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    SolidWorks Simulation 2022 Black Book
    SolidWorks Simulation 2022 Black Book
    SolidWorks Simulation 2022 Black Book
    Ebook920 pages2 hours

    SolidWorks Simulation 2022 Black Book

    By Gaurav Verma and Matt Weber

    ()

    Read preview

    About this ebook

    The SolidWorks Simulation 2022 Black Book, is 9th edition of the book written to help professionals as well as students in performing various tedious jobs of Finite Element Analysis. The book follows a step by step methodology. This book explains the background work running behind your simulation analysis screen. The book covers almost all the information required by a learner to master the SolidWorks Simulation. The book starts with basics of FEA, goes through all the simulation tools and ends up with practical examples of analysis. Chapters on manual FEA ensure the firm understanding of FEA concepts through SolidWorks Simulation. The book contains our special sections named "Why?" and notes. We have given reasons for selecting most of the options in analysis under the "Why?" sections. The book explains the Solver selection, iteration methods like Newton-Raphson method and integration techniques used by SolidWorks Simulation for functioning. A chapter on Topology Study in this edition helps you understand the procedures of modifying component based on analysis results. New tips and notes have been added in this book for various analyses. Some of the salient features of this book are:

     

    In-Depth explanation of concepts
    Every new topic of this book starts with the explanation of the basic concepts. In this way, the user becomes capable of relating the things with real world.

     

    Topics Covered
    Every chapter starts with a list of topics being covered in that chapter. In this way, the user can easy find the topic of his/her interest easily.

     

    Instruction through illustration
    The instructions to perform any action are provided by maximum number of illustrations so that the user can perform the actions discussed in the book easily and effectively. There are about 750 illustrations that make the learning process effective.

     

    Tutorial point of view
    The book explains the concepts through the tutorial to make the understanding of users firm and long lasting. Each chapter of the book has tutorials that are real world projects.


    "Why?"   
    The book explains the reasons for selecting options or setting a parameters in tutorials explained in the book.  

     

    Project
    Projects and exercises are provided to students for practicing.

     

    For Faculty
    If you are a faculty member, then you can ask for video tutorials on any of the topic, exercise, tutorial, or concept. As faculty, you can register on our website to get electronic desk copies of our latest books, self-assessment, and solution of practical. Faculty resources are available in the Faculty Member page of our website  once you login. Note that faculty registration approval is manual and it may take two days for approval before you can access the faculty website.
     

    LanguageEnglish
    PublisherCADCAMCAE Works
    Release dateJan 12, 2022
    ISBN9798201972752
    SolidWorks Simulation 2022 Black Book
    Author

    Gaurav Verma

    Gaurav Verma is currently a Full Professor at the Panjab University, Chandigarh, India (Dr. SS Bhatnagar University Institute of Chemical Engineering and Technology, and Adjunct Faculty at the Department of Nanoscience and Nanotechnology). He is a former CV Raman Post-Doctoral fellow from the Department of Chemical Engineering, Massachusetts Institute of Technology (MIT), USA. His research focuses on the areas of applied nanoscience and nanostructured materials.

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      Book preview

      SolidWorks Simulation 2022 Black Book - Gaurav Verma

      Chapter 1

      Introduction to Simulation

      The major topics covered in this chapter are:

      •Simulation.

      •Types of Analyses performed in SolidWorks Simulation.

      •FEA

      •User Interface of SolidWorks Simulation.

      Simulation

      Simulation is the study of effects caused on an object due to real-world loading conditions. Computer Simulation is a type of simulation which uses CAD models to represent real objects and it applies various load conditions on the model to study the real-world effects. SolidWorks Simulation is one of the Computer Simulation programs available in the market. In SolidWorks Simulation, we apply loads on a constrained model under predefined environmental conditions and check the result (visually and/or in the form of tabular data). The types of analyses that can be performed in SolidWorks are given next.

      Types of Analyses Performed in SolidWorks Simulation

      SolidWorks Simulation performs almost all the analyses that are generally performed in Industries. These analyses and their uses are given next.

      Static Analysis

      This is the most common type of analysis we perform. In this analysis, loads are applied to a body due to which the body deforms and the effects of the loads are transmitted throughout the body. To absorb the effect of loads, the body generates internal forces and reactions at the supports to balance the applied external loads. These internal forces and reactions cause stress and strain in the body. Static analysis refers to the calculation of displacements, strains, and stresses under the effect of external loads, based on some assumptions. The assumptions are as follows.

      1.All loads are applied slowly and gradually until they reach their full magnitudes. After reaching their full magnitudes, load will remain constant (i.e. load will not vary against time).

      2.Linearity assumption: The relationship between loads and resulting responses is linear. For example, if you double the magnitude of loads, the response of the model (displacements, strains, and stresses) will also double. You can make linearity assumption if:

      •All materials in the model comply with Hooke’s Law that is stress is directly proportional to strain.

      •The induced displacements are small enough to ignore the change is stiffness caused by loading.

      •Boundary conditions do not vary during the application of loads. Loads must be constant in magnitude, direction, and distribution. They should not change while the model is deforming.

      If the above assumptions are valid for your analysis, then you can perform Linear Static Analysis. For example, a cantilever beam fixed at one end and force applied on other end; refer to Figure-1.

      If the above assumptions are not valid, then you need to perform the Non-Linear Static analysis. For example, an object attached with a spring being applied under forces; refer to Figure-2.

      Dynamic Analysis

      In general, we have to perform dynamic analysis on a structure when the load applied to it varies with time. The most common case of dynamic analysis is the evaluation of responses of a building due to earthquake acceleration at its base. Every structure has a tendency to vibrate at certain frequencies, called natural frequencies. Each natural frequency is associated with a certain shape, called mode shape that the model tends to assume when vibrating at that frequency. When a structure is excited by a dynamic load that coincides with one of its natural frequencies, the structure undergoes large displacements. This phenomenon is known as ‘resonance’. Damping prevents the response of the structures to resonant loads. In reality, a continuous model has an infinite number of natural frequencies. However, a finite element model has a finite number of natural frequencies that is equal to the number of degrees of freedom considered in the model.

      The first few modes of a model (those with the lowest natural frequencies), are normally important. The natural frequencies and corresponding mode shapes depend on the geometry of the structure, its material properties, as well as its support conditions and static loads. The computation of natural frequencies and mode shapes is known as modal analysis. When building the geometry of a model, you usually create it based on the original (undeformed) shape of the model. Some loading, like a structure’s self-weight, is always present and can cause considerable changes in the structure’s original geometry. These geometric changes may have, in some cases, significant impact on the structure’s modal properties. In many cases, this effect can be ignored because the induced deflections are small.

      The following few topics – Random Vibration, Response Spectrum analysis, Time History analysis, Transient vibration analysis, and Vibration modal analysis are extensions of dynamic analysis.

      Random Vibration

      Engineers use this type of analysis to find out how a device or structure responds to steady shaking of the kind you would feel riding in a truck, rail car, rocket (when the motor is on), and so on. Also, things that are riding in the vehicle, such as on-board electronics or cargo of any kind, may need Random Vibration Analysis. The vibration generated in vehicles from the motors, road conditions, etc. is a combination of a great many frequencies from a variety of sources and has a certain random nature. Random Vibration Analysis is used by mechanical engineers who design various kinds of transportation equipment.

      Response Spectrum Analysis

      Engineers use this type of analysis to find out how a device or structure responds to sudden forces or shocks. It is assumed that these shocks or forces occur at boundary points, which are normally fixed. An example would be a building, dam, or nuclear reactor when an earthquake strikes. During an earthquake, violent shaking occurs. This shaking transmits into the structure or device at the points where they are attached to the ground (boundary points).

      Mechanical engineers who design components for nuclear power plants must use response spectrum analysis as well. Such components might include nuclear reactor parts, pumps, valves, piping, condensers, etc. When an engineer uses response spectrum analysis, he is looking for the maximum stresses or acceleration, velocity and displacements that occur after the shock. These in turn lead to maximum stresses.

      Time History Analysis

      This analysis plots response (displacements, velocities, accelerations, internal forces, etc.) of the structure against time due to dynamic excitation applied on the structure.

      Transient Vibration Analysis

      When you strike a guitar string or a tuning fork, it goes from a state of inactivity into a vibration to make a musical tone. This tone seems loudest at first, then gradually dies out. Conditions are changing from the first moment the note is struck. When an electric motor is started up, it eventually reaches a steady state of operation. But to get there, it starts from zero RPM and passes through an infinite number of speeds until it attains the operating speed. Every time you rev the motor in your car, you are creating transient vibration. When things vibrate, internal stresses are created by the vibration. These stresses can be devastating if resonance occurs between a device producing vibration and a structure responding to. A bridge may vibrate in the wind or when cars and trucks go across it. Very complex vibration patterns can occur. Because things are constantly changing, engineers must know what the frequencies and stresses are at all moments in time. Sometimes transient vibrations are extremely violent and short-lived. Imagine a torpedo striking the side of a ship and exploding, or a car slamming into a concrete abutment or dropping a coffeepot on a hard floor. Such vibrations are called shock, which is just what you would imagine. In real life, shock is rarely a good thing and almost always unplanned. But shocks occur anyhow. Because of vibration, shock is always more devastating than if the same force were applied gradually.

      Vibration Analysis (Modal Analysis)

      By its very nature, vibration involves repetitive motion. Each occurrence of a complete motion sequence is called a cycle. Frequency is defined as so many cycles in a given time period. Cycles per seconds or Hertz. Individual parts have what engineers call natural frequencies. For example, a violin string at a certain tension will vibrate only at a set number of frequencies, which is why you can produce specific musical tones. There is a base frequency in which the entire string is going back and forth in a simple bow shape.

      Harmonics and overtones occur because individual sections of the string can vibrate independently within the larger vibration. These various shapes are called modes. The base frequency is said to vibrate in the first mode, and so on up the ladder. Each mode shape will have an associated frequency. Higher mode shapes have higher frequencies. The most disastrous kinds of consequences occur when a power-driven device such as a motor for example, produces a frequency at which an attached structure naturally vibrates. This event is called resonance. If sufficient power is applied, the attached structure will be destroyed. Note that ancient armies, which normally marched in step, were taken out of step when crossing bridges. Should the beat of the marching feet align with a natural frequency of the bridge, it could fall down. Engineers must design so that resonance does not occur during regular operation of machines. This is a major purpose of Modal Analysis. Ideally, the first mode has a frequency higher than any potential driving frequency. Frequently, resonance cannot be avoided, especially for short periods of time. For example, when a motor comes up to speed it produces a variety of frequencies. So it may pass through a resonant frequency.

      Buckling Analysis

      If you press down on an empty soft drink can with your hand, not much will seem to happen. If you put the can on the floor and gradually increase the force by stepping down on it with your foot, at some point it will suddenly squash. This sudden scrunching is known as buckling.

      Models with thin parts tend to buckle under axial loading. Buckling can be defined as the sudden deformation, which occurs when the stored membrane(axial) energy is converted into bending energy with no change in the externally applied loads. Mathematically, when buckling occurs, the total stiffness matrix becomes singular. In the normal use of most products, buckling can be catastrophic if it occurs. The failure is not one because of stress but geometric stability. Once the geometry of the part starts to deform, it can no longer support even a fraction of the force initially applied. The worst part about buckling for engineers is that buckling usually occurs at relatively low stress values for what the material can withstand. So they have to make a separate check to see if a product or part thereof is okay with respect to buckling. Slender structures and structures with slender parts loaded in the axial direction buckle under relatively small axial loads. Such structures may fail in buckling while their stresses are far below critical levels. For such structures, the buckling load becomes a critical design factor. Stocky structures, on the other hand, require large loads to buckle, therefore buckling analysis is usually not required.

      Buckling almost always involves compression; refer to Figure-3. In mechanical engineering, designs involving thin parts in flexible structures like airplanes and automobiles are susceptible to buckling. Even though stress can be very low, buckling of local areas can cause the whole structure to collapse by a rapid series of ‘propagating buckling’. Buckling analysis calculates the smallest (critical) loading required buckling a model. Buckling loads are associated with buckling modes. Designers are usually interested in the lowest mode because it is associated with the lowest critical load. When buckling is the critical design factor, calculating multiple buckling modes helps in locating the weak areas of the model. This may prevent the occurrence of lower buckling modes by simple modifications.

      Thermal analysis

      There are three mechanisms of heat transfer. These mechanisms are Conduction, Convection, and Radiation. Thermal analysis calculates the temperature distribution in a body due to some or all of these mechanisms. In all three mechanisms, heat flows from a higher-temperature medium to a lower temperature one. Heat transfer by conduction and convection requires the presence of an intervening medium while heat transfer by radiation does not.

      There are two modes of heat transfer analysis.

      Steady State Thermal Analysis

      In this type of analysis, we are only interested in the thermal conditions of the body when it reaches thermal equilibrium, but we are not interested in the time it takes to reach this status. The temperature of each point in the model will remain unchanged until a change occurs in the system. At equilibrium, the thermal energy entering the system is equal to the thermal energy leaving it. Generally, the only material property that is needed for steady state analysis is the thermal conductivity.

      Transient Thermal Analysis

      In this type of analysis, we are interested in knowing the thermal status of the model at different instances of time. A thermos designer, for example, knows that the temperature of the fluid inside will eventually be equal to the room temperature(steady state), but he is interested in finding out the temperature of the fluid as a function of time. In addition to the thermal conductivity, we also need to specify density, specific heat, initial temperature profile, and the period of time for which solutions are desired.

      Till this point, we have learned the basics of various analyses that can be performed in SolidWorks. Now, we will learn about the studies that can be performed in SolidWorks.

      Drop Test Studies

      Drop test studies simulate the effect of dropping a part or an assembly on a rigid or flexible floor. To perform this study, the floor is considered as planar and flat. The forces that are considered automatically for this study are gravity and impact reaction.

      Fatigue Analysis

      The fatigue is more over a study than analysis. But it is generally named as analysis. This analysis is used to check the effect of continuous loading and unloading of forces on a body. The base element for performing fatigue analysis are results of static, nonlinear, or time history linear dynamic studies.

      Pressure Vessel Design Study

      Pressure Vessel Design study allows you to combine the results of static studies with desired factors and interpret the results. The Pressure Vessel Design study combines the results of the static studies algebraically using a linear combination or the square root of the sum of the squares.

      Design Study

      Design Study is used to perform an optimization of design. Using the Design Study, you can:

      •Define multiple variables using simulation parameters, or driving global variables.

      •Define multiple constraints.

      •Define multiple goals using sensors.

      •Analyze models without simulation results. For example, you can minimize the mass of an assembly with the variables, density and model dimensions, the constraint, and volume.

      •Evaluate design choices by defining a parameter that sets bodies to use different materials as a variable.

      Till this point, you have become familiar with the analyses that can be performed by using SolidWorks Simulation. But how the software analyze the problems, the answer is FEA.

      FEA

      FEA, Finite Element Analysis, is a mathematical system used to solve real-world engineering problems by simplifying them. In FEA by SolidWorks, the model is broken into small elements and nodes. Then, distributed forces are applied on each element and node. The cumulative result of forces is calculated and displayed in results. The elements in which a model can be broken into, are given in Figure-4, Figure-5, and Figure-6.

      Optimum process of FEA through SolidWorks Simulation

      With the knowledge of the basics discussed above, we can summarize the process of performing analysis as follows:

      1. Construct the part(s) in a solid modeler. It is surprisingly easy to accidentally build flawed models with tiny lines, tiny surfaces, or tiny interior voids. The part will look fine, except with extreme zooms, but it may fail to mesh. Most systems have checking routines that can find and repair such problems before you move on to an FEA study. Sometimes, you may have to export a part, and then import it back with a new name because imported parts are usually subjected to more time consuming checks than native parts. When multiple parts form an assembly, always mesh and study the individual parts before studying the assembly. Try to plan ahead and introduce split lines into the part to aid in mating assemblies and to locate load regions and restraint (or fixture or support) regions. Today, construction of a part is probably the most reliable stage of any study.

      2. Defeature the solid part model for meshing. The solid part may contain features, like a raised logo, that are not necessary to manufacture the part, or required for an accurate analysis study. They can be omitted from the solid used in the analysis study. That is a relatively easy operation supported by most solid modelers (such as the suppress option in SW) to help make smaller and faster meshes. However, it has the potential for introducing serious, if not fatal, errors in a following engineering study. This is a reliable modeling process, but its application requires engineering judgment.

      For example, removing small radius interior fillets can greatly reduces the number of elements and simplifies the mesh generation. But, that creates sharp reentrant corners that can yield false infinite stresses; refer to Figure-7. Those false high stress regions may cause you to overlook other areas of true high stress levels. Small holes lead to many small elements (and long run times). They also cause stress concentrations that raise the local stress levels by a factor of three or more. The decision to disfeature them depends on where they are located in the part. If they lie in a high stress region you must keep them. But disfeaturing them is allowed if you know they occur in a low stress region. Such decisions are complicated because most parts have multiple possible loading conditions and a low stress region for one load case may become a high stress region for another load case.

      3. Combine multiple parts into an assembly. Again, this is well automated and reliable from the geometric point of view and assemblies look as expected. However, geometric mating of part interfaces is very different for defining their physical (displacement, or temperature) mating. The physical mating choices are often unclear and the engineer may have to make a range of assumptions, study each, and determine the worst case result. Having to use physical contacts makes the linear problem require iterative solutions that take a long time to run and might fail to converge.

      4. Select the element type. Some FEA systems have a huge number of available element types (with underlying theoretical restrictions). The SolidWorks system has only the fundamental types of elements. Namely, truss elements (bars), frame elements (beams), thin shells (or flat plates), thick shells, and solids. The SW simulation system selects the element type (beginning in 2009) based on the shape of the part. The user is allowed to convert a non-solid element region to a solid element region, and vice versa. Knowing which class of element will give a more accurate or faster solution requires training in finite element theory. At times a second element type study is used to help validate a study based on a different element type.

      5. Mesh the part(s) or assembly, remembering that the mesh solid may not be the same as the part solid. A general rule in an FEA is that your computer never has enough speed or memory. Sooner or later you will find a study that you cannot execute. Often that means you must utilize a crude mesh(or at least crude in some region) and/or invoke the use of symmetry or anti symmetry conditions. Local solution errors in a study are proportional to the product of the local element size and the gradient of the secondary variables (i.e., gradient of stress or heat flux). Therefore, you exercise mesh control to place small elements where your engineering judgment estimates high stress (or flux) regions, as well as large elements in low stress regions.

      The local solution error also depends on the relative sizes of adjacent elements. You do not want skinny elements adjacent to big ones. Thus, automatic mesh generators have options to gradually vary adjacent element sizes from smallest to biggest.

      The solid model sent to the mesh generator frequently should have load or restraint (fixture) regions formed by split lines, even if such splits are not needed for manufacturing the parts. The mesh typically should have refinements at source or load regions and support regions.

      A mesh must look like the part, but that is not sufficient for a correct study. A single layer of elements filling a part region is almost never enough. If the region is curved, or subjected to bending, you want at least three layers of quadratic elements, but five is a desirable lower limit. For linear elements you at least double those numbers.

      Most engineers do not have access to the source code of their automatic mesh generator. When the mesher fails you frequently do not know why it failed or what to do about it. Often you have to re-try the mesh generation with very large element sizes in hopes of getting some mesh results that can give hints as to why other attempts failed. The meshing of assemblies often fails. Usually the mesher runs out of memory because one or more parts had a very small, often unseen, feature that causes a huge number of tiny elements to be created. You should always attempt to mesh each individual part to spot such problems before you attempt to mesh them as a member of an assembly.

      Automatic meshing, with mesh controls, is usually simple and fast today. However, it is only as reliable as the modified part or assembly supplied to it. Distorted elements usually do not develop in automatic mesh generators, due to empirical rules for avoiding them. However, distorted elements locations can usually be plotted. If they are in regions of low gradients you can usually accept them.

      You should also note that studies involving natural frequencies are influenced most by the distribution of the mass of the part. Thus, they can still give accurate results with meshes that are much cruder than those that would be acceptable for stress or thermal studies.

      6. Assign a linear material to each part. Modern FEA systems have a material library containing the linear mechanical, thermal, and/or fluid properties of most standardized materials. They also allow the user to define custom properties. The property values in such tables are often misinterpreted to be more accurate and reliable than they actually are. The reported property values are accepted average values taken from many tests. Rarely are there any data about the distribution of test results, or what standard deviation was associated with the tests. Most tests yield results that follow a bell shaped curve distribution, or a similar skewed curve.

      When you accept a tabulated property value as a single number to be used in the FEA calculation remember it actually has a probability distribution associated with it. You need to assign a contribution to the total factor of safety to allow for variations from the tabulated property value.

      The values of properties found in a material table can appear more or less accurate depending on the units selected. That is an illusion often caused by converting one set of units to another, but not truncating the result to the same number of significant figures available in the actual test units. For example, the elastic modulus of one steel is tabulated from the original test as 210 MPa, but when displayed in other units

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