SolidWorks

Engineering Design and Technology Series

Lesson 4
Analyzing the Structure

When you complete this lesson, you will be able to:

Understand what SolidWorks Simulation does;
Describe the stages of a Structural Analysis;
Understand the environment of the analysis including fixtures and loads;
Use SolidWorks Simulation;
View the results of an analysis.

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Analysis of the Structure

During this lesson, you will use SolidWorks Simulation to analyze the beam
structure.

What is SolidWorks Simulation?

SolidWorks Simulation is a structural analysis tool for designers that is added into
SolidWorks. With this software you can analyze the solid model directly. You can
also easily set up units, material type, external loads and more by using a study.
You can make changes to the solid model and update the structural analysis
results.
There are several steps to the analysis:
1. Create a design in SolidWorks.
SolidWorks Simulation can analyze parts and assemblies.
2. Create a new static study in SolidWorks Simulation. SolidWorks Simulation
projects will contain all the settings and results of a problem and each project
that is associated to the model. This includes: adding fixtures, adding external
loads and meshing the model.
3. Run the analysis. This is sometimes called solving.
4. Viewing the SolidWorks Simulation results which includes plots, reports and
eDrawings.

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Structural Analysis
Structural Analysis is an Engineering process that uses Physics and Mathematics
to predict how a structure will behave under external loads such as weights and
pressures. Buildings, bridges, aircraft, ships and automobiles are among the many
products that require structural analysis.
Through structural analysis we can determine Stresses, Factor of Safety and
Displacements.
Stresses: The external loads applied to a structure create internal forces and
stresses that may cause the structure to fail or break.
Factor of Safety: The factor of safety (FOS) is a ratio of the actual stress divided
by the maximum stress the material can handle.

MaximumStressunderLoading
-------------------------------------------------------------------------------- = FOS
MaximumStressoftheMaterial

If the FOS > 1, the structure is safe. If the FOS < 1, the structure is considered
unsafe.
Displacements: As mentioned in a previous lesson, the external loads applied to a
structure can force the structure to move from it’s unloaded position. The
displacement is the distance a point moves from it’s original position.
Structural analysis is used in many fields of the manufacturing industry:
Buildings and Bridges
Floors, walls and foundation.
Aircraft
Aircraft fuselage, wings and landing gear.
Ships
Hulls, bulkheads and superstructure.
Automobiles
Chassis, body and crash testing.

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Why Do Design Analysis?

After building your design in SolidWorks, you may need to answer questions like:
Does the truss cover the required span?
What is the most efficient design for the truss?
What is the maximum load that the truss can handle?
In the absence of analysis tools, expensive prototype-test design cycles take place
to ensure that the product’s performance meets customer expectations. Design
analysis makes it possible to perform design cycles quickly and inexpensively on
computer models instead. Even when manufacturing costs are not important
considerations, design analysis provides significant product quality benefits,
enabling engineers to detect design problems far sooner than the time it takes to
build a prototype. Design analysis also facilitates the study of many design
options and aids in developing optimized designs. Quick and inexpensive analysis
often reveals non-intuitive solutions and benefits engineers by allowing them to
better understand the product’s behavior.

Structural Analysis Stages

SolidWorks Simulation walks you through several stages of structural analysis.
This is what is happening behind the scenes:
Pre-Processing- In this stage, you add the required information about the
structure and the environment where lives. This includes materials, fixtures
and external loads applied to the structure.
Analysis- The model is broken down into tiny pieces called elements using a
process called meshing. In this project, the elements are Beam Elements.
This information is then used to create a finite element model and is solved.
This includes the Analyze page of the SolidWorks Simulation wizard.
Post-Processing- The results are presented to you in a graphic form so you
can identify the problem areas. This includes the Optimize and Results pages
of the SolidWorks Simulation wizard.
Once all the stages are complete, you can save all the analysis information with
the model. When the analysis information is saved, future changes will be faster.

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Design Cycle
The Design Cycle is used to make a change to the model or the pre-processing
information. Model changes would be size changes such as the length of beams.
Changes to the pre--processing information would include changes to the
material, fixtures or loading. Either change forces the model to be re-analyzed,
cycling until the best solution is reached.

SolidWorks
Design
Cycle
SolidWorks
Simulation

No
Satisfied?

Yes
Prototype

Changes in the Model

The SolidWorks part is now very simple, but sides and braces will be added and
you will see why they are important aspects of the structure. Let’s open it and take
a look at the model and what it represents.
1 Open the part file again.
Click Open .
From the Open window, browse to the
Bridge Design Project\Student\
Lesson 3 folder.
Select TRUSS_1.sldprt and click
Open.
This is the same part that was used in the
previous lesson.

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Create a Study
In order to perform a structural analysis, a new study must be created.
SolidWorks Simulation uses a Study to store and organize all the data associated
with a structural analysis.
The study is also used to specify the type of analysis that you are running. Many
types are available. They include:
Static
Frequency
Buckling
Thermal
Drop test
Fatigue
Nonlinear
Linear Dynamic
Pressure Vessel Design
In this project we will be using a Static analysis. This type of study is used to the
predict where a structure will fail due to stress.
Access the study from the Simulation pull-down menu.
2 Create a new study.
Click Simulation, Study. Use the default name Study 1
and click Static.
Click .

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FeatureManager Design Tree and Simulation Study Tree

The FeatureManager Design Tree appears above the Simulation Study Tree on
the left side of the screen. The upper tree lists the features of the model geometry
while the lower tree lists the features of the analysis or simulation model.

FeatureManager Model
Design Tree

Simulation Simulation
Study Tree Model

The Environment
The environment describes how the
structure is used. In this case, the model
represents a structure crossing a river.
From knowing the placement of the
structure and the external loads that
must cross it, we can determine two
critical items required for SolidWorks
Simulation: the Fixtures and the
External Loads.

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Fixtures
The Fixtures are the areas of the Structure
structure that will be fixed or limited
in movement. We define the span as
the crossing distance that is not
supported, 350mm in this case. On
each end, there is 25mm of overlap
where the structure ends are supported
by the abutment or shore. The span is
always less than the full length of the
structure.
The fixtures are defined at the ends of Load
the model in four places.

Abutment

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External Loads
The model must have External
Loads that impose forces onto the
structure. Let’s say a rectangular
stack of bricks is sitting in the
center of the span, crossing the
structure. Assume that the total
weight of the bricks is 40N.
There are four loading points, one
for each point where the beams
connect near the center of the span.
This means that the load on each
point is 40N/4 = 10N (about
2.25lbs).

Why is the load in the center?

When using structural analysis
model, engineers like to perform
what is called a “worst case”
analysis. This is the situation
where the structure is most likely
to break due to the conditions of
the environment.
Placing the load at the center of
the span is the worst case for a
truss structure like this.

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How much do you think it will hold?

The structure is fairly weak at this point, but you will strengthen it as you go
through this manual. What is the maximum force it can withstand? Take a guess.
Force = __________N
Note: If you are thinking in terms of pounds (lb), start thinking in metric terms. Convert
pounds to newtons (N) using this formula:
1 lb = 4.4482 N

Unit Settings
The Units can be set to create consistent results throughout the analysis. In this
example, mm and MPa will be selected for use.
3 Set the units.
Click Simulation, Options and click OK. Click
the Default Options tab. Under Units, select
mm for Length/Displacement and
N/mm^2 (MPa) for Pressure/Stress.
Click OK.

Pre-Processing
The first stage of the structural analysis is the pre-processing, gathering all the
required information and applying it to the simulation model. The information
that we will supply or create includes:
Material - The material of the beams.
Fixtures - Positions that cannot move freely.
External Loads - Forces that are applied to the model.
Mesh - A simulation model, based on the model, that breaks the beams up
into small pieces called elements.

Material
The Material is a required value that sets the material properties and appearance of
the model geometry. In this case it will be applied to all the beams at once.
4 Set the material.
Click Simulation, Material, Apply Material to All. Expand the Woods folder and
select Balsa. Click Apply and Close.

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What are Joints?

Joints are generated automatically
where the centerlines of beams meet.
These joints will be used to locate the
fixtures and external loads that follow.

Fixtures
Fixtures are used to limit movement of certain
points in the model. The points where the ends
of the structure sit on the abutment will be
assigned fixtures.

What type of fixtures?

In this project, the bridge will be placed on the
abutment so that it crosses the span. The
bridge will contact the abutment but it will not
be glued or attached in any way.
5 Add fixtures.
Click Simulation, Loads/Fixture, Fixtures. Click Immovable (No translation)
and select the joints as shown.

Note: To correct errors, right-click in the box where the selections are listed and select
Clear selections. When the box is emptied, try selecting again.

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6 Size of symbols.
Expand the Symbol Settings section and increase the
Symbol Size to 150. This makes the symbols larger and
more visible. Click .

External Forces
The total force on the structure will be divided equally into four 5N forces placed
near the center of the structure.

Forces
Forces have direction and a value (magnitude). They can be a a direct force like
hanging a weight or a moment that twists or bends like turning a doorknob.

Gravity
Gravity uses the weight of the structure as a load. It is not significant in this
project and will not be considered.
7 Add forces.
Click Simulation, Loads/Fixture, Force. Click Joints
and select the visible joints as shown.

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8 Set direction.
Click in the Direction field and expand the Flyout FeatureManager Design Tree.
Click the feature Top Plane.

9 Set units.
Make sure that Units are set to SI.

10 Assign force.
Click Normal to Plane and set the value to 10N as
shown. Click Reverse direction to get the arrows pointing
down.
Click .

Tip: The Symbol Settings options can be used like those in fixtures to increase or
reduce the size of the symbol. These have been set to 150.

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11 Save.
Click Save to save the model and simulation data.

Tip: It is a good idea to save periodically and prevent unintentional loss of data.

Meshing the Model

The mesh must be created to generate the small pieces used in the analysis. The
analysis model is made up of a series of connected nodes and elements.

Node

Element

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12 Meshing.
Click Simulation, Mesh, Create. A mesh is created using the geometry of the
model.

Note: This step is automatically included within Simulation, Run but is shown here to
highlight the mesh.

Analysis
The analysis portion is the easy part. SolidWorks Simulation takes your input and
does the work to find the results. You will use the default settings so that the
results will be faster.

Expectations
In the previous lesson, beam calculations were used to determine a rough
displacement based on a simplified analysis of a simply supported beam. That
analysis determined that the displacement was approximately 35mm. We expect
that the displacement we get from the simulation analysis falls in the same order
of magnitude; between 3.5mm and 350mm; hopefully close to the 35mm result.
13 Run.
Click Simulation, Run. When the run is
complete, you will see two features in the
Results folder of the Simulation Study
Tree.
The simulation is ready for post-processing.

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Some Terminology
While the analysis is running, let’s look at some terminology that will help with
interpretation of the results.

Bending and Displacement

Bending is caused by a load that is
applied to a beam. The load causes
the beam to bend and move in the
direction of the load.
The Displacement is the
movement of the beam from it’s
original position. The “worst case”
displacement occurs when the load
is at the center of the beam.
You can see displacement if it is
large enough, but it is usually very
small.
Is there a place in your house
where the floor creaks when you
walk over it? The creaking is
caused by the displacement of the
floor beam bending under a load-
your weight!

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Tension and Compression

While the beam bends, the top portion of the beam (the face where the load is
applied) compresses (pushing together) while the opposite face sees tension
(pulling apart).
Compression

Tension

Search on tension and compression for more information.

Stresses
Stress is a quantity measured by force per
unit area inside a structure that is caused by
external loads applied outside of the
structure. You cannot see stress but it can
cause your structure to break.
Common units are Newtons per meter
squared, Pascals and pounds per square inch
(psi).
Stress can cause the beam to break under a
load. SolidWorks Simulation provides maps that show areas of high and low stress
on the structure.

Yield Strength
How much can the beam take before it breaks? We use the Yield Strength as the
limit of the beam’s strength based on the stresses that the beam sees. Both the
material and beam section contribute to the strength.
Note: In metals, the material will often bend under load but will return to its original
shape when the load is removed. The yield strength is the point where the material
bends and stays bent after the load is removed. This is called a Plastic
Deformation.

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Factor of Safety
The Factor of Safety (FOS) is a quick way to see the results of the analysis. It is
defined as the ratio of the highest stress and the yield stress of the material. If the
FOS > 1, the design is . If the FOS < 1, the design is failing.
Note: Engineers generally design for a FOS of more than 2. Structures are generally
“over designed” for safety and reliability.

Search on stress (physics), yield strength or factor of safety for more

information.

Post-Processing
Once the analysis is complete, post-processing can begin. Post-processing
produces two plots in the Results folder of the Simulation Study Tree that can be
viewed and modified. These plots will help you understand and modify the bridge
structure.
As post-processing begins, two plots are posted in the Results folder:
Stress 1 (-STRMAX-High axial and bending) and
Displacement1 (-Res disp-).
The stress plot is selected and viewed automatically.
14 Stress distribution.
The display shows the model with displacement. The Stress Distribution is
represented by the colors on the displaced model. The chart shows the
distribution; warm colors for higher stresses, cool colors for lower stresses.

Note: The joints can be hidden. Right-click Joint group and select Hide or Show.

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15 Displacement.
Double-click the Displacement1 (-Res disp-) plot to view it.

Interpreting the Results

The stress and displacement plots are helpful because they tell us the actual values
and where they are highest. What is a MPa? Lets get some sense of what the
results mean. Here are results so far (yours may vary):

Stress Displacement

39.014MPa (Megapascals) 3.885e+001mm

Numbers
The displacement is shown in scientific notation. (your results may have a
different combination of formats).
3.880e+001 means 3.880 X 101 or 3.880 X 10^1= 3.880 X 10 =______mm
What is that in inches? Divide the result above by 25.4 = ______in

Units
Understanding units is important in interpreting the results. Length units like mm
or inches are familiar. Stress may not be. Stress units are those of pressure,
measuring force/area. You may have seen psi (pounds per square inch) when you
pump up a bicycle tire. Here is a tire pressure in common units:
60 psi = 4.136854e+005 Pa = 0.4136854 MPa (1MPa = 1N/mm^2=1,000,000 Pa)

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Creating a New Plot

What we need to know is: how much stress can the structure withstand? The best
solution is to create a Factor of Safety plot. It is a three step process.
16 Factor of Safety Plot.
Right-click on the Results folder in the
Simulation Study Tree and select Define
Factor of Safety Plot.

Keep the default settings and click Next .

Keep the Multiplication factor at 1 and click
Next .
Click Areas below factor of safety and
click .

Note: The current factor of safety is listed as

0.512642, or about 0.5, in the dialog box.
This is less than the minimum value of at
least 1.

What does the Factor of Safety Plot Tell Us?

The areas below factor of safety are shown as red on the plot. If a FOS of 1 is the
limit, that means that the loading is too heavy for the structure to support.
The load must be reduced.

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Iterating Changes
Since the structure cannot support the load, the next step is to find out what load
the structure can support. To do this, we will change the load, re-analyzing the
structure until we can get the FOS to about 1. This is called iterating.

Determine the Load

Before we iterate a change and decrease the load, we need to decide how much of
an decrease is required. The current information tells us that the FOS is about 0.5
for a load of 4 X 10N = 40N.
If we multiply the FOS times the total load, the result should produce a FOS of
about 1.
FOS X Total Load = 0.5 X 40N = 20N or 5N per face
Using iteration, we will reanalyze the model to see if this formula can be
validated.

Editing Simulation Data

Simulation data, such as an external load, can be edited to reflect the new value.
The results will not update until the analysis has been rerun.
17 Edit external load.
Right-click the feature
Force-1 (:Per item: -10 N:) and select Edit
Definition. Set the load to 5N and click .

18 Rerun.
Click Simulation, Run to rerun the analysis.
19 Factor of Safety.
Double-click the result Factor of Safety1 (-Automatic-). The FOS is blue
meaning greater than 1.
20 Close the part.
Click File, Close and click Save to save changes.

Conclusion
From the analysis, it is obvious that the structure was inadequate to support the
initial load. Using SolidWorks Simulation, we were able to iterate and find the
highest load that the structure could hold.

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