Sei sulla pagina 1di 146

# Dassault Systmes Confidential Information

SolidWorks 2012

## Dassault Systmes Confidential Information

Prerequisites
Course Design Philosophy
Using this book
Conventions used in this book
Class Introductions

## Dassault Systmes Confidential Information

SolidWorks

Simulation Professional
Frequency/
Buckling

Nonlinear
Fatigue

Optimization

Static
Composites

SolidWorks
Motion

Thermal

Drop Test

Pressure
Vessel

Dynamics

## What is Finite Element Analysis?

Example: Brick road from home to mailbox measure the distance of a
curved path using yard stick

## Curved path is approximated by straight segments

Measure using a yard stick

Stress Results

## Dassault Systmes Confidential Information

Represent how the given model is attached to the rest of the world
Fixed on a Surface or Edge or Point
Allow Sliding or Rotation

## Fixtures used to reduce the size of the problem to a component

level or subassembly level

Torque, Moment
Pressure

## Split the fitting into small tetrahedral

pieces and approximate the
deformation on each piece

Example of a fitting

## FEA for structural analysis

Example of a bracket

## Split the surfaces of bracket into small

triangular pieces and approximate the
deformation on each piece
9

## Split the members of frame into small

straight pieces and approximate the
deformation on each piece
10

## MESH Approximate representation of the

CAD geometry using Tetrahedra or Triangles
ELEMENTS Tetrahedra or Triangles in the
Mesh
NODES - Points at which different elements are
jointed together; nodes are the locations where
values of unknowns (usually displacements)
are to be approximated

11

## Using Stress Results to Validate Design

Stresses at a point are defined by 6 quantities 3 normal stress and
3 shear stresses depend on orientation of coordinate system

## VON is independent of coordinate system

Principal Stresses 3 normal stresses specified in a
special coordinate system for which shear stresses
are zero
Factor of Safety =

12

## Assumptions in Linear, Static Analyses

Response is proportional to the applied loads
If you double the load, deformation also gets
doubled
If you remove the load, model has no deformation
Material is linearly elastic
The part returns to its original shape if the loads are
removed (no permanent deformation)
strains, and stresses
13

Small deformation

Large deformation

1.

Material?

2.

Steel 1040

## Physical Working Condition?

3.

Pressure or force
Bolted or Welded

## Modeling in SolidWorks Simulation

4.

TRAINING

Is my Design OK (Results)

Factor of Safety
Stress

14

## Dassault Systmes Confidential Information

Lesson 1
The Analysis Process

15

## Dassault Systmes Confidential Information

Lesson 1 Topics
Introduction to the Simulation interface
Perform linear static analysis Static
study
Material properties
Restraints
Mesh
Run
Influence of mesh density on displacement
and stress results
Post-processing
16

## SolidWorks Simulation interface

CommandManager tab
Analysis library

Toolbar

Study tree
Study tabs

17

## Dassault Systmes Confidential Information

18

Lesson 1: Results

## von Mises Stresses in coarse study

19

Lesson 1: Results

## von Mises Stresses in default study

20

Lesson 1: Results

## von Mises Stresses in fine study

21

Lesson 1: Results

22

Lesson 1 Results

23

## Dassault Systmes Confidential Information

Exercise 1: Bracket

24

F
0 .1

234.7 N m
3
u 0.426 10
25

26

## Dassault Systmes Confidential Information

Lesson 1: Questions

27

Lesson 2
Dassault Systmes Confidential Information

28

Lesson 2: Topics

## Using SolidWorks Configurations

Use of mesh controls, automatic transition
FEA Convergence issues
Different boundary conditions

fillet configuration

no fillet configuration

29

30

## Dassault Systmes Confidential Information

Lesson 2: Results
No fillet configuration

31

Lesson 2: Results

## 1- When increasing the number of elements, will the stresses converge?

2- Why?

32

Lesson 2: Results

## Fillet, Mesh Control

No Mesh Control

Mesh Control
33

Lesson 2: Results

34

## Can greatly simplify the model

Can also affect results

35

## Dassault Systmes Confidential Information

Exercise 4: C-bracket

No fillet
Filleted edge

36

## Dassault Systmes Confidential Information

Exercise 4
Fixed hole

Stress concentrations

37

38

0.5 mm

39

0.5 mm

40

## Dassault Systmes Confidential Information

Lesson 2: Questions

41

## Dassault Systmes Confidential Information

Lesson 3
Assembly Analysis with Contact

42

## Dassault Systmes Confidential Information

Lesson 3: Topics
Assembly Analysis Basics
Interference Detection
Global and Local Contact/
Gaps conditions

43

## Dassault Systmes Confidential Information

Interference Detection

44

Global contact

## Dassault Systmes Confidential Information

Default: Bonded
Global contact conditions
No penetration
Bonded (No clearance)
Allow Penetration

Component Contact

## Uncheck Global Contact box

Overrides Global Contact

45

## Dassault Systmes Confidential Information

Contact/Gap Hierarchy

## Global and Component contact apply only to initial touching areas

Global contact for most common condition, component and local
contact as needed
46

## For structural studies

No Penetration
Bonded
Allow Penetration
Shrink Fit
Virtual Wall

## For thermal studies

Insulated (similar to Free in a static study)
Thermal contact resistance

## Friction at the local level for touching entities

Initial gap (clearance) can be ignored or accounted for by specifying it
here
47

225 N

i)
ii)

## Global No Penetration contact

Local contact

Fixed

225 N

48

Lesson 3: Results

## (You can plot stresses in exploded configuration)

49

Lesson 3: Results

50

51

## Dassault Systmes Confidential Information

Lesson 3: Questions

52

Lesson 4
Dassault Systmes Confidential Information

53

Lesson 4: Topics

## Analyze shrink-fit problem

Use of symmetry
Review stress results in local coordinate
systems
Solver options to eliminate rigid body
modes

54

## Contact conditions (local only) Shrink fit

1 - Program creates a shrink fit condition between selected faces.
2 - The faces may or may not be cylindrical.

(NOTE: Virtual wall a sliding support (roller), with friction and wall elasticity capability)

55

## Dassault Systmes Confidential Information

Boundary conditions

56

## Contact and Mesh

57

Lesson 4: Results

## Hoop stress (using local cylindrical coordinates)

Why is there a jump in the hoop stress value across the interface?
Would the assembly experience a similar jump58in radial stresses?

59

## Dassault Systmes Confidential Information

Incorrect solution

Correct solution

60

## Dassault Systmes Confidential Information

Lesson 5
Assembly Analysis with Connectors

61

## Dassault Systmes Confidential Information

Lesson 5: Topics

Connectors
Rigid
Spring
Pin
Elastic Support
Bolt
Spot Weld
Edge Weld
Bearing
Global and local contact conditions
62

## Dassault Systmes Confidential Information

Connectors

Spring
Pins (three in all)

63

225 N

Fixed
225 N

64

## Dassault Systmes Confidential Information

Lesson 5: Results

65

Exercise 10 & 11

66

## Exercise 12: Shock Absorber

Simplify the model

## 1. Suppress the original

helical spring from the
analysis.
2. Introduce Spring Connector.

67

68

## Exercise 13: Spot Welds

Connector types Spot Welds

Spot Welds

Spot Welds

69

## Spot Welds - solid models - stress results

We notice high stresses in the vicinity of welds. Would the subsequent mesh refinement in these regions
bring more accurate stress distribution?
70

## Dassault Systmes Confidential Information

Lesson 6
Compatible/Incompatible Meshing

71

Lesson 6: Topics

## Compatible solid element mesh with Bonded contacts

Incompatible solid element mesh with Bonded contacts
Simplified bonding for incompatible solid meshes

72

73

74

Bonding

## Surface based contact. Results at the contact interface are uniform

but solution time is longer.
75

Bonding

## Node based contact. Results at the contact interface may be

patchy but solution time is lower.
76

## Dassault Systmes Confidential Information

Lesson 7
Assembly Analysis Mesh Refinement

77

## Dassault Systmes Confidential Information

Lesson 7: Topics
Analyze larger assembly using solid
elements
Define multiple contact conditions
Analyze mesh quality and question the
results of the simulation

78

## Dassault Systmes Confidential Information

Displacement (Rigid connection)

79

Bolt connectors

Bolt type
Tight fit
Material
Bolt series
80

Virtual wall

## Type of contact that replaces modeling a

component
Rigid or Flexible

81

Lesson 7: Results

## Mesh parameters are not ideal leading to

excessive von Mises stress results
82

Lesson 7: Results

## Mesh parameters improved, so did the results of

the simulation.
(NOTE: The time required to complete the simulation increased as well.)
83

84

85

## Dassault Systmes Confidential Information

Lesson 7: Questions

86

## Dassault Systmes Confidential Information

Lesson 8
Analysis of Thin Components

87

## Dassault Systmes Confidential Information

Lesson 8: Topics

Shell Elements
Mid-plane and surface shell element meshing
Alignment of shell mesh
Evaluating mesh sizes
Evaluating results for shell elements
Reaction forces
Solid vs. Shell meshing

88

Lesson 8: Results
Solid Elements Von Mises Stress
55449 DOF

987978 DOF
(2 element per thickness)

89

## Dassault Systmes Confidential Information

Shell elements
Defined by:
Existing surface or sheet metal
bodies
Mid-plane surfaces
Outside/inside faces of solid bodies

Mid-plane surface

Outside faces
90

## Dassault Systmes Confidential Information

Shell Type

Kirchoff Theory
span
20
thickness

Mindlin Theory
span
10
20
thickness

Thin shells ignore shear deformation through the thickness of the shell

91

## Shell Element Alignment

Shell Elements - Alignment

## Incorrect stress result representation

92

Lesson 8: Results
Shell Elements (midplane) Von Mises Stress

Bottom
(orange)

## Dassault Systmes Confidential Information

Top (gray)

93

Lesson 8: Results
Shell vs. Solid Elements
Shell elements can greatly decrease the required computational time.
Dassault Systmes Confidential Information

## Modeling with shell elements is more demanding than with solids.

* See results of Exercise 16

94

## Shell elements generated

automatically for sheet metal
features

95

96

## Exercise 17: Shell Mesh Using Outer/Inner Faces

Shell Elements (surfaces) Von Mises Stress

Bottom
(orange)

Top (gray)

Top

Bottom
97

## Spot Welds - shell model - stress results

Both solid and shell models predict similar behavior. Which one would you choose?

98

99

## Dassault Systmes Confidential Information

Self-guided exercise

Design double sided fillet welds connecting the container handle to the square plates.

100

## Dassault Systmes Confidential Information

Lesson 8: Questions

101

## Dassault Systmes Confidential Information

Lesson 8: Questions

102

## Dassault Systmes Confidential Information

Lesson 9
Mixed Meshing Shells & Solids

103

## Dassault Systmes Confidential Information

Lesson 9: Topics

Mixed meshing
Solid-shell bonding
Shell offset
Mesh failure diagnostics

104

Mixed meshing

## Why Mixed Meshing?

Some design assemblies may contain bulky parts suitable for solid mesh, as well as thin
parts ideal for shell elements.
105

## Compatibility problems in mixed solid and shell element meshing

Use of mixed mesh in simulation
How many DOF does a solid
element have?

element have?

106

## Hinge formed at the connecting edge

May introduce rigid body modes if not
handled properly
Mesh incompatible at the interface
Bond generated through multi-point
constraints internally (mortar bonding)

107

Hinge

Shell offset

Mid-surface
Top surface
Bottom surface
Ratio

## By default, mesh located at mid-plane

Orientation important when defining
shells with different thickness

108

## Mesh failure diagnostics

Incompatible mesh
Mesh control
Auto-looping
Check geometry
Switch mesher
109

## Dassault Systmes Confidential Information

Lesson 9: Results

Why are the stresses highest at the base near the support and bonded contacts?
110

111

## Dassault Systmes Confidential Information

Lesson 9: Questions

112

## Dassault Systmes Confidential Information

Lesson 10
Mixed Meshing Solids, Beams & Shells

113

## Lesson 10: Topics

Beam elements
Joints
Bonding of beams
Post-processing of beam elements

114

Beam elements

6 DOFs
115

Joints

## joints are connected to two or more beam members.

joints are connected to a single member only
116

Bonding of beams

## Bond joints or entire beam to

target entities
Beam profile imprinted on target entities
Accurate results at the interface

117

118

## Stress: Axial, bending,

worst-case, torsional, shear
Displacement
Axial force diagrams
Shear & bending moment
diagrams
Reaction forces & moments

119

120

121

122

123

Lesson 11
Design Study

124

## Lesson 11: Topics

Design Study performing several studies for different
input data (model geometry or loads)
Stresses in vehicle suspension when vehicle is:

Moving at constant acceleration on a smooth road
Moving at a constant speed on a banking road

125

126

127

128

129

130

## Dassault Systmes Confidential Information

Lesson 12
Thermal Stress Analysis

131

## Static analysis with temperature load

Use of various contact conditions
Temperature dependent material properties
Soft spring and Inertia relief options

132

## Lesson 12: Results

Averaging across boundaries ON

133

134

135

Lesson 13

136

## What do FEM results depend on?

1. Mesh
2. Type and order of the elements used (Draft or High quality)
3. Other phenomena (numerical errors, modeling errors etc.)
What is our Goal? Is it just to obtain a solution?
Make sure our results are close to some defined accurate solution.
(typical parameter is strain energy density)
How to achieve it?
1. Modify and refine the mesh topology

137

1st order
(Draft Quality)

5th order

2nd order
(High Quality)

138

139

140

Summary

## Max. displacement difference: 0.2%

Max. Von Misses stress difference:10%

141

## Dassault Systmes Confidential Information

Lesson 14
Large Displacement Analysis

142

## Lesson 14: Topics

Surface contact
Contact analysis with the large
displacement option
bending stresses
Limitations of the linear material model

143

144

145

146