SolidWorks® 2011 SolidWorks Simulation Dassault Systémes SolidWorks Corporation 300 Baker Avenue Concord, Massachusetts 01742 USA© 19952010, Dasa yates lors Corton ‘Daum Stimee 8 cpa, 300 Bak Aveo nt, as 61782 USA Al Ris Reseed ‘Thlntemaion adh fia dca ns dome cruitment by Dassault Stes Sold Works Coporaon WsSoiaiost ‘omer maybe es or nite in ay om adethecgros writen pomstn of DS Sodas, ‘Besa dd tha ood tbeterno/the eens, Alimmnies gvenby BS ‘StWiis stot software and came eset fein eee semen nchng a deomed a modifica or aera ofan er fteing wants nthe ens prem Patent Notes DERE SS eats” Saigsereaot san Gane oro aha Same Sma Seow Teco eras HRT A ater nc teint sere pay US. Pe Oommen Soeaelg neta Uso ig ee “Trademarks and Product Names for SolidWorks Products and Services SolidWoas 3D ParSueam NET. 30 ConeeCennl Drains an he eins logo ae abe alc nd Shar ay ed ered (Grout, Fate Plt Xpress, Photons, ‘otal abd Xchange re aca DS Soden Fest Works aregineredademak of Geometi Li Sato 211, SoWerks Entre POM, SoldWons Simao, Sidon Flow Sino a cDruings Profesor! ar rit hanes of DS Soioas ‘hr band ot rod names re rama or repitered ademas of ftrespectve biden ecueat Number: PMTIIAD.ENG sumer conmarensormae- seam a Ted forch a FAR 32257-19(Commreal Compass Soware= ican ha nana camer Ee re ea Seeacre nanny in onetime tte Sere ee Sd Portions ofthis softnare © 1986-2010 Siemens Prodi ‘reenter ge ieeearanare weieaees nay ioierserteag meh ‘rt tr. Fights reserved, Patents Pending, = Peart Sash ct Sr er en Sie aa re ea ae Aare stioee ete SERS Rae aie reseagege semanas ‘Aout Salons. ‘Copyright Notices fr SolidWorks Simulation Prodece ations of is software ©2068 Solero Cmporsion GLSS © 1992-2007 Compton! Applicatons an Sem ipo, ie Afi resere Copyright Notices fr Enterprise POM Product (usin Viewer Tecnology © Cop 192-210, (© Copsright 1995-2010, Onell gk resend Erni Al igi seme Copyright Notices for oDrawings Products tions of hi sofware © 200-2010 Tech So 3D. Potions of hi stare © 198-200 Deamon. Pons f hi sofware 198-2010 Open Dein Dine Al igh reseed Potions of th stare © 1995-209 Spal Capra, “Th satnare tse np on be week fhe Incpendet PEC GrpIntroduction About This Course Prerequisites Course Design Philosophy Using this Book Laboratory Exercises About the Training Files Windows® XP Conventions Used in this Book Use of Color: What is Solid Works Simulation? What Is Finite Element Analysis? Build Mathematical Mode! Defeaturing Idealization Clean-up Build Finite Element Model Solve Finite Element Model Analyze Results Errors in FEA, ContentsContents SoliWorks 2011 Finite Elements. 10 Element Types Available in SolidWorks Simulation 10 First Order Solid Tetrahedral Elements . ul Second Order Solid Tetrahedral Elements 2 First Order Triangular Shell Elements 2B Second Order Triangular Shell Elements : 4 Beam Elements. . 4 ‘Choosing Between Solid and Shell Elements 15 Draft vs. High Solid und Shell Elements : 15 Degrees of Freedom : 1s Calculations in FEA. 16 Interpretation of FEA Results 0 Principal Stresses: PI, P2, and P3, a : 18 Units of Measurement. 19 Limitations of SolidWorks Simulation 19 Linear Material 0 ‘Small Structural Deformations : 20 Static Loads. 21 Summary. ener’) Lesson 1: ‘The Analysis Process Objectives: 23 The Analysis Process 24 Stages in the Process. . m4 Case Study: Stress in a Pate. ey Project Description 24 SolidWorks Simulation Interface o 26 Solid Works Simulation Options 28 Plot Settings... 2» Preprocessing New Study. : - Assigning Material Properties... 2 Fixtures ou Fixture Types - 34 Display/Tlide Symbols oe 35 Extemal Loads « .... 38 Size and Color of Symbols. 41 Preprocessing Summary : : 2 Meshing 8 ‘Curvature Based Mesh a Mesh Density a Element Sizes : B Minimum Number of Elements in a Cirele 44 Ratio 4 Mesh Quality a wi 46‘SolidWorks 2011 ‘contents Postprocessing a Result Plats 7 Editing Plots 48 Nodal vs. Element Stresses... 49 Show as Tensor Plot Option 50 Modilying Result Plots 50 Other Plot Controls. 32 Other Plots 59 Multiple Studies © Creating New Studies 6 Copy Parameters 61 ‘Check Convergence and Accuracy 64 Results Summary 65 ‘Comparison With Analytical Results 66 Reports or Summary o References. o Questions o Exercise I: Bracket. 7 Exercise 2: Compressive Spring Stiffness si Exercise 3: Container Handle a Lesson 2: Mesh Controls, Stress Concentrations and Boundary Conditions Objectives : 8s Mesh Control 86 Case Study: The L Bracket 86 Project Description 86 ‘Sages in the Process 86 Run All Studies. 89 ‘Analysis with Local Mesh Refinement 90) Mesh Conteols, 90 Results 95 Results Comparison 95 Stress Singularities 95 Case Study: Analysis of Bracket witha Filet 7 Case Study: Analysis ofa Welded Bracket. 101 Understanding the Effet of Boundary Congitions 102 Conclusion 103 Summary 108 Questions 104 Exercise 4: C-bracket 10s Exercise S: Bone Wrench 4 Exercise 6: Foundation Bracket 9Contents Lesson 3: ‘Assembly Analysis with Contacts Lesson 4: ‘Symmetrical and Free Self-Equi Objectives: Contact Analysis Case Study: Pliers with Global Contact Project Description Stages in the Process. Applying Materials to Assemblies ‘Component Contact ‘Component Contaet: Options ‘Component Contact: Default setting ‘Component Contact: Hierarchy and Conflicts ‘Viewing Assembly Results Conclusion Handle Contact Required Force - Pliers with Local Contact Local Contact Local Contact Types. [No Penetration Local Contact Options [No Penetration Local Contact: Accuracy [No Penetration Local Contact: Remarks Contact Stresses Summary Questions Exercise 7: Two Ring Assembly rated Assemblies Objectives Shrink Fit Parts Case Study: Shrink Fit Project Description Symmetry... Stages in the Process. Defeaturing Rigid Body Mode Shrink Fit Contact Condition Plot Results in Local Coordinate System Cylindrical Coordinate Systems Saving All Plots What's Wrong Feature .- Analysis with Soft Springs Soft Springs. Inenial Relief SolidWorks 2011 129 1B0 Bo bo Bo BI 132 3 Ba 4 7 2 BS. 138 9 Bo 140 142 143 143 14s 4s 146 147 si 152 152 2152 152 132 2153 2 1SS 156 158 158 162 162 162 163 163SoteWorks 2011 Lesson 5: Summary, Exercise 8: Chain Link Exercise 9: Chain Link 2 Assembly Analysis with Connectors Lesson 6: Objectives Connecting Components Connectors Connector Types Case Study: Vise Grip Plies. Project Description Stages in the Process, Spring Connector Types Spring Connector Options Pin/Bolt Force Summary Exercise 10: Lift Assembly. Exercise 11: Analysis with Base (optional) Exercise 12: Shock Absorber Exercise 13: Spot Welds-Solid Mesh ‘Compatible/incompatible Meshes Lesson 7: Objectives Compatible / Incompatible Meshing. Case Study: Rotor. Project Description Compatible Mesh Incompatible Mesh ‘Automatic Switch to Incompatible Mes Incompatible Bonding Options Discussion. Summary Assembly Analysis Mesh Refinement Objectives Mesh Control in an Assembly Case Study: Cardan Joint Problem Statement Part 1: Draft Quality Coarse Mesh Analysis Remote Load Bolt Tight fit and Diameter Bolt Pre-oad Local Contact Sets No Penetration Local Contact Options Rotational and Axial StilTness Knowledge Base Contents 166 167 182 237 238 238 238 29 240 203 24s 248 248 254 256Contents SolidWorks 2011 Part 2: High Quality Mesh Analysis Required Number of Solid Elements in Thin Features. Aspect Ratio Plot Jacobian Summary Questions Exercise 14: Bolt Connectors Exercise 15: Awning, ‘Components ‘Objectives. Thin Components Case Study: Pulley Project Description Part 1: Mesh with Solid Elements. Symmetry Fixtures Part 2: Refined Solid Mesh, Solid vs. Shell Creating Shell Elements Part 3: Shell Elements ~ Mid-plane Surface Thin vs. Thick Shells Shell Mesh Colors ‘Changing Mesh Orientation Shell Element Alignment ‘Automatic Shell Surface Re-aligment Applying Symmetry Restraints Deformed Results, Results Comparison Computational Effort Case Study: Joist Hanger Project Deseription Summary Questions Exercise 16: Bracket. Exercise 17: Shell Mesh Using Outer/nner Faces. Exercise 18: Spot Welds - Shell mesh Exercise 19: Edge Weld Connector Exercise 20: Container Handle Weld 259 260 260 262 268 268 269 2B 25 276 216 27 277 278 281 283 283 283 285 287 287 289 290 293 206 297 297 208 299SolidWorks 2011 Contents Lesson 9: Mixed Meshing Shells & Solids Objectives... 327 ‘Mixed Meshing Solids and Shells 328 Bonding Shells and Solids 329 Mixed Mesh: Supported Analysis Types . 329 Case Study: Pressure Vessel cio 329 Project Description : 330 ‘Analyze the Assembly 330 Preparing the Mode! : 32 Material. 34 Steel Identification Systems 3M UNS Index 3M Other Indices. 334 ‘Bulk and Shear Moduli 2336 Bonding Entities with Clearance 337 Shell Face o Shell Face Bonding 337 Shell Edge to Shell Face Bonding 337 Shell to Solid Bonded Contact 338 Failure Diagnostics. 341 Meshing Small Features 341 Summary 347 Questions 347 Exercise 21: Mixed Mesh Analysis M9 Lesson 10: Mixed Meshing Solids, Beams & Shells. Objectives, 359 Mixed Meshing, 360 ‘Case Study: Particle Separator 360 Project Description 360 Bement Choices 360 Beam elements 361 Stages in the Process. 361 ‘Beam Mesh 363 Beam Joints: Locations. 365 Beam Joint Types 365 Section Properties 366 ‘Connected and Disconnected Joints 367 Sphere Diameter Defining Beam Joint 368 Cross-seetion Ist and 2nd Directions 33 Bending Moment and Shear Force Diagrams. x Summary 316 Exercise 22: Beam Elements 317 Exercise 23: Cabinet 387 Exercise 24: Frame Rigidity 395contents Lesson 11: Design Study Lesson 12: ‘SolidWorks 2011 Objectives. . Design Study. oo Case Study: Suspension Design Project Description Stages in the Process. Part 1: Multiple Load Cases Desian Studies Parameters. a Design Study Results Design Study Options Part 2: Geometry Modification Design Study Graph Summary Exercise 2 Design Study Thermal Stress Analysis Lesson 13: Adaptive Meshing Objectives ‘Thermal Stress Analysis Case Study: Bimetallie Strip, Project Deseription Material Properties Importing Temperatures Averaging Stress Question Examining Results in Local Coordinate Systems (Optional). Saving Model in its Deformed Shape. 5 Summary. Objectives Adaptive Meshing Case Study: Support Bracket Project Description Geometry Preparation h-Adaptivity Study h-Adaptivity Options b-Adaptive Plots Convergence Graph Review h-adaptive Solution Strain Energy Error is NOT Stress Error 397 398 398 398 398 399 400 405 407 408 412 414 41s a 422 422 22 23 429 431 436 436 438 439 4a 442 442 442 443 447 450 450 451 452SolidWorks 2011 Contents p-Adaptivity Study 453 p-Adaptive Solution Method 43 hs. p Elements 455 Method Comparison 459 hhys. p Elements - Summary 460 ‘Which Solution Method is Better? 461 Summary. 461 Lesson 14: Large Displacement Analysis ‘Objectives 463 ‘Small vs, Large Displacement Analysis 464 Case Study: Clamp 465 Project Description 465 Past 1: Small Displacement Linear Analysis 465 Results Discussion 467 Contact Solution in Small and Large Displacement Analyses. . 467 Part 2: Large Displacement Nonlinear Analysis, 467 Permanent Deformation 469 Solid Works Simulation Premium. 470 Summary. 470 (Questions 470 ‘Appendix A: ‘Meshing, Solvers, and Tips & Tricks Meshing Strategies an Geometry Preparation an Defeaturing, 473 dealization 44 Clean-up 474 Mesh Quality “Aspeet Ratio Check 475 Jacobian Cheek 476 Mesh Controls. 478 Automatic Tvials For Solids. 480 Meshing Stages 480 Failure Diagnostics. 481 ‘Tips for Meshing Parts 481 Tips for Meshing Assemblies 482 Tips for Using Shell Elements 485 Hardware Considerations in Meshing. 484 Solvers in SolidWorks Simulation 484 Choosing a Solver. 485 Appendix B: Customer Help and Assistance ‘Customer Help and Assistance 488Contents SolisWorks 2011,IntroductionIntroduction About This Course Prerequisites Course Design Philosophy Recommended Length Using this Book Laboratory Exercises Sollaworks 2011 The goal of this course is to teach you how to use the Solid Works Simulation software to help you analyze state structural behavior of your SolidWorks part and assembly models The focus ofthis course is on the fundamental skills and concepts ‘central to the successful use of SolidWorks Simulation 2011. You should view the training course manual asa supplement to, and not a replacement for, the system documentation and on-line help. Once you have developed a good foundation in base skills, ou ean refer tothe ‘n-ne help for information on less frequently ucel command options. Students attending this course are expected to have the following: = Mechanical design experience, ‘= Experience with the Windows™ operating system. ‘= Complete the course SolidtWorks Essentials, ‘= Completed the on-line Solid Works Simulation tutorials that are available under Help. You can access the on-line tutorials by clicking Help, SolidWorks Simulation, Tutorial. ‘This course is designed around a process- or task-based approach to training. Rather than focusing on individual features and functions, a process-based traning course emphasizes processes and procedures ‘you should follow to complete a particular task. By utilizing case ‘studies to illustrate these processes, you lear the necessary commands, ‘options, and menus in the context of completing a design task, The minimum recommended length ofthis course is three days ‘This raining manual is intended to be used in classroom environment under the guidance of an experienced SolidWorks Simulation instructor. ts not intended to be a self-paced tutorial. The examples and case studies are designed to be demonstrated “live” by the ‘There may be slight differences in results in certain lessons due to service pack upgrades, et. Laboratory exercises give you the opportunity to apply and practice the material covered during the lecture/demonstration portion of theSolidworks 2011 About the Training Files Windows® XP in this Book Introduction ‘A complete set ofthe various files used throughout this course can be downloaded from the SolidWorks website, wurw.salidworks.com. Click on the link for Suppor, 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. Direct URL -worw.solidworks.com/trainingfiiessimulation The files are supplied in signed, sel-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 Exereises folder contains any files that are required for doing the laboratory exercises. The sereen shots in this manual were made using SolidWorks 2011 and, SolidWorks Simulation 2011 running on Windows® 7. Ifyou 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 This manual uses the following typographic conventions: ‘Convention Meaning ‘Bold Sans Serif | SolidWorks Simulation commands and ‘options appear in this style. For example, “Rightclick External Loads and sele Force” means rightclick the External ‘Loads ieon in the SolidWorks Simulation Study tree and select Force from the shorteut Feature names and file names appear inthis style. For example, Double lines precede and follow seetions of the procedures. This provides separation between the steps ofthe procedure and lange blocks of explanatory text. The steps themselves are numbered in sans seribold 17 Do this step,Introduction Use of Color SolidWorks 2014 The Solid Works and SolidWorks Simulation user interface make extensive use of color to highlight selected geometry and to provide you with visual feedback. This greatly inereases the inuitiveness and se of use ofthe SolidWorks Simulation software, To take maximum advantage of this, the training manuals are printed in full colo. Also in many cases, we have Radius somm— used additional color in the illustrations to communicate concepts, identify features, and otherwise convey important information. For example, we right show the fillet areas of a part ina different color, © highlight areas for mesh control, even though by default, the SolidWorks Simulation software would not display the results in that aus Sr Absround |“ Redius 6mm, 4 PacesSolidworks 2011 What is ‘SolidWorks ‘Simulation? Introduction Solid Works Simulation is design analysis tool based on a numerical technique called Finite Element Analysis or FEA, SolidWorks ‘Simulation belongs to the family of engineering analysis soltware 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 COSMOS Works software, one of the frst SolidWorks Gold Products. COSMOS Works soon became the top-selling, add-in analysis software for Solid Works 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, COSMOS Works was renamed for 2009 to SolidWorks Simulation, Solid Works isa paramette, slid, feature-based CAD system. AS ‘opposed to many other CAD systems that were originally developed in ‘a UNIX envionment and only later ported to Windows, Solid Works 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 Solid Works and Solid Works Simulation i possible ‘because both ofthe programs are native Windows OS applications. Solid Works Simulation comes in different “bundles”, or applications, designed to best suit the needs of different users. With the exception of Solid Works SimulationXpress, which i 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 stati, thermal, buckling, Frequency, drop test, optimization and fatigue analysis of parts and assemblies SolidWorks Simulation Premium All capabilities of Solid Works Simulation Professional plus nonlinear and dynamic analyses In this volume, we introduce Solid Works Simulation through a seties of hhands-on lessons intermixed with FEA fundamentals. We recommend that you study the lessons in the order presented in the text. As you zo through the lessons, note that explanations and steps described in detail in earlier lessons are not repeated laterIntroduction What Is Finite Element Analysis? ‘soidWorks 2011 Each subsequent lesson assumes familiarity with software funetions and the FEA background discussed in previous lessons. Each lesson builds on the skills and experience gained from the previous lessons, Before we proveed 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, 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, luid dynamics, and ‘others. In mechanical engineering, FEA is widely used for solving structural, vibration, and thermal problems. FEA is not the only too! available for numerical analysis, Other ‘numerical methods used in engineering includ the Finite Difference Method, Boundary Element Method, or Finite Volumes Method. However, due to its versatility and high numerical efficieney, FEA has ccome 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 o 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 Solid Works Simulation. A powerfl 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 constrains 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 vehiele erash dynamics, metal forming, or analysis of biostructures.Soliaworks 2011 Introduction Regardless ofthe project complexity or the field of application, the fndamental steps in any FEA project are always the same, he it for ‘example a structural, thermal, or acoustic analysis. The starting point for any analysis isthe geometric model. In our ease, this isa 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 mode! intended for analysis. ‘The discretization process, beter known as meshing, splits the ‘geometry into relatively small and simply-shaped entities, called Finite tlements, The elements are called “finite” to emphasize the fact that they are nol infinitesimally small, but only reasonably small in ‘comparison tothe overall model size. ‘When working with finite elements, the FEA solver approximates the ‘wanted solution (for example, deformations or stresses forthe entire siodel withthe 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 (estate, thermal, frequency), material properties, londs and restraints are defined and the model is split into Finite elements. Solution ‘Computing the desired results. Postprocessing Analyzing the results, We fallow the preceding three steps every time we use SolidWorks Simulation. rom the perspective of FEA methodology, we list the following FEA steps: Building the mathematical model ‘Building the Finite element model w the Finite element model lyzing the results 1 2 3 4Introduction Build Mathematical Model Defeaturing Idealization Clean-up ‘SolidWorks 2011 Analysis with SolidWorks Simulation starts wit the geometry represented by a SolidWorks model ofa part or assembly. This ‘geometry must be meshable into a correct and reasonably smal, finite element mesh, By small, we do not refer tothe element size, bu the ‘number of elements in the mesh. This requirement of meshabilty has very important implications. We must ensure that the CAD geometry indeed meshes and thatthe produced mesh provides the correct solution ofthe data of interest, such as displacements, stresses, temperature distribution, and So on. Often, but not always, this nevessity of meshing requires modifications to the CAD geometry. Such modifications can take the form of