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Position: Horizontal
5.86 & Vertical .46,
both from top left corner

SolidWorks Simulation Professional Training

SolidWorks 2009

Image courtesy of National Optical Astronomy

Observatory, operated by the Association of Universities
for Research in Astronomy, under cooperative agreement
with the National Science Foundation.

Six types of analysis

Frequency
Frequency

Fatigue
Fatigue

2007 SolidWorks Corp. Confidential.

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Buckling
Buckling

Optimization

Thermal
Thermal

Drop
Drop Test
Test

VAR logo here

Position: Horizontal
5.86 & Vertical .46,
both from top left corner

Lesson 1
Frequency Analysis

Image courtesy of National Optical Astronomy

Observatory, operated by the Association of Universities
for Research in Astronomy, under cooperative agreement
with the National Science Foundation.

Frequency Analysis

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What if loads are changing very slowly with time ? Can we still use the
assumption of Static analysis ?
Yes, if the frequency of the applied load is significantly lower than the first
natural frequency of the structure. If not, a dynamic analysis is required to
check if the structure is likely to resonate.

2007 SolidWorks Corp. Confidential.

Frequency Analysis

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Can we use symmetry in frequency analysis?

What do we get from Frequency analysis ?

Frequency values and deformation modeshapes
Cannot get actual values of displacements
only obtained deformation mode
Actual values of displacements depends on
amplitude of imposed loads and damping

2007 SolidWorks Corp. Confidential.

Lesson 1 Description

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Tuning fork designed to emit a

lower A tone (440 Hz)

What are the boundary

conditions?

How will loading effect the

natural frequencies?

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Lesson 1 Results

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Lesson 1 with loading

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Frequency analysis with loads

Loads affect the natural frequency

Compressive loads decrease resonant

frequencies and tensile loads increase.
Example: changing the tension on a violin
string the increasing the tension will increase
frequency.

Use the Direct Sparse solver

If Solver option is set to Automatic, then
Direct Sparse solver will be used when loads
are defined for a frequency study

2007 SolidWorks Corp. Confidential.

Exercise 1: Car Suspension Bulkhead

2007 SolidWorks Corp. Confidential.

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Exercise 2: Blower Fan

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Sensitivity Study Design Scenarios

With increasing rpm the blades become stiffer.

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10

Exercise 3: Impeller

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Frequency Analysis of an impeller rotating at 20000 rpm

Mixed Meshing
Bonded contact sets between Solid and Shell

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11

VAR logo here

Position: Horizontal
5.86 & Vertical .46,
both from top left corner

Lesson 2
Frequency Analysis of Assemblies

Image courtesy of National Optical Astronomy

Observatory, operated by the Association of Universities
for Research in Astronomy, under cooperative agreement
with the National Science Foundation.

Lesson 2 Topics

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Remote Mass to represent certain components

Frequency of assembly depends on exact masses of components
Geometry of some components may not be exactly represented in
SW model
Engine Component is modeled as point mass with appropriate
mass and inertia characteristics

Contact-sets for frequency analysis

Bonded or Free

2007 SolidWorks Corp. Confidential.

13

Lesson 2 Topics

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We cannot define No Penetration contact for Frequency

Analysis
Frequency Analysis requires constant mass and stiffness
For No Penetration Contact model, Stiffness depends on deformation
(not constant)
See example below:

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14

Lesson 2 - Results

All Bonded

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Bonded and Free (with pins)

15

Exercise 4: Particle Separator

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16

VAR logo here

Position: Horizontal
5.86 & Vertical .46,
both from top left corner

Lesson 3
Buckling Analysis

Image courtesy of National Optical Astronomy

Observatory, operated by the Association of Universities
for Research in Astronomy, under cooperative agreement
with the National Science Foundation.

Lesson 3 Topics

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A small increase in load causes an abrupt large increase in deformation

Large compressive force
Associated with slender components subjected to axial compressive force
Buckling Load Factor =

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18

Lesson 3 Topics

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Mixed Mesh with Shells, Beams, & Solids

Bonded Contact for Mixed Mesh
Static Study Review Stresses
Buckling Study
Linear vs Nonlinear Buckling

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19

Lesson 3

2007 SolidWorks Corp. Confidential.

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20

Lesson 3 Results

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21

Exercise 5: Stool

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What are the boundary conditions?

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Exercise 5 Results

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Buckling shapes
Buckling modal shape #1

Buckling modal shape #2

Look at the values of the displacements. Why are these values so large?
2007 SolidWorks Corp. Confidential.

23

Exercise 6: Lamp Shade

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Buckling analysis of a lamp shade

Compare the buckling load factors for two configurations

2007 SolidWorks Corp. Confidential.

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VAR logo here

Position: Horizontal
5.86 & Vertical .46,
both from top left corner

Lesson 4
Thermal Analysis

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Observatory, operated by the Association of Universities
for Research in Astronomy, under cooperative agreement
with the National Science Foundation.

Thermal analysis analogy to stress analysis

2007 SolidWorks Corp. Confidential.

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26

Thermal analysis - Conduction

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Heat Flux = - Thermal_Conductivity * Area * Temperature_gradient

Thot

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Tcold

27

Thermal conductivity of materials

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28

Thermal Analysis - Convection

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Heat flux = Convection_coefficient * Area * Difference in Temperature

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Convection coefficient

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30

Thermal Analysis - Radiation

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Thermal energy emitted by bodies in the form of electromagnetic

waves because of their temperature

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31

Types of Radiation Surface to ambient

Stefan-Boltzmann constant

Surfacetemperature

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Ambienttemperature

= 5.67E-8 W/m2K4
Emissivity of the radiating surface (between 0 and 1)
Aluminum (polished) 0.04-0.06
Copper (commercial) 0.07
Steel (polished) 0.52-0.56
Steel (rough) 0.95-0.98
Porcelain 0.92
2007 SolidWorks Corp. Confidential.

32

Types of Radiation Surface to surface

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Radiation heat transfer between two surfaces

also depends on:
shape of faces
relative orientation of faces
distance between the faces
Radiation View Factor The fraction of thermal energy leaving the surface of
object 1 and reaching the surface of object 2, determined entirely from
geometrical considerations. It is the fraction of object 2 visible from the surface
of object 1.
A multiplier to the previous equation that takes above factors into account and
calculated internally by SolidWorks Simulation. It is unitless and ranges
between 0 and 1.
A concave face can radiate to itself; Planar and convex faces do not radiate to
themselves. Such effects are automatically considered.
2007 SolidWorks Corp. Confidential.

33

Lesson 4 Topics

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Microchip generates 25 Watts of heat power

Connectors are insulated
Four studies
STUDY 1: Steady state heat transfer
STUDY 2: Transient thermal analysis
Study how the temperature increases in the first 300 seconds after power is
first turned on

STUDY 3: Transient thermal analysis

Heat-power is increased gradually in the first 30 seconds and then slowly
turned off in the next 30 seconds

STUDY 4: Transient thermal analysis with thermostat

Heat-power is controlled (turned on and off) by a thermostat in order to prevent
the microchip from overheating

2007 SolidWorks Corp. Confidential.

34

Thermal Resistance

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Resistance to heat flow at the junction of two

components - Tiny air gaps will always exist between
the two contacting surfaces due to their roughness

Thermal Resistance depends on:

1. Surface Flatness
2. Roughness of surfaces
3. Contact-force between surfaces
4. Thermal interface material (e.g., thermal
grease, elastomer, adhesive, etc.)

2007 SolidWorks Corp. Confidential.

Typical Thermal resistance values

Dry Joint

2.9 C/W

Thermal grease (0.003 in gap)

0.9 C/W

Elastomer (0.010 in thick)

1.8 C/W

Adhesive (0.009 in thick)

2.7 C/W
35

Lesson 4 Results

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STUDY 1: Steady state thermal analysis

2007 SolidWorks Corp. Confidential.

36

Lesson 4 Results

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STUDY 2: Transient thermal analysis

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Lesson 4 Results

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STUDY 3: Transient thermal analysis after heat-power is turned on and

then turned off

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Thermostat

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Heat-power or flux condition is turned on or off based on the

temperature at the specified vertex
Obtained results will slightly overshoot the target temperature

2007 SolidWorks Corp. Confidential.

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Lesson 4 Results

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STUDY 4: Transient thermal analysis with thermostat

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40

Exercise 7: Cup

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41

VAR logo here

Position: Horizontal
5.86 & Vertical .46,
both from top left corner

Lesson 5
Thermal Analysis with Radiation

Image courtesy of National Optical Astronomy

Observatory, operated by the Association of Universities
for Research in Astronomy, under cooperative agreement
with the National Science Foundation.

Lesson 5 Topics

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Steady state heat transfer including conduction, convection and

radiation
Conductivity of materials applied by materials properties of solids
Convection is applied to the surfaces exposed to the atmosphere
Radiation between the bulb and lamp-surfaces
Bulb generates 100 Watts of heat power

2007 SolidWorks Corp. Confidential.

43

Lesson 5 Results

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Results temperature distribution

Why is the tip at

such a high
temperature?

Notice small effect on the temperature of the reflector.

2007 SolidWorks Corp. Confidential.

44

Lesson 5 Results

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Heat flux distribution

Notice heat flux concentrations near the corners.

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45

VAR logo here

Position: Horizontal
5.86 & Vertical .46,
both from top left corner

Lesson 6
Advanced Thermal Stress Analysis

Image courtesy of National Optical Astronomy

Observatory, operated by the Association of Universities
for Research in Astronomy, under cooperative agreement
with the National Science Foundation.

Lesson 6 Topics

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Study 1 Steady state thermal analysis

Study 2 Static study to get deformation due thermal effects
Microchip generates heat power of 5.26 W
Face of acrylic gasket is kept at 336.5 K
Ambient temperature is 298K

2007 SolidWorks Corp. Confidential.

47

Lesson 6 Results

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Thermal analysis - results

Temperature section view

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Heat fluxes vector plot

48

Lesson 6 Results

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Stress analysis results

Von Mises stresses

2007 SolidWorks Corp. Confidential.

Energy norm error plot

49

Lesson 6 Discussion

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Thermal and Static analysis

had different contact conditions
and therefore different meshes
What is the contact condition
between the gasket and the
housing?
Is this contact valid during the
static analysis?

2007 SolidWorks Corp. Confidential.

50

Exercise 6: Gas Tank

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Thermal analysis and stress analysis of a gas tank

2007 SolidWorks Corp. Confidential.

51

VAR logo here

Position: Horizontal
5.86 & Vertical .46,
both from top left corner

Lesson 7
Fatigue Analysis

Image courtesy of National Optical Astronomy

Observatory, operated by the Association of Universities
for Research in Astronomy, under cooperative agreement
with the National Science Foundation.

Why Consider Fatigue?

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Traditionally designers consider the

ultimate strength of their
components. Design for Strength
But in-service load is rarely static in
nature; there is usually a cyclical
variation.
Designers should use a Design for
Life rather than a Design for
Strength approach.

2007 SolidWorks Corp. Confidential.

53

S-N Curve

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Failure under repeated loading cycles

Maximum stress is smaller than yield strength of material
Material Testing Several test
specimens are subjected to
repeated cyclic loads until
failure.
S-N Curve Plot of number of
cycles (N) to failure for different
stress levels (S)

2007 SolidWorks Corp. Confidential.

54

High Cycle fatigue (HCF); Low Cycle Fatigue (LCF)

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Typically S-N curve is represented on a Log-log scale

Analysis of High Cycle Fatigue (more than 1000 cycles) in
COSMOSWorks
Infinite life
Part 1

Part 2

Part 3

Stress amplitude, Sa (ksi)

Su

Fatigue S-N curve

S103
Sy

Se

2007 SolidWorks Corp. Confidential.

Number of cycles, N

55

Theory of accumulative damage

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Damage Factor For Stress S1,

the life is N1 cycles. Damage
factor for 1 cycle of S1 is 1/N1
Damage factor for L1 cycles of S1
stress is L1/N1
Miners Rule
Failure due to fatigue occurs
when the damage factor reaches
1.0.

2007 SolidWorks Corp. Confidential.

56

Linear Damage Rule

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Miners Rule - Linear damage rule. Assumptions:

Ignores effects of load sequence - Damage caused by a stress cycle
is independent of where it occurs in the load history.
Rate of damage accumulation is independent of the stress level.

The linear damage rule is used in its simple form when you
specify that fatigue events do not interact with each other in
the properties of the study. When you set the interaction
between events to random, the program uses the ASME
code to evaluate the damage by combining event peaks.

2007 SolidWorks Corp. Confidential.

57

Stress definitions
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Pulsating

Fully reversed

m = a R = 0

m = 0, R = -1

Cyclic
m > 0 R > 0

Stress ratio:

min
max

Mean stress:

max min 1

Alternating stress:
2007 SolidWorks Corp. Confidential.

2
max min 1
2

58

Effect of Mean Stress - 1

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Stress amplitude, Sa

Tensile mean stress is

decreases fatigue life
sm> 0

0
sm= 0

sm< 0

Most SN curves are

produced under zero mean
stress

Stress amplitude, logSa

2007 SolidWorks Corp. Confidential.

time

Compressive mean stress

is beneficial or has negligible
effect on the fatigue
durability.

Negative Mean Stress

Zero Mean Stress
Positive Mean Stress
No. of cycles, logN

2*106

59

Types of Loading

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Constant
Amplitude
Loading

Variable
Amplitude
Loading
2007 SolidWorks Corp. Confidential.

60

Fatigue results

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Life plot:

Number of cycles to cause a fatigue failure.

Damage plot:

Amount of life consumed by fatigue events.

Factor of safety:

FOS<1 (structure is damaged), FOS>1 (structure has life left)

Biaxiality indicator:

2007 SolidWorks Corp. Confidential.

Distribution of

1
2

(3 is ignored)

61

Lesson 7 Topics

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One million cycles of pressure load of 6.89 MPa

and heat-flux of 1471 Watt/sq m
First perform thermal study to get temperature
distribution
Next perform static study to get stress
distribution due to temperature difference
Perform another static study to get stress
distribution due to internal pressure of 6.89 MPa
Create a fatigue study that will take as input the
two static studies

2007 SolidWorks Corp. Confidential.

62

Lesson 7 Results

Areas with Damage Factor greater than 1

2007 SolidWorks Corp. Confidential.

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All life has been take up vessel fails

63

Exercise 9: Basketball Rim

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Fatigue analysis of a basketball rim

2007 SolidWorks Corp. Confidential.

64

VAR logo here

Position: Horizontal
5.86 & Vertical .46,
both from top left corner

Lesson 8
Advanced Fatigue Analysis

Image courtesy of National Optical Astronomy

Observatory, operated by the Association of Universities
for Research in Astronomy, under cooperative agreement
with the National Science Foundation.

Lesson 8 Topics

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Vehicle moving at a constant

speed on a banked road
Variable amplitude loading

2007 SolidWorks Corp. Confidential.

66

Modifying Factors
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Several factors have to be taken into account while using the

empirical S-N curve for simulation of real-life model:
Corrosive environment kc
Surface conditions ks
Size factor kl
Mode of loading km
Temperature factor kt
Reliability factor kr
Notch effects kf
Fretting conditions kfret

Fatigue Strength Reduction Factor =kc* ks* kl* km* kt* kr* kf* kfret
2007 SolidWorks Corp. Confidential.

67

Modifying Factors Corrosion conditions

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Long life (typically high cycle) fatigue issue

kc = 0.1 1
(reference value is
fatigue strength in air
environment)

Reproduced from Metal Fatigue in

Engineering by Stephens R.I. et. all,
Copyright @ 2001 John Wiley & Sons, Inc.
This material is reproduced with permission
of John Wiley & Sons, Inc.
2007 SolidWorks Corp. Confidential.

68

Modifying Factors Surface condition

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Due to scratches, pits and machining marks on the surface

Fatigue originates on the surface!

ks = 0.1 - 1

Reproduced from Metal Fatigue in

Engineering by Stephens R.I. et. all,
Copyright @ 2001 John Wiley & Sons, Inc.
This material is reproduced with permission
of John Wiley & Sons, Inc.
2007 SolidWorks Corp. Confidential.

69

Modifying Factors Size effect

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Size of the test specimen is not the same as the real-life model.
Voids and defects in material will increase as size of the model
increases.
For models with circular cross-sections:
Diameter less than 0.3in (8mm)

kl = 1

Diameter between 0.3in (8mm) and

10in (25mm)

kl = 0.869 *(diameter inch)-0.097

(approx. 0.7 0.8)

For non-circular model determine effective diameter by equating

the volume of material stressed at and above 95% of the
maximum stress to the same volume in the rotating-bending
70
specimen.
2007 SolidWorks Corp. Confidential.

Modifying Factors Loading condition

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S - N curves are different for different types of tests.

120

Stress
(ksi)

70

Bending
Axial

50

Torsion

Su ,axial
0.75 0.9
Su , bending
(Su Fatigue limit )

30
10

10

10

10

10

Number of cycles, Log(N)

2007 SolidWorks Corp. Confidential.

71

Modifying Factors High Temperature

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High temperature reduces the material fatigue resistance.

2007 SolidWorks Corp. Confidential.

Reproduced from Metal Fatigue in Engineering by Stephens R.I. et.

all, Copyright @ 2001 John Wiley & Sons, Inc. This material is
reproduced with permission of John Wiley & Sons, Inc.

72

Modifying Factors Low Temperature

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Low temperature increases the material fatigue resistance.

IMPORTANT!
The resistance of the
material against the
growth of the cracks
decreases.
(crucial in Damage
Tolerant Design
methodology)
Not recommended to rely
on this phenomenon!

2007 SolidWorks Corp. Confidential.

Reproduced from Metal Fatigue in Engineering by Stephens R.I. et.

all, Copyright @ 2001 John Wiley & Sons, Inc. This material is
reproduced with permission of John Wiley & Sons, Inc.

73

Modifying Factors Reliability factor

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Account for the scatter in the test-data in S-N curve fitting.

Reliability factor between 0.52 1.00 from handbooks
Desired
probability of
failure P in
engineering is
generally smaller
than 0.01.

2007 SolidWorks Corp. Confidential.

Reproduced from Metal Fatigue in

Engineering by Stephens R.I. et. all,
Copyright @ 2001 John Wiley & Sons, Inc.
This material is reproduced with permission
of John Wiley & Sons, Inc.
74

Modifying Factors Notch effects

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Fatigue notch factor effect kf depends on the stress

concentration factor Kt, geometry (fillet or notch) and material:

K t 1

k f 1
a

r is radius of fillet or notch

a is material constant

300

0.001
Ultimate Strength in psi
2007 SolidWorks Corp. Confidential.

1.8

75

Modifying Factors Fretting

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Relative motion of two connected components (bolted

connections) causes surface debris promoting surface cracks.

Reproduced from Metal Fatigue in Engineering by Stephens R.I. et.

all, Copyright @ 2001 John Wiley & Sons, Inc. This material is
reproduced with permission of John Wiley & Sons, Inc.

Requires experience, reduction in the fatigue strength may

reach up to 90%!
Micro-motion is enough to cause fretting surface cracks.
2007 SolidWorks Corp. Confidential.

76

Lesson 8 Results

2007 SolidWorks Corp. Confidential.

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77

Lesson 8 Results

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Most of the damage is not caused by the highest mean stress

cycles (they do not occur as frequently), but rather it is caused
by the intermediate mean stress cycles.

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78

VAR logo here

Position: Horizontal
5.86 & Vertical .46,
both from top left corner

Lesson 9
Drop Test Analysis

Image courtesy of National Optical Astronomy

Observatory, operated by the Association of Universities
for Research in Astronomy, under cooperative agreement
with the National Science Foundation.

Drop test analysis

VAR logo

Evaluate the effect of the impact of a part or an assembly

with a rigid or flexible planar surface
Calculates impact and gravity loads automatically. No other
loads or restraints are allowed
Equlibrium of forces:
Inertial_forces + Elastic_forces = Gravitational_force + Impact_force
(Damping is ignored)

Dynamic problem forces and displacements are changing

with time
Explicit time integration to solve the problem
2007 SolidWorks Corp. Confidential.

80

Input and results in drop test

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Input:

Drop height or Velocity at impact

Gravity
Orientation
Observation time - For how long after impact should one observe or
capture the solution?
Stiffness of the impacted surface (wall)

Results:
Observe displacements and stresses at various times
Contact force at surface of impact

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81

Lesson 9 Topics

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Goals

Drop test analysis

Analysis Basics
Analysis Setup
Post-processing options for
drop test analysis

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82

Key Results

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Rigid target Von Mises stresses

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83

Key Results

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Rigid target stress time history graph

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84

Key Results

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Soft target Von Mises stresses

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85

Key Results

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Vertex 1 resultant acceleration history

Rigid target

Soft target

Soft target reduces the acceleration peaks.

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86

Key Results
Elastic Material

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Elasto-Plastic
Material

87

Exercise 10: Clip

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Drop test of a clip

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88

VAR logo here

Position: Horizontal
5.86 & Vertical .46,
both from top left corner

Lesson 10
Optimization Analysis

Image courtesy of National Optical Astronomy

Observatory, operated by the Association of Universities
for Research in Astronomy, under cooperative agreement
with the National Science Foundation.

Design optimization

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Find the best design by changing geometry

Objective. Defines the best design. For example, minimum material.
Design Variables. Select the dimensions that can change and set
their ranges. For example, the diameter of a hole can vary from 0.5
to 1.0 while the extrusion of a sketch can vary from 2.0 to 3.0.
Constraints. Set the conditions that the optimum design must satisfy.
For example, stresses should not exceed certain values and the
natural frequency should be in a specified range.

Before creating an optimization study, you should create at

least one study (Static or Frequency or Buckling or Thermal)
that you will use to define the objective function and
constraints.
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90

Design optimization - objective

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The objective defines the goal of the

optimization process
You can specify only one objective in an
optimization study

Minimize volume or mass

For assemblies with different materials, the
optimum design that minimizes volume will be
different from the optimum design that
minimizes mass

Maximize buckling load factor

Maximize or Minimize resonance
frequency
2007 SolidWorks Corp. Confidential.

91

Design optimization design variables

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Design variables are the changeable dimensions of the model.

Any dimension can be defined as a design variable. For each
design variable, you need to specify the lower and upper bounds
as well as a tolerance.

Make sure that design variables do not contradict with any

relations specified in the model

Diameter of hole is increased

2007 SolidWorks Corp. Confidential.

92

Design optimization - constraints

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Constraints - The conditions that the optimized design must

satisfy
A constraint is associated with the initial study
For static studies. Nodal or element stresses, strains, or
displacements
For buckling studies. First through tenth buckling load
factors
For frequency studies. First through tenth resonant
frequencies
For thermal studies. Temperatures, temperature gradients,
or heat fluxes
2007 SolidWorks Corp. Confidential.

93

Lesson 10 Topics

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Find the best design that satisfies the following conditions:

Maximum stress is less than 100 MPa
Maximum deformation is less than 1mm
Smallest natural frequency is more than 80 Hz
Design variables are:
Height of side plate (vary between 50mm to 100mm)
Cut-out of legs (Vary between 100mm to 250mm)
Length of back-plate (Vary between 150mm to 375mm)

2007 SolidWorks Corp. Confidential.

94

Lesson 10 Basics

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Optimization procedure

Step 1.
Define the
objective
Step 2.
Specify the design
variables
Step 3.
Specify the
constrains

2007 SolidWorks Corp. Confidential.

95

Key Results

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Optimization procedure Design results

Before Optimization
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After Optimization

96

Key Results

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Optimized Design Results

Von Mises stresses

VM .max 99.1MPa VM .Opt . Limit 100MPa

Resultant Displacements

uRe s.Max 0.52mm 1.00 mm

Fundamental frequency

80 Hz 1.Max 81.35 Hz 150 Hz

Mass is minimized, all constrains have been satisfied

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97

Key Results

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How did our objective converge?

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98

Exercise 11: Cantilever Bracket

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Optimization of a cantilever bracket

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99

VAR logo here

Position: Horizontal
5.86 & Vertical .46,
both from top left corner

Lesson 11
Pressure Vessel Analysis

Image courtesy of National Optical Astronomy

Observatory, operated by the Association of Universities
for Research in Astronomy, under cooperative agreement
with the National Science Foundation.

Lesson 11 Topics

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Pressure Vessel Design study Combines the results of the

static studies
Dead loads, Live loads (approximated by static loads), Thermal loads,
Seismic loads

Stress Intensity = P1 P3
P1 = First Principal Stress
P3 = Third Principal Stress

Stress Linearization ASME Boiler and Pressure Vessel

Code (Section VII, Division 2, Appendix 4)
Load-case Combinations Linear combination or SRSS
(Sum Root Sum of Squares)

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101

Limitations

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User to ensure same materials are used for all the studies
Cannot get a REPORT from Pressure Vessel Study

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102

Lesson 11 Results

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103

Lesson 12 Results

2007 SolidWorks Corp. Confidential.

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104