraic equations. Those equations can be solved
with two classes of solution methods: direct and iterative.

Direct methods solve the equations using exact numerical techniques.

Iterative methods solve the equations using approximate techniques
where, in each iteration, a solution is assumed and the associated errors
are evaluated. The iterations continue until the errors become
acceptable.
SolidWorks Simulation offers two solvers types:

I
I

Choosing a
Solver

Direct Sparse solver

FFEPlus (iterative)

In general, all solvers give comparable results if the required solver

options are supported. While all solvers are efficient for small problems
(25,000 degrees of freedom or less), big differences in performance
(speed and memory usage) occur in solving large problems.

If a solver requires more memory than available on the computer, the

solver uses disk space to store and retrieve temporary data. When this
situation occurs, a message appears saying that the solution is going out
of core, and the solution progress slows down. If the amount of data to
be written to the disk is very large, the solution progress can be
extremely slow.

489

Appendix A

SolidWorks 2012

Meshing, Solvers, and Tips & Tricks

The following factors help you choose the proper solver:

Size of the problem

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In general, FFEPlus is faster in solving problems with degrees of

freedom (DOF) over 100,000. This solver becomes more efficient
as the problem gets larger.

Computer resources

The Direct Sparse solver, in particular, becomes faster with more

memory available on your computer.

Analysis options

Element type

Material properties

When the moduli of elasticity of the materials used in a model are

very different (like Steel and Nylon), iterative solvers are less
accurate than direct methods. The Direct Sparse solver is
recommended in such cases.

A solver can be selected

in the study properties.
Since the choice of the
most suitable solver
requires some
experience, an automatic
selection has been
implemented as well.
Use this option if you
are not sure which solver
is best suited for your
analysis.

490

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Appendix B
Customer Help and
Assistance

491

Appendix B

SolidWorks 2012

Customer Help and Assistance

SolidWorks Simulation features extensive apparatus to help you with

various information needs.

SolidWorks
Simulation Help

Nearly every dialog window contains a help icon. Use this as your
initial help option. Here you will find answers to most of the common
questions relevant to the desired topic or SolidWorks Simulation
function.

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Customer Help
and Assistance

The above figures show how to access SolidWorks Simulation help

files from the most common dialogs that you may encounter in
SolidWorks Simulation.

492

SolidWorks 2012

Appendix B
Customer Help and Assistance

Select Research on the Simulation menu to

display the Analysis Research tab in the Task
Pane.

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Online Resources

This area contains countless resource information

in organized and accessible form. The
functionality of some of the links in the Analysis
Research dialog is described in the following
text.

Search Knowledge Base

This database contains numerous targeted, well-organized and

maintained articles on various topics in analysis theory, SolidWorks
Simulation usage and troubleshooting, licensing, and many other
practical areas. We strongly encourage users to use this feature as often
as possible. Valid subscription and internet connection are required to
access this information database.

Search Matweb

A search query in this field will take you directly to the free online
material database matweb.com (free Premium membership is also
available). Internet connection is required to use this feature.

Downloads

The latest upgrades and service packs (SP) can be downloaded from the
web download page that can be accessed via this feature.

493

Appendix B

SolidWorks 2012

Customer Help and Assistance

Complete customer account information and customer service and

maintenance links can be accessed via the Customer service portal
accessible from www.solidworks.com website. The portal allows you
to submit service and enhancement requests, search the knowledge
base, view the information on the online seminars and various
discussion forums and much more.

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Customer Support
Portal

Customer Phone
Support

494

Subscription customers have access to the dedicated phone and email

technical support. Please contact your local reseller for the local
technical support telephone number and email address. A customer
serial number is always required.

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Index

A
activate SW configuration 96
adaptive meshing 446
analysis process 24
analysis research 336
animate plot 58
annotating plots 138
artificial restraints 157
aspect ratio 479
aspect ratio plot 262
automatic looping 484
averaging stress 435
axial stiffness 256

B
beam elements 363
beam joint types 367
beam joints 367
bearing load 212
bending moment diagram 369, 377
bolt force 203
bolts
pre-load 246
tight fit 245
bonded 142
bonded contact 229
bonding
shell edge to shell face 339
shell face to shell face 339
shell to solid 340
boundary conditions 102
bulk modulus 338

C
CommandManager 27
component
local options 141
connector
bearing 191
bolt 191
elastic support 191
link 191
pin 191, 195
rigid 190
spot weld 191
spring 190, 198
contact 130
bonded 142
bonding shells and solids 330331,
378

component options 140

contact set 142, 151
free 142
large displacement contact 471
local contact sets 250
local options 140
no penetration 142143, 250
shrink fit 142, 158
surface contact 470
virtual wall 142
contact stress 146, 162
convergence 64
convergence graph 454
copy parameters 61
create study 32
Curvature Based Mesh 43
customer support portal 494
cylindrical coordinate system 160

fixtures 34
definition 42
symmetry 280
flow/thermal effects tab 432
force type 38

D
defeaturing 155
define force 39
design check plot 266
design scenario 402, 404, 411
graph 416

I
idealization 478
importing temperatures 433
inertial relief 165
iso plots 52, 59

E
Elastic 191
element types 10
element values 50
elements
first order shells 13
first order tetrahedral 11
second order 12
second order shells 14
external loads 38, 42

F
failure diagnostics 343, 485
find contact sets 250, 252, 369
fixture type
circular symmetry 34
fixed geometry 34
hinge 34
on cylindrical face 35
on flat face 35
on spherical face 35
roller/sliding 34
symmetry 34
use referene geometry 35

G
gap analysis 130
gap clearance 254
geometry preparation 476
gravity load 421
H
h-adaptive 449
accuracy bias 451
solution parameter 450
target accuracy 451
Hoop Stress 161

J
jacobian 264
jacobian check 480

K
knowledge base 258, 493
L
large displacement 467
local contact options 141
local contact sets 250
Local mesh control 91
local mesh refinement 90

M
material 336
material properties 42
assigning 32
thermal 427
materials
apply to assemblies 131
Matweb 493
Maximum element size 44
mesh

495

Index

R
remote load 242
reports 67
Restraint Type 34
restraint types 34
result folder 28
results 95
rigid body mode 157
rotational stiffness 256
run analysis 47
Run Analysis After Meshing 281

thermal stress analysis 426

thin components 278
treat as solid 307

S
saving all plots 164
saving deformed model 442
section plot 52, 59, 144
set mesh options 45
shear force diagram 369, 377
shear modulus 338
shell elements 285, 487
shell meshing
automatic surface alignment 292
shell mesh alignment 289, 291
thin/thick shells 287
show plot 47
shrink fit 154
shrink fit contact 142
simulation interface 26
simulation options 28
simulation study tree 26
simulation toolbar 27
singularities 95
soft springs 164
SolidWorks 5
solvers 489
spot weld 191
spring connector options 198
steel identification systems 336
strain plot 5960
stress
averaging 435
contact 146
principal 18
stress singularities 95
studies
create 61
multiple studies 52
renaming 31
symbols
cylindrical system icon 161
display/hide 35, 41
fixture 37
joint 365, 369, 380
mesh control 91
size and color 41
symmetry 154
symmetry fixtures 280

W-Z
zero strain temperature 432

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aspect ratio 262

compatible 231
compatible/incompatible 229230
control 86, 90
control in an assembly 240
controls 482
details 62
display/hide 46
incompatible 234
jacobian 264
local mesh refinement 90
quality 46, 479
ratio 44
required elements 262
shell elements 285
thin vs. thick elements 287
mesh control 86
mesh control symbols 91
Mesh Density 43
mesh details 62
meshing 43
adaptive 446
automatic looping 484
beam elements 363
h vs. p elements 457, 459
h-adaptive 449
hardware considerations 488
mixed 330, 362
p-adaptive 457
shell elements 487
stages 484
strategies 476
Minimum element size 44
Minimum Number of Elements in a
Circle 44
mixed meshing 230, 330, 362
moment load 310
multiple studies 52, 60

SolidWorks 2012

N
nodal values 50
nodal vs. element stresses 49
P
p-adaptive 457
Parameters 404
permanent deformation 473
pin force 203
plot settings 29
plots
bending moment 369, 377
design check 266
editing 48
iso 52, 59
modify result plots 50
result 47
save all 164
section 52, 59, 144
shear force 369, 377
postprocessing 47
preprocessing 31
Pressure Load 281
principal stresses 18, 98
probe 52

496

T
tangential stiffness 257
temperature load 431432, 437
temperatures
importing 433
thermal material properties 427

U
units 19
UNS index 336

V
virtual wall 142
Von Mises Stress 17