Finite Element Analysis

Using SolidWorks Simulation

Part - 2

S VinothKumar
Sr. Application Engineer - Simulation

Static Analysis using shell mesh for a Rectangular

Shaped Part
In part -1, we have seen that how a part can be analyzed as a solid element
model and here in now we will be analyzing the same component as a shell
element model.
The shell models can be used for the thin components whereas, the
thickness will be very less compare to the length or width of it.
Shell elements will be used wherein places like of component having
uniform thickness.

Static Analysis using shell mesh for a Rectangular

Shaped Part
Shell elements can be created by using the surface bodies. Even with the
use of existing solid bodies, the shell elements can be created.
In the simulation tree right click on the component and select the Define
shell by selected faces options.
Following to this you will get a shell definition dialogue box as shown in
the next image.

Static Analysis using shell mesh for a Rectangular

Shaped Part
In the shell definition box, select the components face for creating the
surface and enter the thickness value along with the offsetting options
defined. (Top face, mid face, bottom face & offset face).
Thickness offsetting will be made based on the offsetting selection and the
components face selection.
After applying the
shell
definition
option, the parts
solid icon changed
to shell.

Static Analysis using shell mesh for a Rectangular

Shaped Part
Once the part is converted for shell meshing, apply the loads and restraints
on the edges of the shell or the shell faces.
Defining the loads and restraints on the non shelled faces are not valid.

Static Analysis for Assemblies

Generally the assembly consists of two or more components which will
perform the movement to satisfy the functional requirement and some of
the components may be welded together.
While performing the analysis for the assemblies, these conditions are to be
considered and mapped without any mistakes to simulate the real time
scenario.
Herein FEA, we called the definition of component interaction in the
assemblies as contact definition.
In contact definition, basically there are three types of contacts are
available to simulate the real time scenario of the assemblies.

Static Analysis for Assemblies

The three different types of contacts are,
Bonded Contact
No Penetration Contact
Allow Penetration Contact

Bonded contact defines that, if the component faces are in contact with the
other component, those areas are to be considered as the bonded faces.
(similar to the consideration of welding)

Static Analysis for Assemblies

No penetration contact defines that, if two components are not in contact
initially and due to the motion or force, one may touches the other. During
this, the components will observe the interaction of the other component
and it will move on to the other way where, the path for movement is
available based on the component constraint.

Static Analysis for Assemblies

Allow penetration contact defines that, if two components are not in contact
initially and due to the motion or force, one may touches the other. During
this, the components will observe the interaction of the other component
and it will tend to collide with each other based on the component
constraint. (available only for the contact checking purpose)

Static Analysis for Assemblies

In assembly contacts, we have three different levels of definition as follows
global contact
component contact
local contact

The assembly contact will behaves based on the following hierarchy

precedence.

Static Analysis for Assemblies

The system will responds for the local contact definition for the face or
edge selection at first. Then it will obey the component level contact
condition then, for the global contact definition.
The local contact definition will required for the selection of faces or edges
based on the element types (face solid element, edges shell element).

During the time of applying the local contact definition we need to define
the contact interaction level where available as,
None to Node Contact
Node to Surface Contact
Surface to Surface contact

Static Analysis for Assemblies

The none to node contact available only for faces that are initially touching.
This contact formulation is available with the No Penetration contact type
for static, nonlinear, and thermal studies. For static and nonlinear studies,
this contact type prevents interference between the source and target faces
but allows them to move away from each other to form gaps.

This formulation is faster than node to surface and surface to surface, but it
is the least accurate for general structural problems with sliding or large
rotations.

Static Analysis for Assemblies

The none to surface contact does not require that the faces are initially
touching.

For static and nonlinear studies, this contact type prevents interference
between the source and target faces but allows them to move away from
each other to form gaps.

The Node to Surface option gives better results if the contact area between
the two faces becomes very small or reduce to a line or point

Static Analysis for Assemblies

The surface to surface contact is more general than node to node and node
to surface contacts. Suitable for complex contacts with general loading.

In most cases, it gives more accurate results but requires more time and
resources.

Not recommended when the area of contact between a source face and
target face becomes too small or reduces to a line or point during
deformation. In such cases, use the Node to Surface option.

Static Analysis for Assemblies

The surface to surface contact is more general than node to node and node
to surface contacts. Suitable for complex contacts with general loading.

In most cases, it gives more accurate results but requires more time and
resources.

Not recommended when the area of contact between a source face and
target face becomes too small or reduces to a line or point during
deformation. In such cases, use the Node to Surface option.

Static Analysis for Assemblies

While validating the assemblies, the connection between the component
plays the vital role to simulate the real time scenario.

As discussed in the previous slides regarding the component contacts, the

required level of contacts (No penetration) have been applied for an
assembly (Two plates will be clamped by using the bolts and nuts).
In practical it will be done by using the bolt and nuts. But, in simulation
environment it is not required to have the virtual physical model every
time. To resolve this, we have the list of connectors available and it will
virtually make the connections between the components.

Static Analysis for Assemblies

Types of connectors available in SolidWorks Simulation are as follows,
Bolt connector
Bearing connector
Pin connector
Spring connector

Static Analysis for Assemblies

Bolt connector
The bolt connector formulation is an approximation of a complex
nonlinear behaviour. It provides accurate results when the bolts are under
tension. In loading scenarios where the bolts are under compressive loads, the
axial forces of bolt connectors may not be accurate. In such cases, a decrease
in preload bolt force can result in a "loosening" of the bolt and loss of contact
between the bolt and the components. This behaviour cannot be captured by
the bolt connector formulation in Simulation. For these cases, model the actual
bolt and define no penetration contact sets between the bolt and the
components.

Static Analysis for Assemblies

Bearing connector
Define a bearing connector between split cylindrical faces of a shaft
and cylindrical or spherical faces of a housing.
Use a bearing connector when the housing is not much stiffer than the shaft. If
the components supporting the shaft are much more rigid than the shaft, use a
bearing fixture.
A Bearing connector simulates the interaction between a shaft and a housing
through a bearing. You have to model the geometries for the shaft and the
housing. You can define a bearing connector between split cylindrical faces of
a shaft, and cylindrical or spherical faces of a housing.

Static Analysis for Assemblies

Pin connector
In practical applications, often you might want to know the effects of
pins on their adjacent parts or the assembly rather than the stress distribution
on the pins themselves. For such applications, instead of the traditional
approach, you can use pin connectors to represent the behaviour of the pins in
the assembly virtually.

All applicable studies model the spring used for a pin connector as linear
elastic. You can estimate the axial and rotational stiffness values based on the
actual pin geometry

Static Analysis for Assemblies

Spring connector
Can define a spring connector with entities (faces or edges) belonging
to solid, surfaces and sheet metal bodies.
The three types of springs available are listed below:
Compression Extension

These are general purpose springs that

generate forces as soon as parts
connecting them start to move.

Compression

You can use them to model rubber

bumpers or springs that provide a
compressive interface when sandwiched
between two parts.

Tension

You can use them to model cables or

ropes that cannot take compressive loads
but can significantly affect the overall
stiffness under tension.

Static Analysis for Assemblies

Here we will be discussing about the application of contacts and connectors
in a plate assembly analysis.
Two plates were clamped with each other by using the four bolt
connections as shown in the below figure.

Static Analysis for Assemblies

The static analysis study were created and the local contact of No
Penetration was applied as shown in the below figure.
In the study tree, right click on the connections and select the contact set
option. Further to this, a dialogue box for defining the contact sets will be
appearing and you need to select the faces of the component where the
contacts need to be defined.

Static Analysis for Assemblies

To apply the bolt connectors to the assembly, right click on the
connections in the study tree and select the option of Bolt. Further
to this a dialogue box of connectors will be appearing along with
the options for selecting the various types of fasteners.
Then select the concentric edges of the holes at different
components in the relevant boxes and apply the value of the axial
load or tightening torque.

Static Analysis for Assemblies

Once the connectors have been applied, in the graphics area a virtual image
of bolt will be displayed as shown in the below image.
The important criteria in defining the bolt connectors is specifying the
Axial loads of the bolts or the tightening torque value of the bolts.

Static Analysis for Assemblies

Further to the definition of contacts and the connectors apply the boundary
and loading conditions of the assembly.
Then make the analysis to run for the solving the problem. While the study
was solving, you can be able to see in the study solver display stating as
solving contact constraints. This will be available only at the time of
contact applied to the model.

Static Analysis for Assemblies

After solver completed the run, the results will be displayed by default for
the stress plot.
We can clearly observe here the maximum stress occurs in the area of
bolting location. This is possible only by defining the component contacts
and the connectors for the assembly.

Static Analysis for Assemblies

Also the gap between the plates can be visualized very clearly in the
deformed scaled image as shown below.

While running the analysis for assemblies, ensure that the proper assembly
contacts are defined along with the correct level of connectors to get the
error free results.