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Can I and How Do I...with SolidWorks Simulation Tools?

Hawk Ridge Systems Simulation Team

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Agenda

• Introductions

• Presentation Description

• Presentation Format

• Your Questions

• Conclusion

• Wrap-Up

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Introductions

• Jared Conway, Simulation Services Manager

• Glenn Whyte, Simulation Product Manager

• Damon Tordini, Simulation Applications Specialist

• Chris Ma, Simulation Engineer

The Hawk Ridge Systems Simulation Team

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Presentation Description

Whether you’re looking to bring SolidWorks Simulation tools into your design process or you’re a SolidWorks Simulation user,

this is the presentation for you. The panel will field your questions about the tools’ capabilities and how-to type functionality questions.

Can I and How Do I...with SolidWorks Simulation Tools?

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Presentation Format

• Start with an example/pre-submit question

• Take a question from the audience (Raise your hand if you have a question)

• Panel will either answer or research

• Take another question, answer a researched question or answer a pre-submit question

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We’re Ready, Time to Take Your Questions

SolidWorks Simulation(FEA)

• Ground Contact (Cus-DH)• Dynamic Bolts (Cus-JP)• Fatigue (Cus-DH)• Results Convergence (HRS-DT)• Submodeling (Cus-DH)• Results Convergence (HRS-DT)• Convection (SWW-CM)• Joints (SWW-GW)• Adhesives (SWW-DT)• Non-Uniform Pressure (SWW-

CM)

SolidWorks Motion(Kinematics)

• Component Intraction (Cus-CD)

SolidWorks Flow Simulation(CFD)

• Model Preparation (HRS-CM)

SolidWorks Plastics(Injection Molding)

• Configurations (HRS-CM)

SolidWorks Sustainability(Life Cycle)

• Enable The Addin (HRS-JC)

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Component Interaction, Chase D.

• Software: SolidWorks Motion• Answer: Yes, no hardcoded limit but it will take time. • Explanation:

• Limited by processing power, solver is single threaded.• Simplify assembly as much as possible in advance.• Simplify analysis phases, let components settle before moving them.• When possible use contact groups to minimize number of contacts.• Start with stiff contact like steel and then move to your selected material.• Solver suggestions: WSTIFF, low accuracy, low contact resolution,

sufficient FPS to capture contact and Impact contact type.• Turn off animate while solving option.

• Back

Can I simulate how hundreds of components interact with each other?

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Ground Contact, David H.

• Software: SolidWorks Simulation• Answer: A virtual wall is the best option. No meshing required. It allows

separation and interaction the same as no penetration.• Explanation:

• Fixed: Does not allow interface separation vertically or horizontally.

• Roller Slider: Does not allow separation.• Model Ground, Bonded: Same limitations as fixed plus additional component

modeled.• Model Ground, No Penetration: Ground needs to be

modeled.

How do I simulate realistic ground contact?

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Configurations, HRS

• Software: SolidWorks Plastics• Answer: Yes, but the option needs to be turned on.• Explanation:

• Default settings require 1 file for every configuration or set of process conditions.

• Enable the option through the SolidWorks Plastics Settings: Help > Settings > SolidWorks Configuration Integration.

• To copy the process conditions from an existing analysis:1. Start the Model Manager.2. Copy and paste the setup.3. Name the pasted setup with EXACT same name as your new configuration

Can I use configurations for different process conditions or geometries?

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Model Preparation, HRS

• Software: SolidWorks Flow Simulation• Answer: From http://blog.hawkridgesys.com/

1. Simplify and start simple.2. CTRL+Q with verification on rebuild turned on.3. Import diagnostics.4. Tools > check.5. Interference detection.6. Flow simulation > tools > check geometry and leak tracker.

• Explanation:• Common problems: Long solve time, “solver terminated abnormally”, unexplainable results or solver

errors like “face is not lying on boundary between fluid and solid” and “unresolved…”

How do I setup my model for SolidWorks Flow Simulation?

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Enable The Add-In, HRS

• Software: SolidWorks Sustainability• Answer: Tools > Sustainability or on the evaluate tab.• Explanation:

• Not enabled through tools > add-ins.• Replaces SustainabilityXpress in the tools pull down menu.• Sustainability adds the ability to run life-cycle analyses

on assemblies in addition to parts and also offers moreinput and output options.

• Data from PE-International of Stuttgart Germany, provider of software and consulting services in sustainable design and life-cycle analysis for over 20 years.

How do I enable the software?

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Dynamic Bolt, James P.

• Software: SolidWorks Simulation• Answer: Currently not possible, would need to be addressed with a

nonlinear dynamic analysis or simplification in linear dynamic.• Explanation:

• Harmonic analysis is a linear dynamic analysis which inherentlydoes not include nonlinearities such as the no penetration contact that is part of a bolt connector definition. Bolts could be modeled and meshed but contact would be bonded. Springs or soft components could act as first-order idealization of contact. Preload would be difficult to include.

• Nonlinear dynamic supports bolt connectors but would require long run times and a simulation at each frequency to obtain the same results as a harmonic analysis.

How do I model a bolted connection in a harmonic analysis?

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Fatigue, David H.

• Software: SolidWorks Simulation Professional / SolidWorks Simulation Premium• Answer: Yes, using the fatigue study. For better accuracy, consider a nonlinear study for the event.• Explanation:

• Fatigue analysis allows the user to create a standard linear static stress analysis to represent one loading event, and then define how many cycles of that load the product will endure. The amount of damage, or product life that’s been used up, is shown.

• The stresses that are calculated in the “event” study can have a major impact on the estimated product life. Nonlinear may predict this event more accurately.

Can I accurately predict the life of my product?

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Results Convergence, HRS

• Software: SolidWorks Simulation• Answer: Using the adaptive mesh capability.• Explanation:

• The h-adaptive mesh capability in SolidWorks Simulation automatically refines the mesh of your model only in the necessary areas and checks that an acceptable level of error has been achieved.

• Inaccurate stress results (such as stress singularities) can be discovered using this tool.

• More information at http://blog.hawkridgesys.com.

How do I know that my results are numerically accurate?

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Submodeling, David H.

• Software: SolidWorks Simulation Professional and Premium• Answer: Use Submodeling to enhance accuracy and add more complex

mesh and conditions to a sub-region of the model.• Explanation:

• Submodeling allows us to transfer loading conditions from a master model into a sub-region of that model. In doing so, we can increase mesh density, add more complex conditions and run multiple iterations without the overhead of the large complex model.

• In this example, the master analysis (with coarse mesh, bonded contact conditions) takes 30 seconds to run, where the bracket submodel takes 15 seconds. I ran a 10-iteration optimization routine on the submodel in half the time it would have taken in the master model.

• Including bolted connections and no penetration contact? 90 minutes to run in the master model, 30 minutes using the submodeling approach.

How can I make my complex analysis more efficient?

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Pressure Distribution, SWW

• Software: SolidWorks Premium• Answer: Non-uniform pressure as a function of x and y.• Explanation:

• SolidWorks has the ability to specify a non-uniform pressure distribution as a function of x and y.

• The equation used is p(X,Y) = V* (A + B*X + C*Y + D*X*Y + E*X^2 + F*Y^2), where V is the pressure specified in the input box, A, B, C, D, E, and F are user-specified constants.

• If the non-uniform pressure cannot be described by the above equation, then the face can be split using split lines, and the user can apply a non-uniform pressure distribution to each resulting face.

How do I specify a pressure distribution that varies with height?

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Convection in Simulation, SWW

• Software: SolidWorks Simulation Professional• Answer: Thermal simulation, convection boundary condition.• Explanation:

• In a thermal analysis, the user can specify a convection coefficient and ambient temperature on a face or set of faces that is used to calculate heat transfer due to convection.

• Convection can also be imported from Flow Simulation. (FloXpress does not include this feature but can provide some input on how the flow behaves)

Can you specify cooling due to convection in Simulation?

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Weldment Joints, SWW

• Software: SolidWorks Simulation• Answer: Depends on connection type.• Explanation:

• When modeling weldments as beams, the members are modelled as a line element and the joint is a node connecting each line. This is a simple, perfect, approximation.

• When modeling weldments as solids, the true geometry of the joint is respected, and you can add connecting components like bolts and welds.

• In a mixed mesh, the shape of the weldment cross-section is imprinted on the solid part, producing accurate representation of the loading on that joint.

How can I address weldment joints?

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Contact Stresses/Forces, SWW

• Software: SolidWorks Simulation• Answer: Examine stresses or contact forces

between parts.• Explanation:

• Method 1: Leave interface area as bonded, and examine difference in normal or principal stresses across part boundary. Compare to adhesive specs.

• Method 2: Apply no penetration local contact set in area of thermal pad and bonded contacts at edges. Examine contact/friction forces.

How can I predict when an adhesive will fail?

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Conclusion

• What you see is what you get but always ask the question.

• Check the documentation, check the KB, check the forum, talk to your VAR or contact HRS.

• Sometimes you may have to settle on a different approach or relative results but in the long-run it is unlikely that you can’t get something to help you make a design decision.

• If there is a limitation, submit an enhancement request in the SolidWorks Customer Portal.

Always ask the question: there is probably a way.

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Wrap-Up

Contact Information

• Get in touch by email: simulationservices@hawkridgesys.com

• Visit our website: www.hawkridgesys.com

• Get in touch by telephone: 877.266.4469 – US | 866.587.6803 - CANADA

• http://dropbox.hightail.com/hrssimulationservices

Still have questions?