SOLIDWORKS SOLIDWORKS Simulation. Dassault Systèmes SolidWorks Corporation 175 Wyman Street Waltham, MA U.S.A.

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1 SOLIDWORKS 2015 SOLIDWORKS Simulation Dassault Systèmes SolidWorks Corporation 175 Wyman Street Waltham, MA U.S.A.

2 , Dassault Systèmes SolidWorks Corporation, a Dassault Systèmes S.A. company, 175 Wyman Street, Waltham, Mass USA. All Rights Reserved. The information and the software discussed in this document are subject to change without notice and are not commitments by Dassault Systèmes SolidWorks Corporation (DS SolidWorks). No material may be reproduced or transmitted in any form or by any means, electronically or manually, for any purpose without the express written permission of DS SolidWorks. The software discussed in this document is furnished under a license and may be used or copied only in accordance with the terms of the license. All warranties given by DS SolidWorks as to the software and documentation are set forth in the license agreement, and nothing stated in, or implied by, this document or its contents shall be considered or deemed a modification or amendment of any terms, including warranties, in the license agreement. Patent Notices SolidWorks 3D mechanical CAD software is protected by U.S. Patents 5,815,154; 6,219,049; 6,219,055; 6,611,725; 6,844,877; 6,898,560; 6,906,712; 7,079,990; 7,477,262; 7,558,705; 7,571,079; 7,590,497; 7,643,027; 7,672,822; 7,688,318; 7,694,238; 7,853,940; 8,305,376; 8,581,902, and foreign patents, (e.g., EP 1,116,190 B1 and JP 3,517,643). edrawings software is protected by U.S. Patent 7,184,044; U.S. Patent 7,502,027; and Canadian Patent 2,318,706. U.S. and foreign patents pending. Trademarks and Product Names for SolidWorks Products and Services SolidWorks, 3D ContentCentral, 3D PartStream.NET, edrawings, and the edrawings logo are registered trademarks and FeatureManager is a jointly owned registered trademark of DS SolidWorks. CircuitWorks, FloXpress, PhotoView 360, and TolAnalyst, are trademarks of DS SolidWorks. FeatureWorks is a registered trademark of Geometric Ltd. SolidWorks 2014, SolidWorks Enterprise PDM, SolidWorks Workgroup PDM, SolidWorks Simulation, SolidWorks Flow Simulation, edrawings, edrawings Professional, SolidWorks Sustainability, SolidWorks Plastics, SolidWorks Electrical, and SolidWorks Composer are product names of DS SolidWorks. Other brand or product names are trademarks or registered trademarks of their respective holders. COMMERCIAL COMPUTER SOFTWARE - PROPRIETARY The Software is a "commercial item" as that term is defined at 48 C.F.R (OCT 1995), consisting of "commercial computer software" and "commercial software documentation" as such terms are used in 48 C.F.R (SEPT 1995) and is provided to the U.S. Government (a) for acquisition by or on behalf of civilian agencies, consistent with the policy set forth in 48 C.F.R ; or (b) for acquisition by or on behalf of units of the department of Defense, consistent with the policies set forth in 48 C.F.R (JUN 1995) and (JUN 1995). In the event that you receive a request from any agency of the U.S. government to provide Software with rights beyond those set forth above, you will notify DS SolidWorks of the scope of the request and DS SolidWorks will have five (5) business days to, in its sole discretion, accept or reject such request. Contractor/ Manufacturer: Dassault Systèmes SolidWorks Corporation, 175 Wyman Street, Waltham, Massachusetts USA. Copyright Notices for SolidWorks Standard, Premium, Professional, and Education Products Portions of this software Siemens Product Lifecycle Management Software Inc. All rights reserved. This work contains the following software owned by Siemens Industry Software Limited: D-Cubed 2D DCM Siemens Industry Software Limited. All Rights Reserved. D-Cubed 3D DCM Siemens Industry Software Limited. All Rights Reserved. D-Cubed PGM Siemens Industry Software Limited. All Rights Reserved. D-Cubed CDM Siemens Industry Software Limited. All Rights Reserved. D-Cubed AEM Siemens Industry Software Limited. All Rights Reserved. Portions of this software Geometric Ltd. Portions of this software incorporate PhysX by NVIDIA Portions of this software Luxology, LLC. All rights reserved, patents pending. Portions of this software DriveWorks Ltd. Copyright Adobe Systems Inc. and its licensors. All rights reserved. Protected by U.S. Patents 5,929,866; 5,943,063; 6,289,364; 6,563,502; 6,639,593; 6,754,382; Patents Pending. Adobe, the Adobe logo, Acrobat, the Adobe PDF logo, Distiller and Reader are registered trademarks or trademarks of Adobe Systems Inc. in the U.S. and other countries. For more DS SolidWorks copyright information, see Help > About SolidWorks. Copyright Notices for SolidWorks Simulation Products Portions of this software 2008 Solversoft Corporation. PCGLSS Computational Applications and System Integration, Inc. All rights reserved. Copyright Notices for SolidWorks Enterprise PDM Product Outside In Viewer Technology, Oracle 2011, Microsoft Corporation. All rights reserved. Copyright Notices for edrawings Products Portions of this software Tech Soft 3D. Portions of this software Jean-Loup Gailly and Mark Adler. Portions of this software Dconnexion. Portions of this software Open Design Alliance. All rights reserved. Portions of this software Spatial Corporation. The edrawings for Windows software is based in part on the work of the Independent JPEG Group. Portions of edrawings for ipad copyright Silicon Graphics Systems, Inc. Portions of edrawings for ipad copyright Apple Computer Inc. Document Number: PMT1540-ENG

3 Contents Introduction About This Course Prerequisites Course Design Philosophy Using this Book Laboratory Exercises About the Training Files Windows Conventions Used in this Book Use of Color Color Schemes What is SOLIDWORKS Simulation? What Is Finite Element Analysis? Build Mathematical Model Defeaturing Idealization Clean-up Build Finite Element Model Solve Finite Element Model Analyze Results Errors in FEA i

4 Contents SOLIDWORKS 2015 Finite Elements Element Types Available in SOLIDWORKS Simulation First Order Solid Tetrahedral Elements Second Order Solid Tetrahedral Elements First Order Triangular Shell Elements Second Order Triangular Shell Elements Beam Elements Choosing Between Solid and Shell Elements Draft vs. High Solid and Shell Elements Degrees of Freedom Calculations in FEA Interpretation of FEA Results Principal Stresses: P1, P2, and P Units of Measurement Limitations of SOLIDWORKS Simulation Linear Material Small Structural Deformations Static Loads Summary Lesson 1: The Analysis Process Objectives The Analysis Process Stages in the Process Case Study: Stress in a Plate Project Description SOLIDWORKS Simulation Interface SOLIDWORKS Simulation Options Plot Settings Preprocessing New Study Assigning Material Properties Fixtures Fixture Types Display/Hide Symbols External Loads Size and Color of Symbols Preprocessing Summary Meshing Curvature Based Mesh Mesh Density Element Sizes Minimum Number of Elements in a Circle Ratio Mesh Quality ii

5 SOLIDWORKS 2015 Contents Postprocessing Result Plots Editing Plots Nodal vs. Element Stresses Show as Tensor Plot Option Modifying Result Plots Other Plot Controls Other Plots Multiple Studies Creating New Studies Copy Parameters Check Convergence and Accuracy Results Summary Comparison With Analytical Results Reports Summary References Questions Exercise 1: Bracket Exercise 2: Compressive Spring Stiffness Exercise 3: Container Handle Lesson 2: Mesh Controls, Stress Concentrations and Boundary Conditions Objectives Mesh Control Case Study: The L Bracket Project Description Stages in the Process Run This Study Analysis with Local Mesh Refinement Mesh Controls Results Results Comparison Stress Singularities Case Study: Analysis of Bracket with a Fillet Case Study: Analysis of a Welded Bracket Understanding the Effect of Boundary Conditions Conclusion Summary Questions Exercise 4: C-bracket Exercise 5: Bone Wrench iii

6 Contents SOLIDWORKS 2015 Lesson 3: Assembly Analysis with Contacts Objectives Contact Analysis Case Study: Pliers with Global Contact Project Description Stages in the Process Applying Materials to Assemblies Component Contact Component Contact: 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 Self-Contact No Penetration Local Contact Properties No Penetration Local Contact: Accuracy No Penetration Local Contact: Remarks Contact Stresses Summary Questions Exercise 6: Two Ring Assembly Lesson 4: Symmetrical and Free Self-Equilibrated 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 iv

7 SOLIDWORKS 2015 Contents Analysis with Soft Springs Soft Springs Inertial Relief Summary Exercise 7: Chain Link Exercise 8: Chain Link Lesson 5: Assembly Analysis with Connectors and Mesh Refinement Objectives Connecting Components Connectors Connector Types Mesh Control in an Assembly Case Study: Cardan Joint Problem Statement Part 1: Draft Quality Coarse Mesh Analysis Remote Load Automatic Conversion of Toolbox Fasteners to Bolts Bolt Tight fit and Diameter Bolt Strength Data Bolt Pre-load Contact Visualization Plot Local Contact Sets Rotational and Axial Stiffness Virtual Wall, Axial and Tangential Stiffness Part 2: High Quality Mesh Analysis Required Number of Solid Elements in Thin Features Aspect Ratio Plot Jacobian Summary Questions Exercise 9: Vise Grip Pliers Spring Connector Types Spring Connector Options Pin/Bolt Force Exercise 10: Lift Assembly Exercise 11: Analysis with Base (optional) Exercise 12: Spot Welds-Solid Mesh Exercise 13: Bolt Connectors Exercise 14: Awning v

8 Contents SOLIDWORKS 2015 Lesson 6: Compatible/Incompatible Meshes Objectives Compatible / Incompatible Meshing Case Study: Rotor Project Description Compatible Mesh Incompatible Mesh Automatic Switch to Incompatible Mesh Incompatible Bonding Options Discussion Summary Lesson 7: Analysis of Thin 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-alignment Render shell thickness in 3D Applying Symmetry Restraints Deformed Results Results Comparison Computational Effort Case Study: Joist Hanger Project Description Summary Questions Exercise 15: Bracket Exercise 16: Shell Mesh Using Outer/Inner Faces Exercise 17: Edge Weld Connector Exercise 18: Container Handle Weld vi

9 SOLIDWORKS 2015 Contents Lesson 8: Mixed Meshing Shells & Solids Objectives Mixed Meshing Solids and Shells Bonding Shells and Solids Mixed Mesh: Supported Analysis Types Case Study: Pressure Vessel Project Description Analyze the Assembly Preparing the Model Material Steel Identification Systems UNS Index Other Indices Bulk and Shear Moduli Bonding Entities with Clearance Shell Face to Shell Face Bonding Shell Edge to Shell Face Bonding Shell to Solid Bonded Contact Failure Diagnostics Meshing Small Features Incremental Meshing Summary Questions Exercise 19: Mixed Mesh Analysis Lesson 9: Beam Elements- Analysis of a Conveyor Frame Objectives Project Description Element Choices Beam Elements Truss Elements Stages in the Process Slenderness Ratio Section Properties Connected and Disconnected Joints Sphere Diameter Defining Beam Joint Beam Joints: Locations Beam Joint Types Render Beam Profile Beam Stress components Cross-section 1st and 2nd Directions Bending Moment and Shear Force Diagrams Summary Questions vii

10 Contents SOLIDWORKS 2015 Lesson 10: Mixed Meshing Solids, Beams & Shells Objectives Mixed Meshing Case Study: Particle Separator Project Description Stages in the Process Beam Mesh Beam Imprint Summary Exercise 20: Cabinet Exercise 21: Frame Rigidity Lesson 11: Design Study Objectives Design Study Case Study: Suspension Design Project Description Stages in the Process Part 1: Multiple Load Cases Design Studies Parameters Design Study Results Design Study Options Part 2: Geometry Modification Design Study Graph Summary Exercise 22: Design Study Lesson 12: Thermal Stress Analysis Objectives Thermal Stress Analysis Case Study: Bimetallic Strip Project Description Material Properties Importing Temperatures Averaging Stress Question Examining Results in Local Coordinate Systems (Optional) Saving Model in its Deformed Shape Summary viii

11 SOLIDWORKS 2015 Contents Lesson 13: Adaptive Meshing Objectives Adaptive Meshing Case Study: Support Bracket Project Description Geometry Preparation h-adaptivity Study h-adaptivity Options h-adaptive Plots Convergence Graph Review h-adaptive Solution Strain Energy Error is NOT Stress Error p-adaptivity Study p-adaptive Solution Method h vs. p Elements Method Comparison h vs. p Elements - Summary Which Solution Method is Better? Summary Lesson 14: Large Displacement Analysis Objectives Small vs. Large Displacement Analysis Case Study: Clamp Project Description Part 1: Small Displacement Linear Analysis Results Discussion Contact Solution in Small and Large Displacement Analyses Part 2: Large Displacement Nonlinear Analysis Permanent Deformation SOLIDWORKS Simulation Premium Summary Questions ix

12 Contents SOLIDWORKS 2015 Appendix A: Meshing, Solvers, and Tips & Tricks Meshing Strategies Geometry Preparation Defeaturing Idealization Clean-up Mesh Quality Aspect Ratio Check Jacobian Check Mesh Controls Automatic Trials for Solids Meshing Stages Failure Diagnostics Tips for Meshing Parts Tips for Meshing Assemblies Tips for Using Shell Elements Hardware Considerations in Meshing Solvers in SOLIDWORKS Simulation Choosing a Solver Appendix B: Customer Help and Assistance Customer Help and Assistance x