2018 - SW Simulation - Prof
2018 - SW Simulation - Prof
2018 - SW Simulation - Prof
Simulation Professional
ENG
www.sysprice.com.br
SOLIDWORKS
SOLIDWORKS Simulation
Professional
Introduction
About This Course . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Course Design Philosophy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Using this Book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Laboratory Exercises . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
About the Training Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Windows 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
User Interface Appearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Conventions Used in this Book . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Use of Color . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
More SOLIDWORKS Training Resources. . . . . . . . . . . . . . . . . . . . . . 4
Local User Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
What is SOLIDWORKS Simulation?. . . . . . . . . . . . . . . . . . . . . . . . . . 5
Limitations of SOLIDWORKS Simulation Professional . . . . . . . . . . . 6
Lesson 1:
Frequency Analysis of Parts
Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Modal Analysis Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Required Material Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Frequencies and Mode Shapes . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Fundamental Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Case Study: The Tuning Fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Project Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Stages in the Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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Manufacturing Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Add Preserved Region . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Specified Thickness Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Specify De-mold Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Specify Symmetry Planes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Mesh Effects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Load Cases in Topology Studies. . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Export Smoothed Mesh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Exercise 7: Topology Analysis of a Stool . . . . . . . . . . . . . . . . . . . . 107
Lesson 7:
Thermal Analysis
Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Thermal Analysis Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Mechanisms of Heat Transfer. . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Conduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Convection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Radiation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Material Properties for Thermal Analysis . . . . . . . . . . . . . . . . . 115
Case Study: Microchip Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Project Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Stages in the Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Steady-State Thermal Analysis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Interfacial Conductance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Initial Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Thermal Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Heat Flux. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Heat Flux Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Heat Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Transient Thermal Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Importing Convective Effect from
SOLIDWORKS Flow Simulation . . . . . . . . . . . . . . . . . . . . . . . 126
Transient Data Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Results Comparison . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Transient Analysis with Time Varying Load . . . . . . . . . . . . . . . . . . 129
Time Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Temperature Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Transient Thermal Analysis using a Thermostat . . . . . . . . . . . . . . . 131
Symmetry Boundary Condition in Thermal Analysis . . . . . . . . 134
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Exercise 8: Thermal Analysis of a Cup . . . . . . . . . . . . . . . . . . . . . . 135
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
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Lesson 8:
Thermal Analysis with Radiation
Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Case Study: Spot Light Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Project Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Stages in the Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Steady State Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Review of Analysis Parameters . . . . . . . . . . . . . . . . . . . . . . . . . 146
Heat Flux Singularities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Lesson 9:
Advanced Thermal Stress2D Simplification
Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Thermal Stress Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Case Study: Metal Expansion Joint . . . . . . . . . . . . . . . . . . . . . . . . . 152
Project Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Stages in the Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Thermal Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
2D Simplification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Prescribed Temperature Condition . . . . . . . . . . . . . . . . . . . . . . . 158
Meshing Considerations in Thermal Analysis . . . . . . . . . . . . . . 158
Thermal Stress Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Importing Temperatures and Pressures from
SOLIDWORKS Flow Simulation . . . . . . . . . . . . . . . . . . . . . . . 162
Reference Temperature at Zero Strains . . . . . . . . . . . . . . . . . . . 162
3D model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Exercise 9: Thermal Stress Analysis of a
Microchip Testing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Thermal Stress Study . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Change in Thermal Boundary Conditions . . . . . . . . . . . . . . . . . 175
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Exercise 10: Thermal Stress Analysis of a Gas Tank . . . . . . . . . . . . 178
Exercise 11: Thermal Stress Analysis of a
Thermoelectric Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Problem Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Loading Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Goal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
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Lesson 10:
Fatigue Analysis
Objective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Fatigue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
Stages of Failure due to Fatigue . . . . . . . . . . . . . . . . . . . . . . . . . 188
High vs. Low Cycle Fatigue . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Stress-life (S-N) Based Fatigue . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Fatigue Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Case Study: Pressure Vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Project Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Stages in the Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Thermal Study. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
Thermal Stress Study . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
Static Pressure Study . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Fatigue Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
S-N Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Fatigue Study . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Derive from Material Elastic Modulus . . . . . . . . . . . . . . . . . . . . 203
Constant Amplitude Events Interaction . . . . . . . . . . . . . . . . . . . 203
Alternating Stress Computation . . . . . . . . . . . . . . . . . . . . . . . . . 203
Mean Stress Correction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Fatigue Strength Reduction Factor . . . . . . . . . . . . . . . . . . . . . . . 206
Damage Factor Plot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Damage Result Discussion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Fatigue Study with Dead Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Dead Loads in Fatigue Analysis . . . . . . . . . . . . . . . . . . . . . . . . . 209
Bolts in Fatigue Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Find Cycle Peaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Exercise 12: Fatigue Analysis of a Basketball Rim . . . . . . . . . . . . . 214
Exercise 13: Fatigue of Trailer Hitch . . . . . . . . . . . . . . . . . . . . . . . . 220
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Lesson 11:
Variable Amplitude Fatigue
Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
Case Study: Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
Project Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
Stages in the Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
Discussion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
Fatigue Study . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
Variable Amplitude Fatigue Event . . . . . . . . . . . . . . . . . . . . . . . 227
Rainflow Cycle Counting Method . . . . . . . . . . . . . . . . . . . . . . . 227
Variable Loading Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Bins for Rainflow Counting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
Noise in Random Loading History . . . . . . . . . . . . . . . . . . . . . . . 233
Fatigue Strength Reduction Factor . . . . . . . . . . . . . . . . . . . . . . . 233
Rainflow Matrix Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
Results. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
Fatigue Literature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Lesson 12:
Drop Test Analysis
Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
Drop Test Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
Case Study: Camera . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
Project Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
Stages in the Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
Rigid Floor Drop Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
Drop Test Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
Dynamic Analysis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
Damping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
Solution Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
Graphing Results. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
Linear vs. Nonlinear Solution . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
Elastic Floor, Elasto-Plastic Material . . . . . . . . . . . . . . . . . . . . . . . . 250
Elasto-Plastic Material Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
Elasto-Plastic Model Parameters . . . . . . . . . . . . . . . . . . . . . . . . 253
Processing Elasto-Plastic Results . . . . . . . . . . . . . . . . . . . . . . . . 254
Discussion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
Drop Test with Contact (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . 255
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
Exercise 14: Drop Test of a Clip . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
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Lesson 13:
Optimization Analysis
Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
Optimization Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
Case Study: Press Frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
Project Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
Design Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
Stages in the Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
Static and Frequency Analyses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
Optimization Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
Design Study. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
Optimization Goal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
Design Variable Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
Define Constraints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
Constraint Tolerance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
Constraint Definition Procedure . . . . . . . . . . . . . . . . . . . . . . . . . 271
Postprocessing Optimization Results . . . . . . . . . . . . . . . . . . . . . 272
Local Trend Graphs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
Exercise 15: Optimization Analysis of a Cantilever Bracket . . . . . . 277
Exercise 16: Optimization of Heat Sink . . . . . . . . . . . . . . . . . . . . . . 280
Lesson 14:
Pressure Vessel Analysis
Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
Case Study: Pressure Vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
Project Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
Stages in the Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
Stress Intensity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
Membrane and Bending Stresses (stress linearization) . . . . . . . 284
Basic Stress Intensity Limits. . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
Pressure Vessel Analysis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
Load Case Combinations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
General Primary Membrane Stress Intensity . . . . . . . . . . . . . . . 287
Manhole Nozzle Flange and Cover . . . . . . . . . . . . . . . . . . . . . . . . . 288
Stress Linearization. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
viii
Introduction
1
Introduction SOLIDWORKS
2
SOLIDWORKS Introduction
About the A complete set of the various files used throughout this course can be
Training Files downloaded from the SOLIDWORKS website, www.solidworks.com.
Click on the link for Support, then Training, then Training Files, then
SOLIDWORKS Simulation Training Files. Select the link for the
desired file set. There may be more than one version of each file set
available.
Direct URL:
www.solidworks.com/trainingfilessimulation
The files are supplied in signed, self-extracting executable packages.
The files are organized by lesson number. The Case Study folder
within each lesson contains the files your instructor uses while
presenting the lessons. The Exercises folder contains any files that are
required for doing the laboratory exercises.
Windows The screen shots in this manual were made using the SOLIDWORKS
software running a mixture of Windows® 7 and Windows 10. You may
notice slight differences in the appearance of the menus and windows.
These differences do not affect the performance of the software.
User Interface Throughout the development of the software, there have been some
Appearance cosmetic User Interface changes, intended to improve visibility, that do
not affect the function of the software. As a policy, dialog images in the
manuals which exhibit no functional change from the previous version
are not replaced. As such, you may see a mixture of current and “old”
UI dialogs and color schemes.
Conventions Used This manual uses the following typographic conventions:
in this Book
Convention Meaning
Bold Sans Serif SOLIDWORKS Simulation commands and
options appear in this style. For example,
External Loads Advisor > Force means
click the External Loads Advisor icon on the
Simulation tab of the CommandManager.
Typewriter Feature names and file names appear in this
style. For example, Fixed Geometry-1.
Double lines precede and follow sections of
17 Do this step the procedures. This provides separation
between the steps of the procedure and large
blocks of explanatory text. The steps
themselves are numbered in sans serif bold.
3
Introduction SOLIDWORKS
4
SOLIDWORKS Introduction
5
Introduction SOLIDWORKS
6
Lesson 1
Frequency Analysis of Parts
Objectives Upon successful completion of this lesson, you will be able to:
Perform a frequency analysis with and without supports.
Investigate rigid body modes.
Discuss the role of supports in a frequency analysis.
Perform a frequency analysis with a prestress condition.
Use design scenarios to conduct design sensitivity studies
(optional).
7
Lesson 1 SOLIDWORKS
Frequency Analysis of Parts
Modal Analysis Every structure has its preferred frequencies of vibration called
Basics resonant frequencies. Each such frequency is characterized by a
specific shape of vibration.
When excited with a resonant frequency, a structure vibrates in a shape.
This is called a mode of vibration.
Recall that structural static analysis calculates nodal displacements as
the primary unknowns: [K]d = F where [K] is known as the stiffness
matrix, d is the unknown vector of nodal displacements, and F is the
known vector of nodal loads.
In dynamic analysis, we additionally consider damping [C] and
mass [M].
·· ·
M d + C d + K d = Ft
8
SOLIDWORKS Lesson 1
Frequency Analysis of Parts
For example, the figure below shows the natural modes (shapes) of
vibration for an unsupported plate with a hole model, used in Lesson 1
of the SOLIDWORKS Simulation training manual. Each mode
corresponds to a specific natural frequency.
UNSUPPORTED PLATE
MODE 1 MODE 2
MODE 3 MODE 4
MODE 5 MODE 6
9
Lesson 1 SOLIDWORKS
Frequency Analysis of Parts
Required Material The following material properties are required in a frequency analysis:
Properties
Modulus of elasticity (also called Young’s modulus)
Poisson’s ratio
Mass density
10
SOLIDWORKS Lesson 1
Frequency Analysis of Parts
Case Study: In this case study, we will determine natural frequencies and
The Tuning Fork corresponding mode shapes of a tuning fork. This model introduces the
concept of rigid body modes and presents their corresponding
frequencies.
The model is first run with a fixed boundary condition simulating the
fork being held by a human hand. We will also solve the model using
no boundary conditions to see how the results are affected. We will then
learn how to properly interpret the results of a frequency analysis.
In addition, when an applied load exists, the stiffness of the model can
change (called stress stiffening or softening). This additional stiffness is
known as the stress stiffness and can either add or subtract from the
overall elastic stiffness of the model. To investigate this, a load will be
applied to the end of the fork, and its effects will be investigated.
Project A tuning fork, shown in the figure, is
Description designed to emit a lower A tone at the
fundamental frequency of 440 Hz.
First, perform a frequency analysis to
confirm that the tuning fork vibrates at
the correct frequency.
In addition, determine the effects on
the resonant frequency when a load of
450 N is applied to the end of the fork.
Will the frequency be higher or lower?
Stages in the Some key stages in the analysis of this part are shown in the following
Process list:
Apply Fixtures
The end of the tuning fork will be fixed, attempting to simulate
being held in a person’s hand.
Mesh the model
Postprocess Results
The results of the initial analysis will be post-processed to properly
investigate their meaning.
No Fixed Geometry
The fixture will be removed to reveal additional modes of vibration.
Effects of Applied Load
A load will be applied to the tuning fork to see how an applied
prestress condition affects the modes of vibration.
11
Lesson 1 SOLIDWORKS
Frequency Analysis of Parts
Frequency In the first part of this case study, we will examine the tuning fork with
Analysis With a Fixed Geometry boundary condition to see if the fundamental
Supports frequency is indeed 440 Hz (lower A tone).
12
SOLIDWORKS Lesson 1
Frequency Analysis of Parts
5 Define a fixture.
Apply a Fixed Geometry fixture to the face of the
ball at the end of the stem.
6 Mesh the model.
Mesh the model with High quality elements and
the default Maximum element size of 1.475 mm.
Use Curvature mesh.
Generally, a less refined mesh is acceptable for a frequency analysis as
compared to the mesh required for a stress analysis on the same model.
Nevertheless, since the model size is small, we use the mesh that is
created with the default element size.
7 Run the analysis.
The List Modes window opens and displays the frequencies of all four
modes calculated in the study with supports. Notice that the first
mode is not 440 Hz as we expected.
13
Lesson 1 SOLIDWORKS
Frequency Analysis of Parts
Animate the plot and observe that in the first natural frequency, both
arms of the fork oscillate in phase (both arms in the same direction) and
in the xz-plane. This is not how we expect the arms to oscillate when
the fork emits a lower A sound. Therefore, we will investigate higher
modes.
14
SOLIDWORKS Lesson 1
Frequency Analysis of Parts
MODE 1 MODE 2
229 Hz 232 Hz
MODE 3 MODE 4
423 Hz 444 Hz
15
Lesson 1 SOLIDWORKS
Frequency Analysis of Parts
16
SOLIDWORKS Lesson 1
Frequency Analysis of Parts
Frequency Looking at the first three modes of this analysis, it is revealed that if the
Analysis tuning fork was unsupported, these mode shapes would not occur.
Without Furthermore, the human hands are simply incapable of creating a
Supports completely rigid support as in the model. Let us try modeling the fork
without the rigid support.
17
Lesson 1 SOLIDWORKS
Frequency Analysis of Parts
Rigid Body Modes Examining the List Modes window for the without supports study
reveals that the first six modes have the associated frequency of 0 Hz
(or very close to 0 Hz). The first six modes of vibration correspond to
the rigid body modes. Because the tuning fork is not supported, it has
six degrees-of-freedom as a rigid body: three translations and three
rotations.
Fundamental The first elastic mode of vibration where the tuning fork experiences
Frequency elastic deformation is Mode 7. Mode 7 has a frequency of 444 Hz, very
close to what we expected as the fundamental mode of vibration for the
tuning fork.
Effect of Why didn’t the frequency analysis with supports produce the first
Restraints mode with a frequency close to the operating frequency of 440 Hz?
If we closely examine the first three modes of vibration of the
supported tuning fork, we notice that the first three modes need the
support in order to exist. Without it, the tuning fork cannot vibrate in
any of these three modes.
Because human fingers cannot generate a rigid support used in this first
study, none of the first three modes are likely to occur. If any signs of
these three modes do occur, they are quickly damped by the flexible
support of the human “grip”.
In effect, the tuning fork, with or without supports, ends up vibrating
the way it was designed to, with a frequency of 440 Hz: mode 4 as
calculated in the analysis with supports, or mode 7 as calculated in the
analysis without supports. These two modes are identical.
Frequency We now continue with a frequency analysis that accounts for stress
Analysis with stiffening. This type of analysis is called a frequency analysis with
Load preload or frequency analysis with prestress.
Compressive and tensile loads change the capacity of a structure to
resist bending. Tensile forces increase bending stiffness; this
phenomenon is called stress stiffening. Compressive loads decrease
resistance to bending; this phenomenon is called stress softening.
Stress stiffening or softening can be important both in static and
frequency analyses because it affects the resultant stiffness of a
structure and therefore changes its vibration properties and its response
to a load.
In a static analysis, an accurate solution that considers the effect of
loads on the stiffness requires nonlinear analysis.
Important! When running a frequency study with an applied load, the model must
be supported in some way in the direction of the load. Turning on the
soft-springs option is not sufficient. Without a support, a singular
stiffness matrix will be produced and the model will not run.
18
SOLIDWORKS Lesson 1
Frequency Analysis of Parts
Effects of The effect of the change in stiffness due to the applied load will only
Prestress change the magnitude of the natural frequencies. The mode shapes are
governed by the actual geometry of the model and will not change with
an applied prestress.
We can generalize our findings by noting that compressive stresses will
decrease the natural frequencies. For example, the analysis of the
natural frequencies of a compressed column demonstrate that natural
frequencies decrease with an increased load. Note that a load
magnitude corresponding to a zero frequency will cause buckling.
Tensile stresses have the opposite effect. For example, when tuning a
guitar string, the tension in the string is increased to produce a higher
frequency, which corresponds to a higher note.
19
Lesson 1 SOLIDWORKS
Frequency Analysis of Parts
Summary Using the model of a tuning fork, we can see how SOLIDWORKS
Simulation can be used to calculate natural frequencies and mode
shapes of a structure.
The frequency analysis with and without supports allows us to
investigate rigid body modes where the structure can displace without
experiencing elastic deformation.
A very important point to remember is that while a frequency analysis
provides important information about the vibration properties of a
structure, it does not, by itself, calculate vibration amplitudes or
stresses.
We demonstrated the effect of stress softening on the natural
frequencies of the tuning fork due to a compressive force. Stress
softening and stiffening effects are automatically taken into account if
there is a load present. These effects are very common in rotating parts
such as turbines, motor rotors, and wind turbines, however any loading
condition that results in a prestress must be taken into account to
properly perform a frequency analysis.
20
SOLIDWORKS Exercise 1
Frequency Analysis of a Car Suspension Bulkhead
21
Exercise 1 SOLIDWORKS
Frequency Analysis of a Car Suspension Bulkhead
22
SOLIDWORKS Exercise 1
Frequency Analysis of a Car Suspension Bulkhead
23
Exercise 2 SOLIDWORKS
Frequency Analysis of a Blower Fan
Exercise 2: In this exercise, you will perform a frequency analysis on a blower fan
Frequency both with and without a centrifugal load.
Analysis of a This exercise reinforces the following skills:
Blower Fan Frequency Analysis with Load on page 18
Postprocessing Frequency Results on page 15
Design Scenarios from SOLIDWORKS Simulation manual
Axis of
Rotation
24
SOLIDWORKS Exercise 2
Frequency Analysis of a Blower Fan
Part 2: Analysis Now, we will perform the analysis with an applied centrifugal load to
With Load simulate the blade spinning about the axis of rotation. Follow the
procedure below:
10 Create new study.
Copy Study section into a new study named section preload.
25
Exercise 2 SOLIDWORKS
Frequency Analysis of a Blower Fan
Note The FFEPlus solver cannot be used while including the effects of
loading in frequency analysis.
13 List the natural frequencies.
Prestress has the biggest effect on the first frequency, also called the
fundamental or natural frequency. It has increased from 75 Hz to
95 Hz. The other four frequencies have increased as well.
With Prestress
The results show that the natural frequencies of the turbine blade differ
significantly if a centrifugal load causing tensile stresses is considered
in analysis.
26
SOLIDWORKS Exercise 2
Frequency Analysis of a Blower Fan
The result of the design study lists frequencies of all five modes for the
five scenarios.
27
Exercise 2 SOLIDWORKS
Frequency Analysis of a Blower Fan
Note A design scenario can be run for other parameters. You are encouraged
to use the design scenario feature to investigate the effect of element
size on natural frequencies, or in other words, to perform a convergence
analysis of frequencies. The natural frequencies decrease with mesh
refinement as the model becomes softer when smaller elements are
used. Therefore, natural frequencies converge “from above”. In this
case, those effects are very small and have almost no practical
importance, but are useful to investigate as a learning tool.
Summary In this exercise we extracted natural frequencies of a cooling fan blade.
In the first part we assumed stationary fan. As the fan begins to rotate,
centrifugal load results in stress stiffening and subsequent increase in
the natural frequencies of the blade. This was subject of the second part
of this exercise. The last section utilized the design study to establish
the variation of the natural frequencies on the speed of rotation.
At the fan velocity of 3000 rpm (50 Hz), the first natural frequency of
the blade is close to 96 Hz. This represents nearly double of the fan
velocity and the resonance due to some imperfection or unbalance is
therefore unlikely. Because at higher speeds the fan rpm surpasses the
lower natural frequencies of the blades, resonance may develop. This
frequency interval therefore may warrant more attention.
28
SOLIDWORKS Exercise 3
Frequency Analysis of an Impeller
5 Apply Restraints.
To simulate shaft support, select the cylindrical
face of the hole at the bottom and make it Fixed
Geometry.
6 Apply an angular velocity of 20,000 rpm.
Select Axis1 as the reference.
29
Exercise 3 SOLIDWORKS
Frequency Analysis of an Impeller
8 Create Mesh.
Create a High quality mesh using the
Maximum element size of 10.5 mm. Use
Standard mesh.
9 Set study properties.
Request 5 frequencies.
10 Run the analysis.
Note Since there are loads present in this analysis, their effect on the
frequency results will be automatically accounted for.
30
SOLIDWORKS Exercise 3
Frequency Analysis of an Impeller
11 Review results.
f1 = 1182.1 Hz f2 = 1182.2 Hz
f3 = 1182.3 Hz f4 = 1185 Hz
Notice that the first modes of vibration are reserved for blades only and
the corresponding frequencies are very close.
31
Exercise 3 SOLIDWORKS
Frequency Analysis of an Impeller
32
Lesson 2
Frequency Analysis of
Assemblies
Objectives Upon successful completion of this lesson, you will be able to:
Understand the concepts of natural frequencies in assemblies.
Approximate the real contacts and connectors with the appropriate
contact entities.
33
Lesson 2 SOLIDWORKS
Frequency Analysis of Assemblies
Case Study: In this analysis, we will investigate the natural frequencies and
The Engine corresponding mode shapes of an assembly. This model introduces the
Mount concept of a frequency analysis of an assembly. Various contact
conditions can exist within an assembly and we will develop a way to
properly model them in a frequency analysis.
Project The engine frame supports a heavy
Description engine in the configuration shown in the
figure to the right. Analyze the frame to
determine if there are any resonant
frequencies within the speed range of
the engine.
The frame is connected to a secondary
rigid structure at the four locations
depicted in the figure.
The engine itself is not the focus of this
analysis, so it can be treated as a remote
mass.
To simplify the simulation, we will also assume that the intermediate
components directly connected to the engine are very stiff and light in
comparison to the engine mass. This will allow us to suppress them
from the analysis. We will still have to model the other connections in
the assembly.
Stages in the Some key stages in the analysis of this assembly are shown in the
Process following list:
Remote Mass
Because we are only interested in the frame, we can exclude the
engine from the analysis by treating it as a remote mass.
Set up Connections
Connections, contacts, and boundary conditions must be applied to
the model.
Mesh the assembly
Postprocess Results
All Bonded In the first part of this case study, we will use bonded contact for all of
Contact the parts in the assembly. This will assume that everything is perfectly
Conditions connected and actually treats the assembly as it would treat a single
part file. As we will discuss later, this assumption causes the model to
act stiffer than it actually would because there is no play in between the
connections.
34
SOLIDWORKS Lesson 2
Frequency Analysis of Assemblies
Remote Mass Whenever a mass of a body is significant and the stresses and
deformations are not important, the object can be conveniently treated
as remote mass rigidly connected to the load bearing faces. This idea is
identical to the Remote Load/Mass feature introduced in the
SOLIDWORKS Simulation course.
Note We assume that the suppressed sub-assembly is rigid and its mass is
small in relation to the rest of the structure.
To demonstrate the issue that arises when trying to obtain vibrational
characteristics of assemblies, we will first assume that the engine
mount assembly is rigidly connected to a secondary rigid structure.
This is seldom the case, as typically the mounting would be achieved
via resilient mounts.
35
Lesson 2 SOLIDWORKS
Frequency Analysis of Assemblies
Mass Properties Simulation model may differ from the SOLIDWORKS CAD model in
a few aspects such as material assigned to some of its parts, connectors
etc. It is therefore important to evaluate mass properties on the
simulation model.
Introducing: Mass Properties enables you to evaluate mass properties on the
Mass Properties simulation model. The command considers most of the simulation
features such as solids, beams, sheet metals and shells along with their
thickness and material definitions, remote masses and bolt and pin
connectors. The following properties are calculated: mass, volume,
surface area, center of mass, and principal moments of inertia.
Where to Find It Shortcut Menu: Right-click study name in the Simulation analysis
tree and click Mass Properties
Menu: Simulation, Mass Properties
Use in Instructions Select all or any of the assembly parts for the calculation, and the
output Unit system.
36
SOLIDWORKS Lesson 2
Frequency Analysis of Assemblies
3 Mass properties.
Determine the mass properties of the entire simulation model, and the
supporting frame.
The total mass values of the assembly and of the supporting frame are
54.01 kg and 6.76 kg, respectively.
4 Define fixtures.
Define Fixed Geometry fixtures for the four faces shown in the figure.
Connecting the Because frequency analysis requires constant stiffness and mass of the
Assembly Parts structure, we cannot define No Penetration contacts. Consequently, we
also cannot use bolted connections, for example.
When a No Penetration contact is specified, the structure may change
its configuration multiple times as the loads are applied to it.
In the figure above, depending upon the load magnitude, the two
cantilever beams act as two independent structures, or two beams in
contact. In both cases, the vibrational characteristics will be very
different.
37
Lesson 2 SOLIDWORKS
Frequency Analysis of Assemblies
38
SOLIDWORKS Lesson 2
Frequency Analysis of Assemblies
Animate each of the modes to see what the direction the structure
oscillates as it freely vibrates at the corresponding natural frequency.
Bonded and In the previous part of this lesson, we explained why the concept of
Allow natural frequencies is more involved due to the changing configuration
Penetration of the No Penetration contacts between the respective assembly
Contacts components. Because No Penetration contacts are not allowed in
frequency studies, we chose to approximate all contacts as bonded. As
will be concluded later in this lesson, such an approach makes the
assembly stiffer.
39
Lesson 2 SOLIDWORKS
Frequency Analysis of Assemblies
40
SOLIDWORKS Lesson 2
Frequency Analysis of Assemblies
The frequency results have changed, and the design could be modified
to avoid these frequency ranges.
8 Plot modal shapes for first four modes.
41
Lesson 2 SOLIDWORKS
Frequency Analysis of Assemblies
Discussion The frequency results show that the model in the second part of the
lesson, with a combination of bonded and allow penetration contact
conditions, is softer than the model with all contacts bonded - this is as
expected. It can be seen that the order of the corresponding modes
remains the same - this, however, does not always need to be the case.
The above two studies do not provide perfectly accurate answers, but
may serve as insight into what could be the boundaries for the
corresponding modes. Care must be taken when processing these
results since the mode numbers are not always in correspondence (i.e.
mode shape 1 of one study may not be mode shape 1 of the other). For
example, the shape seen in mode 1 of the all bonded study is actually
the shape seen in mode 2 of the bonded and free study. Therefore, we
must compare the modes whose shapes are the same, not necessarily
the mode number.
Summary In this lesson, we investigated the concept of frequency in assemblies.
It was shown that due to the requirement of a constant stiffness matrix,
No Penetration contacts are not allowed in the frequency analysis and
an alternate approximated approach is required. For example, various
contacts and connectors in the assemblies have to be approximated
with the help of bonded and allow penetration contacts, pins, spot
welds, etc. Based on combinations of these features, we typically create
a model that exhibits a stiffer/softer response, providing us with good
information on the bounds of the vibrational characteristics of the
original assembly.
Note The true vibration characteristics of such an assembly can be obtained
by subjecting the assembly to a shock load and by studying the
structural response (displacements, velocities, etc). This is the subject
of the SOLIDWORKS Simulation Premium: Dynamics training manual.
The range of the lowest four natural frequencies from both studies is 89
Hz - 673 Hz (5400 rpm - 40,380 rpm). Some frequencies would
therefore fall within the range of operating rpm for higher performance
engines. If resilient mounts were used the results would be
considerably different.
42
SOLIDWORKS Lesson 2
Frequency Analysis of Assemblies
43
Exercise 4 SOLIDWORKS
Frequency Analysis of a Particle Separator
Exercise 4: In this exercise, you will perform a frequency analysis on a frame that
Frequency holds up a particle separator. This exercise reinforces the following
Analysis of a skills:
Particle Frequencies and Mode Shapes on page 10
Separator All Bonded Contact Conditions on page 34
Postprocessing Frequency Results on page 15
44
SOLIDWORKS Exercise 4
Frequency Analysis of a Particle Separator
Discussion Even though the model was made up of numerous different parts and
element types, all of the contact conditions were bonded. This means
that although being an assembly, all of the parts are perfectly connected
and it behaves as if it were modeled as a single part.
45
Exercise 4 SOLIDWORKS
Frequency Analysis of a Particle Separator
46
Lesson 3
Buckling Analysis
Objectives Upon successful completion of this lesson, you will be able to:
Perform buckling analysis.
Understand buckling factors of safety and decide whether the
product fails in strength or stability.
47
Lesson 3 SOLIDWORKS
Buckling Analysis
KE + i KS i = 0
48
SOLIDWORKS Lesson 3
Buckling Analysis
Buckled Arch
Buckled Strut
Buckling Factor of The buckling factor of safety (BFS) is a number by which the applied
Safety (BFS) load Papp must be multiplied in order to obtain the buckling load
magnitude Pcr .
P cr
BLF = -----------
P app
Note that the buckling mode presents the shape of the structure at the
onset of buckling and provides insight into the post-buckled shape.
However it says nothing about the actual magnitude of deformation.
This is analogous to a modal analysis, which provides qualitative
information on modes of vibration, but not on the actual magnitude of
displacements.
Buckling Analysis As previously mentioned, linear buckling analysis typically
Considerations overestimates the buckling load. Loads and supports are applied with
perfect accuracy and no misalignment. In reality, the load is always
applied with some misalignment; walls are never perfectly flat,
supports are never perfectly rigid, and so on.
To conclude this issue, we repeat that considering the combined effects
of discretization error (minor effect) and modeling error (major effect),
the results of a buckling analysis must be interpreted with caution.
49
Lesson 3 SOLIDWORKS
Buckling Analysis
Case Study: In this case study, we will perform a buckling analysis on a particle
Particle separator. The particle separator and its loading conditions are the same
Separator as the model featured in Lesson 10 of the SOLIDWORKS Simulation
training manual. We will calculate the bucking factor of safety of the
model and learn to properly interpret the buckling results.
Project The loads on the support frame consist of the
Description weight of the particle separator structure itself
that will be applied using gravity. An additional
load of 150 N will be applied to the front of the
structure in the downward direction to simulate
the presence of an additional component that
will be attached to the separator. Finally, on the
intake of the particle separator, a 75 N normal
and 45 N along direction 1 loads will be applied
to simulate additional loading that the separator
might experience during installation.
50
SOLIDWORKS Lesson 3
Buckling Analysis
51
Lesson 3 SOLIDWORKS
Buckling Analysis
52
SOLIDWORKS Lesson 3
Buckling Analysis
Buckling
BFS Value Interpretation of Results
Status
BFS > 1 No buckling Applied loads are less than the estimated critical loads.
0 < BFS < 1 Buckling Applied loads exceed the estimated critical loads.
BFS = 1 Buckling Applied loads are exactly equal to the estimated critical loads.
Buckling occurs if you reverse all load directions. For example,
BFS = - 1 No buckling
if you apply a tensile force on a bar, the BFS is negative.
- 1 < BFS < 0 No buckling Buckling occurs if you reverse all load directions.
BFS < - 1 No buckling Buckling does not occur, even if you reverse all load directions.
Results The results indicate that the separator is likely to withstand a load that
Discussion is up to 21 times as large as what is already applied.
Of course, this is valid only if the load is applied as in the FEA model.
Any imperfections in load application or any deviation from the
symmetry of the frame lowers the buckling factors of safety as well as
the yield strength factor.
Imagine a slender beam under a compressive load. A small load offset
causes a misalignment between the line of action of the force and the
neutral axis of the structure. Under that offset load, the beam must
resist the compressive load partly in axial compression, partly in
bending.
Because the slender beam is much weaker in bending than in pure axial
compression, a large increase in deformation due to bending occurs.
This, in turn, rapidly degrades the ability of the beam to sustain any
loads.
53
Lesson 3 SOLIDWORKS
Buckling Analysis
Will the structure The stress factor of safety of 19 is comparable to the buckling factor of
Buckle or Yield safety of 21. It is hard to predict which failure would occur first when
First? the results are this close.
In many instances yielding changes geometry which in turn reduces the
buckling factors of safety and a structure collapses by a combination of
material yielding and buckling.
A nonlinear analysis, available in SOLIDWORKS Simulation
Premium, is required to describe these complex problems.
Summary In this lesson we conducted buckling analyses and made use of the
stress analysis results from the SOLIDWORKS Simulation course.
While the stress analysis assesses the performance of the design in
strength (yielding is the criterion), buckling analysis evaluates the
stability of the structure.
Safety factors related to material yield strength and to buckling were
explained.
In many situations, buckling, rather than excessive stress, is often the
predominant mode of failure for slender structures under compressive
loads.
Questions 1. Onset of buckling implies that the total stiffness of the structure
(summation of the structural elastic stiffness and ________
stiffness due to the loads) becomes (very large / zero / negative).
2. Onset of buckling (does / does not) coincide with the onset of
yielding at the material point where the largest stress occurs.
3. At buckling failure, yielding always occurs (before / at the same
time / after / all answers are correct) the onset of buckling.
4. For slender structures subjected to compressive loads, buckling (is /
is not) likely the mode of the failure.
54
SOLIDWORKS Exercise 5
Buckling Analysis of a Stool
Exercise 5: In this exercise, you will perform a buckling analysis on a stool. This
Buckling exercise reinforces the following skills:
Analysis of a Buckling Analysis on page 48
Stool Calculating Buckling Loads on page 52
55
Exercise 5 SOLIDWORKS
Buckling Analysis of a Stool
56
SOLIDWORKS Exercise 5
Buckling Analysis of a Stool
The results of the stool stress study show a maximum von Mises
stress of approximately 138 MPa [20,015 psi].
The yield strength of AISI Steel is 207 MPa [30,000 psi], as stated in
the material property definition.
57
Exercise 5 SOLIDWORKS
Buckling Analysis of a Stool
This plot shows the distribution of the factor of safety related to the
yield strength based on the von Mises stress.
Note The upper limit in the legend was set to 100.
11 Create buckling study named stool buckling.
58
SOLIDWORKS Exercise 5
Buckling Analysis of a Stool
Animate both of the above plots to understand how the stool buckles in
each mode.
Important! It is vital to understand that the modal displacement amplitude plots are
purely qualitative just like the results of the frequency analysis. The
numerical values shown in the above plots are not real displacements.
The plots show the deformed shapes at the onset of buckling based on
the assumptions of the linear buckling theory. The numerical values can
be used to relate the displacement of some parts of the model with
respect to each other, but the actual magnitudes are not known. A non-
linear analysis would be required for the correct displacement results
and post-buckling behavior.
59
Exercise 5 SOLIDWORKS
Buckling Analysis of a Stool
Will the Stool Buckle The stress factor of safety is lower than the lowest buckling factor of
or Yield First? safety. However, while the stress factor of safety is conservative, it
describes the load causing the first instance of yielding in the structure;
the buckling factors are non-conservative.
Most likely, one of the legs will yield before it buckles. Yielding
changes the geometry and reduces the buckling load so that finally the
stool collapses in a combination of material yielding and buckling.
To analyze this, we require the nonlinear analysis available in
SOLIDWORKS Simulation Premium.
Relationship We have already stated that a compressive load induces a stress
Between Buckling stiffness that is subtracted from the elastic stiffness.
and Frequency
Analyses Buckling takes place when this resultant stiffness drops to zero. How
does that relate to frequency analysis?
Try This! We suggest that you append this exercise with the following analysis:
Create a frequency study and calculate the fundamental frequency of
stool for different load magnitudes.
Observe that the fundamental frequency (as well as higher frequencies)
drops with the increase of the compressive load magnitude.
Find the load magnitude for which the fundamental frequency drops to
zero. This will be the buckling load.
60
SOLIDWORKS Exercise 6
Cabinet
Exercise 6: In this exercise, you will perform a buckling analysis on a cabinet. This
Cabinet exercise reinforces the following skills:
Buckling Analysis on page 48
Calculating Buckling Loads on page 52
61
Exercise 6 SOLIDWORKS
Cabinet
We can see that the maximum stress of 42.1 MPa is located at the lower
front joint. This translates into a factor of safety in yielding in beams of
4.6.
5 Review stress results in shells and solids.
62
SOLIDWORKS Exercise 6
Cabinet
The image above is derived from the von mises stress result plots (steps
4 and 5). A low value for the factor of safety is caused by the edge
bond. We will ignore this low value as unrealistic and conclude that 4.6
represents the factor of safety in yielding.
In the next part of this exercise, we will assess the performance of the
cabinet in stability.
8 Create buckling study.
Create a Buckling study named buckling analysis.
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Exercise 6 SOLIDWORKS
Cabinet
9 Copy folders.
Copy the Parts, Joint Group and External Loads folders from the
stress analysis study to the buckling analysis study.
Do not copy the Fixtures and Connections folders.
Note Due to the nature of the buckling solution, buckling study setup will
somewhat differ from that of the stress analysis study. Similarly to
frequency analysis, No penetration contacts and some connectors
(bolts for example) are not permitted in buckling analysis. In such
situations, only the estimates or the lower and upper limits of the
buckling loads can be extracted. In our case, we will simulate the No
Penetration contact by excluding the Base and adding two additional
fixtures.
10 Exclude Base from analysis.
11 Add fixtures.
Define a Fixed Geometry
fixture on the four edges of the
bolt holes previously bonded to
the Base.
Note Step 11 and 13 above assume infinite stiffness of the excluded Base in
the vertical direction and ignore any friction between the Base and the
Cabinet. Can you comment on whether the current model for the
buckling study is stiffer or softer than the model used in the stress
analysis study? What is the consequence on the critical buckling load
that we will obtain from this study?
64
SOLIDWORKS Exercise 6
Cabinet
14 Define Contacts.
Copy eight bonded beam contacts from static study to the buckling
study.
15 Apply mesh control.
Apply mesh control with the
default parameters on the two
beams indicated in the figure.
Note This mesh control is specified in order to improve bonding with the
side faces of the solid bodies.
16 Create mesh.
Create a High quality Curvature based mesh with the following
parameters: Maximum element size = 51.54 mm, Minimum element
size = 5mm, Min number of elements in a circle = 16, Element size
growth ratio = 1.6.
17 Set buckling analysis study properties.
Request 5 buckling modes.
18 Run buckling analysis.
65
Exercise 6 SOLIDWORKS
Cabinet
66
Lesson 4
Load Cases
Objectives Upon successful completion of this lesson, you will be able to:
Understand and use the Load Case manager feature to analyze
multiple load combinations.
67
Lesson 4 SOLIDWORKS
Load Cases
Load Cases A load case manager interface allows you to take the loads defined in a
simulation study, and combine them to define so called primary load
cases such as Dead load, Wind load etc. Primary load cases can be
further linearly combined into so called secondary load combinations,
for example 1.3*Dead load + 2*Wind load. This way it is possible to
quickly evaluate effects of various load combinations on your model.
Case Study: A simple scaffolding Stand
Scaffolding model consists of one Platform with
horizontal platform with wooden flat
68
SOLIDWORKS Lesson 4
Load Cases
Load combinations The specific load combinations must follow the local guidelines and
codes. For the purpose of this lesson, we will consider a load
combination for Dead loads and Live loads as follows: 2*Dead loads+
2 Live loads.
The objective of this lesson is to calculate maximum displacement of
the scaffolding.
Stages in the The basic steps are:
Process Define static study.
Define fixtures, loads, contacts and mesh.
Define primary load cases.
Define Dead load and Live load.
Define load combinations.
Define linear combination of load cases using the following
equation: 2*Dead load+2*Live load.
Analyze the results.
Review the available output to determine whether the
displacements are below the required limit.
69
Lesson 4 SOLIDWORKS
Load Cases
The tubing of the two side brace subassemblies are modeled using the
beam elements. To simplify mesh, the corner gussets are excluded from
analysis and are simulated with the help of the beam joints.
No penetration
contacts
Suppressed corner
gusset, Beam joint
Braces rest atop the horizontal tubing of the two stands; this
connection is simulated using already defined no penetration contacts.
The middle plates on the Braces are welded to
the diagonal tubings. This connection is
simulated with the bonded contacts.
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SOLIDWORKS Lesson 4
Load Cases
4 Wooden flat.
The wooden flat is not crucial for the results of this simulation and it
was already excluded from analysis.
5 Material.
AISI 304 Steel is already assigned to all the components. This material
has a yield strength of 206.8 MPa.
6 Contact between Platform frame and Stands.
The Platform frame brackets are freely set atop the horizontal
tubings of the Stands. Their interaction is simulated with the No
Penetration contacts.
The four no penetration contacts have
already been defined.
7 Vertical distributed force.
A 3,500 N total vertical force was
already defined on the top faces of the
Platform frame members.
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Lesson 4 SOLIDWORKS
Load Cases
Suppressed corner
Note In the absence of gravity (some considered load cases do not include
gravity load), braces are unrestrained in the vertical direction.
Depending on the configuration of the problem, this lack of restrains
may lead to initial instabilities. Addition of four small stabilizing forces
in the vertical direction will help provide the required stability.
10 Gravity.
Gravity is defined in the negative Y direction.
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SOLIDWORKS Lesson 4
Load Cases
11 Mesh controls.
Mesh control was already applied on the two middle brace plates with
18.4mm for Element Size, and 1.5 for Ratio.
Additional mesh control with Number of Elements=30 was applied on
the four vertical tubings of the Braces.
Note Both of the above mesh controls are defined to improve the resolution
of the bonded contacts.
12 Show mesh.
High quality, Curvature based mesh was already created.
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Lesson 4 SOLIDWORKS
Load Cases
74
SOLIDWORKS Lesson 4
Load Cases
You should see two primary load cases (Dead load and Live load),
one secondary load combination Base combination, and one
simulation sensor for maximum resultant displacement to track the
result.
75
Lesson 4 SOLIDWORKS
Load Cases
Initial Load Case The first row on the Load Case View has all study features active. It is
so called Initial Load Case which cannot be edited.
Initial Load
Case
20 Review results.
The Results View tab shows results for the monitored sensors, and
provides an overview of the input loads and fixtures.
The maximum calculated displacement for the primary load cases are
2.21mm for the Dead load case, and 12.2mm for the Live load case.
The maximum displacement for the secondary load combination, Base
combination, is approximately 27mm.
76
SOLIDWORKS Lesson 4
Load Cases
Note You can also activate results for any of the primary load cases (Dead
load or Life load).
22 Review stress results in solids.
Under Results folder, define VON: von Mises Stress plot for Solid
and Shells.
77
Lesson 4 SOLIDWORKS
Load Cases
Note Because the load case results were tracked with the help of one
displacement sensor (step 17 on page 75), the same plot is also defined
in the Load Case Results folder.
25 Save results.
Save the results and close the model.
78
SOLIDWORKS Lesson 4
Load Cases
Summary This lesson introduced the load case feature which allows you to
quickly compute results for various combinations of loads.
Load case manager interface allows you to first define so called
primary load cases. Primary load cases are defined by combining the
load features defined in the External Loads folder of a simulation
study. In this study, you defined two primary load cases: Dead load
and Live load.
Primary load cases can then be further combined using a linear
expression into so called secondary load combinations. In this study
you defined one secondary load combination, Base combination, as
2*Dead load + 2*Life load.
On launching simulation, each primary load case is solved individually
as a separate static simulation. Results for a secondary load
combination is then obtained by combining the results of the primary
load cases using the load combination equation. T
The load case manager enables you to postprocess both results for each
load case, and for the load combination.
79
Lesson 4 SOLIDWORKS
Load Cases
80
Lesson 5
Submodeling
Objectives Upon successful completion of this lesson, you will be able to:
Understand and use the Submodeling feature to analyze structural
details.
Post-process results on submodel.
81
Lesson 5 SOLIDWORKS
Submodeling
Parent Study The parent study must meet certain conditions in order to proceed with
the submodeling study:
The parent study must be static or nonlinear static with more than
one body and not be the submodeling study itself.
The parent study cannot be a 2D simplification study.
The selected bodies that compose the submodel may not have the
No penetration contact with unselected bodies that result in contact
pressure across the cut boundary.
The selected bodies that compose the submodel may not share
connectors with unselected bodies.
Body not suitable for submodeling
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SOLIDWORKS Lesson 5
Submodeling
83
Lesson 5 SOLIDWORKS
Submodeling
Part 1: Parent For the parent study, you will use the entire assembly model. A solved
Study model from lesson Load Cases is used here as the parent study.
1 Open an assembly file.
Open Scaffolding from the Lesson05\Case Study folder.
2 Review geometry. Split features
Show Top Level
Annotations.
The assembly model features
splits necessary to define the
submodel. The corner
intended for submodeling is identified with the annotation.
84
SOLIDWORKS Lesson 5
Submodeling
Parent Load Cases Currently, results from load cases defined in the parent study cannot be
in Submodeling used in the submodeling study. By default, only Initial load case
Study results are used.
85
Lesson 5 SOLIDWORKS
Submodeling
5 Save results.
Save the results, but keep the model open.
Part 2: Child Child study will simulate behavior at the joint location identified at the
Study beginning of the lesson.
1 Review parent study geometry.
The assembly model features splits
necessary to define the submodel.
Split features
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SOLIDWORKS Lesson 5
Submodeling
Selecting In general, the further you go from the critical detail (i.e. the more
Components for components you include in your submodeling study), the better.
Submodeling However, this way, you will also create larger model that will take
more time to solve. Hence, some reasonable engineering judgment is
necessary. Since the primary interest in this study is the bracket, we
need to select a few neighboring components as well.
Alternatively, you can select the same components from the Bodies
List of the Submodel dialog in the Define Submodel property
manager.
Click OK.
Note It may take a minute or two for the computer to create the submodeling
study.
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Lesson 5 SOLIDWORKS
Submodeling
Submodel Fixtures Because the submodel solution is a subset of the solution from the
parent study, all fixtures are transferred directly from the parent study
and its result, and can not be modified. This also implies that no
additional fixtures can be defined in the submodel study (Hide All and
Show All are the only commands available under the Fixtures folder).
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SOLIDWORKS Lesson 5
Submodeling
7 Create mesh.
Create High quality,
Curvature based
mesh. Use the
default mesh
parameters.
Notice that the
resulting mesh has
focused refinement
on the bracket in contact with the tube.
8 Run study.
The study takes about 2 minutes to solve on a 3 GHz computer with 12
GB RAM.
9 Review stress results.
Activate Stress - solids and shells plot.
Change the legend Max value to the material yield strength, 206.8
MPa.
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Lesson 5 SOLIDWORKS
Submodeling
The peak stresses are very isolated and would not cause failure of the
material. Better contact resolution would results in more distributed
stress. Probing on the load contact face reveals more realistic maximum
stress of approximately 110 MPa.
11 Plot energy norm error.
The plot shows practically no error in the critical region. This suggests
that the stress results are likely reliable in the critical contact region.
Remember, however, that to prove the stress reliability, one would have
to study convergence of stresses with various mesh refinement.
12 Save and Close the file.
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SOLIDWORKS Lesson 5
Submodeling
Summary This lesson introduced the submodeling feature that allows users to
study detailed stress distributions in complex regions such as joints,
without need to generate fine mesh the entire assembly. The procedure
is divided in two steps.
In the first step, the entire assembly is meshed with coarser mesh
settings to save the computational time. Coarser mesh will likely not
provide reliable stress details in complex regions such as joints, but
must provide reliable displacements.
In the second step user selects bodies in the vicinity of the critical
region and defines a submodeling child study. All loads and fixtures are
automatically transferred from the parent model to the child study. User
only needs to create fine and detailed mesh and run the calculation.
Because the calculation is performed on a significantly smaller
submodel, the computational time will be significantly smaller while
the results quality in the studied region will significantly improve when
compared to those from the parent study.
Questions What is submodeling? What are some of the benefits of
submodeling?
The selected bodies that compose the submodel (may/may not)
have No penetration contact with unselected bodies that result in
contact pressure across the cut boundary.
How are the loads defined in a submodeling (child) study?.
91
Lesson 5 SOLIDWORKS
Submodeling
92
Lesson 6
Topology Analysis
Objectives Upon successful completion of this lesson, you will be able to:
Perform a topology analysis.
Create a load case study to combine multiple loads for a topology
optimization.
Export an optimized shape.
93
Lesson 6 SOLIDWORKS
Topology Analysis
Full Load
800 Newtons
94
SOLIDWORKS Lesson 6
Topology Analysis
Rest Load
200 Newtons
Side Load
115 Newtons
95
Lesson 6 SOLIDWORKS
Topology Analysis
1 Open part.
Open Linkage from the Lesson06\
Case Studies folder.
2 Observe the static simulations.
There are four static simulations which
have already been setup.
Observe the setup for each of the
simulations.
The Combined Loads simulation
combines all the loads and fixtures from the
Full Load, Rest Load and Side Load
simulations and will be used later in the
lesson.
3 Run all simulations.
Click Run All Studies .
4 Create topology study.
Create a Topology Study named topology full load.
Click OK .
5 Copy folders.
Copy the Parts, Fixtures and External Loads folders from the
full load study to the topology full load study.
Goals and A topology study is always optimized towards a goal. There are three
Constraints goals available: Best Stiffness to Weight ratio, Minimize Maximum
Displacement and Minimize Mass with Displacement constraint.
Best Stiffness to This goal is designed to minimize the compliance of the structure while
Weight ratio reducing the weight by a specified amount. (Compliance is the opposite
of stiffness.) If no other goal is defined, Best Stiffness to Weight
ratio is used with a 30% reduction in mass.
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SOLIDWORKS Lesson 6
Topology Analysis
6 Minimize mass.
Click Minimize Mass with Displacement constraint .
Here, we will eliminate as much mass from the part as possible while
ensuring that the maximum displacement does not exceed 1.3 times
what it would be without any material removed.
Click Constraint Value and enter 1.3.
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Lesson 6 SOLIDWORKS
Topology Analysis
98
SOLIDWORKS Lesson 6
Topology Analysis
Specify Symmetry The Specify Symmetry Planes constraint can be used to specify
Planes symmetry. Symmetry can be applied across one, two or three planes
with Half Symmetry, Quarter Symmetry or One-Eighth Symmetry,
respectively.
7 Symmetry constraint.
Click Specify Symmetry Plane .
It is our intention that the part will be symmetric about the center of the
bike. Therefore, click Half Symmetry.
Select the Right Plane as the plane of symmetry.
Click OK .
8 De-molding direction.
Click Specify De-molding Direction .
Click Mid-Plane (Both Directions) and ensure
Determine central mid plane automatically is
selected.
Select the edge of the part as shown for Select Pull
Direction.
Click OK .
9 Create mesh.
Click Create Mesh .
Create a Draft quality, Curvature-based mesh with a Maximum
element size of 3 mm and a Minimum element size of 1 mm.
Click OK .
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Lesson 6 SOLIDWORKS
Topology Analysis
Mesh Effects When a Topology study is run, the material density and the Young’s
modulus are reduced uniformly and redistributed to elements within the
model. The elements that have the material properties redistributed to
them make up the resulting geometry. Therefore, element size has a
significant effect on the shape of the end part.
Below are the resulting geometries of the structure with the same setup
and different element sizes (element size is abbreviated, “ES”).
10 Run.
Click Run .
Note The simulation will take approximately eight minutes to run.
11 Results.
The resulting plot shows locations
where material can be removed.
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SOLIDWORKS Lesson 6
Topology Analysis
12 Smoothed Mesh.
Right-click the Material Mass1 plot and
click Edit Definition .
Click OK .
The plot shows a smoothed mesh of the final
shape.
13 New Topology study.
We will now create a new Topology study that
combines multiple loads.
Click Topology Study and name the new study combined load
topology.
Click OK .
14 Copy Folders.
Copy the Parts, Fixtures and External Loads folders from the
Combined Loads static stress study to the combined load topology
study.
Copy the Manufacturing Controls from topology full load study to
the combined load topology study.
15 Goals.
Here, we will find the best stiffness to weight ratio while reducing the
mass by 50%.
Under Goals and Constraints, click Best Stiffness to Weight
ratio .
With Reduce mass by (percentage) selected, enter 50%.
Click OK .
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Lesson 6 SOLIDWORKS
Topology Analysis
Load Cases in The only way to combine multiple loading conditions within a
Topology Topology study is with the Multiple Load Cases command. This
Studies command was covered in Load Cases on page 67.
When load cases are considered in a Topology study, there are a two
algorithms that can be used. The first algorithm is used by default and it
works by creating parts which maintain proportional stiffness in each
direction of load.
The second algorithm works by first observing the responses of the
loads on the design space. The structure is then made stiffer in the
directions of highest deformation. This algorithm is called the Min Max
formulation and can be accessed through the properties of the
simulation.
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SOLIDWORKS Lesson 6
Topology Analysis
Likewise, unsuppress the fixtures and the loads of the Side Load study
in the Side Load Case loading condition.
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Lesson 6 SOLIDWORKS
Topology Analysis
Click OK .
The plot shows a smoothed mesh of the final
shape.
Export Once the final shape has been determined, the shape can be exported as
Smoothed Mesh a solid body, a surface body or a graphical body.
Where to Find It Right-click the Material Mass plot and click Export Smoothed
Mesh
22 Export shape.
Click Export Smoothed Mesh .
Under Save mesh into, click New part
file and name the part, Nonparametric
Shape.
Under Advanced Export, click Solid
Body.
Click OK .
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SOLIDWORKS Lesson 6
Topology Analysis
105
Lesson 6 SOLIDWORKS
Topology Analysis
106
SOLIDWORKS Exercise 7
Topology Analysis of a Stool
Exercise 7: In this exercise, you will perform a topology analysis on a chair. This
Topology exercise reinforces the following skills:
Analysis of a Topology Analysis on page 94
Stool Goals and Constraints on page 96
Manufacturing Controls on page 98
Load Cases in Topology Studies on page 102
107
Exercise 7 SOLIDWORKS
Topology Analysis of a Stool
5 Manufacturing Controls.
Click Specify Symmetry Plane .
Specify Half Symmetry across the Right Plane.
6 Multiple Load Cases.
Click Multiple Load Cases .
Create three load cases, one for each of the loading conditions.
Name the load cases Weight of Person, Back Support and Arm
Support and configure the load cases respectively.
108
Lesson 7
Thermal Analysis
109
Lesson 7 SOLIDWORKS
Thermal Analysis
Structural Thermal
Displacement Temperature
Strain Temperature gradient
Stress Heat flux
Load Heat source/Heat sink
Prescribed displacements Prescribed temperatures
Convection coefficients
Elastic supports
(film coefficients)
Elastic modulus Thermal conductivity
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SOLIDWORKS Lesson 7
Thermal Analysis
111
Lesson 7 SOLIDWORKS
Thermal Analysis
112
SOLIDWORKS Lesson 7
Thermal Analysis
Forced Convection In forced convection, a fan or a pump is used to accelerate the flow of
the fluid over the face of the solid. The rapid motion of the fluid over
the face of the solid maximizes the temperature gradient and increases
the rate of heat exchange.
Radiation Thermal radiation is the thermal energy emitted by bodies, due to their
temperature, in the form of electromagnetic waves. All bodies with a
temperature above absolute zero emit thermal energy.
Because radiation does not require a VACUUM
medium, it is the only form of heat
transfer in a vacuum.
Heat transfer by radiation becomes
more significant at higher
temperatures. Note that the amount of
radiated heat is proportional to the
fourth power of absolute temperature.
Thermal radiation occupies a narrow range in the radiation spectrum as
shown in the figure below.
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Lesson 7 SOLIDWORKS
Thermal Analysis
114
SOLIDWORKS Lesson 7
Thermal Analysis
Material Properties We conclude this theoretical section with a review of the material
for Thermal properties required in a thermal analysis.
Analysis The following material properties are specifically required as input to
various types of thermal analyses:
Type of Thermal
Material Property Definition
Analysis
Conductivity Thermal conductivity indicates the Steady state and
effectiveness of a material in transferring transient analysis
heat energy by conduction.
Specific Heat Specific heat of a material is the quantity Transient analysis
of heat needed to raise the temperature of only
a unit mass of the material by one degree
of temperature.
Mass Density Although not directly used in thermal Transient analysis
analysis, mass density is required to only
provide information on mass because
specific heat is defined as heat per unit of
mass
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Lesson 7 SOLIDWORKS
Thermal Analysis
Case Study: In this case study, we will perform a steady-state thermal analysis of a
Microchip microchip assembly. The concept of thermal resistance is introduced to
Assembly model the glue between the microchip and heat sink. We will learn to
properly apply thermal boundary conditions as well as thermal loads.
In addition, several transient thermal analyses (analyses of heat flow,
which changes with time) will be performed to show how the
microchip assembly will respond to changing heat loads.
Project The CAD model of a Connectors
Description microchip assembly consists Microchip
of five components:
Copper heat sink
Ceramic microchip
Three copper terminals
(connectors)
Heat Sink
The ceramic microchip
generates heat, which
dissipates to the environment by convection through all external faces
of the ceramic microchip and all external faces of the copper heat sink.
The three terminal connectors are insulated, meaning they do not
dissipate any heat. The ambient temperature around the assembly is
27°C [300 K].
The ceramic microchip and copper heat sink are connected by a layer
of Arctic Silver 5 high conductance glue, 25 m thick. It would be very
difficult to mesh this layer if we modeled it as an assembly component.
Instead of explicitly modeling this glue layer, we will account for it by
defining a thermal resistance between the bonded faces of the
microchip and the heat sink.
Stages in the Steady-state analysis
Process The steady-state temperature distribution in the model will be
calculated. By steady-state, we mean the final temperature of the
model after enough time has been allowed for heat flow to reach
equilibrium and the temperature field to stabilize.
Transient analysis (step heat load)
The temperature time history is calculated for 300 seconds, starting
from the time when the heat power is first applied. By “step heat
load,” we mean that the entire heat load is applied at time 0 and
stays constant throughout the analysis.
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SOLIDWORKS Lesson 7
Thermal Analysis
Note The interface between the microchip and heat sink cannot be treated as
a perfect bond. A thin layer of thermal glue is applied between the two
surfaces, and its effect will be modeled as a thermal resistance.
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Lesson 7 SOLIDWORKS
Thermal Analysis
Interfacial Two solid surfaces never form a perfect contact when they are pressed
Conductance together. Tiny air gaps always exist between the two contacting
surfaces due to their roughness.
Through the interface between the two contacting faces, two modes of
heat transfer exist. The first is conduction through points of solid-to-
solid contact, which is very effective. The second is conduction through
the gas-filled gaps, which can be poor due to their low thermal
conductivity.
To treat the thermal contact resistance, an interfacial conductance hc is
“sandwiched” between the two solid bodies in question. The
conductance hc is similar to the convection heat-transfer coefficient and
has the same units (W/m2 K) or the equivalent in IPS.
Introducing: Thermal contact resistance is the inverse of hc (conductance) and is
Thermal Resistance equal to L/KA (A is the area of contact). Typical values of interfacial
conductance are summarized in the table below:
Contacting Faces Interfacial Conductance (hc) (W/m2 °K)
Iron/aluminum 45,000
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SOLIDWORKS Lesson 7
Thermal Analysis
4 Define thermal
contact resistance.
Define a Contact Set
for the touching faces
on the heat sink and
microchip parts.
Explode the view for
easy selection of the
contact faces.
Select Thermal
Resistance as Type.
Select the Thermal
Resistance check box.
Select Distributed, and
then enter 2.857e-6 Km2/W as the distributed thermal resistance
(thermal resistance over a unit of area).
Click OK.
Note The conductance (hc) of the 25 m layer of Arctic Silver 5 material is
approximately 350,000 W/m2K. The distributed value of thermal
resistance is the inverse of the interfacial conductance; 1/350,000 =
2.857e-6 m2K/W.
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Lesson 7 SOLIDWORKS
Thermal Analysis
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SOLIDWORKS Lesson 7
Thermal Analysis
Insulation Any boundary that has not had any mode of heat transfer defined will
be assumed to be insulated. This is the case with the connector pins in
the model. No heat will be allowed to transfer across these boundaries.
Initial Temperature No initial temperature of the model is needed when analyzing a steady-
state problem. Steady-state thermal analysis, by definition, pertains to
the situation where the temperature field has stabilized under the
defined conditions.
The initial temperature may only shorten or lengthen the time required
to obtain thermal equilibrium, but does not affect the steady-state
conditions. Therefore, initial temperature is irrelevant for a steady-state
analysis.
Thermal Results To examine what results are available in a
thermal analysis, right-click the Thermal1
plot and select Edit Definition to open the
Thermal Plot window.
Note that temperature (TEMP), as a scalar
entity, is available for display only as a fringe
plot. Temperature gradients and heat flux (both
resultants and components), are vector
quantities and can be displayed in fringe or
vector format.
Thermal analysis plots can be modified or controlled using basically
the same methods we are familiar with from static analysis. Animate,
Probe, and so on work exactly the same as in a static analysis.
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Lesson 7 SOLIDWORKS
Thermal Analysis
Heat Flux While temperature is related to the energy level stored in a system
relative to the same object (from the same material) at zero degrees,
heat flux provides information on the direction and the density of
energy flow throughout the object.
W J
The units of heat flux, ------2 = ------------2- , represent the fact that every second
m sm
one Joul leaves/enters/flows through one m2 of the surface
perpendicular to the direction of the flux component.
BTU
The corresponding units in the English (IPS) system are -------------2- .
s in
Heat flux is a vector with three components and a resultant.
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SOLIDWORKS Lesson 7
Thermal Analysis
Heat Flux Results As we discussed earlier in the lesson, heat flux is most similar to stress
in structural analysis. Therefore, like stress, heat flux magnitude tends
to approach infinity at the sharp corners. For this reason, higher density
meshes are recommended if the heat flux results are of importance to
the designer.
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Lesson 7 SOLIDWORKS
Thermal Analysis
Heat Power Heat power indicates the variation of energy leaving/entering every
second through the boundary. To obtain the total or average heat power
for a specific entity, List selected command has to be used.
The basic unit for the hear power is Watt, W = J-- in the SI system
s
Btu
of units, and ----------
s in the English system of units.
Transient The results of the steady-state thermal analysis, which we have just
Thermal completed, describe the situation where sufficient time has elapsed and
Analysis the heat flow has stabilized so that the temperature field reaches
equilibrium.
Note that we do not know at what time this stabilized situation occurs.
The results only display what the stabilized state will look like. The
amount of time depends on the initial temperature conditions, which
are not defined in a steady-state thermal analysis.
To analyze temperature changes in time, a transient thermal analysis is
required.
We assume that prior to turning on the power, all model components
are at a room temperature of 25°C. At time t = 0 s, the power is turned
on and the microchip starts generating 25 W of heat power (25 Joules
every second). Our objective is to monitor the temperature changes
during the first 300 seconds of operation, with particular attention to
the temperature of the middle connector.
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SOLIDWORKS Lesson 7
Thermal Analysis
Click OK.
The simulation will be run for 300 seconds and the results are saved
every 10 seconds.
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Lesson 7 SOLIDWORKS
Thermal Analysis
Importing Note that it is possible to first run a detailed fluid dynamics simulation
Convective Effect using SOLIDWORKS Flow Simulation and then import the resulting
from convection coefficients directly into the thermal study in
SOLIDWORKS SOLIDWORKS Simulation. (See the SOLIDWORKS Flow
Flow Simulation Simulation tutorial titled Conjugate heat transfer for an example of the
analysis of heat transfer within an air-cooled electronic package.) This
option is very useful for simulations with forced convection in which
the convection coefficient is unknown or difficult to compute by hand.
Introducing: As previously discussed, the Temperature command is used in
Temperature transient thermal analysis. The command provides SOLIDWORKS
Simulation with an initial condition from which it will begin its
calculations.
Where to Find It Shortcut Menu: Right-click Thermal Loads in the simulation study
tree and click Temperature
CommandManager: Simulation > Thermal Loads > Temperature
Menu: Simulation, Loads/Fixture, Temperature
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Thermal Analysis
Transient Data For transient simulation it is not possible to define transient data sensor
Sensors to monitor desired quantities in time. Data stored in the transient data
sensor can then be used to generate various graphs for the selected
quantities.
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Lesson 7 SOLIDWORKS
Thermal Analysis
Results When we compare the temperature results from the steady state study
Comparison and the results from the last step of the transient 01 study, they both
show the same temperature distribution because both characterize the
same steady-state heat flow.
Notice that the Result window can be split to display two result plots at
the same time using the split panes technique which is identical to that
of SOLIDWORKS.
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SOLIDWORKS Lesson 7
Thermal Analysis
Transient Now, we will add more complexity to the transient thermal analysis.
Analysis with We still want to monitor what happens during the first 300 seconds
Time Varying using 10-second intervals, but heat power will now vary with time.
Load
1 Create new thermal study.
Copy study transient 01 into a new study named transient 02.
2 Create time curve for heat power.
In the study transient 02, we need to amend the definition of heat
power with information on how the heat power changes with time.
In the Thermal Loads folder, right-click Heat Power-1 and select
Edit Definition to open the Heat Power PropertyManager.
In the Heat Power PropertyManager, click the
Use Time curve button and select Edit to
open the Time curve window.
Enter three points to define the time curve:
(0,0), (30,1), (60,0). Double-click on a cell to
create a new row.
To view the curve, click the View
button in the Heat Power
PropertyManager.
Click OK.
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Lesson 7 SOLIDWORKS
Thermal Analysis
Time Curves The heat power time curve describes the following events:
Power is gradually increased to its maximum value during the first 30
seconds. Then power is gradually decreased to 0 over the next 30
seconds. After 60 seconds, no power is generated.
The heat power time curve does not define the actual heat power. It
defines a time-dependent multiplier to the heat-power magnitude
entered in the Heat Power window.
Note that heat flux, convection coefficients, and bulk temperature can
also be made time or temperature dependent.
Having defined heat power as a function of time, we are ready to run
the study transient 02.
Temperature Similar to time dependence of the load using time curves, any thermal
Curves load can be made temperature dependent using temperature curves .
In this lesson, for example, one could specify the heat power magnitude
as a function of temperature. Each finite element then generates a
different level of heat power based on its average temperature.
Note that solutions with temperature curves are significantly more time
demanding as convergence iterations are required.
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SOLIDWORKS Lesson 7
Thermal Analysis
Transient Having analyzed the results for the transient 01 study (the study with
Thermal constant heat power), we decided that the microchip is overheating.
Analysis using Recall that the steady-state temperature measured at the tip of the
a Thermostat middle terminal reached approximately 165oC.
We would like to keep the maximum operating temperature at the
middle terminal below 120oC. To achieve this, the heat power
generated by the microchip needs to be controlled. This can be
simulated by the thermostat feature available in SOLIDWORKS
Simulation.
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Lesson 7 SOLIDWORKS
Thermal Analysis
Where to Find It. Shortcut Menu: Right-click Thermal Loads in the simulation
study tree and click Heat Power
CommandManager: Simulation > Thermal Loads > Heat Power
Menu: Simulation, Loads/Fixture, Heat Power
Use in Instructions In the Heat Power PropertyManager, click the check box next to
Thermostat (Temperature).
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Question: How does the addition of Thermostat change the Heat Power
definition?
Answer: The temperature in the selected location is now monitored. If the
temperature raises above 120oC, the heat power is turned off. If it drops
below 100oC, the heat power is turned on again. The Thermostat
feature is available only for transient thermal analysis.
3 Modify time increment.
Right-click transient 03 and select Properties.
In the Time increment box, enter 5 sec. This will increase the solution
time but will provide more accurate results.
4 Run the analysis.
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Lesson 7 SOLIDWORKS
Thermal Analysis
Symmetry Thermal boundary conditions are easier to use than structural boundary
Boundary conditions because nothing needs to be defined on the faces that fall on
Condition in the plane of symmetry.
Thermal Analysis
As we said before, the absence of convection coefficients means that
the faces are insulated; there is no heat flowing through them (heat flux
in the direction normal to the symmetry face is zero). This is exactly
what happens in the absence of any thermal conditions.
Summary In this lesson, the mechanisms of heat transfer: conduction, convection
and radiation were introduced. Different types of thermal analysis
require specific material properties to be input. Comparing structural
and thermal analyses, we found that because of close and direct
analogies, expertise in structural analysis can be easily transferred to
thermal analysis. We eventually used those analogies to identify
singularities in the thermal analysis results.
The concept of a thermal resistance layer was introduced. The use of a
thermal resistance layer allows for a significant simplification of the
finite element model, yet it accurately models heat transfer through a
boundary between assembly components.
We performed both steady-state and transient thermal analyses.
Transient thermal analyses require the definition of initial temperatures,
whereas, steady-state thermal analyses are independent of initial
temperatures.
Time curves were used to define a time-dependent heat power load. We
learned that other entities, such as the convection coefficient and bulk
temperature, can also be made a function of time or temperature.
Finally, the Thermostat feature was defined to control the temperature
at a specific location by adjusting the generated heat power in a
transient analysis.
Questions 1. The three basic modes of heat transfer are: 1. ________ , 2.
________ and 3. ________ .
2. The only unknown in the thermal simulation is (temperature /
temperature gradient / heat flux).
3. While (temperature / temperature gradient / heat flux) is a scalar
quantity and has no sense of direction, (temperature / temperature
gradient / heat flux) are vector quantities and have X, Y and X
components.
4. Heat transfer coefficient (is / is not) one of the results from the
thermal simulation study.
5. Heat transfer coefficient (is / is not) required when specifying the
radiation boundary condition.
6. If run for sufficient amount of time, transient thermal study (must /
does not) always lead to a steady state situation.
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SOLIDWORKS Exercise 8
Thermal Analysis of a Cup
Exercise 8: In this exercise, you will perform a thermal analysis on a cup housing
Thermal that encloses a rotating shaft.
Analysis of a This exercise reinforces the following skills:
Cup Steady-State Thermal Analysis on page 117
Convection on page 112
Vector Plots from the SOLIDWORKS Simulation training manual
Problem Find the steady state temperature distribution of the cup housing due to
Statement the heat produced by a rotating shaft which is in contact with the cup.
Use the Heat Flux command to generate the heat coming from the
rotating shaft.
Procedure Follow the procedure below:
1 Open a part file.
Open Cup from the Lesson06\Exercises folder.
2 Create thermal analysis study.
Create a study named thermal study one. Select Thermal as the
Analysis type.
3 Define material properties.
Select Manganese Bronze (under Copper category).
4 Define heat flux.
Select the inside face. Apply a Heat
Flux of 8177 W/m2 [0.005 BTU/
s/in2].
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Exercise 8 SOLIDWORKS
Thermal Analysis of a Cup
10 Evaluate results.
To examine the accuracy of your results, define a new study and repeat
the analysis with a finer mesh. When you run the analysis with the
finest mesh setting, you will see the same results as in our first study.
Therefore, we know our results are quite accurate for both studies.
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SOLIDWORKS Exercise 8
Thermal Analysis of a Cup
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Exercise 8 SOLIDWORKS
Thermal Analysis of a Cup
138
Lesson 8
Thermal Analysis with
Radiation
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Lesson 8 SOLIDWORKS
Thermal Analysis with Radiation
Case Study: In this case study, we will perform a steady-state thermal analysis of a
Spot Light spot light assembly with radiation. We will learn about radiation as a
Assembly heat transfer mechanism and how it works. The properties that define
heat transfer will be discussed. We will also comment on when
radiation will become a dominant mode of heat transfer and when it can
be ignored.
Project An aluminum reflector and the glass cover house a light bulb producing
Description 50 W [0.0475 BTU/s] of heat power.
Aluminum Reflector Air Side
Vacuum
Side
Convection
Radiation
Glass Aluminum
Glass Bulb
Cover Housing
Glass Cover
Conduction
The reflector side of the aluminum housing as well as the inside face of
the glass cover are exposed to a vacuum. Both the back side of the
housing and the front side of the glass cover are then exposed to air.
Our objective is to find the steady state temperature distribution of the
reflector housing and the glass cover due to the heat produced by the
light bulb. Certain assumptions on the environment as well as the
geometry were made.
Let’s review the heat transfer mechanism in the model. What happens
to the heat generated by the light bulb?
Some of the heat produced by the light bulb is radiated out directly into
the glass cover and the reflector. A small portion of it enters the
reflector directly through the base of the bulb by conduction. Heat that
has reached the reflector either by radiation or conduction is partially
radiated out and partially transferred by conduction through the
aluminum material to the air side of the reflector. It is then dissipated
by convection to the ambient air. Similar mechanism applies also in the
case of the glass cover.
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SOLIDWORKS Lesson 8
Thermal Analysis with Radiation
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Lesson 8 SOLIDWORKS
Thermal Analysis with Radiation
Introducing: Radiation allows for heat to enter or leave a surface due to radiation. It
Radiation is defined by an emissivity of the surface as well as an ambient
temperature of the surroundings.
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SOLIDWORKS Lesson 8
Thermal Analysis with Radiation
Select the outside faces of the light bulb, and under Type, select
Surface to Surface.
This selection means that the selected face radiates heat to the other
surfaces in the model.
The Open system check box should remain unchecked. This selection
accounts for the fact that some heat may be radiated out directly into
space rather than to the reflector or the glass cover. This is, however,
not the case here as all the heat is received by either of the two.
Also under Radiation Parameters, enter 0.7 as the Emissivity for the
bulb material.
Click OK.
Note As was explained in Lesson 7: Thermal Analysis, emissivity is a
material property that depends on the surface temperature and the
surface finish of the body. The emissivity of a black body is 1. The
emissivity of a perfect reflector is 0.
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Lesson 8 SOLIDWORKS
Thermal Analysis with Radiation
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SOLIDWORKS Lesson 8
Thermal Analysis with Radiation
Note In this simulation we assume that the glass cover can be modeled as a
black body. This assumption is, however, not very accurate and will
result in increase of the cover temperature. Correct solution for models
with glass components would require additional parameters such as
radiation absorption available in the HVAC module of SOLIDWORKS
Flow Simulation.
8 Radiation condition on the glass cover - external face.
The external face of the glass cover emits all energy to the ambient
space.
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Lesson 8 SOLIDWORKS
Thermal Analysis with Radiation
Review of Analysis The mechanism for heat transfer has been fully defined. This completes
Parameters the model setup for the thermal analysis.
In preparation for this steady-state thermal analysis, we have defined
the coefficient of convection, heat power, and emissivity. The only
thermal quantity we do not use in this lesson is a heat flux load (heat
power per unit of area).
If a transient thermal analysis was required, then all three quantities
could have been defined as functions of time using time curves.
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SOLIDWORKS Lesson 8
Thermal Analysis with Radiation
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Lesson 8 SOLIDWORKS
Thermal Analysis with Radiation
14 Temperature of glass
cover.
Set the upper limit of
the legend to the
maximum value of
200°C, the maximum
design temperature on
the outside surfaces.
Using the Probe
function we can see that
the maximum
temperature on the
external face of the
glass cover is 316°C,
well above the design limit of 200°C.
It can be seen, that the design temperature of the glass cover external
surface was not met and is of a serious concern. The result indicates
that substantial design changes, including those of using less powerful
bulb, may be required.
However, as mentioned in the Note on page 145, more accurate
modeling of response of glass material to radiation is required.
It also needs to be concluded, that more accurate geometry of the bulb
along with its integral heat sinks may be required. We can therefore
also conclude that this model is too coarse in its problem description.
Heat Flux Recall the L-bracket lesson (see Lesson 2, in the SOLIDWORKS
Singularities Simulation training manual) where we identified stress singularity in a
sharp re-entrant corner.
To conceptualize the singularity of heat flux in a sharp re-entrant edge,
it helps to use the direct analogy between heat flux and stress. Just like
a structural analysis of a model with a sharp re-entrant edge cannot
have a stress solution in the sharp re-entrant edge, a thermal analysis
cannot find heat flux solution in the sharp re-entrant edge. Because of
discretization error, infinite stress does not show, but the heat flux
results are entirely dependent on the element size used to mesh the
edge. With mesh refinement, the heat flux tends to infinity.
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SOLIDWORKS Lesson 8
Thermal Analysis with Radiation
The heat flux concentrations are coincident with the sharp re-entrant
edges. However, as we learned in Lesson 7: Thermal Analysis, heat
flux results in sharp re-entrant edges are meaningless. Theoretically
these results are singular (or infinite).
Summary In this lesson, we have analyzed a steady state heat transfer problem
with conduction, convection, and radiation.
We observed that heat transfer problems with radiation take
considerably more time because the computation of the view factors is
required. We also concluded that radiation as a heat transfer mode
becomes more prominent with increased temperatures.
We also explained that modeling of glass components subjected to
incident radiation needs more sophisticated approach available in the
HVAC module of SOLIDWORKS Flow Simulation.
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Thermal Analysis with Radiation
150
Lesson 9
Advanced Thermal Stress
2D Simplification
Objectives Upon successful completion of this lesson, you will be able to:
Perform thermal stress analysis of assemblies.
Utilize 2D simplification to reduce the problem size.
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Lesson 9 SOLIDWORKS
Advanced Thermal Stress 2D Simplification
Thermal Stress Let us pause for a moment and explain thermal stress analysis, and how
Analysis it is handled by SOLIDWORKS Simulation. Thermal stress analysis is
a type of static analysis, which is a subgroup of the structural class of
problems. Thermal analysis does not belong to this group.
In addition to all regular structural loads, such as forces and
displacements, thermal stress analysis enables the inclusion of loads
due to the constrained thermal expansion or contraction.
In thermal stress analysis, loads due to thermal effects are defined as
nodal temperatures that are imported from the thermal study.
Analysis Name in
Analysis
Analysis Type SOLIDWORKS
Classification
Simulation
Static Static Structural
Thermal stress Static Structural
Thermal Thermal Thermal
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SOLIDWORKS Lesson 9
Advanced Thermal Stress 2D Simplification
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Lesson 9 SOLIDWORKS
Advanced Thermal Stress 2D Simplification
3D model 2D Simplification
The 3D thin wall can be represented as 2D model without any
significant loss of accuracy.
Plane strain: 3D structure loaded by in plane loads and fixed in the
axial direction so that an extension of the model is restricted can be
represented as 2D problem with negligible loss of accuracy.
Consider the example of a pipe (see the figure below), restricted in
axial directions at its ends and subjected to an internal pressure and
temperature loads. Because the pipe is restricted in the axial
direction, we can conclude that it only deforms in its planar
directions (strains occur only in the planar directions, hence the
name plane strain).
3D model 2D Simplification
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Advanced Thermal Stress 2D Simplification
3D model 2D Simplification
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Lesson 9 SOLIDWORKS
Advanced Thermal Stress 2D Simplification
2 Symmetry.
Activate Symmetry configuration to reduce the model size.
3 Create thermal analysis study.
Create a new Thermal study named t distribution.
Click the Use 2D Simplification checkbox located in
the Options dialog.
Note Because the model geometry can be created by revolving the cross-
section profile about an axis, and because all loads are axi-symmetrical,
we can reduce the 3D into a 2D model.
Click OK.
4 2D Simplification
options.
In the 2D Simplification
property manager, specify
Axi-symmetric, select
Front Plane as Section
plane and Axis1 as Axis
of symmetry.
Click OK.
Note Use the Use other side checkbox to switch the side of the cut.
The 2D cut on the new
plane named t
distribution will be
generated. The simulation
model will be built on this
geometry.
5 Materials.
The material properties transfer automatically to SOLIDWORKS
Simulation from the SOLIDWORKS assembly model.
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SOLIDWORKS Lesson 9
Advanced Thermal Stress 2D Simplification
Flange detail
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Lesson 9 SOLIDWORKS
Advanced Thermal Stress 2D Simplification
Flange detail
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SOLIDWORKS Lesson 9
Advanced Thermal Stress 2D Simplification
8 Mesh assembly.
Mesh the assembly with High quality elements. Move the Mesh Factor
all the way to the Fine position to set the Maximum element size to
0.97428mm [0.038357 in]. Use Curvature based mesh.
Note Notice that even with fine setting the 2D mesh completes very quickly.
We were able to fit 2 elements through the thickness of the Bellow.
This could be considered a minimum for reasonable temperature
results.
9 Run the analysis.
The simulation completes in a couple of seconds.
10 Resulting temperatures.
We can see that the temperature in the bellow wall is nearly constant.
Probing on the outside walls shows that the temperature drop is no
more than 2° to 3°C.
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Advanced Thermal Stress 2D Simplification
11 3D plot.
Right-click the resulting temperature plot and select Show as 3D Plot.
The temperatures shown in 3D adds realism to the way the results can
be presented. The cut wedge size can be edited and is used to show the
distribution through the thickness of the walls.
12 Create a vector plot of heat flux.
Right-click the Results folder and select Define Thermal Plot.
Select HFLUXN: Resultant Heat Flux for the Component and W/m^2
for the Units.
Click Show as vector plot.
Click OK.
The arrows clearly indicate the direction of the heat flow through the
walls of the bellow and through the flange.
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Advanced Thermal Stress 2D Simplification
Note To change the arrow size, right-click the plot and select Vector Plot
Options.
Note that the model geometry features sharp re-entrant edges where
heat flux values are singular. This is directly analogous to stresses
being singular at similar locations in a structural analysis.
Thermal Stress Having calculated the temperature distribution, we can now proceed
Analysis with the static stress study.
1 Create a static study.
Create a Static study named thermal stress.
Under Options check the Use 2D Simplification checkbox.
Follow the procedure in step 4 to complete the definition of a 2D axi-
symmetrical static stress study.
2 Include thermal effects in analysis.
Right-click the thermal stress study and select Properties.
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SOLIDWORKS Lesson 9
Advanced Thermal Stress 2D Simplification
5 Flange condition.
The expansion joint flanges are
bolted to the flanges of the
connecting pipes. While
significant deformations and
stresses of the Bellow are
caused by its temperature load
(steps 6 and 7), we must not
forget that the entire piping
system is subjected to the same
temperature environment. The
entire system therefore
thermally expands. This
system expansion causes
significant deformations and
stresses and can lead to a
serious system failure. Crucial
function of the expansion joint
is to alleviate these stresses by
means of deforming its soft
bellow. We will simulate the
effect of the system expansion
as prescribed horizontal
displacement of 4mm.
Right-click the Fixtures and
select Advanced Fixtures.
Select the indicated edge of the Flange and specify 4mm in the Along
Plane Dir 1 field.
Click OK.
Note The Front Plane is the default choice for the reference entity in 2D
model and can not be changed.
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Lesson 9 SOLIDWORKS
Advanced Thermal Stress 2D Simplification
6 Pressure.
The low pressure steam is transported
at a pressure of 3 bars [0.3 MPa,
43.51 psi].
Right-click the External Loads
folder and select Pressure.
Select the three edges indicated in the figure. Additionally, select the
remaining internal faces of the Bellow. Enter 0.3 N/mm^2 (MPa).
Click OK.
Note We could use mesh of the same density as in the thermal study.
However, because the walls of the Bellow are severely bent as it
expands and deforms, three to four high quality elements through the
thickness are required for reliable stress solution.
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SOLIDWORKS Lesson 9
Advanced Thermal Stress 2D Simplification
9 Mesh assembly.
Mesh the assembly with High quality elements. Move the Mesh Factor
all the way to the Fine position to set the Maximum element size to
0.97428mm [0.038357 in]. Use Curvature based mesh.
Note With the above mesh density we were able to fit 4 elements in the
Bellow.
10 Mesh details.
For the book keeping purposes, review the details of the mesh. Note,
that the 2D mesh features approximately 26000 nodes. In 2D, and
without any additional contact conditions, the solution of such
simulation poses no problem.
11 Run the thermal stress study.
It takes a couple of seconds to complete the study.
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Advanced Thermal Stress 2D Simplification
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SOLIDWORKS Lesson 9
Advanced Thermal Stress 2D Simplification
Introducing: Energy The Energy norm error is calculated based on differences between
Norm Error nodal and element stresses (see the Introduction to Analysis lesson of
the SOLIDWORKS Simulation training manual for the definition of
nodal and elemental stresses). Although it provides a measure of the
error in energy norm, not in stress, it can still be viewed to represent the
relative distribution of stress errors in homogeneous meshes. High
values at the regions with sharp re-entrant corners should, therefore, be
ignored.
Apart from singularities, if a high stress error coincides with the
location where stress results are of interest, these stress results cannot
be considered reliable.
Where to Find It Shortcut Menu: Right-click Results in the simulation study tree
and click Define Stress Plot
CommandManager: Simulation > Results Advisor > New Plot >
Stress
Menu: Simulation, Plot Results, Stress
Use in Instructions Under Display, select ERR: Energy Norm Error as the Component.
The low magnitudes suggest that the stress results in the bellow are
reliable.
Note The stresses in the model are predominantly affected by the prescribed
displacement and temperature. You can verify yourself that both are
nearly equally contributing to the maximum stress result. The
contribution of the pressure load is minimal.
3D model We mentioned that 2D simplification leads to a dramatic reduction in
the model size. To demonstrate this fact, we will now attempt the
solution with the traditional 3D approach.
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Lesson 9 SOLIDWORKS
Advanced Thermal Stress 2D Simplification
15 Model Configuration.
Change the configuration to 3D
symmetry.
18 Mesh details.
Note that this mesh features staggering 1.5 million of nodes while we
only have two elements meshing the wall of the bellow. This represents
nearly a 5750% increase compared to the 2D mesh. As you can see, the
current 3D model is not the best way to approach this problem.
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SOLIDWORKS Lesson 9
Advanced Thermal Stress 2D Simplification
It can be observed that the stress solution is very close to that obtained
form the 2D model. However, the size and the time required to obtain it
clearly shows that a 3D approach would not be a suitable choice here.
Summary We conducted a two step simulation of the expansion joint, a part of the
piping system transporting low pressure hot steam. The solution was
obtained in two steps.
First, a thermal study was conducted with the primary objective of
calculating temperatures for the thermal stress study. Then, a thermal
stress study was conducted with a model that was properly restrained
and loaded by the temperatures obtained in the thermal study. In
addition to the temperature load, the bellow of the joint was loaded by
the steam pressure and the prescribed displacements representing the
expansion of the piping system due to the same temperature load.
The maximum stress in the model reached approximately 363 MPa in
the bellow. Because this magnitude significantly exceeds the material
yield strength, the below design has to be modified. Because the bellow
is loaded cyclically, the next step in the validation of the design would
be fatigue simulation.
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Lesson 9 SOLIDWORKS
Advanced Thermal Stress 2D Simplification
170
SOLIDWORKS Exercise 9
Thermal Stress Analysis of a Microchip Testing Assembly
Exercise 9: In this lesson, you will analyze a microchip testing assembly consisting
Thermal Stress of a ceramic insert, a nylon housing, and an acrylic gasket.
Analysis of a This exercise reinforces the following skills:
Microchip Convection on page 112
Testing Heat Flux on page 122
Assembly Thermal Stress Analysis on page 161
positioned on a platform
inside the testing chamber; it
is not connected to any other
secondary structure. Housing
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Exercise 9 SOLIDWORKS
Thermal Stress Analysis of a Microchip Testing Assembly
4 Heat power.
Define 5 W [0.004739 BTU/s]
Heat power on the microchip
part.
Microchip
Note The sign of heat power distinguishes between heat entering (heat
source) and heat leaving the model (heat sink). “+” denotes heat power
(or heat flux) entering the model, “-” denotes leaving the model.
5 Convection on assembly outside faces.
Apply Convection to the outside faces, as shown in the figures below.
Specify 300 W/m2K [0.0001 BTU/s in2°F] as the Convection
Coefficient and 298K [25°C, 77°F] for the Bulk temperature.
Note The top face is not selected for the convection because it is not exposed
to the air flow. instead, a constant temperature is assigned to it in the
next step.
6 Temperature on face of acrylic Prescribed Temperature
gasket.
Apply 65°C [338.15°K or 149°F]
Temperature on the top face of the
acrylic gasket.
7 Mesh controls.
Apply mesh controls to the microchip component. Use the default
local Element size of 1.55mm [0.06in] and the default settings for the
Ratio parameter.
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SOLIDWORKS Exercise 9
Thermal Stress Analysis of a Microchip Testing Assembly
8 Mesh assembly.
Mesh the assembly with Draft quality elements and the Maximum
element size of 3.10mm [0.122 in]. Use Curvature based mesh.
Note The gasket part was hidden in the above figure to see the details of the
housing geometry.
9 Run the analysis.
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Exercise 9 SOLIDWORKS
Thermal Stress Analysis of a Microchip Testing Assembly
Thermal Stress Having calculated the temperature distribution, you can now proceed
Study with the static stress analysis.
1 Create a static study.
Create a Static study named th stress.
2 Include thermal effects in analysis.
Include the temperature load in the stress study and set the Reference
temperature at zero strain to 25°C [77°F].
3 Study properties.
Utilize the Use inertial relief option to stabilize the model.
Note Use of this feature further reflects the fact that the assembly is placed
into the test chamber free of any external constraints.
4 Bolt connectors.
Define two Standard or Counterbore
Screw connectors threaded into the
acrylic base. The bolts have the
following parameters:
Head Diameter = 10mm [0.394in],
Nominal Shank Diameter = 6.35mm
[0.25in], Tight fit = OFF, Material =
AISI 1020 Steel, Preload = 90 N
[20.23 lb] Axial force.
5 Gasket vs. housing interface.
Define a No penetration, Surface
to Surface contact between the
touching faces of the gasket and
the housing.
6 Mesh control.
Apply identical mesh control to microchip.
7 Mesh assembly.
Mesh the assembly with Draft quality elements and the Maximum
element size of 3.10mm [0.122 in]. Use Curvature based mesh.
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SOLIDWORKS Exercise 9
Thermal Stress Analysis of a Microchip Testing Assembly
We notice that, as expected, the gasket has slightly separated from the
housing.
Note Because the model is not restrained, the absolute values of the
displacements may be misleading. This is due to the fact that the entire
model may have slightly displaced as rigid body.
Change in Thermal The fact that the gasket separates from the housing due to structural
Boundary behavior changes the boundary conditions for the thermal analysis. The
Conditions global contact in the thermal analysis was set as bonded. This means
that there was zero thermal resistance between the gasket and housing.
Heat was allowed to pass through the interface perfectly. A zero
thermal resistance condition between the gasket and the housing
becomes invalid as soon as the gasket separates from the housing. A
nonlinear analysis would be required to capture this effect.
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Exercise 9 SOLIDWORKS
Thermal Stress Analysis of a Microchip Testing Assembly
The energy norm error confirms our conclusions on the mesh quality in
the vicinity of the microchip component and around the bolt holes.
Finer mesh would be needed in this region in order to obtain more
reliable stress data.
176
SOLIDWORKS Exercise 9
Thermal Stress Analysis of a Microchip Testing Assembly
177
Exercise 10 SOLIDWORKS
Thermal Stress Analysis of a Gas Tank
Exercise 10: In this exercise, you will perform a thermal stress analysis on a propane
Thermal Stress tank.
Analysis of a This exercise reinforces the following skills:
Gas Tank Convection on page 112
Heat Flux on page 122
Thermal Stress Analysis on page 161
Note An online calculator for heat flux due to solar radiation, in different
parts of the USA, can be found on the web site: http://rredc.nrel.gov/
solar/old_data/nsrdb/redbook/atlas/Table.html. In this study, the solar
heat flux on the propane tank was calculated in San Diego, CA in the
month of June.
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SOLIDWORKS Exercise 10
Thermal Stress Analysis of a Gas Tank
While the outside face temperature should not pose any problems, the
maximum temperature on the inside face may be controlled to limit the
expansion of the gas.
179
Exercise 10 SOLIDWORKS
Thermal Stress Analysis of a Gas Tank
Direction of point
selection for
Probe feature
Define a section plot using Plane1 and probe the temperatures in the
section plot.
In the Probe dialog, form a path by selecting points in the direction
shown in the figure above.
11 Graph temperatures.
In the Probe Results window, under Report Options, click the Plot
button to generate a path plot of the variation of the temperature along
the specified trajectory.
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SOLIDWORKS Exercise 10
Thermal Stress Analysis of a Gas Tank
Thermal Stress The results from the thermal analysis will now be used to perform a
Analysis thermal stress analysis.
1 Create a thermal stress analysis.
Create a new Static study named static study to determine the
stresses and displacements induced in the tank if it was left out in the
sun for 3 hours. Copy the material properties from the previous study.
2 Apply restraints.
Select the face where the tank is attached to
the grill. Also, select an edge at the top
where the lifting ring holds the tank. Apply
a Fixed Geometry fixture to these entities.
3 Setup thermal stress analysis.
Right-click on the static study and choose
Properties.
Click the Flow/Thermal Effects tab.
Select Temperature from thermal study
and select steady state.
Set the Reference temperature at zero strain as 289K [16°C or
60°F].
4 Mesh the model.
Mesh the model with the same settings.
5 Run the analysis.
6 Plot displacement.
We can see that the tank expanded on the sunny side of the face.
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Exercise 10 SOLIDWORKS
Thermal Stress Analysis of a Gas Tank
The stress of 126 MPa is well below the Yield strength of the material
(620 MPa). We can see, however, that the stresses are rather localized
at the location of the fixture. Because the tank is so thin, it is a perfect
candidate for meshing with shell elements, so surfaces would need to
be created if this were desired.
182
SOLIDWORKS Exercise 11
Thermal Stress Analysis of a Thermoelectric Cooler
183
Exercise 11 SOLIDWORKS
Thermal Stress Analysis of a Thermoelectric Cooler
Solder Bismuth
Alumina
Sn-40Bi- Telluride
(Al2O3)
0.1Cu (Bi2Te3)
184
SOLIDWORKS Exercise 11
Thermal Stress Analysis of a Thermoelectric Cooler
Loading In this problem we are concerned with the structural integrity of the
Conditions TEC when exposed to the maximum designed loading conditions, i.e.
the maximum temperature differential of 55°C. Therefore, the
boundary conditions of the problems are set to their typical values, as
depicted in the figure below.
Convection 5 W/(m^2.K)
on all exposed TEC faces
Convection 20 W/(m^2.K) on
specimen channel (outside faces only)
and the heat sink No convection on inside
faces of specimen channel
Theat sink=60°C
(surface temperature)
Goal Perform necessary simulation to help you decide whether the solder
joints and the Bismuth Telluride pellets are designed safely or are likely
to fail.
The assembly file Device for this exercise is located in the
Lesson06\Exercises folder.
As you are building the simulation study, consider the following points:
Can I simplify the geometry and use smaller model to solve the
problem?
How fine mesh and in what regions of the model do I need to solve
the problem reliably?
How do I efficiently apply convective conditions on all exposed
faces?
185
Exercise 11 SOLIDWORKS
Thermal Stress Analysis of a Thermoelectric Cooler
186
Lesson 10
Fatigue Analysis
Objective Upon successful completion of this lesson, you will be able to:
Understand the basic concepts in fatigue.
Understand the required information to proceed with fatigue
analysis.
Understand the concept of S-N curves.
Setup a fatigue analysis with multiple constant amplitude events.
Evaluate results of a fatigue analysis.
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Lesson 10 SOLIDWORKS
Fatigue Analysis
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SOLIDWORKS Lesson 10
Fatigue Analysis
High vs. Low Based on the stress magnitudes and the expected number of cycles
Cycle Fatigue needed to cause the damage, fatigue can be divided into the following
two basic groups:
High Cycle Fatigue, where the magnitudes of alternating stresses
are moderate and cause none or small levels of plastic deformations
in the material. The parts loaded in this manner are assumed to
resist a high number of loading cycles (from 1000 to 1e6 cycles)
before the fatigue failure occurs.
The method used to describe high cycle fatigue is referred to as a
stress-life (S-N) based approach. The material resistance against a
certain number of loading cycles is reflected in the S-N curve,
which typically relates the number of cycles at certain stress level
required to cause fatigue failure. The fatigue analysis available in
SOLIDWORKS Simulation is based on this approach and is the
subject of further discussion in the remainder of the training
manual.
Low Cycle Fatigue, where the alternating stresses have higher
magnitudes, causing significant plastic deformations. Due to the
high stress levels, parts subjected to the repetitive loading tend to
fail under a relatively small number of cycles, hence the name Low
Cycle Fatigue. The strain-life based approach, suitable for the
description of this class of problems, requires special codes and is
not part of the current release.
Stress-life (S-N) The SOLIDWORKS Simulation Professional training manual (along
Based Fatigue with the accompanying training lessons) treats the stress-life (S-N)
based approach to high cycle fatigue in detail.
Fatigue Loading In general, structures experience various types of loading histories over
the course of their service lives. The type of loading history may be
rather simple (the definition of some maximum/minimum load is
clearly defined) or random (the description is significantly more
complex). However, even some random loading histories may exhibit
such characteristics that enable us to treat them as deterministic
loading.
In general, the loading histories can be divided into two distinct groups:
constant amplitude loading
variable amplitude loading
189
Lesson 10 SOLIDWORKS
Fatigue Analysis
Constant Amplitude All cycles of a constant amplitude event have the same alternating and
Loading mean stresses. A constant amplitude fatigue event is fully defined by an
alternating stress, mean stress, stress ratio, and the number of cycles.
The terms characterizing the constant amplitude event are described as
follows:
Stress
Time
Smax and Smin are the maximum and minimum stress magnitudes in
a stress cycle.
Salt is the alternating stress.
Smean is the mean stress calculated from Smean = (Smax + Smin) / 2.
Mean stress magnitude has a significant impact on the fatigue
resistance of the structures and is discussed in more detail later in
the lesson.
Stress ratio R = Smin / Smax. Two typical loading histories, zero
based and fully reversed, are shown in the figures below with the
corresponding values for R and Smean.
Stress
Stress
Time
Time
190
SOLIDWORKS Lesson 10
Fatigue Analysis
Case Study: In this lesson, we will perform a constant amplitude fatigue analysis of
Pressure Vessel a pressure vessel. The pressure vessel is subjected to both a pressure
and thermal loading cycle. We will learn how to define the S-N curve
that governs fatigue failure. The interaction of multiple loading events
will be discussed. In addition, we will learn how to properly interpret
fatigue results. Finally, we will see the effect of a constant, unchanging
load on the fatigue study.
Project
Description
An Aluminum Alloy 7075-T6 pressure vessel is
to undergo an evaluation for fatigue life of
constant amplitude pressure and thermal stress
loading. The pressure loading oscillates between
negative 0.066 MPa [9.57 psi] (-0.066 MPa [-
9.57 psi]) and 3.3 MPa [478.6 psi]; the thermal
stress is due to a heat flux oscillation between 0
and 1471.8 W/m^2 [0.0009 Btu/(s-in^2)].
In the second part of this lesson the pressure vessel will be additionally
loaded by a significant dead load applied at the center of the top lid.
Our objective is to determine whether or not the vessel will fail after
2,000,000 thermal and 1,900,000 pressure loading cycles.
Stages in the Because of the various loading conditions that the vessel will undergo,
Process there are a number of steps to set up the fatigue analysis:
Thermal study
The thermal study applies a heat flux to the inside of the vessel as
well as convection on the outside.
Thermal stress study
A static study will be needed to see the thermal expansion effects of
the thermal study.
Static study
The second static study needed will be the 3.3 MPa [478.6 psi]
pressure load applied to the inside of the pressure vessel.
Fatigue study
The fatigue study will take into account all of the loading
conditions and run them on the model for a specified number of
cycles.
Postprocess the results
Once the fatigue study is run, the results must be analyzed to decide
if failure has occurred.
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Lesson 10 SOLIDWORKS
Fatigue Analysis
192
SOLIDWORKS Lesson 10
Fatigue Analysis
Thermal Study We will first run the thermal study so that the temperature results can be
exported to the thermal stress study.
4 Mesh Thermal study.
Create a Draft quality mesh with the following parameters:
Maximum element size:101.5784mm,
Minimum element size: 5mm,
Thermal Stress Having completed the Thermal study, we can proceed and compute
Study the thermal stresses.
The static study for the thermal stress analysis contains a bolt and no
penetration contact. To take these conditions into account, we must
create a new mesh. The mesh from the Thermal study cannot be
copied because it has different contact conditions.
7 Mesh Thermal stress study.
Create mesh with the same parameters as in the step 4.
8 Define material for Thermal stress study.
Verify that 7075-T6 (SN) Aluminum alloy is assigned to both parts.
9 Set Thermal stress study properties.
In the Flow/Thermal Effects tab, make sure that the temperature is
read from the Thermal study and that the Reference temperature at
zero strain is set to 25°C [77°F].
10 Run Thermal stress analysis.
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Lesson 10 SOLIDWORKS
Fatigue Analysis
11 Stress results.
We can see that the pressure vessel stress is very high with the
maximum magnitude close to 1026 MPa, well above the yield strength
of the material, 505 MPa.
12 Stress results - plot limits.
Modify the maximum of the legend to show the Yield strength of the
7075-T6 Aluminum, 505 MPa.
We can observe that the stresses above the yield strength are localized
in the vicinity of the bolt head/nut. As this is the location of the
theoretical bolt connector, the stress concentrations in this location are
not real and will be ignored. The thermally induced stresses in the rest
of the vessel are relatively small.
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SOLIDWORKS Lesson 10
Fatigue Analysis
Static Pressure The last study necessary is the static pressure study. The fatigue
Study analysis will use the results of all of the previous studies to determine
failure.
13 Define material for Static Pressure study.
Assign the same Aluminum 7075-T6 Alloy (SN) to both parts.
14 Mesh pressure study.
Copy the mesh from the Thermal stress study into the Static
Pressure study.
Note Because the Thermal stress and the Static Pressure studies are
used in the fatigue study, they both must have identical meshes.
15 Run Static Pressure study.
Each analysis should take less than 5 minutes to completely run
through. You may review the results if you wish. The stresses from
these studies will serve as basic input for the fatigue analysis.
16 Stress results.
We can see that the pressure vessel stress is very high with the
maximum magnitude close to 1283 MPa, well above the yield strength
of the material, 505 MPa.
195
Lesson 10 SOLIDWORKS
Fatigue Analysis
We can observe that the stress above the yield strength are localized in
the vicinity of the bolt head/nut. As this is the location of the theoretical
bolt connector, the stress concentrations in this location are not real and
will be ignored. Detailed simulation of the bolted connection would be
required.
18 Stress results - detail.
Zoom onto the areas of high stress and probe the critical regions.
It can be seen that the stresses distant from the stresses concentrations
are below the yield strength of the material.
Note For high cycle fatigue, the stresses must remain below the yield
strength of the material. You can verify that combining both thermal
stress and stress caused by the pressure does not exceed this value. We
can therefore proceed with the fatigue study.
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SOLIDWORKS Lesson 10
Fatigue Analysis
Fatigue Before continuing with the fatigue study, let’s review some more
Terminology terminology related to stress-life based fatigue and how it is defined.
S-N Curve The behavior of the material in the high cycle fatigue is characterized
by the relation between the alternating stresses (Salt) and the
corresponding number of cycles (N) to failure. A typical S-N curve is
shown in the figure below.
Stress (ksi)
Fatigue strength at
106 cycles
Endurance limit
Fatigue Strength This is the stress at which fatigue failure occurs at a given number of
cycles.
Endurance Limit As the alternating stress gets smaller, the material can take more stress
cycles before it fails due to fatigue. The endurance limit is the highest
alternating stress that does not result in fatigue failure. In other words,
if the alternating stress is equal to or lower than the endurance limit, the
number of stress cycles to cause failure becomes very large (practically
infinite). The endurance limit is usually defined for fully reversed
alternating stresses. The endurance limit is also called the fatigue limit.
Some metals do not have a measurable endurance limit.
Mean Stress Because the stress levels at various locations in the model are different,
Influence the magnitudes of Smax, Smin, and Smean will vary throughout the
model. In other words, each material point will experience different
mean stress magnitude. Because the mean stress has a significant
impact on the fatigue resistance, it is possible to enter up to ten S-N
curves with different stress ratios (R) for each material type. Typically,
only fully reversed (R=-1) fatigue test data is available, and the
influence of the mean stress is accounted for approximately with the
Goodman, Gerber, or Soderberg mean stress correction algorithms; all
three are described later in this lesson.
197
Lesson 10 SOLIDWORKS
Fatigue Analysis
Reliability of S-N Because the results of the fatigue computations are directly dependent
Curve Data on the S-N curve(s) data, the data’s importance cannot be
overestimated.
The most accurate data can be obtained from fatigue testing of the
actual product, or a typical product of the same type and material. As
this is not feasible in most cases, a generic material S-N curve available
in various publications must be used. In most of the cases, the available
curves are obtained from uniaxial fatigue testing on fully reversed
stress cycles. If curves for different mean stress ratios are available, it is
recommended to use them over the mean stress correction algorithms
discussed later in this lesson.
It is also important to note that S-N curves exhibit significant data
scatter, especially at higher cycles. For this reason, most design
handbooks suggest a reliability factor of 0.52, reducing the fatigue
strength. It is always the responsibility of the analyst to verify the
trustworthiness of the material data source.
S-N Curve The interpolation between the S-N data points can be done using the
Interpolation following three schemes:
Log-log - Logarithmic interpolation (base 10) for the number of
cycles and the alternating stress. Use this option when the defined
S-N curves have few data points that are widely scattered on both
axes (number of cycles and alternating stress).
Semi-log - Linear interpolation for stress and logarithmic for
number of cycles. Use this option when the defined S-N curves has
a relatively small stress range compared to the variation in number
of cycles.
Linear - A linear interpolation for both stress and number of cycles
is used. Use this option when the defined S-N curves have many
data points.
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SOLIDWORKS Lesson 10
Fatigue Analysis
Example Suppose that you defined an S-N curve that has the following two data
points (in addition to others):
For a stress of 45,000 psi, the program reads the number of cycles
based on the S-N interpolation scheme as follows:
103.944 = 8,790.
Semi-Log S-N Curve - The X-axis S
represents the logarithm of the
number of cycles and the Y-axis 50,000
represents the stress. At stress
45,000
value of 45,000 psi, the program
performs linear interpolation and 40,000
calculates the number of cycles as
104=10,000. 3 4 5 Log N
N
1000 50,500 100,000
Note If you define multiple S-N curves (with different stress ratios R), the
program uses linear interpolation between the curves to evaluate
corresponding data for a given mean stress.
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Lesson 10 SOLIDWORKS
Fatigue Analysis
Where to Find It Shortcut Menu: Right-click Loading in the simulation study tree
and click Add Event
CommandManager: Simulation > Fatigue > Add Event
Menu: Simulation, Fatigue, Add Event
2 Add Event.
Right-click on Loading and choose
Add Event .
200
SOLIDWORKS Lesson 10
Fatigue Analysis
Important! The additional load which should have been considered in this fatigue
study is preload in the bolted connections causing localized
compressive stress. Because the bolt preload is constant (it does not
oscillate), its inclusion in fatigue study is rather different. This will be
explained in the next part of this lesson. Also, in its effect on fatigue
results is rather small in this case, so its omission in this study is
acceptable.
201
Lesson 10 SOLIDWORKS
Fatigue Analysis
4 Apply material.
The material properties chosen in the static studies will be transferred
to the fatigue study. If the existing material data does not have a fatigue
curve, you need to enter an appropriate curve.
To make sure our material data has a curve, right-click the Parts folder
in the Simulation Study tree and select Apply Fatigue Data to all
Bodies.
Note The material data we selected in the static studies did contain a fatigue
curve, so this has been imported into the fatigue study. It is in this
dialogue that you select the interpolation method and the type of
loading (stress ratio) that was endured during the testing.
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SOLIDWORKS Lesson 10
Fatigue Analysis
Derive from If the fatigue curve is unknown and either an Austenitic or Carbon Steel
Material Elastic is used in the analysis, the Derive from material Elastic Modulus can
Modulus be used with the appropriate steel. The software uses known ASME S-
N curves for these two types of steels. When this option is selected, the
alternating stress values from these known S-N curves are multiplied
by the Young’s Modulus of the unknown material and divided by the
Young’s Modulus of the known material.
As previously stated, the results of the fatigue analysis are highly
dependent on the quality of the input S-N curve. Be sure the material is
either and Austenitic or Carbon steel and proceed with caution when
using this option.
Constant The following interaction scenarios for multiple events are possible:
Amplitude Events
No interaction: The software assumes that events occur
Interaction sequentially, one after the other, without any interaction.
Random interaction: The software considers the possibility of
mixing the stress peaks from different events. This option is more
conservative and is recommended by ASME Boiler and Pressure
Vessel Code.
The selected option should reflect the real situation.
Alternating Stress Alternating stress Salt was defined as Salt = (Smax - Smin) / 2. It was not
Computation specified, however, which component of stress should be used for its
calculation. In SOLIDWORKS Simulation, the following options are
available:
Stress intensity (P1 - P3), which is identical to twice the magnitude
of the maximum shear stress at a given material point
Von Mises stress
Maximum absolute principle stress P1
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Lesson 10 SOLIDWORKS
Fatigue Analysis
Mean Stress The effect of the mean stress is best accounted for by entering multiple
Correction S-N curves for various stress ratios for each material type. As these are
not typically available, various theories accounting for this effect were
devised:
Goodman - recommended for brittle materials
Gerber - experimentally shown to be good for ductile materials
Soderberg - yields conservative results in tension
The following graph illustrates the effect of all three criteria together.
The horizontal axis represents the magnitude of the mean stress Smean
scaled by the value of the material ultimate tensile strength Sultimate.
The vertical axis shows the corresponding correction for the fatigue
strength of the material Sfatigue corresponding to the fully reversed
(R = -1) S-N curve.
The above graph (excluding the Gerber method) also indicates the
experimentally confirmed observation that the fatigue strength of
materials increases as the mean stress Smean becomes compressive.
204
SOLIDWORKS Lesson 10
Fatigue Analysis
Note We selected Gerber mean stress correction to account for the fact that
the material S-N curve used in the 7075-T6 Aluminum Alloy
specification is for fully reversed fatigue (R = -1), while at least one of
the loading events has substantial mean stress (none of the events is
fully reversed with R= -1).
The Fatigue strength reduction factor (Kf) should be set to 1.
Click OK.
205
Lesson 10 SOLIDWORKS
Fatigue Analysis
Fatigue Strength The fatigue strength reduction factor, Kf, accounts for various
Reduction Factor phenomena that may have significant impact on the fatigue strength
Sfatigue. It is a very important factor in the fatigue design and will be
discussed in the next lesson.
Damage Factor The distribution of damage indicates whether there is any life left in the
Plot material or if the material has been exhausted.
Linear Damage Rule In SOLIDWORKS Simulation, damage is based on the linear damage
rule (Miner’s rule). Assume that the S-N curve indicates that it takes N1
cycles at an alternating stress S1 to cause fatigue failure. The theory
states that each cycle causes a damage factor D1 that consumes 1/N1 of
the life of the structure.
Moreover, if a structure is subjected to n1 cycles at S1 alternating stress
and n2 cycles at S2 alternating stress, then the total damage factor is
D = (n1/N1 + n2/N2), where N1 is the number of cycles required to
cause failure under S1, and N2 is the number of cycles required to cause
failure under S2. This rule is referred to as the Linear Damage Rule or
Miner's Rule.
The damage factor, also called usage factor, represents the ratio of the
consumed life of the structure. A damage factor of 0.35 means that
35% of the structure's life is consumed. Failure due to fatigue occurs
when the damage factor reaches 1.0 (100%). The damage is plotted as a
percentage.
206
SOLIDWORKS Lesson 10
Fatigue Analysis
7 Damage plot.
Change the Max limit of the
legend to 100 and review the
resulting Damage plot.
Some regions in red color have
damage greater than 100%. This
result is suggesting a potential
fatigue failure.
Note the bolt region which is all in red color. As we used theoretical
bolt connector to simulate the connection the result here is strongly
polluted. While we are going to ignore this region in this lesson, this
result warrants a further detailed simulation of the connection.
The bent section below the bolt gives an accurate result. The value of
nearly 120% confirms that also this bent region suffers from severe
fatigue failure. This result confirms that the design is inadequate.
207
Lesson 10 SOLIDWORKS
Fatigue Analysis
Damage Result The majority of the damage was caused by the pressure fluctuations
Discussion between -0.066 MPa and 3.3 MPa [-9.57 and 478.6 psi]. The effect of
the other contributor (thermal event) is relatively small. The alternating
von Mises stress due to the fluctuating pressure is approximately
155.1 MPa [22.5 ksi] (see the stress results for Static Pressure
study).
The analyses of the S-N curve suggests that 7075-T6 alloy should be
able to resist the specified oscillations at this stress level. The mean
stress correction, however, reduces the stress values in the SN curve
considerably. Because the pressure event features significant mean
stress, it is significantly impacted by this correction so that 155.1 MPa
actually becomes considerably larger.
In the next part of this lesson we are going to deactivate the mean stress
correction algorithm and compare the results.
Ignoring the region of the bolt connector, we observe that the total
accumulated damage decreased significantly from 120% to 85%. This
result incorrectly indicates that the vessel is safe from fatigue failure at
this location.
This assessment represents a considerable inaccuracy brought into our
fatigue computation by completely ignoring the detrimental effects of
the mean stress.
208
SOLIDWORKS Lesson 10
Fatigue Analysis
Fatigue Study In the second portion of this lesson the pressure vessel will be loaded,
with Dead Load in addition to the fluctuating thermal and pressure loads, with a
66,725 N [15,000 lb] dead load on the top of the lid. Additionally, we
will include the effect of localized compressive stress due to the bolt
preload.
12 Apply dead load in both Thermal
stress and Static Pressure studies.
Apply 6672.5 N [1500 lb] Normal force on
to top of the lid.
Dead Loads in Dead loads in the fatigue analysis do not produce any incremental
Fatigue Analysis damage since no alternating stress exists. However, its presence may
substantially increase/decrease the mean stress magnitudes and thus
considerably change fatigue damage results.
Because dead loads do not cause any alternating stresses, no direct
event definition is possible. Rather we must solve two separate static
studies defining the extremes for each fatigue event.
In our case we will therefore add two more static studies defining the
lower extreme for both thermal (0 W/m^2) and pressure (-0.066 MPa)
fatigue events.
209
Lesson 10 SOLIDWORKS
Fatigue Analysis
Note Since the thermal load fluctuates between 0 and 1471.8 W/m^2 [0.0009
Btu/(s-in^2)], for the lower extreme thermal fatigue event definition we
only need to disable the thermal loading.
16 Run Thermal Stress 0 study.
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SOLIDWORKS Lesson 10
Fatigue Analysis
Find Cycle Peaks If dead loads are present or more complex fatigue events are expected
Find Cycle Peaks event type option may be utilized.
If two studies are selected the fatigue event stresses fluctuate between
the two extremes defined by the two static studies.
Sometime, however, a single fatigue event may fluctuate between three
or more extremes when various loads peak at different times. In such
case each event loading extreme should be defined by a separate static
stress study. Fatigue events then randomly fluctuates between all such
extremes. Random fluctuation is necessary as time information as well
as the load peak sequencing are discarded in fatigue analysis.
211
Lesson 10 SOLIDWORKS
Fatigue Analysis
212
SOLIDWORKS Lesson 10
Fatigue Analysis
Summary In this lesson we simulated the fatigue resistance of the pressure vessel
subjected to a combination of the thermal and pressure loading cycles.
It was found that the vessel fails at the critical location in the bent
below the bolted connection and a use of different material would be
recommended. Addition of the dead load resulted in a significant
reduction in the fatigue damage. This effect, however, should be
considered as additional safety only. The region adjacent to the bolted
connection was strongly affected by the theoretical bolt connection and
the dead load due to its preload. It was excluded from the conclusions
of this simulation. A detailed dedicated simulation would be required
here.
The lesson provided a basic introduction into the fatigue analysis with
multiple constant amplitude fatigue events. Various types of the fatigue
events were discussed and shown: Zero-based (LR=0), various
Loading ratio events and Find Cycle Peaks event types.
The basic concepts and terminology relevant to the high cycle fatigue
were discussed and demonstrated in this lesson. Namely, it was shown
that the mean stress has a significant effect on the fatigue results and
must be accounted for by either specifying multiple S-N curves or
using any of the available mean stress correction algorithms.
The effect and modeling of the dead load was discussed and practiced.
The post-processing plots available in the fatigue analysis were
discussed and shown as well.
Questions 1. Damage Result Discussion on page 208 states that the alternating
stress in the pressure fatigue event is approximately 155.1 MPa
[22.5 ksi]. Verify this statement.
213
Exercise 12 SOLIDWORKS
Fatigue Analysis of a Basketball Rim
Exercise 12: In this exercise, you will analyze a basketball rim for fatigue life using
Fatigue linear analysis. This exercise reinforces the following skills:
Analysis of a Constant Amplitude Loading on page 190
Basketball Rim S-N Curve on page 197
Mean Stress Correction on page 204
Damage Factor Plot on page 206
5 Apply a fixture.
Fix the back face, as shown in the figure.
214
SOLIDWORKS Exercise 12
Fatigue Analysis of a Basketball Rim
Geometrically nonlinear
Linear solution
solution (large displacements)
Note We observe that both linear and nonlinear results are nearly identical.
We are going to use linear results, where stresses are a little higher, in
order to obtain more conservative fatigue estimates. Also, note that the
rim appears to yield. This can be a concern, because in high cycle
fatigue simulation stresses must be limited by the yield strength. A
more careful stress results analysis would be required.
9 Stress concentrations.
Review the stress plot in greater detail with
the upper limit of the legend set to the yield
strength of 505 MPa.
We can see that the yielding occurs at the
location of the stress singularity. More geometry realism would be
needed to eliminate singularity and capture realistic stress distribution.
The rest of the model shows stresses below the yield limit.
215
Exercise 12 SOLIDWORKS
Fatigue Analysis of a Basketball Rim
Notice the five locations depicted in the figure. Aside from the stress
singularity identified in the previous step, the four remaining locations
exhibit stresses below or at the yield. For the highest of the four, the
alternating stress for the zero based fatigue is half the stress magnitude,
255 MPa. This is well below the highest stress data point in the fatigue
S-N curve.
Note Even though stresses at some sharp corners indicated in the figure
above are below the yield point, it is important to understand that all
such locations constitute stress singularities. With the higher mesh
refinement, stresses here would jump well above the yield. Both stress
and fatigue results at these locations will therefore not be accurate. It
may be wise to strengthen these bracket regions somewhat to bring
stresses down more and achieve higher factor of safety.
11 Create fatigue study.
Create a constant amplitude event Fatigue study named rim
fatigue.
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Fatigue Analysis of a Basketball Rim
12 Add event.
Right-click on Loading and choose Add Event .
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Fatigue Analysis of a Basketball Rim
16 Review results.
The resulting Damage and Life plots are shown below.
Life Plot A life plot indicates the maximum number of cycles at the given
loading level before the fatigue failure occurs. Given the maximum
alternating stress level magnitude (in our case 270.1 MPa), the
minimum life plot value can be directly obtained from the material SN
curve.
The above results show very high values of damage, 142%, (low values
for the life plot, 1,000 cycles) at the location of the stress singularity.
We will exclude this location from our conclusions as more realism in
our modeling would be necessary here. As this is a critical location,
manufacturing should pay extra attention to the joint and the weld.
Certainly, adding stronger weld would be recommended here to
alleviate the fatigue concerns.
Aside from the stress singularity location, results indicate very good
fatigue characteristics. More post-processing may be necessary,
however.
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Fatigue Analysis of a Basketball Rim
The fatigue results at all the indicated critical locations are well below
100%. However, since all four locations constitute stress singularities,
no accurate results can be obtained here.
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Exercise 13 SOLIDWORKS
Fatigue of Trailer Hitch
Loading The fatigue test requires that the hitch is Loading plane
Conditions loaded with 2,000,000 cycles of fully
reversed oscillatory force of 7,500 N.
The force is applied in the direction
normal to Loading Plane (Kugelkopf
part).
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SOLIDWORKS Exercise 13
Fatigue of Trailer Hitch
Goal Assess the existing design in static stress and fatigue. The required
factor of safety in static stress is 1.3, and the fatigue damage should be
kept below 100%. If needed, introduce the necessary design changes.
The part for this exercise is located in the Lesson07\Exercises
folder.
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Fatigue of Trailer Hitch
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Lesson 11
Variable Amplitude Fatigue
Objectives Upon successful completion of this lesson, you will be able to:
Understand a variable amplitude loading history and its setup in the
fatigue study.
Postprocess results and analyze the composition of the variable
amplitude loading.
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Case Study: In this lesson, we will perform a variable amplitude fatigue analysis of
Suspension a suspension assembly. We will learn about some of the options when
defining a variable amplitude event as well as how the software
computes its result. In addition, we will learn how to properly post-
process these results.
Project A simple scaled model of a suspension
Description (shown in the figure) was analyzed in
the Design Scenarios lesson of the
SOLIDWORKS Simulation training
manual on the loads caused by:
A stationary vehicle.
A vehicle moving at a constant
acceleration on a smooth road.
A vehicle moving on a bumpy road.
A vehicle moving at a constant
speed on a banked road.
The above cases were each simulated by a specific combination of the
static forces, representing the amplitude of the loading exerted on the
suspension under the corresponding vehicle travel configuration.
Using linear static analysis, we concluded that case 4 represents the
worst loading combination, and the design was subsequently optimized
using the design scenario feature of SOLIDWORKS Simulation.
In reality, as the vehicle travels, the suspension is subjected to a varying
load, which is random and difficult (or impossible) to describe
deterministically. The variation of the load was obtained from a testing
setup and can be seen in the figure below.
Stress
Time
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The graph in the figure is scaled, and the extreme values (1,-1)
correspond to the static load used in the linear static analysis.
Each of the loading cycles inflict a corresponding incremental damage
on the assembly material. The goal of this analysis is to assess the
performance of the previously optimized design in fatigue (after the
suspension has been subjected to the prescribed number of loading
cycles).
Note As in constant amplitude fatigue loading, the time (how long it took to
complete the required number of cycles) is irrelevant.
Stages in the Static study
Process The static study that was setup in Lesson 10 of the SOLIDWORKS
Simulation training manual will be run.
Variable amplitude fatigue study
A variable loading amplitude history curve will be input into the
study and the properties of the fatigue study will be setup.
Postprocess the results
Once the study is run, we will review the relevant results.
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Fatigue Study Now that the static study is complete, we can proceed with the fatigue
study.
7 Define Fatigue study.
Define a new Fatigue study named suspension-Fatigue.
Select Variable amplitude history data under
Options as the type of fatigue study.
Variable Amplitude The loading history shown at the beginning of this lesson needs to be
Fatigue Event decomposed by the software into a form that allows it to apply the tools
used for the constant amplitude analysis (Smax, Smin, Smean, etc.).
Several cycle counting methods have been devised during the past
decades. The most popular one used today is the Rainflow method.
Rainflow Cycle In the Rainflow counting method, the stress history is decomposed into
Counting Method cycles, as demonstrated in the figure below.
Time
Note that each extracted cycle can be characterized by its Smax, Smin,
and Smean. This enables the software to accurately apply various mean
stress correction algorithms, such as Gerber, to account for the
influence of the mean stress and to calculate the incremental damage.
The total damage is then computed by summing all of the partial
damage factors.
Note The description of the Rainflow algorithm is not a subject of this text.
Students are advised to further study the literature listed at the end of
this lesson.
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8 Add event.
Right-click on the Loading folder and
select Add Event .
In the Add Event dialog window, click the Get
Curve button.
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Block
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Note The data for the above S-N curve is for the purpose of the training
lesson only. It is the responsibility of the analyst to obtain the most
relevant material fatigue resistance data.
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Bins for Rainflow The algorithm divides the stress amplitude Y axis in a number of
Counting equally spaced bins, with the constant amplitude magnitude within
each bin. The accuracy of the fatigue results depends on the number of
Rainflow counting bins. A higher number of bins will give a more
accurate result, but take longer to run. However, 32 bins are usually
enough to accurately represent the loading.
Stress
Noise in Random Noise in the loading history is defined as very small peaks that have
Loading History minimal (or no) contribution to the overall results. In general, any
stress peak smaller than the endurance limit can be filtered out since
they do not significantly contribute to the overall damage results.
Fatigue Strength S-N curves characterizing the resistance of the material against fatigue
Reduction Factor are usually obtained under the controlled test conditions at a specified
environment. However, the environment at which the analyzed product
operates can greatly differ from the conditions of the test.
To account for the environment and other important phenomena that
influence fatigue, a strength reduction factor is introduced.
The following are the most important effects that must be considered in
the fatigue design:
Corrosion (Kc) Temperature (Kt)
Loading mode (Km) Reliability (Kr)
Frequency (Kfreq) Notch Effects (Kn)
Size Factor (K1) Fretting (Kfret)
The description of each of the above effects goes beyond the scope of
this text. Because of their significant impact on the fatigue strength,
students are encouraged to review the literature referenced at the end of
this lesson. The compound effect of all of the influences is described by
the Fatigue strength reduction factor:
K f = K c K m K freq K 1 K t K r K n K fret .
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Click OK.
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Rainflow Matrix In the 3D Rainflow chart, the X and Y axes represent the Alternating
Chart Stress and Mean Stress, and the Z-axis represents the number of counts
for a given alternating and mean stress bin. This result gives you the
measure of composition of the loading history. For example, you may
see from this chart whether most of the alternating stress cycles occur
at a negative mean stress or at positive mean stress.
Results We can see that most of the alternating stresses have positive mean
stress. Similarly plot the Rainflow chart for the other three nodes and
the node corresponding to the worst damage location. You will notice
that for all of these Rainflow charts, most of the counted cycles have
positive mean stress.
From the above chart you can see that 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.
Note The results could be verified with a larger number of bins (128 for
example). Note that the duration of the analysis with a higher number
of bins can be significantly longer.
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Fatigue Literature The following literature is suggested for further study of this subject:
Stephens, R. I., Fatemi, A., Stephens, R. R., and Fuchs, M. O., Metal
Fatigue in Engineering, 2001.
Suresh, S., Fatigue of Metals, 2004.
Summary In this lesson, we used the model of suspension that was already
analyzed and optimized, using linear static analysis, in the
SOLIDWORKS Simulation training course. The fatigue analysis
investigated the performance of this design when subjected to a
variable amplitude loading history obtained from the test data.
This lesson demonstrated the definition of the variable amplitude event
and introduced the concept of the Rainflow counting method, bins,
blocks, and the noise filter. Similarly to the case of the constant
amplitude events, the time is also irrelevant when a variable amplitude
event is specified (it does not matter how long it took to complete the
loading history).
However, start time and the time axis values in the loading history
definitions are important to correlate the occurrence of the cycles if the
multiple events are defined.
Matrix plots used to analyze the composition of the load were shown
and discussed as well.
Lastly, it was shown that the assembly passing the yield strength
criteria of the linear static analysis may still fail when subjected to
fatigue. If the design is subjected to a cycling loading history
(irrespective of whether it is a variable or constant amplitude loading),
both static and fatigue analyses must be performed.
Questions 1. Fatigue analysis is computed from the stress results obtained in the
static analysis. The fatigue failure ( Damage 1 ) therefore (does /
does not) imply the onset of yielding.
2. Because components loaded by fluctuating loading typically fail
due to (yielding / buckling / fatigue), the fatigue analysis (is / is not)
essential for safe product design.
3. A GPS navigation system is mounted on the dashboard of a
traveling vehicle. This product (would / would not) need to be
analyzed using a fatigue module of SOLIDWORKS Simulation.
4. A loading history for the above case would fit the (constant
amplitude / variable amplitude) event.
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238
Lesson 12
Drop Test Analysis
Objectives Upon successful completion of this lesson, you will be able to:
Perform a drop test analysis.
Use an elasto-plastic material model.
Analyze results of a dynamic analysis.
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Drop Test Analysis
Drop Test A drop test study is a specific type of dynamic analysis used to model
Analysis the impact force of a short time duration event. Although this type of
analysis is not fully nonlinear as in complete dynamic analysis, drop
test analysis can prove very useful in obtaining a benchmark
simulation.
Case Study: In this study, we will perform a drop test analysis on a camera
Camera assembly. Many of the options in setting up the drop test analysis will
be discussed. Once the analysis has been run, we will learn to properly
interpret the results produced. It will be shown that a drop test analysis
is capable of using an elasto-plastic material model and we will see
how this can affect the results of the simulation. In addition, we will see
that the drop test analysis has some limitations that can be considered
in a fully dynamic simulation.
Project The structural integrity of a camera Bottom Cover
Description is tested by dropping it on a rigid
floor. The testing includes different
drop heights and floor types.
Normally, the testing also includes
different positions of the falling
camera at different areas of the
floor. Due to time considerations,
we will drop the camera in one
position from a height of 2m Lens
Zoom Top Cover
[78.7in].
We will consider the floor to be both rigid as well as flexible in
different analyses. In addition, we will model the camera using an
elasto-plastic material model and see how this changes the results of
the analysis.
You are encouraged to experiment with different dropping heights,
floor positions (horizontal or sloped), and materials.
Stages in the Apply materials.
Process Linear-elastic or elasto-plastic material can be defined for the drop
test.
Drop test setup.
A height or impact velocity can be chosen for the drop test. In
addition, gravity is defined.
Define results options.
Decide how long the simulation will be run and what options will
be saved.
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Drop Test Analysis
Introducing: Drop The drop test analysis is defined by editing three automatically created
Test Folders icons in the Simulation Study tree: Connections, Setup, and Result
Options. Note that the typical connections are not available here in the
drop test study. The Connections folder is used to define the contact in
the model.
Where to Find It Connections can be found in either the Simulation Study tree
or the Simulation CommandManager.
Setup can be found in the Simulation menu as well as the
Simulation Study tree.
Result Options can be found in the Simulation menu as well as the
Simulation Study tree.
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Drop Test The orientation of the impact plane may be normal to gravity or parallel
Parameters to a reference plane. The free falling body moves in the direction of
gravity as a rigid body until impact with the rigid plane. The program
determines the region of impact based on the direction of velocity at
impact and the orientation of the impact plane.
Note In this problem the drop height of 2m [78.7in] is measured from the
camera centroid.
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6 Define gravity.
The direction of gravity is
normal to the horizontal
reference plane. If necessary,
use the arrow button to
control the orientation of
gravity.
Enter one of the following as
the magnitude of
gravitational acceleration:
9.81 and select m/s2
386 and select in/s2
7 Set impact plane orientation.
Under Target, for the Target orientation, select Normal to gravity.
Dynamic Analysis Loss of energy in a drop test normally occurs due to damping, friction,
or plastic deformation (it is possible to use elasto-plastic material, as
we will see later in the lesson).
In this study, we do not define friction and we use a linear material.
Therefore, the impact causes no energy loss and the model continues to
bounce off the impact plane for an indefinite period of time.
The drop test requires a dynamic analysis solver. SOLIDWORKS
Simulation solves this analysis using an explicit method of direct-time
integration. This is a computationally intensive, but numerically stable
technique for small time steps when solving problems in a dynamic
analysis.
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Drop Test Analysis
9 Define sensors.
When we set up our Results Options,
we may want to log data from the Vertex 1
simulation at certain predefined points
on the model.
Vertex 2 Vertex 4
In the SOLIDWORKS
FeatureManager design tree, right
click Sensors and select Add Sensor.
Vertex 3
Under Sensor Type select Simulation
Data.
Under Data Quantity select Workflow Sensitive.
Then select the four vertices shown below. Simulation data will be
logged for these locations.
Select OK.
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Solution Time Solution time after impact is a period of real time for which the
program calculates the response starting from the moment of first
impact. If you specify a drop height, the solution time does not include
the period of free fall of the body.
The program estimates a value for the
E
---
solution time based on the model geometry v ELASTIC WAVE =
and the default material properties for
magnesium. E - modulus of elasticity
- density of material
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Drop Test Analysis
The default solution time is based on the time that it takes for the elastic
wave generated by impact to travel through the model and back. The
program estimates the velocity of the elastic wave from the wave that
starts propagating in the model at the moment of impact.
Assuming that the length of the model is L, the wave takes a time
period approximately equal to 2L/v to travel to the farthest boundary
(where it is reflected) and back to the originating area.
The forces that are opposite to gravity start acting on the model during
this period. The program sets the default solution time to 3L/v. Note
that this value is an estimate intended to help you enter a reasonable
time duration.
Because the impact period is usually very small, the program measures
it in microseconds. The maximum response may occur during impact or
after impact while the body is rebounding. The study can evaluate
multiple impacts and rebounds if you specify an adequate solution time.
While there is no limit on Solution Time After Impact, a longer
solution time requires a longer time to run the analysis.
If a solution is going to take more than sixty minutes, SOLIDWORKS
Simulation issues a prompt to let you know this, and asks:
Would you like to change the solution time and rerun the
analysis?
Graphing Results The number of graph steps per plot is not equal to the number of actual-
time steps. Time steps are selected internally by the solver and the time
interval between steps may vary to assure stability of the numerical
solution.
The relation between the number of plots and the number of time
instances where the data is saved for graphing at selected vertices is
shown in the next figure.
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Drop Test Analysis
Tip Designing a mesh for a complicated drop test study could prove
troublesome. To insure that you have created an appropriate mesh, use
the following procedure:
1. Identify the surface that will first hit the wall during the drop test
study.
2. Create a static study.
3. Apply some G-loading (i.e. 10g).
4. Apply a fixed restraint to the surface identified in step 1.
5. Run an h-adaptive study with the lowest accuracy settings.
6. Create the drop test study and the mesh from the static study.
7. Proceed with drop test study.
Running the static h-adaptive study with low accuracy settings will
ensure that the quality of the mesh in the region of impact will obtain
fair results.
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Linear vs. At the end of the SOLIDWORKS Simulation course it was explained
Nonlinear Solution that depending on the magnitude of the loads and the stiffness of the
structure, the model may exhibit large structural deformations; in such
case a nonlinear solution is required.
In impact analysis, the structural deformations are almost always
nonlinear. SOLIDWORKS Simulation therefore uses Large
displacement nonlinear solution as a default option. If it is observed
that no noticeable structural deformations occur during the impact test
(such behavior is rather rare), uncheck Large displacement option to
force a geometrically linear solution.
Normally, in analysis with large deformations, the stress magnitudes
often surpass the yield strength of the material. SOLIDWORKS
Simulation Drop Test module allows for the specification of full elasto-
plastic material model required to correctly model these situations. The
description of this material model goes beyond the scope of this
training and the students are referred to SOLIDWORKS Simulation
Premium: Nonlinear training course.
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This solution is plot number 25 (the last one in the specified range),
showing the von Mises stresses corresponding to the last performed
time step.
Note that the very high stress magnitude (645 MPa [93.5 ksi]) is likely
to damage the magnesium case.
Create and review plots corresponding to other time steps.
16 Animate results.
The most interesting way of reviewing the drop test results is through
animation.
Animate this plot using the default options.
An animated plot shows the camera hitting the horizontal floor with the
rear edge near the viewfinder.
You do not have to use the last plot to see the complete animation; any
one of the twenty-five plots can be used.
17 Plot time history response.
To review the time history response, right-click the Results folder and
select Define Time History Plot. The Time History Graph
PropertyManager opens.
To create a time history plot for all four selected locations, select
Predefined locations and choose the vertices to include in the graph.
Select the VON: von Mises Stress to be plotted in the graph.
Click OK.
We can see that the von Mises stresses are well above the yield point
even at the four monitored sensor locations.
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Drop Test Analysis
Elastic Floor, The camera will now be dropped on an elastic floor. Let us say that the
Elasto-Plastic floor is a 0.4 in thick layer of Nylon 6/10 material.
Material
1 Create new study.
Copy the study free fall 01 into free fall 01 soft.
2 Edit Drop Test setup to add elastic floor.
Edit the Setup to add information about the normal and tangential
stiffness of the floor.
In the Drop Test Setup PropertyManager, under Target select the
Flexible target.
Under Stiffness and thickness, in the Units list, select SI.
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Comparing the maximum von Mises stresses between the studies with
the rigid and flexible target we observe that the maximum value has
reduced from 931 MPa (135 ksi) to approximately 305 MPa (44.4 ksi).
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Elasto-Plastic The two additional necessary parameters for the elasto-plastic material
Model Parameters model in the drop test are the yield stress and the tangent modulus. In
our case, both of these parameters were not in the SOLIDWORKS
material library, so they were obtained from an outside source. Yield
stress is usually a readily available material property, however the
tangent modulus is usually more difficult to find. If the tangent
modulus is unknown, a rough approximation of between E/5 and E/10
can be used.
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Drop Test Analysis
We can see that even with the maximum von Mises stress dropped from
931 MPa (135 ksi) to 375 MPa (54.3 ksi).
Processing Note that the stress results have reduced significantly. Based on the
Elasto-Plastic design criteria it has to be decided whether this amount of yielding at
Results the impact location is still acceptable.
Furthermore, we can see that the maximum stress at the four sensor
location (approximately 142 MPa) is now below the material yield
strength of 165 MPa (23.9 ksi).
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Drop Test with If time permits, you can specify contact conditions between different
Contact parts of an assembly. Use the global, component, and local contact
(optional) settings to simulate the desired contact conditions.
1 Create new study.
Copy the study free fall 01 (rigid floor) into free fall with contact.
2 Create contact conditions.
Edit the camera model by adding a No penetration contact condition
between the TopCover and BottomCover. This way the camera will
be held together only by the two tabs.
Tabs
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Drop Test Analysis
From this plot, we can see that the contact condition is no longer
bonded.
The plot also indicates high stresses around the clips, but the highest
stress of 900 MPa (130.5 ksi) is again located at the impact location at
the corners of the clip. To better understand the stresses at these
regions, more realistic geometry and elasto-plastic material model
would have to be utilized.
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Exercise 14 SOLIDWORKS
Drop Test of a Clip
Exercise 14: In this lab exercise, you will perform a drop test analysis of a clip.
Drop Test of a This exercise reinforces the following skills:
Clip
Rigid Floor Drop Test on page 241
Drop Test Parameters on page 242
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SOLIDWORKS Exercise 14
Drop Test of a Clip
10 Animate results.
Before Impact
Animate the resultant displacement plot to observe how the two faces
collide during impact and then slide after impact.
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Exercise 14 SOLIDWORKS
Drop Test of a Clip
260
Lesson 13
Optimization Analysis
Objectives Upon successful completion of this lesson, you will be able to:
Perform an optimization analysis based on static and frequency
analyses.
Properly post-process optimization results.
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Optimization Analysis
Optimization Design optimization determines the optimum design with respect to the
Analysis selected objective by finding the best combination of allowable values
in the design variables.
The optimum design is subject to imposed constraints.
The optimized design can be further optimized according to a new
objective and new constraints.
The model geometry is updated to the optimized configuration. The
prerequisite studies (in our case, static and frequency) show
corresponding results for the optimized model.
Case Study: In this case study, we will perform an optimization analysis of a press
Press Frame frame. We will learn about many of the different options when defining
an optimization study. The optimization results will then be processed
and we will learn exactly how much better our design will get as a
result of the study.
Project A press frame assembly consists Top Plate
Description of a top plate where a 22,250 N
[5,000 lb.] upward force is
applied, two side plates with
“legs” that are supported along
the bottom faces, and a back
plate connecting the side plates.
We would like to reduce the mass
of the assembly by modifying the
frame geometry. Side Plate
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Load 22,250N
Supports
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Optimization All design constraints are satisfied in the original design configuration.
Analysis We now try to reduce the mass of the press frame assembly while still
satisfying the design constraints.
Design Study The optimization analysis is defined by
three design study parameters:
Variables, Constraints, and Goals.
The optimization study uses the
previously defined studies for
information about the loading and
constraints.
Before proceeding, let us review some terminology used in an
optimization analysis.
Variables Design variables define what can be changed in the model, such as the
wall thickness, hole diameter, fillet radius, and so on.
They must be selected parameters of the SOLIDWORKS model. Up to
25 design variables can be defined in an optimization study.
The visible dimensions are design variables in our optimization study.
Constraints Constraints define allowable ranges of stress, deflection, frequency,
and so on. Both minimum and maximum values can be specified.
Constraints narrow down the optimization space. Note that there are
two possible outcomes of an optimization study.
The first is that the limit of design variable has been reached. The
optimum design then lies on the boundary of this design variable that
has reached a limit of its allowed range of variation.
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The second possible outcome is that the constraint has been reached.
The optimum design then lies on the critical constraint boundary. The
critical constraint refers to the restraint that has been activated; for
example, stress has reached its limit.
Up to 60 constraints can be defined. The constraints can be: stresses,
strains, displacements, buckling load factors, frequencies,
temperatures, temperature gradients, and/or heat fluxes.
Goals Also called the optimization criterion or optimization objective, the
goals defines the objective of the optimization lesson.
In an optimization study, you can choose to minimize mass, volume, or
frequency, or you can choose to maximize frequency or buckling (i.e.,
the load factor).
Optimization Goal The goal of minimizing the mass is potentially based on the two
available studies which we have already completed: press static and
press frequency.
Either study or both studies can be used for the optimization depending
on how the constraints are set up.
If, for example, the constraints pertain only to the deflections or
stresses, which are produced by the press static study, then the
optimization study is based on the prerequisite press static study.
In this case, the optimization study is based on both the press static
and press frequency studies due to the desired constraints.
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Design Variable The definition of the three design variables that we use in this study is
Summary complete. The SOLIDWORKS Simulation design study displays three
design variables under the Variables list.
Define Constraints The last step in the setup of the optimization study is the definition of
constraints.
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23 Final design.
The Results View tab of the design study is activated. The final design
is plotted and the results for each iteration are shown in the design
study. In the first row of the table, if we click on the Initial, Optimal, or
any iteration, the results for that model will be shown. Displaying these
plots allows us to compare the model before, after, and during the
optimization procedure.
BEFORE AFTER
Postprocessing The side plate height has decreased from 100mm to 66.861mm. The
Optimization length of the back plate has been reduced from 375mm to 206.32mm,
Results and the size of cut-out has increased from 100mm to 247.062mm.
In the next paragraphs, we discover that the maximum allowed stress
and the minimum allowed frequency constraints were activated and the
design was modified to honor these constraints.
Important! Before proceeding, note that the SOLIDWORKS model geometry has
changed. For this reason, optimization analysis should never be
conducted on production part files.
An optimization analysis should be conducted using local copies of
parts or assemblies.
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SOLIDWORKS Lesson 13
Optimization Analysis
The maximum von Mises stress is 97.6 MPa. It did not exceed the
maximum allowed stress of 100 MPa.
This result indicates that the constraint defined on stress has been met.
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Lesson 13 SOLIDWORKS
Optimization Analysis
The first natural frequency is 80.96 Hz, which is within the allowed
frequency range of 80-150 Hz.
The frequency constraint has also been met.
25 Examine mass properties of optimized design.
Under Results View, we have a summary of each iteration. We have
information about the values that the variables were changed to as well
as the results with respect to the goals. A red column means that the
iteration did not satisfy all of the design constraints.
It can be seen that the mass of the optimized design dropped from
73.953 kg to 59.6 kg. This translates to approximately 19% reduction
in the material mass.
Note Detailed information about the mass before and after optimization can
also be determined using SOLIDWORKS tools (Tools, Mass
Properties).
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SOLIDWORKS Lesson 13
Optimization Analysis
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Lesson 13 SOLIDWORKS
Optimization Analysis
Local Trend Try creating additional graphs using different design variables and
Graphs constraints.
Local trend graphs show design sensitivities to changes in design
variables. The same relations can be found using a Design Scenario in
place of optimization.
Summary A model of a press frame was optimized to operate within a range of
stresses, displacements, and frequencies. The optimization took fifteen
steps to complete and the final design satisfied all constraints.
Design Local Trend Graphs show the optimization objective and
optimization constraints as functions of the design variables.
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SOLIDWORKS Exercise 15
Optimization Analysis of a Cantilever Bracket
9 Define a goal.
The goal here is to minimize the mass.
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Exercise 15 SOLIDWORKS
Optimization Analysis of a Cantilever Bracket
Design variable 2
Design variable 3
Select the 23.13mm dimension located on the top of the bracket as the
first design variable. Set the lower bound to 10mm and upper bound to
25mm.
Select the 25 mm dimension located on the slanted bottom of the
bracket as the second design variable. Set the lower bound to 10 mm
and upper bound to 25 mm.
Select the 50 mm dimension located on the bottom right side of the
bracket as the last design variable. Set the lower bound to 20 mm and
upper bound to 50 mm.
11 Apply constraint.
Select Stress as the Data Quantity and VON: von Mises stress as the
stress Component.
Select N/mm^2 as the Unit.
Select Is less than and enter 300 N/mm^2 (MPa).
12 Set optimization properties.
Under Quality, select High Quality in the Design Study properties
window.
13 Run optimization analysis.
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SOLIDWORKS Exercise 15
Optimization Analysis of a Cantilever Bracket
We find that the mass has been significantly reduced from the initial
value of 105.252g to approximately 72.8g.
16 Plot stress results in the optimized design.
The maximum von Mises stress of 296.3 MPa is below the limit of 300
MPa.
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Exercise 16 SOLIDWORKS
Optimization of Heat Sink
Problem The heat sink is used to remove heat from an LED light fixture. The
Description light is mounted so that the inside part is facing the space above the
ceiling, while the bottom part is exposed to the room environment. This
heat sink design accommodates five LEDs. The desired maximum
temperature of the heat sink should be 76°C.
280
Lesson 14
Pressure Vessel
Analysis
Objectives Upon successful completion of this lesson, you will be able to:
Apply SOLIDWORKS Simulation Pressure Vessel Design module
to the design of the pressure vessels.
Create linear and SRSS combinations of the load cases.
Evaluate stress results.
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Lesson 14 SOLIDWORKS
Pressure Vessel Analysis
Case Study: The objective of this lesson is to show the functionality of the
Pressure Vessel Pressure Vessel Design module and its application to the vessel
design in accordance with ASME Boiler and Pressure Vessel Code,
Section VIII, Division 2. Other codes and requirements may be
followed as well. We will analyze the same pressure vessel that was
discussed in the Mixed Meshing (Shells and Solids) lesson of the
SOLIDWORKS Simulation training manual.
Project A pressure vessel manufactured from low
Description alloy carbon steel SA515, grade 60 is used to
carry a 700°F hot steam at a pressure of 165
psi. In addition to the gas pressure, the vessel
is subject to various other loading conditions
such as elevated temperature, free nozzle end
forces, moments, and additional stresses due
to the support conditions. Wind and
earthquake conditions are not considered in
this example even though a real life vessel
would have to be analyzed with those
loadings as well.
Evaluate the pressure vessel’s ability to
withstand the given loading conditions.
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SOLIDWORKS Lesson 14
Pressure Vessel Analysis
3 Review supports.
The pressure vessel is supported by four
symmetrically orientated lugs with slotted
bolt holes allowing for the radial expansion
of the vessel.
4 Review mesh.
The design of the mesh was the subject of
the Mixed Meshing (Shells and Solids)
lesson of SOLIDWORKS Simulation
training manual and will not be further
discussed here. You will notice, however
that some parts (manhole nozzle) are
meshed with significantly finer mesh.
To reduce the computational time, other
parts of the vessel are meshed with coarser
draft quality mesh.
Note All of the studies participate in a pressure vessel analysis and must
have identical mesh properties.
5 Review study results.
All studies have been computed beforehand. Open each one and review
its resulting displacements and stresses.
6 Material.
The pressure vessel is manufactured from low alloy carbon steel SA
515, grade 60 with the design stress intensity value at 700° F equal to
Sm = 15.3 ksi.
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Lesson 14 SOLIDWORKS
Pressure Vessel Analysis
Stress Intensity Stress intensity is defined as twice the maximum shear stress and can
be expressed in terms of the principal stresses as P1 - P3. ASME Boiler
and Pressure Vessel Code therefore relies on the Tresca yield criterion
which is more conservative than the von Mises criterion. The
maximum difference between these two criteria is 13%.
Membrane and ASME Boiler and Pressure Vessel Code states possible limiting values
Bending Stresses of the membrane and bending components of the stress intensities.
(stress Since shell elements assume constant shear deformation (or none at all)
linearization) along the cross-section, linear distribution of the stresses is a direct
consequence of this assumption and both membrane and bending
components are readily available.
In solid elements no such assumption on the shear deformation exists
and a stress linearization along a selected trajectory is required. This
lesson demonstrates the linearization procedure towards its end.
Basic Stress ASME Boiler and Pressure Vessel Code defines five stress intensity
Intensity Limits limits which must be satisfied (Section VIII, Division 2, Appendix 4,
Article 4-130)
General Primary Stress Intensity Pm
Local Membrane Stress Intensity PL
Primary Membrane (General or Local) Plus Primary Bending Stress
Intensity PL + Pb
Primary Plus Secondary Stress Intensity PL + Pb + Q
Peak Stress Intensity PL + Pb + Q + F
Nozzle piping transition is then the subject of yet another Article 4-138
of the same Appendix 4.
Other articles of the ASME Boiler and Pressure Vessel Code may apply
as well.
Pressure Vessel Once the static studies have been defined an run, the pressure vessel
Analysis study will account for the combination of the results.
1 Pressure vessel study.
Define a new study. Specify Pressure Vessel Design as a study
Type and name it vessel 1.
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SOLIDWORKS Lesson 14
Pressure Vessel Analysis
Note The temperature load is not included in this combination. In this lesson
the vessel shell will be subjected to the General Primary Membrane
Stress Intensity criterion only. Temperature load is not considered in
this criterion.
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Lesson 14 SOLIDWORKS
Pressure Vessel Analysis
Load Case Pressure vessel module features two methods for the load case
Combinations combinations:
Linear combination. Where the resulting quantity X
(displacement, stress etc.) is computed from:
N
X = x
=1
x
2
X =
=1
Note An SRSS combination of the loads can also be included in a linear
combination as a separate load case. Such combination may be required
if the pressure vessel is subjected to the seismic load.
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SOLIDWORKS Lesson 14
Pressure Vessel Analysis
General Primary The ASME Boiler and Pressure Vessel Code defines General Primary
Membrane Stress Membrane Stress Intensity as:
Intensity not self- limiting.
resulting in failure or gross distortion if above a yield strength
magnitude.
distributed in the structure so that no redistribution of loads occurs
as a result of yielding.
The temperature load is not considered in this stress limit criterion;
Primary Membrane (General or Local) plus Primary Bending Stress
Intensity or Peak Stress Intensity criteria include the temperature loads.
The above definition does not fit the location of our maximum values.
The maximum membrane stress intensity of 29.8 ksi is at the junction
of the shell opening and the nozzle. It is therefore highly localized and
significant redistribution of the load would occur as a result of yielding
at this location. These regions are covered by the Local Membrane
Stress Intensity and the Peak Stress Intensity criteria.
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Lesson 14 SOLIDWORKS
Pressure Vessel Analysis
Manhole Nozzle Manhole nozzle flange and the Manhole cover are modeled using
Flange and solid elements due to their substantial thickness vs. span ratios and the
Cover bolted connections. The ASME Boiler and Pressure Vessel Code does
not specify the limiting stress intensities values for these components.
For flange it states instead the limiting values for the longitudinal,
radial and tangential stresses as 1.5 Sm, Sm and Sm, respectively. (For
the simplicity we assume that flanges are manufactured from the same
material as the pressure vessel body and nozzles.)
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SOLIDWORKS Lesson 14
Pressure Vessel Analysis
Stress Even though the ASME Boiler and Pressure Vessel Code does not
Linearization require us to compute the membrane and bending components for the
flanges and opening covers, other parts of the vessel may be rather
bulky, requiring modeling with solid elements. While shell elements
report directly both the membrane and bending components of the
stress intensities, solid elements results are of general 3D format and
require additional processing (stress linearization). We will practice
this stress linearization of the Manhole nozzle flange.
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Lesson 14 SOLIDWORKS
Pressure Vessel Analysis
On the flange cross section select 2 points defining the trajectory along
which you wish to linearize the stress results.
Click Calculate to obtain the summary.
The Linearize stress dialog shows the summary of the membrane and
bending components.
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SOLIDWORKS Lesson 14
Pressure Vessel Analysis
The resulting Stress Intensity values for the membrane and bending
stress components would be compared against the stress intensity
values set by the ASME Boiler and Pressure Vessel Code.
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Lesson 14 SOLIDWORKS
Pressure Vessel Analysis
The above six graphs show the variations of all stress components
through the cross-section along the line defined by Point 1 and Point 2.
Each graph shows the computed real stress component (shown in red)
and linearized variations (membrane and membrane+bending in blue
and green, correspondingly).
12 Save and close the assembly.
292
Index
B M
Best Stiffness to Weight ratio 96 Material Properties for Thermal
Buckling Load Factor 49, 53 Analysis 115
Bulk Temperature 120 Minimize Mass with Displacement
constraint 97
C Minimize Maximum Displacement 97
Centrifugal Load 26 Mode Shapes 10
Conduction 111
Convection 112 O
Convection Coefficient 146 Optimization Analysis
Define 146 Constraints 268
Forced Convection 113 Define 265
Free Convection 112 Local Trend Graph 275
Objective 266
D Results 272
Damping 8
design scenario 68, 83 P
Drop Test Plot Heat Flux 149
Define 241 Plot Temperature 147
Drop Height. 242, 258
Impact Plane 243 R
Parameters 242 Radiation 113
Response Graph 249 Define 143
Parameters 143
E Stefan-Boltzmann Law 114
Eigenvectors 48 Surface to Surface 143
Elastic Stiffness Matrix 48 Type 143
Reference Temperature at Zero
F Strain. 162, 174
Fatigue Analysis Theory 188 Resonant Frequencies 8
Fundamental Frequency 10
S
G SOLIDWORKS 5
Goals and Constraints 96
T
H Temperature Curves 130
Heat Flux Singularities 148 Thermal Contact Resistance 117
Heat Power 117 Define 119
Define 142 Thermal Resistance 36, 118, 155
Thermostat 131
I Time Curves 129–130
Include Thermal Effects 161, 174 Transient Thermal Analysis 125
Initial Temperature 126
Interfacial Conductance 118, 153 V
Vector Plot 160
L
Linear vs. Nonlinear Buckling 48
List Resonant Frequencies 13
293
Index SOLIDWORKS
294