© Dassault Systèmes | Confidential Information | 2/5/2021 | ref.

: 3DS_Document_2020

SOLIDWORKS Simulation:
Best Practices for solving
Large Assemblies

Nandish DATTI
Product Definition Manager

Mai DOAN
Sr. Product Manager
© Dassault Systèmes | Confidential Information | 2/5/2021 | ref.: 3DS_Document_2020

Mai DOAN, Sr. Product Manager – Nandish DATTI, Product Definition Manager
SOLIDWORKS Simulation – SOLIDWORKS Simulation and Plastics

2
 AGENDA
SIMULATION BEST PRACTICES FOR LARGE ASSEMBLIES

GEOMETRY
INTERACTIONS MESHING SOLVING
PREPARATION
• Isolate sub-assembly • Types of interactions • Independent & Enforced • Solver selections
• Configuration & Symmetry • Level of interactions Common Node Mesh • Simulation Evaluator
• Simplify geometry • Instabilities due to gaps & • Which Mesher? • Remote Loads/ Mass
• Interferences interferences • Mix & Match Draft vs. • Use weak springs
• Element types • Interaction Viewer & High Quality • Managing the result file size
Underconstrained bodies • Mesh Quality Diagnostics
• Connectors • Mesh Failure Diagnostics
 GEOMETRY
INTERACTIONS MESHING SOLVING
PREPARATION
© Dassault Systèmes | Confidential Information | 2/5/2021 | ref.: 3DS_Document_2020

• Isolate sub-assembly
• Configuration & Symmetry
• Simplify geometry
• Interferences
• Element type

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 GEOMETRY
INTERACTIONS MESHING SOLVING
PREPARATION
• Isolate sub-assembly
• Configuration & Symmetry
• Simplify geometry
• Interferences
© Dassault Systèmes | Confidential Information | 2/5/2021 | ref.: 3DS_Document_2020

• Element type

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 GEOMETRY
INTERACTIONS MESHING SOLVING
PREPARATION
© Dassault Systèmes | Confidential Information | 2/5/2021 | ref.: 3DS_Document_2020

• Isolate sub-assembly
• Configuration & Symmetry
• Simplify geometry SOLIDWORKS
• Interferences Simulation
• Element type

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 GEOMETRY
INTERACTIONS MESHING SOLVING
PREPARATION
© Dassault Systèmes | Confidential Information | 2/5/2021 | ref.: 3DS_Document_2020

• Isolate sub-assembly
• Configuration & Symmetry
• Simplify geometry Full Model ½ Symmetry Model
• Interferences No. of nodes 1.2 M 638 K
• Element type
No. of elements 735 K 373 K
No. of DOF 3.7 M 1.9 M
Solve Time (min) 13:13 6:26

~ 50% Solve
Use Symmetry only if Geometry AND Boundary
time reduction
Conditions are symmetrical
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 GEOMETRY
INTERACTIONS MESHING SOLVING
PREPARATION

Remove unnecessary components

© Dassault Systèmes | Confidential Information | 2/5/2021 | ref.: 3DS_Document_2020

• Isolate sub-assembly
• Configuration & Symmetry
• Simplify geometry
• Interferences
• Element type
•

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 GEOMETRY
INTERACTIONS MESHING SOLVING
PREPARATION

Remove unnecessary components

© Dassault Systèmes | Confidential Information | 2/5/2021 | ref.: 3DS_Document_2020

• Isolate sub-assembly
• Configuration & Symmetry
• Simplify geometry
• Interferences
• Element type
•

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 GEOMETRY
INTERACTIONS MESHING SOLVING
PREPARATION
Exclude parts from simulation
© Dassault Systèmes | Confidential Information | 2/5/2021 | ref.: 3DS_Document_2020

• Isolate sub-assembly
• Configuration & Symmetry
• Simplify geometry
• Interferences
• Element type
•

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 GEOMETRY
INTERACTIONS MESHING SOLVING
PREPARATION
Defeature = remove cosmetics (logos, threads,
chamfers, radius, etc.)
© Dassault Systèmes | Confidential Information | 2/5/2021 | ref.: 3DS_Document_2020

• Isolate sub-assembly
• Configuration & Symmetry
• Simplify geometry
• Interferences
• Element type
•

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 GEOMETRY
INTERACTIONS MESHING SOLVING
PREPARATION
Interferences
• If interferences not in key areas  use Independent Mesh
• If interferences in critical areas  eliminate using Cavity tool
© Dassault Systèmes | Confidential Information | 2/5/2021 | ref.: 3DS_Document_2020

• Isolate sub-assembly
• Configuration & Symmetry
• Simplify geometry
• Interferences
• Element type

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 GEOMETRY
INTERACTIONS MESHING SOLVING
PREPARATION

Geometry Type Element Types

© Dassault Systèmes | Confidential Information | 2/5/2021 | ref.: 3DS_Document_2020

Solid Mesh

Thick & Chunky

Linear
• Isolate sub-assembly (Tetrahedron 4)
Parabolic
(Tetrahedron 10)
• Configuration & Symmetry
• Use Simulation features Shell Mesh
• Simplify geometry before simulation Sheet Metal &
• Element type Thin Walled Linear Parabolic
(Shell 3) (Shell 6)

Beam Mesh

Weldments
2 noded Beam / Truss

In addition, consider 2D simplifications whenever

13
applicable: axi-symmetric, plane stress, plane strain
 SIMULATION BEST PRACTICES FOR LARGE ASSEMBLIES

GEOMETRY
INTERACTIONS MESHING SOLVING
PREPARATION
• Isolate sub-assembly • Types of interactions • Independent & Enforced • Solver selections
• Configuration & Symmetry • Level of interactions Common Node Mesh • Simulation Evaluator
• Simplify geometry • Instabilities due to gaps & • Which Mesher? • Remote Loads/ Mass
• Interferences interferences • Mix & Match Draft vs. • Use weak springs
• Element types • Interaction Viewer & High Quality • Managing the result file size
Underconstrained bodies • Mesh Quality Diagnostics
• Connectors • Mesh Failure Diagnostics
 SIMULATION BEST PRACTICES FOR LARGE ASSEMBLIES

GEOMETRY
INTERACTIONS MESHING SOLVING
PREPARATION
• Isolate sub-assembly • Types of interactions • Independent & Enforced • Solver selections
• Configuration & Symmetry • Level of interactions Common Node Mesh • Simulation Evaluator
• Simplify geometry • Instabilities due to gaps & • Which Mesher? • Remote Loads/ Mass
• Interferences interferences • Mix & Match Draft vs. • Use weak springs
• Element types • Interaction Viewer & High Quality • Managing the result file size
Underconstrained bodies • Mesh Quality Diagnostics
• Connectors • Mesh Failure Diagnostics
 GEOMETRY
INTERACTIONS MESHING SOLVING
PREPARATION
 Start with Bonded interactions!
© Dassault Systèmes | Confidential Information | 2/5/2021 | ref.: 3DS_Document_2020

Bonded

• Types of interactions
• Level of interactions
• Instabilities due to gaps &
interferences Contact
• Interaction Viewer &
Underconstrained bodies
• Connectors

Free

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 GEOMETRY
INTERACTIONS MESHING SOLVING
PREPARATION
 Start simple. Use default global bonded interaction!
© Dassault Systèmes | Confidential Information | 2/5/2021 | ref.: 3DS_Document_2020

• Types of interactions
• Level of interactions High
precedence
• Instabilities due to gaps &
interferences Local Interaction
• Interaction Viewer &
Underconstrained bodies
• Connectors
Component Interaction

Global Interaction
Low
precedence
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 GEOMETRY
INTERACTIONS MESHING SOLVING
PREPARATION
Interferences
Case 1: Interferences not in key areas
© Dassault Systèmes | Confidential Information | 2/5/2021 | ref.: 3DS_Document_2020

 Mesh the bodies independently

• Types of interactions
• Level of interactions
• Instabilities due to gaps &
interferences
• Interaction Viewer &
Underconstrained bodies
• Connectors

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 GEOMETRY
INTERACTIONS MESHING SOLVING
PREPARATION
Interferences
Case 2: Interferences are real
© Dassault Systèmes | Confidential Information | 2/5/2021 | ref.: 3DS_Document_2020

• Types of interactions
• Level of interactions
• Instabilities due to gaps &
interferences
• Interaction Viewer &
Underconstrained bodies
• Connectors

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 GEOMETRY
INTERACTIONS MESHING SOLVING
PREPARATION
Interferences
Case 2: Interferences are real
© Dassault Systèmes | Confidential Information | 2/5/2021 | ref.: 3DS_Document_2020

 Specify Shrink fit interaction type

• Types of interactions
• Level of interactions
• Instabilities due to gaps &
interferences
• Interaction Viewer &
Underconstrained bodies
• Connectors

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 GEOMETRY
INTERACTIONS MESHING SOLVING
PREPARATION
Interferences
Case 3: Due to geometry inaccuracies
© Dassault Systèmes | Confidential Information | 2/5/2021 | ref.: 3DS_Document_2020

• Types of interactions
• Level of interactions
• Instabilities due to gaps &
interferences
• Interaction Viewer &
Underconstrained bodies
• Connectors

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 GEOMETRY
INTERACTIONS MESHING SOLVING
PREPARATION
Interferences
Case 3: Due to geometry inaccuracies
© Dassault Systèmes | Confidential Information | 2/5/2021 | ref.: 3DS_Document_2020

 Make necessary geometry modifications

• Types of interactions
Necessary
• Level of interactions geometric
• Instabilities due to gaps & modifications
interferences
• Interaction Viewer &
Underconstrained bodies
• Connectors

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 GEOMETRY
INTERACTIONS MESHING SOLVING
PREPARATION
Gaps
© Dassault Systèmes | Confidential Information | 2/5/2021 | ref.: 3DS_Document_2020

• Types of interactions
• Level of interactions
• Instabilities due to gaps &
interferences
• Interaction Viewer &
Underconstrained bodies
• Connectors

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 GEOMETRY
INTERACTIONS MESHING SOLVING
PREPARATION

Handling the Gaps is much easy now!

 Gap range for bonding
© Dassault Systèmes | Confidential Information | 2/5/2021 | ref.: 3DS_Document_2020

 Gap range to consider contact

• Types of interactions
• Level of interactions  Contact stabilization
• Instabilities due to gaps &
interferences
• Interaction Viewer &
Underconstrained bodies
• Connectors

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 GEOMETRY
INTERACTIONS MESHING SOLVING
PREPARATION
 Specify an appropriate gap value to establish an efficient
bonding or contact!
© Dassault Systèmes | Confidential Information | 2/5/2021 | ref.: 3DS_Document_2020

• Types of interactions
• Level of interactions
• Instabilities due to gaps &
interferences
• Interaction Viewer &
Underconstrained bodies
• Connectors

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 GEOMETRY
INTERACTIONS MESHING SOLVING
PREPARATION
 Use the Interaction Viewer and Underconstrained bodies tools
to ensure appropriate interactions between the components!
© Dassault Systèmes | Confidential Information | 2/5/2021 | ref.: 3DS_Document_2020

• Types of interactions
• Level of interactions
• Instabilities due to gaps &
interferences
• Interaction Viewer &
Underconstrained bodies
• Connectors

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 GEOMETRY
INTERACTIONS MESHING SOLVING
PREPARATION

Virtual Connectors!
© Dassault Systèmes | Confidential Information | 2/5/2021 | ref.: 3DS_Document_2020

 Connect parts together

• Types of interactions  Transfer loads between parts
• Level of interactions
• Instabilities due to gaps &  Resist and take on pre loads / external loads
interferences
• Interaction Viewer &  No geometry, hence no stress calculations!
Underconstrained bodies
• Connectors  Results reported to help with sizing

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 GEOMETRY
INTERACTIONS MESHING SOLVING
PREPARATION
© Dassault Systèmes | Confidential Information | 2/5/2021 | ref.: 3DS_Document_2020

• Types of interactions
• Level of interactions
• Instabilities due to gaps &
interferences
• Interaction Viewer &
Underconstrained bodies
• Connectors

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 GEOMETRY
INTERACTIONS MESHING SOLVING
PREPARATION
 Includes system behaviors without modeling/meshing
respective parts!
© Dassault Systèmes | Confidential Information | 2/5/2021 | ref.: 3DS_Document_2020

• Types of interactions
• Level of interactions
• Instabilities due to gaps &
interferences
• Interaction Viewer &
Underconstrained bodies
• Connectors

29
 SIMULATION BEST PRACTICES FOR LARGE ASSEMBLIES

GEOMETRY
INTERACTIONS MESHING SOLVING
PREPARATION
• Isolate sub-assembly • Types of interactions • Independent & Enforced • Solver selections
• Configuration & Symmetry • Level of interactions Common Node Mesh • Simulation Evaluator
• Simplify geometry • Instabilities due to gaps & • Which Mesher? • Remote Loads/ Mass
• Interferences interferences • Mix & Match Draft vs. • Use weak springs
• Element types • Interaction Viewer & High Quality • Managing the result file size
Underconstrained bodies • Mesh Quality Diagnostics
• Connectors • Mesh Failure Diagnostics
 GEOMETRY
INTERACTIONS MESHING SOLVING
PREPARATION
© Dassault Systèmes | Confidential Information | 2/5/2021 | ref.: 3DS_Document_2020

• Independent & Enforced

Common Node Mesh
• Which Mesher?
• Mix & Match Draft vs.
High Quality
• Mesh Quality Diagnostics
• Mesh Failure Diagnostics

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 GEOMETRY
INTERACTIONS MESHING SOLVING
PREPARATION
© Dassault Systèmes | Confidential Information | 2/5/2021 | ref.: 3DS_Document_2020

• Independent & Enforced

Common Node Mesh
• Which Mesher?
• Mix & Match Draft vs.
High Quality
• Mesh Quality Diagnostics
• Mesh Failure Diagnostics

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 GEOMETRY
INTERACTIONS MESHING SOLVING
PREPARATION
© Dassault Systèmes | Confidential Information | 2/5/2021 | ref.: 3DS_Document_2020

• Independent & Enforced

Common Node Mesh
• Which Mesher?
• Mix & Match Draft vs.
High Quality
• Mesh Quality Diagnostics
• Mesh Failure Diagnostics

 Use BCB for a successful & efficient mesh

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w/ Large Assemblies
 GEOMETRY
INTERACTIONS MESHING SOLVING
PREPARATION

Significant performance enhancements in 2021 BCB

© Dassault Systèmes | Confidential Information | 2/5/2021 | ref.: 3DS_Document_2020

BCB MESH TIME 2021 VS. 2020

2020 2021
• Independent & Enforced
Common Node Mesh 700

• Which Mesher?
600

Mesh time (sec)

500
• Mix & Match Draft vs. 400
High Quality 300
• Mesh Quality Diagnostics 200
• Mesh Failure Diagnostics 100
0
Solids Solids Solids Mixed mesh
Mesh type

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 GEOMETRY
INTERACTIONS MESHING SOLVING
PREPARATION

Draft Quality Element High Quality Element

© Dassault Systèmes | Confidential Information | 2/5/2021 | ref.: 3DS_Document_2020

• Independent & Enforced

Common Node Mesh
Linear Linear Parabolic Parabolic
• Which Mesher?
(Shell 3) (Tetrahedron 4) (Shell 6) (Tetrahedron 10)
• Mix & Match Draft vs.
High Quality
• Mesh Quality Diagnostics
• Mesh Failure Diagnostics
• 1st order element • 2nd order element
• Low # DOF • High #DOF
 preliminary studies  accurate studies

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 GEOMETRY
INTERACTIONS MESHING SOLVING
PREPARATION
© Dassault Systèmes | Confidential Information | 2/5/2021 | ref.: 3DS_Document_2020

• Independent & Enforced

Common Node Mesh
• Which Mesher?
• Mix & Match Draft vs.
High Quality
• Mesh Quality Diagnostics
• Mesh Failure Diagnostics

 Use Mix & Match to reduce the node count while retaining
High Quality elements for critical components
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 GEOMETRY
INTERACTIONS MESHING SOLVING
PREPARATION
© Dassault Systèmes | Confidential Information | 2/5/2021 | ref.: 3DS_Document_2020

• Independent & Enforced

Common Node Mesh
• Which Mesher?
• Mix & Match Draft vs.
High Quality
• Mesh Quality Diagnostics ● New in 2021
• Mesh Failure Diagnostics ● Identifies and isolates poor quality elements (by evaluating
Aspect Ratio, Jacobian Ratio, Skewness, etc. )
● Result: higher quality elements = faster solving time & more
accurate results

37
 GEOMETRY
INTERACTIONS MESHING SOLVING
PREPARATION
© Dassault Systèmes | Confidential Information | 2/5/2021 | ref.: 3DS_Document_2020

• Independent & Enforced

Common Node Mesh
• Which Mesher?
• Mix & Match Draft vs.
High Quality
• Mesh Quality Diagnostics
• Mesh Failure Diagnostics

Mesh Failure Diagnostics: locate and resolve meshing problems

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 SIMULATION BEST PRACTICES FOR LARGE ASSEMBLIES

GEOMETRY
INTERACTIONS MESHING SOLVING
PREPARATION
• Isolate sub-assembly • Types of interactions • Independent & Enforced • Solver selections
• Configuration & Symmetry • Level of interactions Common Node Mesh • Simulation Evaluator
• Simplify geometry • Instabilities due to gaps & • Which Mesher? • Remote Loads/ Mass
• Interferences interferences • Mix & Match Draft vs. • Use weak springs
• Element types • Interaction Viewer & High Quality • Managing the result file size
Underconstrained bodies • Mesh Quality Diagnostics
• Connectors • Mesh Failure Diagnostics
 SIMULATION BEST PRACTICES FOR LARGE ASSEMBLIES

GEOMETRY
INTERACTIONS MESHING SOLVING
PREPARATION
• Isolate sub-assembly • Types of interactions • Independent & Enforced • Solver selections
• Configuration & Symmetry • Level of interactions Common Node Mesh • Simulation Evaluator
• Simplify geometry • Instabilities due to gaps & • Which Mesher? • Remote Loads/ Mass
• Interferences interferences • Mix & Match Draft vs. • Use weak springs
• Element types • Interaction Viewer & High Quality • Managing the result file size
Underconstrained bodies • Mesh Quality Diagnostics
• Connectors • Mesh Failure Diagnostics
 GEOMETRY
INTERACTIONS MESHING SOLVING
PREPARATION

Which solver to
use?
© Dassault Systèmes | Confidential Information | 2/5/2021 | ref.: 3DS_Document_2020

• Solver selections
• Simulation Evaluator
• Remote Loads/ Mass
• Use weak springs
• Managing the result file size

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 GEOMETRY
INTERACTIONS MESHING SOLVING
PREPARATION

 Use the Automatic Solver!

© Dassault Systèmes | Confidential Information | 2/5/2021 | ref.: 3DS_Document_2020

• Solver selections
• Simulation Evaluator
• Remote Loads/ Mass
• Use weak springs
• Managing the result file size • Evaluation is based on the number of equations, load cases,
mesh type, geometric features, contact and connector
features, and available system memory.

42
 GEOMETRY
INTERACTIONS MESHING SOLVING
PREPARATION

 Evaluate whether or not the study setup is correct!

© Dassault Systèmes | Confidential Information | 2/5/2021 | ref.: 3DS_Document_2020

• Know the results file path and available disk space

• Material specification is correct
• Solver selections
• Simulation Evaluator • % error between meshed volume and geometry volume
• Remote Loads/ Mass
• Concerns associated with friction coefficient and Poisson’s
• Use weak springs
• Managing the result file size ratio

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 GEOMETRY
INTERACTIONS MESHING SOLVING
PREPARATION
 Use the Remote load/mass functionality to gain the benefits of
solving time!
© Dassault Systèmes | Confidential Information | 2/5/2021 | ref.: 3DS_Document_2020

Equivalent Remote
load/Mass
• Solver selections Crank assembly
• Simulation Evaluator
• Remote Loads/ Mass
• Use weak springs
• Managing the result file size Save time

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 GEOMETRY
INTERACTIONS MESHING SOLVING
PREPARATION

 Activate the soft spring to prevent the instabilities!

© Dassault Systèmes | Confidential Information | 2/5/2021 | ref.: 3DS_Document_2020

• Solver selections
• Simulation Evaluator
• Remote Loads/ Mass
• Use weak springs
• Managing the result file size

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 GEOMETRY
INTERACTIONS MESHING SOLVING
PREPARATION
 Choose the result quantities wisely before running the simulation!
© Dassault Systèmes | Confidential Information | 2/5/2021 | ref.: 3DS_Document_2020

Displacements
and reactions only
Stresses and
• Solver selections strains also
• Simulation Evaluator
• Remote Loads/ Mass
• Use weak springs
• Managing the result file size

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 SIMULATION BEST PRACTICES FOR LARGE ASSEMBLIES

GEOMETRY
INTERACTIONS MESHING SOLVING
PREPARATION
• Isolate sub-assembly • Types of interactions • Independent & Enforced • Solver selections
• Configuration & Symmetry • Level of interactions Common Node Mesh • Simulation Evaluator
• Simplify geometry • Instabilities due to gaps & • Which Mesher? • Remote Loads/ Mass
• Interferences interferences • Mix & Match Draft vs. • Use weak springs
• Element types • Interaction Viewer & High Quality • Managing the result file size
Underconstrained bodies • Mesh Quality Diagnostics
• Connectors • Mesh Failure Diagnostics
 20 BEST PRACTICES
TO HANDLE LARGE ASSEMBLIES
LIKE A PRO!
GEOMETRY
INTERACTIONS MESHING SOLVING
PREPARATION
• Isolate sub-assembly • Types of interactions • Independent & Enforced • Solver selections
• Configuration & Symmetry • Level of interactions Common Node Mesh • Simulation Evaluator
• Simplify geometry • Instabilities due to gaps & • Which Mesher? • Remote Loads/ Mass
• Interferences interferences • Mix & Match Draft vs. • Use weak springs
• Element types • Interaction Viewer & High Quality • Managing the result file size
Underconstrained bodies • Mesh Quality Diagnostics
• Connectors • Mesh Failure Diagnostics

[email protected] [email protected]
 © Dassault Systèmes | Confidential Information | 2/5/2021 | ref.: 3DS_Document_2020

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Case Studies
SOLIDWORKS Simulation
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51
PLACEHOLDER
PRESENTER VIDEO
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