Tutorial Simulation Professional

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SolidWorks® 2011
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SolidWorks Simulation
Professional
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Dassault Systèmes SolidWorks Corporation

300 Baker Avenue
Concord, Massachusetts 01742 USA
© 1995-2010, Dassault Systèmes SolidWorks Corporation, a COMMERCIAL COMPUTER SOFTWARE -
Dassault Systèmes S.A. company, 300 Baker Avenue, PROPRIETARY
Concord, Mass. 01742 USA. All Rights Reserved. U.S. Government Restricted Rights. Use, duplication, or
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disclosure by the government is subject to restrictions as set
The information and the software discussed in this document forth in FAR 52.227-19 (Commercial Computer Software -
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are subject to change without notice and are not Restricted Rights), DFARS 227.7202 (Commercial
Computer Software and Commercial Computer Software
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commitments by Dassault Systèmes SolidWorks Corporation
(DS SolidWorks). Documentation), and in the license agreement, as applicable.
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No material may be reproduced or transmitted in any form or Contractor/Manufacturer:
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without the express written permission of DS SolidWorks. Avenue, Concord, Massachusetts 01742 USA
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U.S. Patents 5,815,154; 6,219,049; 6,219,055; 6,611,725; Portions of this software incorporate PhysX™ by NVIDIA
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SolidWorks 2011, SolidWorks Enterprise PDM, SolidWorks System Integration, Inc. All rights reserved.
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Simulation, SolidWorks Flow Simulation, and eDrawings

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Copyright Notices for eDrawings Products

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This software is based in part on the work of the Independent
JPEG Group.
Document Number: PMT1141-ENG_DRAFT

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Contents
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Introduction:
About This Course . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Course Design Philosophy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Using this Book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
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Laboratory Exercises . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
About the Training Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Windows® 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Conventions Used in this Book . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Use of Color . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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What is SolidWorks Simulation? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Limitations of SolidWorks Simulation Professional. . . . . . . . . . . . . . . 5
Lesson 1:
Frequency Analysis of Parts
Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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Modal Analysis Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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Required Material Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Frequencies and Mode Shapes . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Fundamental Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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Case Study: The Tuning Fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Project Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Stages in the Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Frequency Analysis With Supports. . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Results. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Note. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Postprocessing Frequency Results . . . . . . . . . . . . . . . . . . . . . . . . 15
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Contents SolidWorks 2011
Frequency Analysis Without Supports . . . . . . . . . . . . . . . . . . . . . . . . 16

Rigid Body Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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Fundamental Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Effect of Restraints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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Frequency Analysis with Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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Effects of Prestress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
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Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Exercise 1:
Frequency Analysis of a Car Suspension Bulkhead . . . . . . . . . . . . . . 21
Exercise 2:
Frequency Analysis of a Blower Fan . . . . . . . . . . . . . . . . . . . . . . . . . 23
Part 1: Analysis Without Load . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
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Part 2: Analysis With Load. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
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Design Study (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
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Exercise 3:
Frequency Analysis of an Impeller . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Lesson 2:
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Frequency Analysis of Assemblies
Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Case Study: The Engine Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
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All Bonded Contact Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Remote Mass. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
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Connecting the Assembly Parts . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Bonded and Allow Penetration Contacts . . . . . . . . . . . . . . . . . . . . . . 36
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Discussion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Exercise 4:
Frequency Analysis of a Particle Separator . . . . . . . . . . . . . . . . . . . . 41
Lesson 3:
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Buckling Analysis
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Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Buckling Analysis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
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Linear vs. Nonlinear Buckling Analysis. . . . . . . . . . . . . . . . . . . . 44

Buckling Load Factor (BLF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Buckling Analysis Considerations . . . . . . . . . . . . . . . . . . . . . . . . 45
Case Study: Particle Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Calculating Buckling Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
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SolidWorks 2011 Contents
Results Discussion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Will the structure Buckle or Yield First? . . . . . . . . . . . . . . . . . . . 49
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Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
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Exercise 5:
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Buckling Analysis of a Stool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
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Exercise 6:
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Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Lesson 4:
Thermal Analysis
Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Thermal Analysis Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Mechanisms of Heat Transfer. . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
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Conduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
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Convection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Radiation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
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Material Properties for Thermal Analysis . . . . . . . . . . . . . . . . . . 65
Case Study: Microchip Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
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Steady-State Thermal Analysis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Interfacial Conductance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
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Initial Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Thermal Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Heat Flux. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
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Heat Flux Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Heat Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
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Transient Thermal Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Importing Convective Effect from SolidWorks Flow Simulation 77
Results Comparison . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Transient Analysis with Time Varying Load . . . . . . . . . . . . . . . . . . . 80
Time Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Temperature Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
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Transient Thermal Analysis using a Thermostat . . . . . . . . . . . . . . . . 82

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Symmetry Boundary Condition in Thermal Analysis . . . . . . . . . 84

Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
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Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Exercise 7:
Thermal Analysis of a Cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Lesson 5:
Thermal Analysis with Radiation
Case Study: Spot Light Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
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Steady State Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Review of Analysis Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . 97
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Heat Flux Singularities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
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Lesson 6:
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Advanced Thermal Stress
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2D Simplification
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Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Thermal Stress Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Case Study: Metal Expansion Joint . . . . . . . . . . . . . . . . . . . . . . . . . 102
Project Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Stages in the Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Thermal Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
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2D Simplification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
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Prescribed Temperature Condition . . . . . . . . . . . . . . . . . . . . . . . 107
Meshing Considerations in Thermal Analysis . . . . . . . . . . . . . . 108
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Thermal Stress Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Importing Temperatures and Pressures from SolidWorks Flow
Simulation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
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Reference Temperature at Zero Strains . . . . . . . . . . . . . . . . . . . 111
3D model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Exercise 8:
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Thermal Stress Analysis of a Microchip Testing Assembly. . . . . . . 121

Thermal Stress Study . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Change in Thermal Boundary Conditions . . . . . . . . . . . . . . . . . 125
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Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Exercise 9:
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Thermal Stress Analysis of a Gas Tank . . . . . . . . . . . . . . . . . . . . . . 128

Exercise 10:
Thermal Stress Analysis of a Thermoelectric Cooler . . . . . . . . . . . . 133
Problem Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Loading Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
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Goal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
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Lesson 7:
Fatigue Analysis
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Fatigue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Stages of Failure due to Fatigue . . . . . . . . . . . . . . . . . . . . . . . . . 138
High vs. Low Cycle Fatigue . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Stress-life (S-N) Based Fatigue . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Fatigue Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Case Study: Pressure Vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Project Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
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Thermal Study. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

Thermal Stress Study . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
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Static Pressure Study . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Fatigue Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
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S-N Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
F
Fatigue Study . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
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Derive from material Elastic Modulus . . . . . . . . . . . . . . . . . . . . 152
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Constant Amplitude Events Interaction . . . . . . . . . . . . . . . . . . . 152
Salt Computation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Mean Stress Correction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Fatigue Strength Reduction Factor . . . . . . . . . . . . . . . . . . . . . . . 154
Damage Factor Plot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Damage result discussion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
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Fatigue study with dead load (optional) . . . . . . . . . . . . . . . . . . . . . . 158
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Dead loads in Fatigue analysis . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Find Cycle Peaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
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Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Exercise 11:
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Fatigue Analysis of a Basketball Rim. . . . . . . . . . . . . . . . . . . . . . . . 163
Lesson 8:
Advanced Fatigue Analysis
Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Case Study: Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
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Discussion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
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Fatigue Study . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Variable Amplitude Fatigue Event . . . . . . . . . . . . . . . . . . . . . . . 173
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Rainflow Cycle Counting Method . . . . . . . . . . . . . . . . . . . . . . . 173

Variable Loading Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Bins for Rainflow Counting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Noise in Random Loading History . . . . . . . . . . . . . . . . . . . . . . . 179
Fatigue Strength Reduction Factor . . . . . . . . . . . . . . . . . . . . . . . 179
Rainflow Matrix Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
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Results. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
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Fatigue Literature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
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Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Lesson 9:
Drop Test Analysis
Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Drop Test Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Case Study: Camera . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
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Rigid Floor Drop Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

Drop Test Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
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Dynamic Analysis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Solution Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
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Graphing Results. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
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Linear vs. Nonlinear Solution . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
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Elastic Floor Drop Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
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Elasto-Plastic Material Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Elasto-Plastic Model Parameters . . . . . . . . . . . . . . . . . . . . . . . . 200
Processing Elasto-Plastic Results . . . . . . . . . . . . . . . . . . . . . . . . 201
Discussion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Drop Test with Contact (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
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Exercise 12:
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Drop Test of a Clip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Lesson 10:
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Optimization Analysis
Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Optimization Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
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Case Study: Press Frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Design Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Static and Frequency Analyses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
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Optimization Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213

Design Study. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Optimization Goal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
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Design Variable Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Define Constraints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
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Constraint Tolerance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

Constraint Definition Procedure . . . . . . . . . . . . . . . . . . . . . . . . . 218
Postprocessing Optimization Results . . . . . . . . . . . . . . . . . . . . . 220
Local Trend Graphs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
Exercise 13:
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Optimization Analysis of a Cantilever Bracket . . . . . . . . . . . . . . . . 225

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Lesson 11:
Pressure Vessel Analysis
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Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
Case Study: Pressure Vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
Stress Intensity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
Membrane and Bending Stresses (stress linearization) . . . . . . . 232
Basic Stress Intensity Limits. . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
Pressure Vessel Analysis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
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Load Case Combinations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233

General Primary Membrane Stress Intensity . . . . . . . . . . . . . . . 234
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Manhole Nozzle Flange and Cover . . . . . . . . . . . . . . . . . . . . . . . . . 235
Stress Linearization. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
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Contents
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SolidWorks 2011
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1
Introduction
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Introduction SolidWorks 2011
About This The SolidWorks Simulation Professional training course is a direct

Course extension of SolidWorks Simulation. Throughout this course it is
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assumed that students are familiar with the concepts discussed in the
SolidWorks Simulation or similar course, and that they have basic
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familiarity with the software. The goal of this course is to teach you
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how to use the SolidWorks Simulation Professional software to help
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you analyze the structural behavior of your SolidWorks part and
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assembly models in buckling, fatigue, and when subjected to various
thermal loads. The course also covers frequency analysis, optimization,
drop test (time dependent impact analysis), and analysis of pressure
vessels.
The focus of this course is on the fundamental skills and concepts
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central to the successful use of SolidWorks Simulation 2011. You
should view the training course manual as a supplement to, and not a
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replacement for, the system documentation and on-line help. Once you
have developed a good foundation in basic skills, you can refer to the
Prerequisites
E on-line help for information on less frequently used command options.
Students attending this course are expected to have the following:
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I Mechanical design experience.
I Experience with the Windows™ operating system.
I Completed the on-line SolidWorks tutorials that are available under
Help. You can access the on-line tutorials by clicking Help,
SolidWorks Tutorials.
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I Completed the introductory SolidWorks Simulation (or similar)

course.
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Course Design This course is designed around a process- or task-based approach to
Philosophy training. Rather than focusing on individual features and functions, a
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process-based training course emphasizes processes and procedures

you should follow to complete a particular task. By utilizing case
studies to illustrate these processes, you learn the necessary commands,
options and menus in the context of completing a design task.
Course Length The recommended minimum length of this course is one day.
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Using this Book This training manual is intended to be used in a classroom environment
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under the guidance of an experienced SolidWorks Simulation

instructor. It is not intended to be a self-paced tutorial. The examples
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and case studies are designed to be demonstrated “live” by the

instructor.
Please note, there may be slight differences in results in certain lessons
due to service pack upgrades, etc.
Laboratory Laboratory exercises give you the opportunity to apply and practice the
Exercises material covered during the lecture/demonstration portion of the
course.
2
SolidWorks 2011 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.
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Click on the link for Support, then Training, then Training Files, then
SolidWorks Simulation Training Files. Select the link for the desired
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file set. There may be more than one version of each file set available.
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Direct URL:
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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
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required for doing the laboratory exercises.
Windows® 7
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The screen shots in this manual were made using SolidWorks 2011 and
SolidWorks Simulation 2011 running on Windows® 7. If you are
E running on a different version of Windows, you may notice differences

in the appearance of the menus and windows. These differences do not
affect the performance of the software.
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Conventions Used This manual uses the following typographic conventions:
in this Book
Convention Meaning
Bold Sans Serif SolidWorks Simulation commands and
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options appear in this style. For example,

“Right-click External Loads and select
Force” means right-click the External
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Loads icon in the SolidWorks Simulation

study tree and select Force from the shortcut
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menu.
Typewriter Feature names and file names appear in this
style. For example, Fixed Geometry-1.
Double lines precede and follow sections of
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17 Do this step the procedures. This provides separation

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between the steps of the procedure and large

blocks of explanatory text. The steps
themselves are numbered in sans serif bold.
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Use of Color The SolidWorks and SolidWorks Simulation user interface make
extensive use of color to highlight selected geometry and to provide
you with visual feedback. This greatly increases the intuitiveness and
ease of use of the SolidWorks Simulation software. To take maximum
advantage of this, the training manuals are printed in full color.
3
Introduction SolidWorks 2011
Also, in many cases, we have Radius 50mm

used additional color in the
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illustrations to communicate
concepts, identify features,
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and otherwise convey
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important information.
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For example, we might show
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the fillet areas of a part in a Radius 5mm
All Around Radius 6mm, 4 Places
different color, to highlight
areas for mesh control, even
though by default, the SolidWorks Simulation software would not
display the results in that way. Please note, there may be slight
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differences in results in certain lessons due to service pack upgrades,
etc.
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What is SolidWorks Simulation is a design analysis tool based on a numerical
technique called Finite Element Analysis or FEA. SolidWorks
SolidWorks
Simulation?
E Simulation belongs to the family of engineering analysis software
products developed by SRAC, now part of SolidWorks Corporation.
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Established in 1982, SRAC pioneered the implementation of FEA into
desktop computing. In 1995, SRAC entered the emerging mainstream
FEA software market by partnering with SolidWorks Corporation and
creating COSMOSWorks software, one of the first SolidWorks Gold
Products. COSMOSWorks soon became the top-selling, add-in analysis
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software for SolidWorks Corporation. The commercial success of

COSMOSWorks integrated with SolidWorks CAD software resulted in
the acquisition of SRAC in 2001 by Dassault Systemes, the parent
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company of SolidWorks Corporation. In 2003, SRAC merged with
SolidWorks Corporation. COSMOSWorks was renamed for 2009 to
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SolidWorks Simulation.
SolidWorks is a parametric, solid, feature-based CAD system. As
opposed to many other CAD systems that were originally developed in
a UNIX environment and only later ported to Windows, SolidWorks
has, from the very beginning, been developed specifically for the
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Windows operating system. SolidWorks Simulation has also been

specifically developed for the Windows operating system. Full
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integration between SolidWorks and SolidWorks Simulation is possible

because both of the programs are native Windows OS applications.
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4
SolidWorks 2011 Introduction
SolidWorks Simulation comes in different “bundles”, or applications,

designed to best suit the needs of different users. With the exception of
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SolidWorks SimulationXpress, which is an integral part of SolidWorks,
all SolidWorks Simulation bundles are add-ins. A brief description of
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the capabilities of different bundles is as follows:
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I SolidWorks SimulationXpress
The static analysis of parts with simple types of loads and supports.
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I SolidWorks Simulation
The static analysis of parts and assemblies.
I SolidWorks Simulation Professional
The static, thermal, buckling, frequency, drop test, optimization and
fatigue analysis of parts and assemblies.
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I SolidWorks Simulation Premium
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All capabilities of SolidWorks Simulation Professional plus nonlinear
and dynamic analyses.
E In this volume, we introduce SolidWorks Simulation Professional

through a series of hands-on lessons intermixed with FEA
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fundamentals. It is assumed that the user is familiar with the basics of
the finite element method and the material discussed in the SolidWorks
Simulation course. We recommend that you study the lessons in the
order presented in the text. As you go through the lessons, note that
explanations and steps described in detail in earlier lessons are not
repeated later.
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Each subsequent lesson assumes familiarity with software functions

and the FEA background discussed in previous lessons. Each lesson
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builds on the skills and experience gained from the previous lessons.
Limitations of
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With any FEA software, we need to take advantage of its strengths as

SolidWorks well as work within its limitations. Analysis with SolidWorks
Simulation Simulation Professional is conducted under the following assumptions:
Professional I material is linear
I deformations are small
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I loads are static

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These assumptions are typical of the FEA software used in the design
environment, and the vast majority of FEA projects are run
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successfully within these limitations. For a detailed discussion of each,

consult the SolidWorks Simulation training manual.
For analyses requiring nonlinear material, nonlinear geometry, or
dynamic analysis, tools such as SolidWorks Simulation Premium can
be used. Some dynamic and nonlinear analyses capabilities are also
included in some modules of SolidWorks Simulation Professional.
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6
Introduction
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SolidWorks 2011
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Lesson 1
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Objectives Upon successful completion of this lesson, you will be able to:
I Perform a frequency analysis with and without supports.
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I Investigate rigid body modes.

I Discuss the role of supports in a frequency analysis.
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I Perform a frequency analysis with a prestress condition.

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I Use design scenarios to conduct design sensitivity studies

(optional).
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Lesson 1 SolidWorks 2011
Modal Analysis Every structure has its preferred frequencies of vibration called
Basics resonant frequencies. Each such frequency is characterized by a
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specific shape of vibration.
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When excited with a resonant frequency, a structure vibrates in a shape.
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This is called a mode of vibration.
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Recall that structural static analysis calculates nodal displacements as
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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].
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·· ·
M d + C d + K d = F(t)
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The equation above is traditionally referred to as the equation of
E motion for damped forced vibration. In the absence of damping and

external forces, it reduces to M d·· + K d = 0 (equation of motion for
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free vibration).
Notice that this equation relates the inertial and elastic forces at any
time instance if the motion exists. If no motion exists (i.e. no initial
impetus causing the motion), the equation still provides a very
important relation between the mass properties of the structure and its
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stiffness. After some derivations (which are not a subject of this text,
but can be found in any introductory text on vibrations), we would
extract the structural characteristics in the form of:
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I natural frequencies: Frequencies at which the structure prefers to
oscillate (if excited). Often these values are referred to as resonant
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frequencies.
I (natural) modes of vibration: Unique shapes of vibrations
corresponding to specific natural frequencies.
Note that any real structure has an infinite number of natural
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frequencies and modes. The maximum number of modes that can be

extracted is limited to the number of degrees-of-freedom.
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In resonance, inertial and elastic stiffness cancel. In effect, the structure

loses its stiffness. The only factor controlling the vibration amplitude in
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resonance is damping. If damping is low, and most often it is low, the

amplitude may reach dangerous levels.
After you complete the two lessons in frequency analysis included in
this volume, you are encouraged to “re-use” some of the previous
models and conduct frequency analyses on them.
8
SolidWorks 2011 Lesson 1
For example, the figure below shows the natural modes (shapes) of
vibration for an unsupported plate with a hole model, used in Lesson 1
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of the SolidWorks Simulation training manual. Each mode corresponds
to a specific natural frequency.
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UNSUPPORTED PLATE
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MODE 1 MODE 2
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MODE 3 MODE 4
E MODE 5 MODE 6
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When you analyze the results of a frequency analysis of a symmetric
model, note that the modes of vibration are either symmetric or anti-
symmetric. This is one reason why symmetric boundary conditions
cannot apply to modal analysis. Also, observe that the higher the mode
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of vibration, the more complex the mode shape.

A frequency analysis can be WHEEL ASSEMBLY
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conducted on both parts and MODE 2
assemblies. If an assembly is DEFORMED SHAPE
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analyzed, all parts must be

bonded; no contact/gap
conditions are allowed. If
assembly parts interfere, as with
assemblies intended for shrink fit
analysis, this interference must
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be eliminated prior to performing

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UNDEFORMED SHAPE
a frequency analysis This will be
investigated further in Lesson
2: Frequency Analysis of Assemblies.
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Required Material The following material properties are required in a frequency analysis:
Properties I Modulus of elasticity (also called Young’s modulus)
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I Poisson’s ratio
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I Mass density
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Important! In order to model inertial stiffness, material properties specified for a
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frequency analysis model must include material density (not specific
gravity).
Frequencies and While every real life structure has an infinite number of natural
Mode Shapes frequencies and associated modes of vibration, only a few of the lowest
modes are important in the response of a structure to dynamic loading.
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The frequencies of these first few modes are usually well-spaced apart;
frequencies of higher modes are spaced closer.
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A frequency analysis calculates resonant frequencies and their
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associated modes of vibration. It is important to understand that
resonant frequencies and the associated modes of vibrations are the
only things calculated by a frequency analysis.
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Fundamental The fundamental frequency is the lowest resonant frequency. Because
Frequency the natural frequency value is proportional to the level of energy
required to excite the structure at a particular mode, a structure
oscillating at its fundamental frequency would require the least amount
of energy when compared to all of the higher natural frequencies.
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Important! A frequency analysis does not calculate displacements or stresses. We

repeat this important statement later in this lesson.
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In most cases, products are designed to avoid resonance. Knowing

what excitation frequencies our product will be exposed to, we design
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the product in such a way that its natural frequencies do not coincide
with the excitation frequencies.
To bring the natural frequency of a structure out of the critical range,
we can change its geometry, materials, characteristics of the shock
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isolators, or we can appropriately place mass elements. The effect of

these actions can be analyzed with a frequency analysis.
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While mechanical resonance is avoided in many mechanical systems,

resonance is not always a “bad” thing. Indeed, some devices are
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designed to work in resonance. Some obvious examples are musical

instruments, machines like soil compactors, pneumatic hammers, and
so on.
In this lesson, we analyze one of those devices whose design is based
on the principle of resonance: a tuning fork.
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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
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concept of rigid body modes and presents their corresponding
frequencies.
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The model is first run with a fixed boundary condition simulating the
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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
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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
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applied to the end of the fork, and its effects will be investigated.
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Project A tuning fork, shown in the
Description figure, is designed to emit a
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fundamental frequency of
440 Hz. First, perform a
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frequency analysis to confirm
that the tuning fork vibrates at
the correct frequency.
In addition, determine the
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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
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Process list:
I Apply Fixtures
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The end of the tuning fork will be fixed, attempting to simulate

being held in a person’s hand.
I Mesh the model
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I Run the analysis

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I Postprocess Results
The results of the initial analysis will be post-processed to properly
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investigate their meaning.

I No Fixed Geometry
The fixture will be removed to reveal additional modes of vibration.
I 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.
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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
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Supports frequency is indeed 440 Hz (lower A tone).
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Procedure The frequency analysis is performed as follows:
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1 Open part.
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Open the part named tuning fork, and review its geometry.
2 Create frequency study.
Create a study named with supports, selecting Frequency as the
Analysis type.
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3 Set the study properties.
Right-click the study with supports, and select Properties.
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Under Options enter 4 for Number of frequencies, so that the first
four natural frequencies are calculated.
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The default number of requested frequencies is five.

The solver type for this problem is not important. We will use the
Automatic solver selection.
4 Review material properties.
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The material property of Chrome Stainless Steel is automatically

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transferred from the SolidWorks model.

5 Define a fixture.
Apply a Fixed Geometry fixture to the face of the
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ball at the end of the stem.
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6 Mesh the model.

Mesh the model with High quality elements and the default Maximum
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element size of 1.475 mm.
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Generally, a less refined mesh is acceptable for a frequency analysis as
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compared to the mesh required for a stress analysis on the same model.
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Nevertheless, since the model size is small, we use the mesh that is
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created with the default element size.
7 Run the analysis.
Results After the solution is complete, SolidWorks Simulation creates four
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deformation plots corresponding to the four requested frequencies.
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Stress and strain results are not available in frequency analysis
(remember, frequency analysis does not solve a real time dependent
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8 List resonant frequencies.
Let us review the summary of
results in the Results folder.
Right-click the Results folder
and select List Resonant
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Frequencies.
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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.
Note SolidWorks Simulation generated four deformation plots in the
Results directory. A procedure to select the default plots that should be
generated automatically when a study completes was discussed in the
SolidWorks Simulation training manual, Lesson 1.
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9 Plot first mode of vibration.

Having extracted the natural frequencies, we will
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now plot the shape of the corresponding modes.
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Right-click on the Results folder and select
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Define Mode Shape/Displacement Plot.
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Set the Units to mm. Under Plot Step, request 1st
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mode. The corresponding natural frequency will be
shown as well. Click OK.
10 Show the deformed model on the plot.

Under Settings, select Superimpose model on the deformed
shape.
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Animate the plot and observe that in the first natural frequency, both
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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.
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Postprocessing The magnitude of the maximum displacement in the above plot is

Frequency Results 1.234e4 mm [486 in.], as compared to the length of the tuning fork
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which is about 102 mm [4 in]. (Notice that the deformation scale for
this plot is 1:0.00087)
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As previously stated, the magnitude of the displacement result is
meaningless in a frequency analysis. Displacement results can be used
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only to compare relative displacements between different portions of
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the model and only within the same mode of vibration.
Meaningful displacement results require the execution of a dynamic
analysis, where time-dependent force excitation of the initial impetus
exists causing the model to vibrate.
A frequency analysis only calculates the natural (resonant) frequencies
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and associated modes (shapes) of vibrations. It extracts these important
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structural properties by analyzing the equation of motion for free
vibrations (i.e. no damping) without any initial conditions causing
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actual motion.
11 Review other mode shapes.

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Display the plots of the mode shapes associated with all four computed
natural frequencies. You can make use of automatically generated
deformation plots corresponding to the four computed natural
frequencies.
Superimpose the undeformed model on the deformed shape.
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While a given plot is displayed, right-click the plot icon and select
Animate. Review animated results for all four modes. The animated
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results can be saved in an avi format.
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MODE 1 MODE 2
229 Hz 232 Hz
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MODE 3 MODE 4
423 Hz 443 Hz
The lower A frequency of 440 Hz, which we expected to be the first

mode, is actually the fourth mode.
15
Note To display the deformation plots without the displacement contours,

you must edit the plot and uncheck the Show colors checkbox.
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Frequency Looking at the first three modes of this analysis, it is revealed that if the
F
Analysis tuning fork was unsupported, these mode shapes would not occur.
ut
Without Furthermore, the human hands are simply incapable of creating a
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completely rigid support as in the model. Let us try modeling the fork
Supports
without the rigid support.
1 Create new frequency study.

Duplicate the study with supports into a new study named without
supports.
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2 Delete or suppress fixtures in the study.
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Right-click the fixture and select Suppress.
3 Define study properties.
E Right-click without supports, select Properties, and increase the

Number of frequencies to 10.
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4 Run the analysis.

Right-click the Results folder, and select List Resonant
Frequencies.
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-
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6 Review the mode shapes.

Plot and animate the first six mode shapes to reveal that these are the
rigid body modes associated with the six degrees-of-freedom (three
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translational and three rotational).

Note The FFEPlus iterative solver must be used for a frequency analysis
with rigid body modes. The Direct Sparse solver is not suitable for
solving frequency analysis problems with rigid body modes.
16
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
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(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
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six degrees-of-freedom as a rigid body: three translations and three
F
rotations.
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Fundamental The first elastic mode of vibration where the tuning fork experiences
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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?
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If we closely examine the first three modes of vibration of the
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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
E any of these three modes.

Because human fingers cannot generate a rigid support used in this first
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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
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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
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Analysis with stiffening. This type of analysis is called a frequency analysis with
pre-load or frequency analysis with prestress.
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Load
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

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frequency analyses because it affects the resultant stiffness of a

structure and therefore changes its vibration properties and its response
to a load.
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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.
17

Duplicate the study with supports into a new study named
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prestressed.
e
F
2 Apply the loading.
Apply a 450 N [101.16 lbs] compressive
ut
force to the two faces at the end of the tuning
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fork. This is an arbitrary load only applied to
see the effect that the prestress will have on
the frequency study.
3 Run the analysis.
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Right-click the Results folder, and select List Resonant
Frequencies. Notice that all of the frequencies have lowered
significantly from the with supports study.
E
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5 Review the mode shapes.

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Plot and animate the mode shapes themselves to see that, although the
natural frequencies have changed significantly, the associated mode
shapes remain the same.
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
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governed by the actual geometry of the model and will not change with
an applied prestress.
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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.
18
Tensile stresses have the opposite effect. For example, when tuning a
guitar string, the tension in the string is increased to produce a higher
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frequency, which corresponds to a higher note.
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Summary Using the model of a tuning fork, we can see how SolidWorks
F
Simulation can be used to calculate natural frequencies and mode
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shapes of a structure.
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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 very important information about the vibration properties of a
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structure, it does not, by itself, calculate vibration amplitudes or
stresses.
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We demonstrated the effect of stress softening on the natural
frequencies of the tuning fork due to a compressive force. Stress
E softening and stiffening effects are automatically taken into account if

there is a load present. These effects are very common in rotating parts
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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.
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Questions 1. Natural frequencies (are / are not) structural properties. As such,

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their magnitudes and modal shapes (are / are not) primarily

dependent on the structural stiffness and the mass.
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2. If excited by initial impulse, a part (would / would not) always

oscillate in the first (fundamental) frequency mode irrespective of
the type and the direction of this impulse loading. Why?
3. Externally applied load (does / does not) affects the natural
frequencies. Why?
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4. Externally applied compressive loading (does / does not) leads to

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the decrease in the magnitude of the natural frequencies. Why?

5. Frequency simulation (does / does not) require application of the
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fixtures to calculate.
6. Because frequency simulation does not require application of the
fixtures to calculate, I (can / cannot) skip this step when building
the frequency study.
7. Numerical values in the displacement plots of the frequency modes
(are / are not) real displacements of the structure because there (is /
is not) external oscillatory load applied on the structure.
19
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20
SolidWorks 2011 Exercise 1
Frequency Analysis of a Car Suspension Bulkhead
Exercise 1: In this exercise, you will perform a frequency analysis on a car

Frequency suspension bulkhead.
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Analysis of a This exercise reinforces the following skills:
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Car Suspension I Frequency Analysis With Supports on page 12.
F
Bulkhead I Frequency Analysis Without Supports on page 16.
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I Postprocessing Frequency Results on page 15.
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Problem The bulkhead shown is used as part of the
Statement front suspension system of a dirt-road racing
car. It is built from Cast Alloy Steel.
Perform a frequency analysis on the
or D
bulkhead to determine its resonant
frequencies so they can be avoided in the
st
design of the rest of the vehicle.
Procedure Follow the procedure below:
E 1 Open the part.

Open the part named Car_Suspension_Bulkhead.
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2 Create a Frequency study.
Create a study named without supports, selecting Frequency as the
Analysis type.
3 Apply material properties.
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In the SolidWorks Simulation study tree, right-click

Car_Suspension_Bulkhead and select Apply/Edit Material.
Select Cast Alloy Steel from the solidworks material library.
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4 Mesh the part.

Create a High quality mesh with the default mesh parameters.
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5 Set the study properties to compute 10 frequencies.
6 Run the analysis.

-
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21
Exercise 1 SolidWorks 2011
Frequency Analysis of a Car Suspension Bulkhead

The first six modes of vibration correspond to the rigid body modes.
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Because the car suspension bulkhead is not supported, it has six
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degrees-of-freedom as a rigid body: three translations and three
F
rotations.
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The frequencies corresponding to rigid body modes have very small
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numerical values, sometimes zeros.
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E
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Duplicate existing frequency study properties to a new frequency study
named with supports.
9 Define fixed hinge fixtures on four cylindrical faces.
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10 Run the analysis.

-

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22
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.
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Blower Fan I Frequency Analysis with Load on page 17.
F
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I Design Scenarios from SolidWorks Simulation manual.
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Problem Perform a frequency analysis on a
Statement blower fan. The fan is designed to
spin at a range of different
rotational velocities. To simplify
the calculation, use geometry with
or D
a single fan blade. Perform the
st
analysis as both a stationary blade
and as a rotating body to
investigate the effects of the tensile
E stress caused by the centrifugal

force in the rotating blade.
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Part 1: Analysis In the first part of this case study, we will perform a frequency analysis
Without Load on a stationary blower fan blade. Follow the procedure below:
1 Open part file.
Open the part named fan.
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The full configuration presents the full model; the section

configuration presents only one blade. We are only interested in a
single blade, so we use the model in its section configuration.
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2 Change to the section configuration.

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3 Create a frequency study named section.

The material properties of 1060 Aluminum
Alloy, defined in the SolidWorks model, are
automatically transferred to SolidWorks
Simulation.
-
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Axis of
Rotation
23
4 Apply Fixed Geometry fixture.

Support
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5 Request 5 modes of vibration.
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F
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6 Mesh the model.
Create a High quality mesh with the default mesh parameters.
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7 Run the analysis.
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8 List the resonant frequencies.
Review the frequencies of the five calculated modes of vibration.
E No Prestress
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9 Animate the mode shapes.

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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.

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Duplicate the study named section into a new study named section
preload.
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24
11 Apply centrifugal load.

Apply a Centrifugal load. Use an angular velocity
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of 3000 rpm and Axis 1 as a reference.
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F
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Note The FFEPlus solver cannot be used while including the effects of
loading in frequency analysis.
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13 List the natural frequencies.
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Prestress has the biggest effect on the first frequency, also called the
fundamental or natural frequency. It has increased from 75 Hz to
96 Hz. The other four frequencies have increased as well.
E With Prestress
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The results show that the natural frequencies of the turbine blade differ
significantly if a centrifugal load causing tensile stresses is considered
in analysis.
-
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25
Design Study It may be of interest to investigate the effect of different speeds of

(optional) rotation on the natural frequencies of the blade and plot the natural
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frequencies as a function of the speed of rotation. To do that, we could
simply repeat the above analysis with several different centrifugal
e
loads, and summarize the results.
F
ut
Instead of manually repeating the analysis of the model under several
loads, we can use an automatic feature of SolidWorks Simulation called
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a design study. To run a design study, we define the parameters
describing what exactly changes in the model. In our case, we use only
one parameter, which is the angular speed of rotation as defined in the
Centrifugal PropertyManager.
By yourself, define the design scenario for the following values of the
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speed of rotation: 3000, 6000, 9000, 12000 and 15000 rpm.
st
Note To review how to define and run a design scenario, consult Lesson 10
of the SolidWorks Simulation training manual.
E After you define and run the design scenario:

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14 View the summary results.
The result of the design study lists frequencies of all five modes for the
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five scenarios.
15 Create design history graph.
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You can control the appearance of the graph by selecting Options on
26
the tool bar of the graph window. You are encouraged to investigate the
many choices offered by the graph controls.
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Note A design scenario can be run for other parameters. You are encouraged
F
to use the design scenario feature to investigate the effect of element
ut
size on natural frequencies, or in other words, to perform a convergence
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analysis of frequencies.
Note that 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
or D
to investigate as a learning tool.
Summary We demonstrated the effect of stress stiffening due to a centrifugal load
st
on the natural frequencies of a cooling fan blade. Using the design
scenario feature, we established the relation between natural
E frequencies and the speed of rotation of the fan.

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27
Frequency Analysis of an Impeller
Exercise 3: In this exercise, you will perform a frequency analysis on an impeller

Frequency with a prestress condition caused by a centrifugal force.
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Analysis of an This exercise reinforces the following skills:
e
Impeller I Frequency Analysis with Load on page 17.
F
ut
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Problem The impeller shown sits on a shaft rotating
Statement at 20,000 revolutions per minute. Perform
a frequency analysis on the Impeller 01
part and study the effect of stress stiffening
on the natural frequencies of the model.
or D
st
E 1 Open part file.

Open the part named Impeller 01.
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2 Create a frequency study.
Create a frequency study named vibration. Select Frequency as the
Analysis type.
3 Assign Shell thicknesses.
Specify Thin shells with a Shell
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thickness of 1mm for all blades.

4 Apply Alloy Steel to all bodies.
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5 Apply Restraints.
To simulate shaft support, select the
cylindrical face of the hole at the bottom
and make it Fixed Geometry.
-
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6 Apply an angular velocity of 20,000 rpm.

Select Axis1 as the reference.
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28
7 Define connection between shells and solids.

To bond shell elements to solid elements, define local contact
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conditions.
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F
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8 Create Mesh.
Create a High quality mesh using the
st
Maximum element size of 10.5 mm.
9 Set study properties.
E Request 5 frequencies.
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Note Since there are loads present in this analysis, their effect on the
frequency results will be automatically accounted for.
11 Review results.
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f1 = 1175.1 Hz f2 = 1175.3 Hz
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f3 = 1175.3 Hz f4 = 1176.9 Hz
Notice that the first modes of vibration are reserved for blades only and
the corresponding frequencies are very close.
29
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30
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Lesson 2
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Frequency Analysis of
st
Assemblies
E
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I Understand the concepts of natural frequencies in assemblies.
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I Approximate the real contacts and connectors with the appropriate
contact entities.
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31
Case Study: In this analysis, we will investigate the natural frequencies and
The Engine corresponding mode shapes of an assembly. This model introduces the
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Mount concept of a frequency analysis of an assembly. Various contact
conditions can exist within an assembly and we will develop a way to
e
properly model them in a frequency analysis.
F
ut
Project The engine frame supports a heavy
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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
or D
rigid structure at the four locations
st
depicted in the figure.
The engine itself is not the focus of this
E analysis, so it can be treated as a remote

mass.
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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.
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Stages in the Some key stages in the analysis of this assembly are shown in the
Process following list:
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I 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.
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I Set up Connections
Connections, contacts, and boundary conditions must be applied to
the model.
I Mesh the assembly
-
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I Run the analysis

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I 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.
32
Procedure The frequency analysis is performed as follows:
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1 Open assembly.
e
Open the assembly named FullBase. Note that all intermediate
F
components are missing. As previously stated, these components are
ut
considered very light and stiff compared to the engine mass so they can
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be suppressed.
Due to the time required to set up the simulations, two pre-defined
studies, all bonded and bonded and allow penetration, have been
prepared beforehand.
The first part of this lesson utilizes the all bonded study.
or D
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Remote Mass Whenever a mass of a body is significant and the stresses and
deformations are not important, the object can be conveniently treated
E 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.
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2 Define remote mass.
In the all bonded study, expand the Parts folder and right-click on
SW3dPS-engine-1.
Select Treat as Remote Mass.
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Under Selection, select the four load-bearing faces that carry the
engine load.
y
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-
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Note We assume that the suppressed sub-assembly is rigid and its mass is
small in relation to the rest of the structure.
PR
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.
33
3 Define fixtures.
Define Fixed Geometry fixtures for the four faces shown in the figure.
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Connecting the Because frequency analysis requires constant stiffness and mass of the
Assembly Parts structure, we cannot define No Penetration contacts. Consequently, we
st
also cannot use bolted connections, for example.
When a No Penetration contact is specified, the structure may change
E its configuration multiple times as the loads are applied to it.

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two independent beams
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two beams in contact

y
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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.
Therefore, in our assembly, the
-
bolted connections as well as the

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No Penetration conditions
between the respective
components will need to be
PR
approximated. In this part of the

lesson, we will assume that all
contacts are bonded.
34
4 Review bonded contacts.

Two bonded contact sets have already been set up. Expand the
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Connections folder and review these contact sets.
e
5 Mesh the assembly.
F
Mesh the assembly with the Draft quality elements and the default
mesh parameters. Use the default Curvature based mesh.
ut
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6 Run the analysis.
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st
E
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If the engine operated in the range of these frequencies, the design
could be modified to avoid the resonant frequencies.
8 Plot modal shapes for first four modes.
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mode 1 (143 Hz)

mode 2 (151 Hz)
-
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mode 3 (392 Hz) mode 4 (756 Hz)
Animate each of the modes to see what the direction the structure
oscillates as it freely vibrates at the corresponding natural frequency.
35
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
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Penetration of the No Penetration contacts between the respective assembly
components. Because No Penetration contacts are not allowed in
e
Contacts
frequency studies, we chose to approximate all contacts as bonded. As
F
will be concluded later in this lesson, such an approach makes the
ut
assembly stiffer.
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In this part of the lesson, we elect to use an alternative approach: some
of the contact will be bonded, some will be set to allow penetration.
1 Select the Frequency - bonded and allow penetration study
tab.
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Some of the settings in this study have already been defined.
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2 Expand and analyze connections.
Notice that all contacts between the struts and the plates are set to
E Allow Penetration.
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The global contact establishes bonding

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between the locknuts and the struts, as

shown in the figure to the right. Note
that it would not be intuitive to assume
these contacts are allowed to penetrate.
-
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36
3 Define pin connectors.

As the contacts between struts are set to allow penetration, the
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connection between some of them and the locknuts must be
established. The bolted connections will be approximated using rigid
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pins.
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Orient the assembly as shown in the figure and define the remaining
E three pins.
Use the exploded view for easier definition.
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Note that the pin connectors in the other three corners have already
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been defined.
4 Restrain assembly.
Similarly to step 3 in the first part of this lesson, apply Fixed
Geometry fixtures to the four faces on the struts.
These restraints can be copied from the previous study.
-
Note The remote mass for the engine has already been defined.
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Create a Draft quality mesh with the default mesh parameters. Use the
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default Curvature based mesh.

6 Run the analysis.
37
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The frequency results have changed, and the design could be modified
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to avoid these frequency ranges.
st
8 Plot modal shapes for first four modes.
E
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mode 1 (93 Hz) mode 2 (105 Hz)
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mode 3 (266 Hz)

mode 4 (564 Hz)
When comparing these results to the results contained in the all

bonded study, we must look at the mode shapes. Modes showing the
-
oscillations in the same directions can be compared.

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38
Discussion The frequency results show that the model in the second part of the
lesson, with a combination of bonded and allow penetration contact
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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
e
remains the same - this, however, does not always need to be the case.
F
ut
The above two studies do not provide perfectly accurate answers, but
may serve as insight into what could be the boundaries for the
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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
or D
must compare the modes whose shapes are the same, not necessarily
the mode number.
st
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,
E No Penetration contacts are not allowed in the frequency analysis and

an alternate approximated approach is required. For example, various
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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
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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
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structural response (displacements, velocities, etc). This is the subject
of the SolidWorks Simulation Premium: Dynamics training manual.
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Questions 1. When No penetration contacts exist in the asssembly, the frequency

characteristics (are / do not need to be) unique. In such case
extraction of unique natural frequencies (is / is not) possible. A
-
similar situation also occurs if the assembly features (Allow

penetration contact / Virtual wall).
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2. When all parts within an assembly are bonded, unique frequency

characteristics (do / do not) exists and (can / can not) be extracted.
PR
3. Shrink fit contact condition (is / is not) allowed in the frequency

simulation of assemblies.
4. Defining bonded contact conditions at a majority of the connections
leads to (stiffer / softer) model and therefore (higher / lower) values
of the natural frequencies.
39
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40
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
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Analysis of a skills:
e
Particle I Frequencies and Mode Shapes on page 10.
F
Separator I All Bonded Contact Conditions on page 32.
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Problem Perform a frequency analysis on the
Statement frame of a particle separator. A static
analysis was performed on the
separator in the Mixed Meshing -
Solids, Shells, and Beams lesson of
or D
the SolidWorks Simulation training
manual. The analysis requires beam,
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shell, and solid elements. The frame
experiences a 400 N load from the
E weight of the separator itself. In

addition, a wind blowing in the -X
direction results in a force couple of
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4,500 N upward and downward on
opposite sides of the frame. The
loading will not be considered in the
frequency calculation.
Model courtesy of Tamoz, spol. s r. o.
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1 Open the assembly.

Open the assembly named particle separator and examine the static
stress study that was run in the Mixed Meshing - Solids, Shells, and
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Beams lesson of the SolidWorks Simulation training manual.

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2 Create a study.
Create a new frequency study called frequency analysis.
3 Copy folders.
Copy the Parts, Joint Group and Fixtures folders from the static
stress study to the frequency analysis.
-
4 Copy contacts.
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Copy all contacts bonding the shells of the separator body.

Note Contact sets involving beams can not currently be copied.
PR
5 Beam contacts.
Define eleven additional beam contacts identical to those defined in the
static stress study.
6 Create mesh.
Create a high quality mesh with a global element size of 25mm. Use
Standard mesh.
41
Frequency Analysis of a Particle Separator
7 Run the analysis.
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9 Animate the mode shapes.
Plot and animate some of the mode shapes.
Discussion
E Even though the model was made up of numerous different parts and
element types, all of the contact conditions were bonded. This means
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that although being an assembly, all of the parts are perfectly
connected. Therefore, the entire model behaves as if it were modeled as
a single part.
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42
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F
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Lesson 3
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Buckling Analysis
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I Perform buckling analysis.
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I Understand buckling load factors and decide whether the product

fails in strength or stability.
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43
Buckling Analysis
Buckling Buckling refers to sudden large displacements due to compressive

Analysis loads. Slender structures, subject to axial loads, can fail due to buckling
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at load levels lower than those required to cause material failure.
e
Buckling can occur in different modes under the effect of different load
F
levels. In most cases, only the lowest buckling load is of interest.
ut
To grasp the concept of buckling, note that any structural load affects
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structural stiffness by adding a component commonly referred to as
stress stiffness. Tensile loads induce a positive stress stiffness, which
adds to the elastic stiffness of the structure. Compressive loads induce a
negative stress stiffness, which is subtracted from the elastic structural
stiffness causing the structure to soften.
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Buckling takes place when the resultant structure stiffness (a result of
subtracting the stress stiffness induced by compressive load from
st
elastic stiffness) drops to zero.
E The following equation describes the cancellation of resultant stiffness:
KE + λi KS ϕi = 0
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where KE is the elastic stiffness matrix; KS is the stress stiffness matrix;
λ i are eigenvalues that when multiplied by the applied load provide the
critical loading; and ϕ i are the eigenvectors that represent the buckled
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mode shapes.
SolidWorks Simulation offers calculations of any number of buckling
modes and associated buckling loads.
y
The first mode and its associated magnitude of buckling force is most
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important because buckling most often causes catastrophic failure or

renders the structure unusable, even if the structure can withstand the
load in its buckled shape.
Linear vs. Buckling can be thought of as a situation where a very small increase in
Nonlinear the load causes the structure to lose its stability and collapse.
-
Buckling Analysis A linear buckling analysis determines the eigenvalues of the structure
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for given loads and restraints, disregarding any imperfections and

nonlinear effects that always exist in real structures. Those
imperfections and nonlinear effects significantly lower the real
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buckling loads as compared to the buckling loads predicted by a linear

buckling analysis. For this reason, the results of a linear buckling
analysis must be interpreted with caution.
Nonlinear buckling analysis must be used to find accurate values of the
buckling load in many cases and to study post-buckling effects.
44
Buckling Analysis
Some buckling problems that always require nonlinear buckling

analysis and cannot even be approximated by linear buckling analysis
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include:
e
I Inelastic or nonlinear material behavior prior to instability
F
I Re-alignment of applied pressure during deformation
ut
I Large displacements prior to buckling
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Buckling should always be considered as a potential mode of failure in
structures that consist of slender members in compression. In fact,
many structural disasters are initiated by buckling, and only the final
destruction is caused by excessive stresses in the post-buckling stage.
In SolidWorks Simulation, a buckling analysis can be conducted on
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parts and assemblies. If an assembly is analyzed, all parts must be
bonded; no contact/gaps conditions are allowed.
st
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Buckled Arch
Buckled Strut
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Buckling Load The buckling load factor (BLF) is a number by which the applied load
Factor (BLF) Papp must be multiplied in order to obtain the buckling load magnitude
Pcr .
y
P cr
BLF = -----------
P app
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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

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displacements.
Buckling Analysis As previously mentioned, linear buckling analysis typically
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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.
45
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
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Separator as the model featured in Lesson 10 of the SolidWorks Simulation
training manual. We will calculate the bucking load factor of the model
e
and learn to properly interpret the buckling results.
F
ut
Project The loads on the support frame consist of the
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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
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the separator. Finally, on the intake of the
particle separator, a 75 N normal and 45 N
st
along direction 1 loads will be applied to
simulate additional loading that the separator
E might experience during installation.

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Stages in the I Perform stress analysis.

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Process We will perform the previously defined stress analysis to determine

the factor of safety. This is the same study as performed in the
Mixed Meshing - Beams, Shells, and Solids Lesson of the
SolidWorks Simulation training manual.
I Buckling study.
-
We will create and run the buckling study by copying most of the
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information from the static study.

I Postprocess the results.
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Once the study is run, we will determine what loading is necessary

for buckling to occur. In addition, we will determine which failure
mode will come first, yielding or buckling.
46
Buckling Analysis

Open the assembly named particle separator and run the static
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stress study that was run in the Mixed Meshing - Solids, Shells, and
Beams lesson of the SolidWorks Simulation training manual.
e
F
We can see that the loading does not cause the material to reach its
yield strength. We can conclude that the factor of safety for yielding is
ut
approximately 35.
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2 Create buckling study.
Create a Buckling study named buckling analysis.
3 Copy folders.
Copy the Parts, Joint Group and Fixtures and External Loads
folders from the static stress study to the buckling analysis.
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4 Copy contacts.
st
Copy all contacts bonding the shells of the separator body.
Note Contact sets involving beams can not currently be copied.
E 5 Beam contacts.
Define eleven additional beam contacts identical to those defined in the
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static stress study.
6 Create mesh.
Create a high quality mesh with a global element size of 25mm. Use
Standard mesh.
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Note Similarly to frequency analysis, No penetration contacts and some

connectors (bolts for example) are not permitted in buckling analysis.
7 Set buckling analysis study properties.
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Request 2 buckling modes and the Direct sparse solver.
8 Run the study.
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9 List buckling load factors.

Right-click on the Results folder and
select List Buckling Load Factors.
-
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The lowest positive value

of the buckling load factor
is the factor of safety in
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buckling which can be

used to determine the
buckling load.
47
Buckling Analysis
10 Plot 1st buckling mode.

Create a displacement plot for the
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first buckling mode.
e
You’ll notice the highly deformed
F
crossbeam. This occurs due to the
ut
loading condition. This shape is an
approximation of the deformation at
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the onset of the buckling failure.
The buckling load factor is 21.91
which means that the structure is safe
from buckling. If the loading was
multiplied by the buckling load
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factor, however the structure could
st
buckle.
Note
E Similar to the frequency analysis, the displacement magnitudes do not

represent real displacements. Displacement plots should be understood
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as deformed shapes which a structure would assume during the
buckling failure.
Conclusion The factor of safety in buckling (21.9) is significantly smaller than the
factor of safety in strength (35). Buckling is therefore the governing
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phenomenon and must be considered during the design.

Calculating To calculate the buckling load(s) for a particular mode, multiply all the
y
Buckling Loads applied loads by the BLF for that mode.
The second buckling mode is mostly of academic importance. If the
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separator is going to buckle, it will do so in the first buckling mode.

The second mode deformation may occur in some cases if the
deformation in the first mode is restrained.
Let us summarize the meaning of the buckling load factor as reported
in the buckling analysis.
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Buckling
BLF Value Interpretation of Results
Status
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BLF > 1 No buckling Applied loads are less than the estimated critical loads.
0 < BLF < 1 Buckling Applied loads exceed the estimated critical loads.
BLF = 1 Buckling Applied loads are exactly equal to the estimated critical loads.
Buckling occurs if you reverse all load directions. For example,
BLF = - 1 No buckling
if you apply a tensile force on a bar, the BLF is negative.
48
Buckling Analysis
Buckling
BLF Value Interpretation of Results
Status
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e
- 1 < BLF < 0 No buckling Buckling occurs if you reverse all load directions.
F
BLF < - 1 No buckling Buckling does not occur, even if you reverse all load directions.
ut
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Results The results indicate that the separator is likely to withstand a load that
Discussion is up to 20 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 load factors as well as the
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yield strength factor.
Imagine a slender beam under a compressive load. A small load offset
st
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
E resist the compressive load partly in axial compression, partly in

bending.
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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.
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Will the structure The stress factor of safety of 35 is higher than the buckling factor of
Buckle or Yield safety of 21.9. The structure would therefore buckle before it would
First? yield.
-
In many instances yielding changes geometry which in turn reduces the

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buckling load factors and a structure collapses by a combination of

material yielding and buckling.
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A nonlinear analysis, available in SolidWorks Simulation Advanced

Professional, is required to describe these complex problems.
49
Buckling Analysis
Summary In this lesson we conducted buckling analyses and made use of the
stress analysis results from the SolidWorks Simulation course. While
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the stress analysis assesses the performance of the design in strength
(yielding is the criterion), buckling analysis evaluates the stability of
e
the structure.
F
ut
Safety factors related to material yield strength and to buckling load
factors were explained.
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As is seen, buckling, rather than excessive stress, is often the
predominant mode of failure for slender structures under compressive
loads.
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Questions 1. Onset of buckling implies that the total stiffness of the structure
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(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. Yielding always occurs (before / at the same time / after / all

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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.
PR
50
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:
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Analysis of a I Buckling Analysis on page 44.
e
Stool I Calculating Buckling Loads on page 48.
F
ut
Problem In preparation for destructive testing of
Statement a steel stool, we would like to predict
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its mode of failure and approximate the
highest magnitude load it can sustain
without failing. In particular, we would
like to find out if the stool can
withstand a 8900 N [2000 lb] vertical
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load, and, when it eventually collapses,
is it due to excessive stress or due to
st
buckling?
E
Note that buckling is always a
possibility when slender members, like
stool legs, are under compressive loads.
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1 Open the part named stool.
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2 Create a Static study named stool stress.

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The material properties of AISI 304 steel with a yield strength of

207 MPa [30,000 psi] have been defined in SolidWorks. These
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properties automatically transfer to SolidWorks Simulation.

4 Apply load.
Apply a directional force of 8900 N [2000 lb]
to stool seat. Use the top plane as the reference.
-
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51
5 Apply restraints to stool.

The most accurate description of how the stool would sit would be to
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apply a prescribed displacement of zero in the translational directions.
This would allow for the stools legs to rotate about an axis and buckle.
e
F
To do this, apply a Remote Load/Mass and select Displacement
(Rigid Connection).
ut
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Then specify the Reference Coordinate System as the predefined
coordinate system at the bottom of the leg you are fixing.
Select the three directions under Translation and keep them all as
0mm.
Repeat this for all four legs.
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52
6 Apply mesh control.

Apply a 10mm mesh control to the
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faces of the legs. There should be 20
faces selected.
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ut
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7 Mesh the model.
Mesh the model with the High quality elements with a default
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Maximum element size of 19.309mm. Use the default Curvature
based mesh.
st
8 Run the analysis.
E 9 Plot von Mises stresses.

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The results of the stool 01 study show a maximum von Mises stress of
-
approximately 187 MPa [27122 psi].

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The yield strength of AISI Steel is 207 MPa [30,000 psi], as stated in
the material property definition.
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53
10 Define factor of safety plot.

The factor of safety can be calculated by dividing the yield stress by the
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maximum von Mises stress in the model:
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207/178 = 1.10
F
We can also visualize the distribution of the factor of safety by
ut
displaying the Factor of Safety Plot.
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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.
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11 Create buckling study named stool buckling.

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Set the number of buckling modes to 2.
13 Copy input parameters from static study.
Copy the external loads, fixtures, and mesh from the stool stress
-
study to the stool buckling study.

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54
15 Plot both mode shapes.
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Animate both of the above plots to understand how the stool buckles in
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each mode.
55
Important! It is vital to understand that the displacement plots are purely

qualitative just like the results of the frequency analysis. The numerical
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values shown in the above plots are not real displacements. The plots
show the deformed shapes at the onset of buckling based on the
e
assumptions of the linear buckling theory. The numerical values can be
F
used to relate the displacement of some parts of the model with respect
ut
to each other, but the actual magnitudes are not known. A non-linear
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analysis would be required for the correct displacement results and
post-buckling behavior.
16 List buckling load
factors.
The results indicate that the
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stool withstands a 8900 N
[2000 lb] load.
st
E
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Will the Stool Buckle The stress factor of safety is lower than the buckling factor of safety.
or Yield First? However, while the stress factor of safety is conservative, it describes
the load causing the first instance of yielding in the structure; the
buckling factor is non-conservative.
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Most likely, one of the legs will yield before it buckles. Yielding
changes the geometry and reduces the buckling load so that finally the
y
stool collapses in a combination of material yielding and buckling.
To analyze this, we require the nonlinear analysis available in
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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:
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Create a frequency study and calculate the fundamental frequency of

stool for different load magnitudes.
PR
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.
56
Cabinet
Exercise 6: In this exercise, you will perform a buckling analysis on a stool. This
Cabinet exercise reinforces the following skills:
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I Buckling Analysis on page 44.
e
I Calculating Buckling Loads on page 48.
F
ut
Problem A cabinet is loaded by an isolated 4,450 N
Statement [1,000 lb] force and two 4,450 N [1,000 lb]
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loads distributed along the two corner beams
of the cabinet, as shown in the figure. The
model is manufactured from Aluminum
5052 H32. All other loads and masses (such
as shelf loads, etc.) are not included in this
or D
analysis to keep the model simple. The
bottom of the cabinet, along with the
st
pedestal, are bolted to the floor.
E
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Procedure The buckling analysis is performed as follows:
Open the assembly named Cabinet.
2 Run the static analysis.
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Review the conditions in the stress analysis study and run the
analysis. We can see that the loading does not cause the material to
reach its yield strength. We can conclude that the factor of safety for
y
yielding is 8.47.
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Note The maximum strength and corresponding factor of safety in yileding

may differ somewhat depending on your mesh density.
3 Create buckling study.
Create a Buckling study named buckling analysis.
4 Copy features from the stress analysis study.
-
Copy the Parts, Joint group, External Loads and the Connections
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folders from the stress analysis study to the buckling analysis

study.
PR
Note Similarly to frequency analysis, No penetration contacts and some

connectors (bolts for example) are not permitted in buckling analysis.
Our model therefore uses bonded contacts and fixed edges to simulate
foundation bolts.
5 Mesh the model.
Mesh the model with the High quality elements with a global Element
Size of 55.87mm. Use the default Curvature based mesh.
57
Cabinet
6 Set buckling analysis study properties.

Request five buckling modes and the Direct sparse solver.
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7 Run buckling analysis.
e
F
8 List buckling load factors.
ut
Right-click on the Results folder and select List Buckling Load
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Factors.
The lowest positive value
of the buckling load factor
is the factor of safety in
buckling which can be
or D
used to determine the
buckling load.
st
Fbuckling = 4450 N x 6.24 =
27,768 N.
E
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9 Plot 1st buckling mode.
Create a deformation plot for the first buckling
mode.
We can observe that the skin face loses its
stability and buckle. This shape is an
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approximation of the deformation at the onset

of the buckling failure.
y
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Note Depending on the degree of the structural importance of the skin, we

-
may need to search for higher buckling mode involving the stability
loss of the frame.
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58
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F
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Lesson 4
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Thermal Analysis
st
E
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Objectives Upon completion of this lesson, you will be able to:
I Understand and perform thermal analysis.
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I Perform a thermal analysis of assemblies with thermal resistance.

I Perform a thermal analysis with heat power and convection
y
coefficients.
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I Perform a transient thermal analysis using time curves.

I Perform a transient thermal analysis using the thermostat feature.
I Use thermal symmetry boundary conditions.
I Create section views in results plots.
-
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59
Thermal Analysis
Thermal We have already had considerable exposure to structural analysis,

Analysis Basics performing static, frequency, and buckling analyses, all of which
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represent structural problems. This is our first lesson on thermal
analysis. Therefore, before starting the analysis let us spend some time
e
introducing the basics behind thermal analysis.
F
ut
Thermal analysis deals with heat transfer in solid bodies. Although
thermal analysis seems less intuitive than structural analysis, it is much
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simpler in terms of the computational effort.
The primary unknown in a thermal analysis is temperature, which is a
scalar quantity (as opposed to displacement which is made up of three
directional components). Therefore, only one degree of freedom needs
to be assigned to the nodes of a thermal FE model, regardless of the
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type of element.
st
The important conceptual difference between structural and thermal
analysis is that while structural static analysis deals with the state of
E equilibrium under an applied load, the analogous thermal analysis does

not describe the state of equilibrium.
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Instead, it models the steady state condition where heat flow continues,
but does not change over time. Therefore, the thermal analogy of a
linear static analysis is a steady state thermal analysis, while a dynamic
structural analysis is analogous to a transient (time dependent) thermal
analysis.
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Temperature is the primary unknown in a thermal analysis and is

analogous to displacements in a structural analysis. Other similarities
between thermal and structural analysis are summarized in the
y
following table. Because of these analogous behaviors, experience you
have in performing a structural analysis is directly transferable to
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performing a thermal analysis.

-
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60
Thermal Analysis
Analogies Between Structural and Thermal Analysis
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Structural Thermal
e
Displacement Temperature
F
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Strain Temperature gradient
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Stress Heat flux
Load Heat source/Heat sink
Prescribed displacements Prescribed temperatures
Convection coefficients
or D
Elastic supports
(film coefficients)
st
Elastic modulus Thermal conductivity
Mechanisms of
Heat Transfer
E There are three mechanisms of heat transfer: conduction, convection
and radiation. Before diving into the exercise, lets go over a brief
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description of each mechanism so that we can gain a more complete
understanding of heat transfer.
Conduction Conduction is the most important heat transfer mechanism in solid
bodies. It does not involve any bulk motion of matter. Heat is
transferred by direct collisions between molecules. The energy of the
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molecule that causes the collisions is directly related to temperature.

Non-metallic solids transfer heat by lattice vibrations so there is no
motion of the media as heat propagates through them.
y
Metals are better conductors than nonmetals at normal temperatures

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because they have free electrons that carry thermal energy.

Thermal conductivity is a material property that indicates the
effectiveness of a material in transferring heat energy by conduction. It
is defined as the rate of heat transfer through a unit thickness of the
material per a unit temperature difference. Thermal conductivity is
-
usually denoted as the variable K.

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61
Thermal Analysis
Heat transferred by conduction moves from a hot region to a cooler

region. The magnitude of heat transferred by conduction is proportional
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to the following:
e
I Thermal conductivity, K, of the
F
medium in which heat transfer takes THOT TCOLD
ut
place
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I Temperature gradient: THOT - TCOLD
I Area, A, through which heat transfer
takes place
The magnitude is inversely proportional
to the thickness, L, of the medium.
or D
QCONDUCTION = - K A (THOT - TCOLD) / L L
st
The units of thermal conductivity are W/(m K) in the SI system and
BTU /(ft s °F) in the IPS system.
E Thermal conductivity varies widely for different materials.

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Convection Convection is the heat transfer Tf = Fluid bulk temperature

mode by which heat transfers
between a solid face and an Colder fluid
descends
adjacent moving fluid (liquid or
-
gas). The magnitude of heat

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transferred by convection between

Warmer fluid
a solid body surface and the Gravity
rises
ambient fluid is proportional to the
PR
convection coefficient h, surface TS = Surface temperature

area A, and the temperature
difference between the surface and ambient gas:
QCONVECTION = h A (Ts - Tf)
Generally, there are two modes of convection heat transfer:
I Natural (free) convection
I Forced convection
62
Thermal Analysis
Free Convection In free convection, the motion of the fluid adjacent to a solid face is
caused by buoyancy forces. These forces are induced by changes in the
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density of the fluid due to differences in temperature between the solid
and the fluid.
e
F
For example, when a hot plate is left to cool down in the air, the
particles of air adjacent to the face of the plate get warmer and their
ut
density decreases. Hence, they move upward.
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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.
or D
st
Cold Air Cold Air
Hot Plate
E
Hot Plate
NATURAL CONVECTION FORCED CONVECTION
The table below shows typical convection coefficients.

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Medium Heat Transfer Coefficient, h (W/m2 °K)
Air (natural convection) 5 - 25
Air/superheated steam (forced

20 - 300
convection)
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Oil (forced convection) 60 - 1800
Water (forced convection) 300 - 6000

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Water (boiling) 3000 - 60,000

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Steam (condensing) 6000 - 120,000
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
-
VACUUM
a medium, it is the only form of
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heat transfer in a vacuum.

Heat transfer by radiation becomes
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more significant at higher

temperatures. Note that the amount
of radiated heat is proportional to
the fourth power of absolute
temperature.
63
Thermal Analysis
Thermal radiation occupies a narrow range in the radiation spectrum as

shown in the figure below.
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e
F
ut
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The radiation power of a black body is described by the Stefan-
Boltzmann law, which states that the total emissive power of a black
st
body Q is:
4
Q = σT
E BLACK BODY RADIATION
where σ is the Stefan-Boltzmann constant and T is the absolute

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temperature of the black body. The value of the Stefan-Boltzmann
constant is 5.67x10-8 W/m2 K4 or 3.3063 x 10-15 BTU/s in2 F4.
When a black body of temperature TS and surface area A is immersed in
a medium with ambient temperature TA, the net rate of heat radiated by
the black body is given by:
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4 4
Q RADIATION = σA ( T S – T A )
y
where TS is the absolute temperature of the black body and TA is the
absolute temperature of the surrounding medium (ambient
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temperature).
For non-black body surfaces, the heat radiated is
4 4
Q RADIATION = σεA ( T S – T A )
where ε is the emissivity of the radiating surface, defined as the ratio

-
of the emissive power of the surface to the emissive power of a black

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body at the same temperature.

Materials are assigned an emissivity value between 0 and 1.0. A black
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body, therefore, has an emissivity of 1.0 and a perfect reflector has an

emissivity of 0. The emissivity is a material property that is dependent
on the surface temperature and the surface finish.
64
Thermal Analysis
Material Properties We conclude this theoretical section with a review of the material
for Thermal properties required in a thermal analysis.
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Analysis The following material properties are specifically required as input to
e
various types of thermal analyses:
F
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Type of Thermal
Material Property Definition
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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
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of heat needed to raise the temperature of only
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a unit mass of the material by one degree
of temperature.
Mass Density
E Although not directly used in thermal

analysis, mass density is required to
Transient analysis
only
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provide information on mass because
specific heat is defined as heat per unit of
mass
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65
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
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Assembly model the glue between the microchip and heat sink. We will learn to
properly apply thermal boundary conditions as well as thermal loads.
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F
In addition, several transient thermal analyses (analyses of heat flow,
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which changes with time) will be performed to show how the
microchip assembly will respond to changing heat loads.
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Project The CAD model of a Connectors
Description microchip assembly consists Microchip
of five components:
I Copper heat sink
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I Ceramic microchip
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I Three copper terminals
(connectors)
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Heat Sink
The ceramic microchip
generates heat, which
dissipates to the environment by convection through all external faces
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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].
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The ceramic microchip and copper heat sink are connected by a layer
of Actic Silver 5 high conductance glue, 25 μm thick. It would be very
difficult to mesh this layer if we modeled it as an assembly component.
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Instead of explicitly modeling this glue layer, we will account for it by
defining a thermal resistance between the bonded faces of the
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microchip and the heat sink.

Stages in the I 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.

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I Transient analysis (step heat load)

The temperature time history is calculated for 300 seconds, starting
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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.
I Transient analysis (varying heat load)
The temperature time history is calculated for 300 seconds starting
from the time when the heat power is first applied, but in this case
the heat power takes 30 seconds to reach a maximum value, and
then decreases back to zero in the subsequent 30 seconds.
66
Thermal Analysis
I Transient Analysis (thermostat controlled heat load)

The temperature time history is calculated for 300 seconds from the
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time when the heat power is first turned on, but the power is
controlled (turned on and off) by a thermostat in order to prevent
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the microchip from overheating.
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Steady-State
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We start the lesson with the most basic type of thermal analysis, steady-
Thermal state. Heat power is applied through the microchip itself and that heat
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Analysis dissipates through the heat sink, connector terminal, and through the air
via convection.
Introducing: Heat Heat Power applies a constant heat energy to a part, face, edge, or
Power vertex.
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Where to Find It I Right-click Thermal Loads in the Simulation Study tree and
select Heat Power.
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In the Simulation menu, select Loads/Fixture, then Heat Power.
Procedure
E The steady-state thermal analysis is performed as follows:
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1 Open assembly file.
Open the assembly named regulator.
2 Create a thermal study.
Create a study named steady state.
Select Thermal as the Analysis type.
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3 Define heat power.

Right-click Thermal Loads and
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select Heat Power. Select the
microchip part (use the SolidWorks
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flyout FeatureManager design tree to

select microchip part).
Enter 25 W as the Heat power.
Click OK.
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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
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surfaces, and its effect will be modeled as a thermal resistance.
67
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
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surfaces due to their roughness.
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Through the interface between the two contacting faces, two modes of
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heat transfer exist. The first is conduction through points of solid-to-
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solid contact, which is very effective. The second is conduction through
the gas-filled gaps, which can be poor due to their low thermal
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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.
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Introducing: Thermal contact resistance is the inverse of hc (conductance) and is
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Thermal Resistance equal to L/KA (A is the area of contact). Typical values of interfacial
conductance are summarized in the table below:
E Contacting Faces Interfacial Conductance (hc) (W/m2 °K)

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Iron/aluminum 45,000
Copper/copper 10,000 - 25,000
Aluminum/aluminum 2200 - 12,000
Stainless steel/stainless steel 2000 - 3700

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Stainless steel/stainless steel

200 - 1100
(evacuated gaps)
Ceramic/ceramic 500 - 3000

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Thermal resistance can be effectively used to model thin layers of

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material used to bond (layer of glue) or insulate (kapton thermal pods)

two components. In our lesson, for example, the thin layer of glue,
25 μm thick, is not modeled and is conveniently replaced by thermal
resistance.
Where to Find It I Right-click Connections in the Simulation Study tree and select
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Contact Set. Under the Type pull down menu, select Thermal
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Resistance.
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68
Thermal Analysis
4 Define thermal contact

resistance.
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Define a Contact Set for
the touching faces on the
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heat sink and microchip
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parts. Explode the view for
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easy selection of the
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contact faces.
Select Thermal
Resistance as Type.
Select the Thermal
Resistance check box.
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Select Distributed, and
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then enter 2.857e-6 m2K/W
as the distributed thermal
E resistance (thermal
resistance over a unit of
area).
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Click OK.
Note The conductance (hc) of the 25 μm 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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Introducing: Convection specifies convective flow on the selected faces. It requires
Convection an ambient temperature surrounding the face as well as the convection
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coefficient defined by the type of fluid the face is interacting with.
Where to Find It I In the Simulation Study tree, right-click Thermal Loads and
select Convection.
I In the Simulation menu, select Loads/Fixture, then Convection.
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69
Thermal Analysis
5 Define heat sink convection.

Right-click Thermal Loads and select
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Convection. Select all external faces of
the heat sink part except the face
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where the thermal resistance has been
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defined.
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Assign a Convection Coefficient of
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250 W/m2K for the selected faces. This
high value of a convection coefficient
corresponds to forced air cooling.
Enter 300K as the Bulk Temperature;
300K is the temperature of the ambient
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air.
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Click OK.
6 Define microchip convection.
E Repeat the same procedure for the

microchip part, but enter 100 W/m2
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K as the convection coefficient for all
faces except the face where thermal
resistance has been defined.
Enter 300K as the Bulk
Temperature as you did for the heat
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sink model.
7 Collapse the assembly.
The model setup is complete in preparation for a steady-state thermal
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analysis.
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Note We have already defined the way heat will enter the model when we
applied the heat power. By defining convection, we have defined the
mechanism for heat to leave the model.
8 Mesh the model.
Create a High quality mesh with the default Maximum element size of
-
1.345mm. Use Curvature based mesh.

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9 Run the analysis.

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Insulation For 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.
70
Thermal Analysis
Initial Temperature No initial temperature of the model is needed when analyzing a steady-
state problem. Steady-state thermal analysis, by definition, pertains to
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the situation where the temperature field has stabilized under the
defined conditions.
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The initial temperature may only shorten or lengthen the time required
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to obtain thermal equilibrium, but does not affect the steady-state
conditions. Therefore, initial temperature is irrelevant for a steady-state
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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.
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Note that temperature (TEMP), as a scalar
st
entity, is available for display only as a fringe
plot. Temperature gradients and heat flux (both
E resultants and components), are vector

quantities and can be displayed in fringe or
vector format.
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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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10 Display steady-state temperature distribution.

Double-click on the Thermal1 plot that is automatically generated in
the Results directory.
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Because the maximum temperature is located inside the microchip
volume, it is best to view the temperature distribution using a section
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plot.
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71
Thermal Analysis
11 Display the temperature distribution as a section plot.

Right-click the Thermal1 plot and select Section Clipping. Use
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Right Plane to define the plane of the cut. (For more information on
section clipping, please consult Lesson 1 of the SolidWorks Simulation
e
training manual.)
F
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Note To display the model boundaries in the plot, use plot Settings.
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The temperature distribution is very strongly dependent on the thermal
conductivity of the assembly components. Due to its good conductivity,
the temperature of the heat sink is almost uniform.
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We also see the cooling effect of the heat sink on the ceramic
microchip, which runs colder on the side of the heat sink than on the
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side cooled by convection.
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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 , represent the fact that every second
-
2
m s⋅m
one Joul leaves/enters/flows through one m2 of the surface
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perpendicular to the direction of the flux component.

BTU
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The corresponding units in the English (IPS) system are -------------2- .

s ⋅ in
Heat flux is a vector with three components and a resultant.
72
Thermal Analysis
12 Plot the resultant heat flux distribution.

Define a new plot for HFLUXN: Resultant heat flux.
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e
F
ut
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E We can observe that the greatest amount of energy flowing every
second is located at the cutouts of the heat sink.
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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
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meshes are recommended if the heat flux results are of importance to

the designer.
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13 Probe the results.
Zoom closer to the cutout region and
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probe the location shown in the figure.

The indicated heat flux resultant value
of
3.48e5 W/m2 represents the fact that
every second the energy of 3.48e5
-
Jouls flows through one m2 of the

surface area, which is perpendicular to
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the resultant.
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73
Thermal Analysis
However, the above information does

not mean that all of the indicated
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energy is leaving the heat sink
through this face at the selected node.
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Plot the x component of the heat flux
F
(HFLUXX: X Heat flux) and Probe
ut
the same location.
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We can observe that the heat flux in
the x direction, indicating the heat
leaving the heat sink through this face at the selected node, is much
smaller (1.36e4 W/m2).
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Heat Power Heat power indicates the variation of the of energy leaving/entering
every second through the boundary. To obtain the total or average heat
st
power for a specific entity, List selected command has to be used.
E The basic unit for the hear power is Watt, W = J--

s in the SI system
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Btu
of units, and ----------
s in the English system of units.
14 Total Heat Power.

Right-click on the Results folder and select List Heat Power. Select the
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indicated face and click Update.

The Summary dialog
indicates the total heat
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flow through this face
as 0.08181 Watts out
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of the heat sink.

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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.
74
Thermal Analysis
The results only display what the stabilized state will look like. The
amount of time depends on the initial temperature conditions, which
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are not defined in a steady-state thermal analysis.
e
To analyze temperature changes in time, a transient thermal analysis is
F
required.
ut
We assume that prior to turning on the power, all model components
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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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1 Create new thermal study.
st
Duplicate the study steady state into a new study named
transient 01.
Note
E Two modifications are required to change the study transient 01 (by

default a steady-state analysis) into a transient thermal analysis. First,
we will change the Analysis type from Steady state to Transient.
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The second required modification is the definition of initial
temperatures for the model.
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75
Thermal Analysis
2 Set analysis type to Transient.

Right-click transient 01 and select Properties. This opens the
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Thermal window.
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Select Transient as the Solution type.
F
To set initial conditions and time increment, enter 300 sec for the Total
ut
time and 10 sec for the Time increment.
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Select the Direct Sparse solver.
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st
E
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Click OK.
The will be run for 300 seconds and the results are saved every 10
seconds.
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76
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
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from SolidWorks convection coefficients directly into the thermal study in SolidWorks
Flow Simulation Simulation. (See the SolidWorks Flow Simulation tutorial titled
e
Conjugate heat transfer for an example of the analysis of heat transfer
F
within an air-cooled electronic package.) This option is very useful for
ut
simulations with forced convection in which the convection coefficient
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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.
or D
st
select Temperature.
I In the Simulation menu, select Loads/Fixture, then Temperature.
E 3 Set initial temperatures for components.

We assume that all the assembly components have the same initial
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temperature of 25°C, which happens to be equal to the bulk (ambient)
temperature. However, this equality is not a requirement.
To define the initial temperature, right-click Thermal Loads and
select Temperature.
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Select Initial temperature as Type and enter 25°C. From the

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SolidWorks flyout FeatureManager, select all assembly components:

heat sink, microchip, and three instances of the connector.
Click OK.
Note It is also possible to import the initial distribution of the temperatures
from another SolidWorks Simulation thermal study (see the thermal
study property window on the previous page).
77
Thermal Analysis
4 Run the analysis.
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5 Display temperature plot.
e
Display the temperature plot for the last step (step 30) by right-clicking
F
the Thermal1 plot in the Results folder and selecting Edit Definition.
ut
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E
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Set the Plot Step to 30.
Click OK.
6 Probe middle terminal.
Right-click the temperature plot icon and select Probe. The Probe
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window opens. Probe the corner of the middle terminal.

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78
Thermal Analysis
7 Create response graph.

Still in the Probe dialog window, click the Response button to plot the
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variation of the temperature at the corner of the middle terminal as a
function of time.
e
F
Note To produce a response graph, you can probe the temperature from any
of the 30 time steps.
ut
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st
E
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A review of the temperature/time history shows that the temperature

has practically stabilized (reached steady state) in less than half of the
allotted 300 seconds.
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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.
-
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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.
79
Thermal Analysis
Transient Now, we will add more complexity to the transient thermal analysis.
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Analysis with We still want to monitor what happens during the first 300 seconds
using 10-second intervals, but heat power will now vary with time.
e
Time Varying
F
Load
ut
1 Create new thermal study.
Duplicate the transient 01 study into a new study named
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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.
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In the Thermal Loads folder, right-click Heat Power-1 and select
Edit Definition to open the Heat Power PropertyManager.
st
In the Heat Power PropertyManager, click the
Use Time curve button and select Edit to
E open the Time curve window.

Enter three points to define the time curve: (0,0),
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(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.
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Click OK.
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80
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
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seconds. Then power is gradually decreased to 0 over the next 30
e
seconds. After 60 seconds, no power is generated.
F
ut
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st
E
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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
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also be made time or temperature dependent.

Having defined heat power as a function of time, we are ready to run
y
the study transient 02.
Temperature Similarly to time dependence of the load using time curves, any
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Curves thermal 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.
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Note that solutions with temperature curves are significantly more time
demanding as convergence iterations are required.
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81
Thermal Analysis
3 Run the analysis.
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4 Probe temperature results in middle terminal.
e
Probe the temperature results in the same location as the previous
F
study.
ut
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E
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The temperature reaches its maximum at step 4, or 40 seconds after the

power has been turned on.
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Transient Having analyzed the results for the transient 01 study (the study with
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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
middle terminal reached 180oC.
a Thermostat
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

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simulated by the thermostat feature available in SolidWorks

Simulation.
Introducing: The Thermostat (Transient) feature allows the temperature of a given
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Thermostat feature to be controlled by turning the Heat Power on and off. This
type of feedback control is commonly called on-off control and is used
by almost all domestic thermostats.
Where to Find It. I When defining a Heat Power select the check box next to
Thermostat (Temperature).
82
Thermal Analysis
1 Create new study.

Duplicate the study transient 01 into a new study transient 03.
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2 Define a Thermostat.
e
In the transient 03 study, right-click Heat Power-1 and select Edit
F
Definition to open the Heat Power Property Manager.
ut
Select the Thermostat
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(Transient) check box.
Select the vertex for the
Sensor location. This is
the location where we want
to install thermostat.
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In the Lower bound
st
temperature box, enter a
value of 100°C [373K].
E In the Upper bound

temperature box, enter a
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value of 120°C [393K].
Click OK.
Verify that the heat power
definition does not use any
curve (this would occur if
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you accidently made a

copy of study transient
y
02 instead of transient
01).
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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.

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3 Modify time increment.

Right-click transient 03 and select Properties.
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In the Time increment box, enter 5 sec. This will increase the solution
time but will provide more accurate results.
Note Make sure you use the Direct Sparse solver.
4 Run the analysis.
83
Thermal Analysis
5 Plot time history graph at sensor location.

Create a graph showing the time history of the temperature at the
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sensor location specified earlier.
e
F
ut
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st
E
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The graph clearly illustrates how microchip heat power is controlled by
the thermostat. Because of the heat inertia, the temperature oscillates
between 92°C [365K] and 125°C [398K], even though we specified the
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operating range between 100°C and 120°C.

To keep the microchip temperature below 120°C [393K], as we
y
originally intended, we would have to define the upper bound
temperature in Thermostat definition to be below 120°C [393K]. The
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actual upper bound temperature could be found by trial and error.
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
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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.
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84
Thermal Analysis
Summary In this lesson, the mechanisms of heat transfer: conduction, convection

and radiation were introduced. Different types of thermal analysis
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require specific material properties to be input. Comparing structural
and thermal analyses, we found that because of close and direct
e
analogies, expertise in structural analysis can be easily transferred to
F
thermal analysis. We eventually used those analogies to identify
ut
singularities in the thermal analysis results.
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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.
or D
Transient thermal analyses require the definition of initial temperatures,
st
whereas, steady-state thermal analyses are independent of initial
temperatures.
E 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.
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Finally, the Thermostat feature was defined to control the temperature
at a specific location by adjusting the generated heat power in a
transient analysis.
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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

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quantity and has no sense of direction, (temperature / temperature

gradient / heat flux) are vector quantities and have X, Y and X
components.
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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.
85
86
Lesson 4
PR Thermal Analysis
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SolidWorks 2011
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Thermal Analysis of a Cup
Exercise 7: In this exercise, you will perform a thermal analysis on a cup housing
Thermal that encloses a rotating shaft.
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Cup I Steady-State Thermal Analysis on page 67.
F
I Convection on page 62.
ut
I Vector Plots from the SolidWorks Simulation training manual.
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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.
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1 Open part file.
st
Open the part named Cup.
E 2 Create thermal analysis study.

Create a study named thermal study one. Select Thermal as the
Analysis type.
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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/
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in2].
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5 Define Convection condition.

-
Select the three outside faces.

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Enter 30 W/m2K
[1.0e-5 BTU/s °F in2] for the
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Convection Coefficient and enter

294K [70ºF, 20.85ºC] as the Bulk
Ambient Temperature.
87
Thermal Analysis of a Cup
6 Mesh the model.

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element size of 14.7mm. Use Curvature Based Mesh.
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7 Run the study.
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8 Plot temperature distribution.
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9 Create a vector plot of the Resultant heat flux.
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10 Evaluate results.
To examine the accuracy of your results, define a new study and repeat
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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.
88
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Lesson 5
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Thermal Analysis with
st
Radiation
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Upon successful completion of this lesson, you will be able to:

I Perform a steady state heat transfer analysis with radiation.
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I Properly post-process radiation analysis.
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89
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
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Assembly heat transfer mechanism and how it works. The properties that define
heat transfer will be discussed. We will also comment on when
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radiation will become a dominant mode of heat transfer and when it can
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be ignored.
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Project
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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
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E Glass Cover
Glass Bulb Glass
Cover
Aluminum
Housing
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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.
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Our objective is to find the steady state temperature distribution of the

reflector housing due to the heat produced by the light bulb. Certain
assumptions on the environment as well as the geometry were made.
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Let’s review the heat transfer mechanism in the model. What happens
to the heat generated by the light bulb?
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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

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by convection to the ambient air. Similar mechanism applies also in the

case of the glass cover.
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90
Stages in the I Define Heat Power

Process Heat is generated from the entire volume of the glass bulb.
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I Define Radiation
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The heat generated by the bulb is radiated from the surface of the
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bulb onto the reflector.
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I Define Convection
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Heat is allowed to leave the model through convection on the
opposite side of the bulb and housing.
I Run the study
I Postprocess the results
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Properly analyze the results from the thermal analysis study.
Steady State
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Since we only want to know how the temperature is distributed when
Analysis the light has already been on for a while, we will only perform a
steady-state analysis. If we wanted to know how the light reacted when
E turned on, a transient analysis would be required.

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Procedure The steady-state thermal analysis is performed as follows:
1 Open assembly.
Open the assembly named light.
2 Create thermal study.
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Create a study named radiation. Select Thermal as the Analysis

type.
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The material properties of the reflector (Aluminum 2014), bulb (Glass)
and the Glass cover (Glass) are transferred automatically from the
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SolidWorks models to SolidWorks Simulation.

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4 Define heat power.

Right-click Thermal Loads and select Heat Power.
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Select the bulb from the flyout FeatureManager design tree.
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Enter 50 W [0.0475 BTU/s] under Heat power. This heat power is
generated in the entire volume of the bulb.
Click OK.
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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
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temperature of the surroundings.

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select Radiation.
I In the Simulation menu, select Loads/Fixture, then Radiation.
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5 Radiation condition on the bulb.

To define heat transfer out of the bulb by radiation, right-click
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Thermal Loads and select Radiation.
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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
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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
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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.
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Also under Radiation Parameters, enter 0.7 as the Emissivity for the
bulb material.
Click OK.
Note As was explained in Lesson 4: Thermal Analysis, emissivity is a
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material property that depends on the surface temperature and the

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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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93
6 Radiation condition on the reflector.

To define how the reflector receives the heat radiated out of the bulb,
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we must define the radiation condition on the reflector surface.
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Right-click Thermal Loads and select Radiation. Select the internal
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face of the reflector.
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Under Type, select Surface to surface.
The Open system checkbox should again be unchecked as the system
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inside the bulb is fully closed.

Enter 0.1 as the Emissivity. Note that the reflector is designed to
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reflect radiation, which is why the value of the emissivity coefficient is
low.
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Click OK.
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7 Radiation condition on the glass cover - internal face.

Explode the assembly for easy definition
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of this condition.
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Similarly to the previous steps, define the
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Surface to surface, closed system
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radiation condition. Specify the Emissivity
of 0.97 (most of the radiation is absorbed
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by the glass cover).
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Note
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on the split face exposed to the radiation.
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8 Radiation condition on the glass cover - external face.
The external face of the glass cover emits all energy to the ambient
space.
Right-click Thermal Loads and select Radiation. Select the external
face of the glass cover.
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Under Type, select Surface to ambient.

Enter 25°C [77°F] for the Ambient Temperature, 0.97 for the
Emissivity and 1 for the View Factor.
Click OK.
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Note When surface to ambient type is used, view factor must be input
manually because any geometry blocking the radiation out of the glass
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cover is not part of the model.
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9 Convection condition for Casing.
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To define heat transfer out of the reflector Casing by convection to the
ambient air, right-click Thermal Loads and select Convection.
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Select the external faces of the reflector which are in contact with the
air. These external faces dissipate heat by convection.
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Enter a Convection Coefficient of 50 W/m2K [1.7x10-5 BTU/s in2 F]

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and a Bulk Ambient Temperature of 315 K [41.85 °C or 107.3 °F],
which is the temperature of the air surrounding the back of the reflector
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housing.
Click OK.
10 Convection condition for glass cover.
Because the glass cover faces open space its
-
convection parameters are different.

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Define the Convection condition on the

outside faces of the glass cover with the
Convection Coefficient of 70 W/m2K
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[2.37x10-5 BTU/s in2 F] and the Bulk

Ambient Temperature of 298 K [24.85 °C or
76.73 °F].
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Review of Analysis The mechanism for heat transfer has been fully defined. This completes
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Parameters the model setup for the thermal analysis.
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In preparation for this steady-state thermal analysis, we have defined
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the coefficient of convection, heat power, and emissivity. The only
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thermal quantity we do not use in this lesson is a heat flux load (heat
power per unit of area).
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If a transient thermal analysis was required, then all three quantities
could have been defined as functions of time using time curves.
11 Mesh the model.

Mesh the model with Draft quality elements and the Maximum
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element size of 2.29 mm. Use Curvature based mesh.
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A simulation solves in approximately 7 minutes on Intel Xeon 2
E processor system.
Click the More button in the solver window and notice that most of the
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computational time is spent on the calculation of the view factors. View
factors express the fraction of radiation leaving one area that is
intercepted by the receiving area.
13 Plot temperature
distribution.
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The automatically
created Thermal-1
plot in the Results
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folder shows the
temperature
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distribution.
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Note that the bulb reaches a high temperature of 1226°C [2338.8°F or

1499.15°K]. This is reached inside at the venter of the bulb.
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Because the geometry of the bulb is very approximate, the temperature

result at that location has to be ignored. In reality, vacuum filled bulb
with integrated heat sink would have to be modeled to come closer to
the real problem description at this location. Our current model merely
models the presence of the bulb as a source of heat and the radiation
emittor.
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14 Temperature of glass
cover.
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Set the upper limit of the
legend to the maximum
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value of 200°C, the
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maximum design
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temperature on the
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outside surfaces.
Using the Probe function
we can see that the
maximum temperature
on the external face of
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the glass cover is
319°C, well above the
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design limit of 200°C .
It can be seen, that the design temperature of the glass cover external
E surface was not met and is of a serious concern. The result indicates
that substantial design changes, including those of using less powerful
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bulb, may be 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.
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Heat Flux Recall the L-bracket lesson (see Lesson 2, in the SolidWorks Simulation
Singularities training manual) where we identified stress singularity in a sharp re-
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entrant corner.
To conceptualize the singularity of heat flux in a sharp re-entrant edge,
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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
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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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98
15 Plot heat flux.

Hide the glass cover component and create another plot in the
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Results folder showing the resultant heat flux.
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Right-click the Results folder and select Define Thermal Plot. Select
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the HFLUXN: Resultant heat flux component to be displayed.
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The heat flux concentrations are coincident with the sharp re-entrant
edges. However, as we learned in Lesson 4: Thermal Analysis, heat
flux results in sharp re-entrant edges are meaningless. Theoretically
these results are singular (or infinite).
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Summary In this lesson, we have analyzed a steady state heat transfer problem
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with conduction, convection, and radiation.

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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.
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Lesson 6
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Advanced Thermal Stress
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2D Simplification
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I Perform thermal stress analysis of assemblies.
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I Utilize 2D simplification to reduce the problem size.
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101
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
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type of static analysis, which is a subgroup of the structural class of
problems. Thermal analysis does not belong to this group.
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In addition to all regular structural loads, such as forces and
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displacements, thermal stress analysis enables the inclusion of loads
due to the constrained thermal expansion or contraction.
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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
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Analysis Type SolidWorks
Classification
Simulation
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Static Static Structural
E Thermal stress
Thermal
Static
Thermal
Structural
Thermal
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Case Study: In this lesson, we will perform a simplified analysis of an expansion
Metal joint assembly consisting of a bellow manufactured from AISI 321
Expansion Joint stainless steel, and two carbon steel flanges. Expansion joints are used
to alleviate thermally induced stresses in high temperature piping
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systems. The low structural stiffness of the bellow allows it to deform

in multiple directions and absorb the system deformations.
Project
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The bellow end is welded to the
Flange
Description carbon steel flange. The flanges are
then bolted to the piping system.
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The system is used to transport low

pressure steam at a temperature of
220°C [493.15K, 428°F] and
pressure of 3 bars [0.3 MPa, 43.51
-
psi].
Bellow
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Our objective is to find the stresses

in the assembly.
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Stages in the This type of analysis requires a two step procedure:

Process I Perform a thermal analysis.
The thermal analysis will calculate the temperature distribution in
the model. Because the stress analysis is requested after the flow of
the heat stabilizes, we will run a steady state thermal analysis.
I Perform a static analysis.
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Use the temperature results from the thermal study and perform a
static analysis to find the thermal stresses.
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Thermal We are looking for the steady state solution, meaning the state at which
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Analysis enough time has elapsed for the temperature field to stabilize. Because
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the initial condition affect the time needed to reach the steady state, but
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not the steady state itself, it is not required in the definition of the
thermal problem.
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The initial temperature will only be used as a reference temperature for
the calculation of thermal stresses.
Procedure The steady-state thermal analysis is performed as follows:
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1 Open an assembly file.
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Open Expansion joint from the
Lesson06\Case Study folder.
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2D Simplification Simulation of some engineering problems can be represented in two

dimensions (2D) rather than three dimensions (3D), leading to a
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dramatic reduction of the problem size and the time required to solve it.
Important! If applied correctly, 2D Simplification studies provide exact solution to

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real 3D problems. Simplification implies reduction in the complexity of

the simulation model. If applied incorrectly by user, however,
significant errors are likely to occur.
When considering 2D Simplification, both geometry of the model and
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the applied loading must meet certain conditions. Considering only one
of these two conditions may lead to serious errors. Three types of the
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2D simplifications exist:
I Plane stress: Plane stress represents a 3D situation, where out of
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the plane stress can be assumed to be equal to zero (stresses exists

only in the plane of the object, hence the name plane stress). This
situation occurs only when (a) the thickness of the object is
significantly smaller than the two remaining planar dimensions, and
(b) when the forces and fixtures act only in the two planar
dimensions. Consider the following example of a thin wall loaded
by in plane forces (forces in x and y directions in the next figure).
103
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3D model 2D Simplification
The 3D thin wall can be represented as 2D model without any

significant loss of accuracy.
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I 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
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represented as 2D problem with negligible loss of accuracy.
Consider the example of a pipe (see the figure below), restricted in
E 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
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directions (strains occur only in the planar directions, hence the
name plane strain).
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Because each cross-section deforms identically, it is enough to

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simulate a 2D cross-section only, greatly simplifying the model.

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Long structures, such as pipelines, are often assumed to deform in

the plane strain fashion.
I Axi-symmetry: 3D structure created by revolving its cross-section
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about an axis and subjected to loads can also be represented as a 2D

problem. In the example below, the cylindrical geometry of the
pressure vessel is created by revolving the profile about the axis of
revolution. The pressure and temperature loads, as well as the
fixtures, can also be defined as being revolved. Such situation can
be represented as a 2D model, as shown in the figure below. The
axi-symmetrical solution is an exact solution to the 3D problem.
104
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Introducing: 2D Simplification enables users to reduce the original 3D problem into
2D Simplification a 2D problem with minimal or no loss of accuracy. This way it leads to
E dramatic reduction of the problem size and the required computational

time. 2D simplification is available for static, thermal and nonlinear
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study types.
Where to Find It I Right-click Simulation in the main simulation menu and select
Study. Choose Static, Thermal or Nonlinear as the study Type.
Under Options check Use 2D Simplification.
2 Symmetry
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Activate Symmetry configuration to reduce the model size.

3 Create thermal analysis study.
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Create a new Thermal study named t distribution.
Click the Use 2D Simplification checkbox located
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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.
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105
4 2D Simplification
options.
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In the 2D Simplification
property manager, specify
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Axi-symmetric, select
F
Front Plane as Section
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plane and Axis1 as Axis
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of symmetry.
Click OK.
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Note
E Use the Use other side checkbox to switch the side of the cut.
The 2D cut on the new
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plane named t
distribution will be
generated. The simulation
model will be built on this
geometry.
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5 Materials.
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The material properties transfer automatically to SolidWorks

Simulation from the SolidWorks assembly model.
Note In many instances, the material definition may have to be modified in
SolidWorks Simulation. For example, if the temperature dependence of
some of the material constants (i.e. conductivity, Young’s modulus)
-
cannot be disregarded over the considered temperature range, a

temperature dependent material model must be used. For the specifics
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on how to define a temperature dependent material model, refer to the

Thermal Stress lesson in the SolidWorks Simulation training manual.
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6 Define temperature.
To model the hot steam we will impose the temperature on the inside
walls of the Bellow and the Flange.
Right-click the Thermal Loads and select Temperature.
Select the inside edges of the model exposed to steam.
Under Temperature specify 220°C [493.15K, 428°F].
106
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F
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Flange detail
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Note The edges of the 2D axi-symmetrical model represent the revolved
faces of the 3D model.
Click OK.
7 Define convection.
The heat dissipated from the model through the faces exposed to the
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outside air is modeled using convection.
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Right-click the Thermal Loads and select Convection.
Select all outside edges, as shown in the figure below.
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Flange detail
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Specify 50 W/m2K [1.69859e-5 BTU/s in2°F] as the Convection

Coefficient. This means that each square meter of the selected faces of
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the 3D model dissipates 50 W [0.0001 BTU/s] if the difference

between the face temperature and the ambient air temperature is 1K.
Under Bulk Temperature, enter 298K [25°C, 77°F].
Click OK.
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Prescribed In general, the prescribed temperature can be kept at a constant value

Temperature by means of either heating or cooling. We may not know if the face is
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Condition heated or cooled until we examine the results and determine in which
direction the heat is flowing through the face in question.
In the present case, however, it is clear that the heat is entering the
walls of the Bellow and the Flange where the high temperature is
specified and exists due to the convection through the outside walls.
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Meshing The model is now ready for meshing, but first let us examine some
Considerations in meshing considerations particular to thermal analysis.
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Thermal Analysis If a model is intended only for calculating temperatures, there are no
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special meshing considerations. Meshing with the default element size
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and no mesh controls usually produces a mesh that yields correct
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results.
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Meshing may require more attention if we want to calculate heat flux.
Excessive curvatures of element faces and excessively sharp corners
may cause artificial heat flux concentration.
Even though we are primarily interested in the temperature results (we
require temperatures to calculate thermal stresses), we want to generate
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a mesh that could be used later for the analysis of the heat flux results
as well.
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8 Mesh assembly.
E Mesh the assembly with High quality elements and the Maximum
element size of 0.97427mm [0.03835 in]. Use Curvature based
mesh.
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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.
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9 Run the analysis.

The simulation completes in a couple of seconds.
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108
10 Resulting temperatures.
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We can see that the temperature in the bellow wall is nearly constant.
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Probing on the outside walls shows that the temperature drop is no
more than 2° to 3°C.
E 11 3D plot.
Right-click the resulting temperature plot and select Show as 3D Plot.
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The temperatures shown in 3D adds realism to the way the results can
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be presented. The cut wedge size can be edited and is used to show the
distribution through the thickness of the walls.
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109
12 Create a vector plot of heat flux.

Right-click the Results folder and select Define Thermal Plot.
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Select HFLUN: Resultant Heat Flux for the Component and W/m^2
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for the Units.
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Under Advanced Options select the Show as vector plot checkbox.
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Click OK.
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The arrows clearly indicate the direction of the heat flow through the
walls of the bellow and through the flange.
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Note To change the arrow size, right-click the plot and select Vector Plot
Options.
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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.
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Thermal Stress Having calculated the temperature distribution, we can now proceed
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Analysis with the static stress study.
1 Create a static study.

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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.
110
2 Include thermal effects in analysis.

Right-click the thermal stress study and select Properties.
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F
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Under Flow/Thermal Effects, select Temperatures from thermal
Note
E study.
If results from more than one thermal study are available you can select
the particular thermal study to be utilized for providing thermal input
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for the thermal stress study.
In our case, only the t distribution study is available.
Importing As in the case of the convective effects, it is possible to first run a

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Temperatures and detailed fluid dynamic simulation using SolidWorks Flow Simulation
Pressures from and then import the resulting temperature distributions and pressures
SolidWorks Flow into the SolidWorks Simulation static analysis. This is necessary when
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Simulation the coefficient of convection is unknown due to a complicated flow

around the body. Importing temperatures and pressures from
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SolidWorks Flow Simulation only works for full 3D models.

Reference Reference temperature at zero strains corresponds to the temperature at
Temperature at which we assume no thermal strains exist in the model.
Zero Strains
-
3 Set reference temperature.

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Still in the thermal stress study property window, under the Flow/
Thermal effects tab, enter 25°C [77°F] as the Reference temperature
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at zero strain.
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4 Symmetry.
At the beginning of this lesson we specified Symmetry configuration.
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This condition must now be defined in the simulation study.
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Specify Symmetry
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fixture on the
exposed edge of the
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Bellow.
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5 Flange condition.
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The expansion joint flanges are bolted to the flanges of the connecting
pipes. While significant deformations and stresses of the Bellow are
E 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
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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.
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Right-click the Fixtures and select Advanced Fixtures.

Note The Front Plane is the
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default choice for the
reference entity in 2D model
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and can not be changed.

Select the indicated edge of
the Flange and specify
4mm in the Along Plane
Dir 1 field.
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Click OK.
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112
6 Pressure.
The low pressure steam is transported at a pressure of 3 bars [0.3 MPa,
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43.51 psi].
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Note Because the pressure must be oriented outward, you will see that one
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definition for all edges is not possible. The definition must be split in
two.
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Right-click the External Loads
folder and select Pressure.
Select the three edges indicated in the
figure and specify 0.3 N/mm^2
(MPa).
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Click OK.
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Using the same procedure, define the same pressure on the remaining
internal faces of the Bellow. Make sure that the pressure is oriented
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correctly in the outward direction.
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7 Mesh control - Bellow.
Define mesh control on the entire cross-section of the Bellow (see the
figure below). Specify 0.45mm [0.0177in] for the Element Size and
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1.5 for the Ratio.

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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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8 Mesh control - Flange.

Define identical mesh control on
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the three edges indicated in the
figure below. The global mesh
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size is too coarse for smooth
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stress results in this region.
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9 Mesh assembly.
Mesh the assembly with High quality elements and the Maximum
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element size of 0.97427mm [0.03835 in]. Use Curvature based
mesh.
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Note With the above mesh density we were able to fit 4 elements in the
Bellow.
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10 Mesh details.
For the book keeping purposes, review the details of the mesh. Note,
that the 2D mesh features approximately 25600 nodes. In 2D, and
without any additional contact conditions, the solution of such
simulation poses no problem.
-
11 Run the thermal stress study.

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It takes a couple of seconds to complete the study.

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114
12 Plot resulting displacements.
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F
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Not surprisingly, the maximum deformation on the joint is due to the
E prescribed 4mm displacement of the Flange. Because the Bellow is

very soft in the axial direction, this does not mean automatically that
this loading is responsible for the maximum stress.
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13 Plot von Mises stress.
Set the Max in the legend to the yield strength of the bellow material
AISI 316, 172.4 MPa.
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The maximum stress in the model is approximately 366 MPa located in

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the first bent of the bellow. This significantly exceeds the yield strength
of 172.4 MPa and we conclude that the bellow design would have to be
modified. Perhaps fewer bents with larger diameter would help the
situation. Further more, because bellow needs to qualify for certain
minimum fatigue life, this result suggest that significant re-designs is
necessary.
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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
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the SolidWorks Simulation training manual for the definition of nodal
and elemental stresses). Although it provides a measure of the error in
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energy norm, not in stress, it can still be viewed to represent the relative
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distribution of stress errors in homogeneous meshes. High values at the
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regions with sharp re-entrant corners should, therefore, be ignored.
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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 I Right-click the Results folder and select Define Stress Plot.
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Under Display, select ERR: Energy Norm Error as the
Component.
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14 Plot Energy norm error.
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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

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contribution of the pressure load is minimal.

3D model We mentioned that 2D simplification leads to a dramatic reduction in
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the model size. To demonstrate this fact, we will now attempt the
solution with the traditional 3D approach.
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15 Model Configuration.
Change the configuration to 3D
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symmetry.
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Note The model in the 3D symmetry configuration was reduced a 15
degree wedge. The dimension of the wedge could be reduced further if
desired.
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16 Define study.
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Define a new Thermal study. Name it 3D thermal.
17 Mesh.
E Create mesh with the same parameters as those used in the 2D model
(0.97427mm for both Maximum element size and Minimum element
size, 8 for Min number of elements in a circle and 1.5 for Elements
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size growth ratio).
Note The mesh controls utilized in the 2D study (steps 7 and 8) are not used
in the 3D model. Their use would lead to an unreasonably large mesh.
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18 Mesh details.
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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.
19 Complete the solution.
On your own and if class time permits, complete the 3D solution of the
thermal study. Then, continue with the definition of the static stress
study with all of its loads. As you work on the 3D model, note the
117
significant amount of time needed to define, mesh and solve this

model.
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Below, we are showing the final distribution of the von Mises stress.
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E It can be observed that the stress solution is very close to that obtained
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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 analysis of the expansion joint, a part of the
piping system transporting low pressure hot steam. The solution was
obtained in two steps.
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First, a thermal study was conducted with the primary objective of

calculating temperatures for the thermal stress study. Then, a thermal
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stress study was conducted with a model that was properly restrained
and loaded by the temperatures obtained in the thermal study. In
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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.
Also, the 3D model was dramatically reduced. First, a symmetry was
utilized to cut the 3D model in half. Then, it was noted that both the
-
geometry and loads can be revolved around an axis. The model was
therefore further reduced and 2D axi-symmetrical representation was
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employed.
It was shown that 2D model resulted in an elegant and quick solution.
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Contrary to that, the 3D approach resulted in very large model with the
mesh size nearly 5750% larger than the one used in the 2D model.
Questions 1. State at least two examples where 2D plane stress, plane strain and
axi-symmetry simplifications could be used.
2. The following figure shows a pipe loaded by uniform internal
pressure and a distributed force applied on the top edge. The force
118
magnitude varies along the longitudinal direction of the pipe.

Which of the following 2D simplifications could be applied to
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reduce the size of this problem? (plane strain / plane stress / axi-
symmetry / none)
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Thermal Stress Analysis of a Microchip Testing Assembly
Exercise 8: In this lesson, you will analyze a microchip testing assembly consisting
Thermal Stress of a ceramic insert, a nylon housing, and an acrylic gasket.
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Microchip I Convection on page 62.
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Testing I Heat Flux on page 72.
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Assembly I Thermal Stress Analysis on page 110.
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Problem The gasket and the nylon
Statement housing are connected by Gasket
two bolts, which will not be
included in the analysis. The
assembly is then freely Microchip
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positioned on a platform
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inside the testing chamber; it
is not connected to any other
secondary structure. Housing
E The initial temperature of

the assembly is 25°C [298K, 77°F]. During testing, a microchip housed
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inside a pocket in the nylon housing generates a heat power of 5 W
[0.004739 BTU/s] while the face of the acrylic gasket is kept at a
constant temperature of 65°C [149°F].
The objective of the exercise is to find the thermal stresses in the
assembly.
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Open microchip test from Lesson06\Exercises folder.
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The touching faces between the microchip and the housing are
structurally bonded (glued), while the two faces between the gasket and
the housing can separate. It is assumed that ideal conduction exists
through all of the interfaces.
2 Create thermal study.
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Create a Thermal study named t distribution.

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The material properties transfer automatically to SolidWorks
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Simulation from the SolidWorks assembly model.
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4 Heat power.
Define 5 W [0.004739 BTU/s]
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Heat power on the microchip
part.
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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.
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5 Convection on assembly outside faces.
Apply Convection to the outside faces, as shown in the figures below.
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Specify 300 W/m2K [0.0001 BTU/s in2°F] as the Convection
Coefficient and 298K [25°C, 77°F] for the Bulk temperature.
E
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Note The top face is not selected for the convection because it is not exposed
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to the air flow. instead, a constant temperature is assigned to it in the
next step.
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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.
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7 Mesh controls.
Apply mesh controls to the microchip component. Use the default
local Element size of 1.54mm [0.06in] and the default settings for the
Ratio parameter.
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8 Mesh assembly.
Mesh the assembly with Draft quality elements and the Maximum
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element size of 3.07mm [0.121 in]. Use Curvature based mesh.
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Note
E The gasket part was hidden in the above figure to see the details of the
housing geometry.
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9 Run the analysis.
10 Define section plot of temperature.

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-
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Notice the cylindrical microchip generating heat power from within,

while convection takes place on the surfaces of the model.
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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
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temperature at zero strain to 25°C [77°F].

3 Study properties.
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Utilize the Use soft springs to stabilize model option to stabilize the
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model.
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Note Use of this feature further reflects the fact that the assembly is placed
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into the test chamber free of any external constraints.
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4 Bolt connectors.
Define two Standard or
Counterbore Screw connectors
threaded into the acrylic base.
The bolts have the following
parameters:
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Head Diameter = 10mm
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[0.394in], Bolt Shank Diameter
= 6.35mm [0.25in], Tight fit =
E ON, Material = AISI 1020 Steel,

Preload = 90 N [20.23 lb] Axial
force.
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5 Gasket vs. housing interface.
Define a No penetration,
Surface to Surface contact
between the touching faces of the
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gasket and the housing.

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6 Mesh control.
Apply identical mesh control to microchip.
7 Mesh assembly.
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Mesh the assembly with Draft quality elements and the Maximum
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element size of 3.07mm [0.121 in]. Use Curvature based mesh.

8 Run the th stress study.
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124
9 Plot resulting displacements.
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E We notice that, as expected, the gasket has slightly separated from the
housing.
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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 hay have slightly displaced as rigid body.
Change in Thermal The fact that the gasket separates from the housing due to structural
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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.
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Heat was allowed to pass through the interface perfectly. A zero
thermal resistance condition between the gasket and the housing
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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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125

The maximum stresses can be observed in the location of the
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microchip. Because excessive stresses may cause damage of the
component, the level of stresses needs to be controlled. The current
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mesh is, however, not fine enough to give reliable stress results. A
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study with fine mesh would therefore be required.
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As expected, we can also see higher stress concentrations in the regions
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where the two bolts are defined. Similarly, finer mesh would be
required to asses the effect of stress concentrations in these regions of
the housing and the gasket components.
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11 Plot Energy norm error.

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-
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The energy norm error confirms our conclusions on the mesh quality in
the vicinity of the microchip component. Finer mesh would be needed
in this region in order to obtain more reliable stress data.
126
Summary This exercise showed the thermal stress simulation of a microchip

testing assembly. A two step procedure was utilized. First, the
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temperature distribution in the model was obtained from a thermal
study. Then, the computed temperatures were transferred into a static
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stress study for the calculation of displacements and stresses.
F
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In the thermal study, the contact between the gasket and the housing
was assumed perfectly bonded, allowing for ideal conduction without
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any resistance. In the static stress simulation, this contact was set to No
penetration. As the model expands, the gasket deforms and detaches
from the housing. This causes a change in the thermal contact.
Depending on the degree of this separation a nonlinear simulation may
be required in order to update the geometry for thermal calculation.
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The energy norm error plot at the end of the exercise indicated that
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finer mesh would be required in order to obtain reliable stress data.
Because the model is not attached to any secondary object, the thermal
E stress simulation was conducted with a model that was restrained using
the soft spring option.
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127
Thermal Stress Analysis of a Gas Tank
Exercise 9: In this exercise, you will perform a thermal stress analysis on a propane
Thermal Stress tank.
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Gas Tank I Convection on page 62.
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I Heat Flux on page 72.
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I Thermal Stress Analysis on page 110.
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Problem A propane tank is attached to a grill. It sees
Statement a fixed temperature from the grill, heat
flux due to solar radiation, as well as
convection due to a breeze. Use these
conditions to calculate the thermal stresses
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experienced by the grill.
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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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1 Open the assembly file.

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Open the assembly named Gas_Tank.

2 Create thermal analysis study.
Create a study named steady state. Select Thermal as the Analysis
type.
-
Select Brass for the Part-1 and Alloy steel for the Tank body.
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4 Define heat flux.

Select the three faces of the tank exposed to the
sun. Apply a heat flux of 200 W/m2.
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128
5 Define boundary conditions on the tank.

Select all faces on the tank except for the rectangular face on the back
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of the tank where it is connected to the grill and the valve. Apply a
convection coefficient of 5 W/m2K and a bulk temperature of 294.6K
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[21.45°C or 70.6°F].
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E 6 Define prescribed temperature.
Select the rectangular face on the back of
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the tank.
Apply a temperature of 27°C [80.6°F or
300°K].
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7 Mesh the model.

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Mesh the model with High quality elements and the Maximum
element size of 18.64 mm. Use Curvature based mesh.
8 Run the thermal analysis.
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129
9 Plot temperature distribution.
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10 Evaluate and graph thermal results on a section plot.
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Direction of point
selection for
Probe feature
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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.

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130
11 Graph temperatures.
In the Probe Results window, under Report Options, click the Plot
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button to generate a path plot of the variation of the temperature along
the specified trajectory.
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Thermal Stress The results from the thermal analysis will now be used to perform a
Analysis thermal stress analysis.
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1 Create a thermal stress analysis.

Create a new Static analysis study named static study to determine
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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
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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.
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3 Setup thermal stress analysis.

Right-click on the static study and
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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].
131
4 Mesh the model.

Copy the mesh from the steady state thermal study into static study.
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5 Run the analysis.
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6 Plot displacement.
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We can see that the tank expanded on the sunny side of the face.
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-
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The stress of 131 MPa is well below the Yield strength of the material
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(620 MPa). We can see, however, that the stresses are rather localized.
For a more accurate solution, a finer mesh would be recommended.
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.
132
Thermal Stress Analysis of a Thermoelectric Cooler
Exercise 10: In this exercise, you will Heat sink, Cu

Thermal Stress asses the safety of the
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Analysis of a thermoelectric cooler (TEC)
device. Thermoelectric
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Thermoelectric
coolers are devices using
F
Cooler Peltier effect to force the
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transport of heat with
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TEC devices
consumption of electrical
energy. Heat pumps working Specimen channel, Al 1060
on this principle have many Ceramic plates
uses. Typically they are used (Al2O3, Alumina)
for cooling as more efficient
means exist to provide
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heating. However, if one
st
device for cooling and
Conductors, Cu
heating is necessary, TEC is Semiconductor pellets
(Bi2Te3, Bismuth Telluride)
E an ideal candidate. TEC are

frequently used for cooling electronic components and small
instruments, as is the case in this example.
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This exercise reinforces the following skills:
I Convection on page 62.
I Heat Flux on page 72.
I Thermal Stress Analysis on page 110.
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Problem The figure above show typical configuration for the use of TECs. A
Description laboratory device depicted in the figure above show an aluminum
specimen channel where tested samples are placed. The six TECs,
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arranged in series on the top of the channel must rapidly cool the
aluminum channel and pump the heat into the copper heat sink. The
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cooling or heating effect takes place immediately when current is

turned on. Alternating the current with some system control can
effectively keep the predefined temperature environment in the
specimen channel. by alternatively cooling or heating the aluminum
channel.
-
Due to the significant

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temperature difference that

may exist between the top Solder joint
(Sn-40Bi-0.1Cu)
and bottom Alumina plates,
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significant thermal stresses

and structural deformations
may develop causing failure
of the Bismuth Telluride
Structural failure of Bismuth
pellets or of the solder joints. Telluride (Bi2Te3) pellets
133
All bonded connections

(Alumina ceramic plates and
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Bismuth Telluride Ceramic plate
semiconductor pellets to Cu to Cu conductor
e
contact
conductors) are soldered with
F
Sn-40Bi-0.1Cu lead free solder
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material. The maximum design
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temperature differential and
the maximum heat load are Bismuth Telluride pellet
to Cu conductor contact
equal to 55°C and 8W,
correspondingly.
Materials The following table lists all required material specifications.
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Solder Bismuth
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Alumina
Sn-40Bi- Telluride
(Al2O3)
0.1Cu (Bi2Te3)
E Young’s
modulus
380 GPa - 43.6 GPa
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Poisson’s ratio 0.27 - 0.3
Yield strength 200 MPa -
Tensile strength - 26.8 MPa -
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Shear strength - 23.6 MPa -

Coefficient of 8.4e-6 °C-1 - 18e-6 °C-1
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thermal
expansion
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Conductivity 40 W/(m-K) - 2.27 W/(m-K)

Specific Heat 930 J/(kg-K) -
Density 3950 kg/m^3 - 7700 kg/m^3
-
Note Some properties of Bismuth Telluride are highly dependent on the

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temperature and the manufacturing process. The values in the above

table can be used for this exercise only and should not be used for real
life applications.
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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.
134
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Convection 5 W/(m^2.K)
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on all exposed TEC faces
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Convection 20 W/(m^2.K) on
specimen channel (outside faces only)
and the heat sink
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No convection on inside
faces of specimen channel
st
Theat sink=60°C
E
(surface temperature)
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Tspeciment channel=5°C (surface temperature)
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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.
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The assembly file Device for this exercise is located in the

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Lesson06\Exercises folder.
As you are building the simulation study, consider the following points:
I Can I simplify the geometry and use smaller model to solve the
problem?
I How fine mesh and in what regions of the model do I need to solve
-
the problem reliably?

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I How do I efficiently apply convective conditions on all exposed

faces?
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135
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136
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Lesson 7
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Fatigue Analysis
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Objective Upon successful completion of this lesson, you will be able to:
I Understand the basic concepts in fatigue.
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I Understand the required information to proceed with fatigue

analysis.
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I Understand the concept of S-N curves.
I Setup a fatigue analysis with multiple constant amplitude events.
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I Evaluate results of a fatigue analysis.

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137
Fatigue Analysis
Fatigue It is observed that repeated loading and unloading weakens objects

over time even when the induced stresses are considerably less than the
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allowable stress limits. This phenomenon is known as fatigue. Each
cycle of stress fluctuation weakens the object to some extent. After a
e
number of cycles, the object becomes so weak that it fails. Fatigue is
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the prime cause of the failure of many objects, especially those made of
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metals. Examples of fatigue failure can include rotating machinery,
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bolts, airplane wings, consumer products, offshore platforms, ships,
vehicle axles, bridges, and bones.
Linear and nonlinear structural studies do not predict failure due to
fatigue. They calculate the response of a design subjected to a specified
combination of restraints and loads. If the analysis assumptions are
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observed and the calculated stresses are within the allowable limits, it
can be concluded that the design is safe for this combination of loads
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regardless of how many times the load is applied.
Results of static studies are used as the basis for defining a fatigue
E study. The number of cycles required for fatigue failure to occur at a

location depends on the material, composition, and type of loading.
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Stages of Failure The following are three stages of failure due to fatigue:
due to Fatigue I Stage 1: One or more cracks develop in the material. Cracks can
develop anywhere in the material but usually occur on the boundary
faces due to higher stress fluctuations. Cracks can occur because of
many reasons including imperfections in the microscopic structure
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of the materials and surface scratches caused by tooling or

handling.
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I Stage 2: Some or all the cracks grow as a result of continued
loading.
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I Stage 3: The ability of the design to withstand the applied loads

continue to deteriorate until failure occurs.
Because the surface of the model is exposed to various environmental
conditions (moisture, etc.) and is usually the location of the highest
stress, this is where cracks are most likely to form and begin to
-
propagate. Therefore, strengthening the surfaces and high quality

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surface treatment increase the life of the model under fatigue.

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138
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
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two basic groups:
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I High Cycle Fatigue, where the magnitudes of alternating stresses
F
are moderate and cause none or small levels of plastic deformations
ut
in the material. The parts loaded in this manner are assumed to
resist a high number of loading cycles (from 1000 to 1e6 cycles)
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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
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required to cause fatigue failure. The fatigue analysis available in
SolidWorks Simulation is based on this approach and is the subject
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of further discussion in the remainder of the training manual.
E I 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
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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 with
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Based Fatigue the accompanying training lessons) treats the stress-life (S-N) based
approach to high cycle fatigue in detail.
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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
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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:
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I constant amplitude loading

I variable amplitude loading
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139
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
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alternating stress, mean stress, stress ratio, and the number of cycles.
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The terms characterizing the constant amplitude event are described as
F
follows:
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Stress
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Time
E I Smax and Smin are the maximum and minimum stress magnitudes in
a stress cycle.
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I Salt is the alternating stress.
I 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.
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I Stress ratio R = Smin / Smax. Two typical loading histories, zero

based and fully reversed, are shown in the figures below with the
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corresponding values for R and Smean.
Stress
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Stress
Time
Time
-
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In the constant amplitude loading case, the concept of time is

irrelevant, i.e. only the number of cycles with the above characteristics
is important.
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Variable Amplitude A variable amplitude fatigue event is a load history record that defines
Loading the fluctuation history of a load. The time values do not play any role
for fatigue studies with a single variable amplitude event. The time may
be required to correlate between several loading events. Variable
amplitude loading is the subject of Lesson 8: Advanced Fatigue
Analysis.
140
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
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and thermal loading cycle. We will learn how to define the S-N curve
that governs fatigue failure. The interaction of multiple loading events
e
will be discussed. In addition, we will learn how to properly interpret
F
fatigue results. Finally, we will see the effect of a constant, unchanging
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load on the fatigue study.
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Project An Aluminum Alloy 7075-T6 pressure
Description vessel is to undergo an evaluation for fatigue
life of constant amplitude pressure and
thermal stress loading. The pressure loading
oscillates between negative 1.38 MPa
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[200 psi] (-1.38 MPa [-200 psi]) and
6.89 MPa [1000 psi]; the thermal stress is
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due to a heat flux oscillation between 0 and
1471.8 W/m^2 [0.0009 Btu/(s-in^2)].
E 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.
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Our objective is to determine whether or not the vessel will fail after
1,500,000 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:
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I Thermal study
The thermal study applies a heat flux to the inside of the vessel as
well as convection on the outside.
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I Thermal stress study

A static study will be needed to see the thermal expansion effects of
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the thermal study.

I Static study
The second static study needed will be the 6.89 MPa [1000 psi]
pressure load applied to the inside of the pressure vessel.
-
I Fatigue study
The fatigue study will take into account all of the loading
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conditions and run them on the model for a specified number of

cycles.
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I Postprocess the results

Once the fatigue study is run, the results must be analyzed to decide
if failure has occurred.

Open Pressure Vessel from the Lesson07\Case Studies folder.
141
Fatigue Analysis
2 Select Symmetry configuration.

Because the geometry and the loads are
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symmetrical, we can isolate a wedge section for the
analysis.
e
F
ut
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Note Analogously to a thermal stress study requiring an execution of the
st
thermal study first, a fatigue study is directly based on the results of the
structural studies which must be completed beforehand.
E Because the pressure vessel is subjected to the combination of pressure

and thermal loading cycles, the following studies have to be completed
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before the fatigue analysis: structural static, thermal, and thermal stress.
All three studies were prepared beforehand.
3 Review SolidWorks Simulation Studies.
The Thermal study applies 1471.8 W/m^2 [0.0009 Btu/(s-in^2)] heat
flux to the inside of the pressure vessel and a convective condition of
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8.8308 W/(m^2.K) [3e-6 Btu/(s-in^2F)] with the 298.15K [77°F]

ambient temperature to the outside surfaces.
y
The Thermal stress study is performed to obtain the stresses from
the temperature field obtained in the Thermal study.
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The Static Pressure study has 3.9 MPa [1000 psi] pressure applied to
the inside surfaces of the vessel.
A no penetration contact condition and bolt connector are used in both
structural studies.
-
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142
Fatigue Analysis
Thermal Study We will first run the thermal study so that the temperature results can be
exported to the thermal stress study.
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4 Mesh Thermal study.
e
Create a Draft quality mesh with the following parameters:
F
Maximum element size:101.5784mm,
ut
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Minimum El element size: 5mm,
Minimum number of elements in a circle: 8,
Element size growth ratio: 1.2.

Note Mesh controls have been predefined.
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5 Assign materials in Thermal study.
Verify that 7075-T6 (SN) Aluminum alloy is assigned to both parts.
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6 Run thermal analysis.
E
Thermal Stress Having completed the Thermal study, we can proceed and compute
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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.
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7 Mesh Thermal stress study.

Create mesh with the same parameters as in the step 4.
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8 Define material for Thermal stress study.
Verify that 7075-T6 (SN) Aluminum alloy is assigned to both parts.
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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 298.15K [77°F].
10 Run Thermal stress analysis.
-
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143
Fatigue Analysis
11 Stress results.
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e
F
ut
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st
E We can see that the pressure vessel stress is very high with the
maximum magnitude close to 939 MPa, well above the yield strength
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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.
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y
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-
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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.
144
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
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failure.
e
13 Define material for Static Pressure study.
F
Assign the same Aluminum 7075-T6 Alloy (SN) to both parts.
ut
14 Mesh pressure study.
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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.
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Each analysis should take less than 5 minutes to completely run
through. You may review the results if you wish. The stresses from
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these studies will serve as basic input for the fatigue analysis.
16 Stress results.
E
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y
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We can see that the pressure vessel stress is very high with the
maximum magnitude close to 1391 MPa, well above the yield strength
-
of the material, 505 MPa.

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17 Stress results - plot limits.

Modify the maximum of the legend to show the Yield strength of the
7075-T6 Aluminum, 505 MPa.
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145
Fatigue Analysis
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e
F
ut
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st
We can observe that the stress above the yield strength are localized in
E 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.
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18 Stress results - detail.
Zoom onto the areas of high stress and probe the critical regions.
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y
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-
It can be seen that the stresses distant from the stresses concentrations
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are below the yield strength of the material.

Note For high cycle fatigue, the stresses must remain below the yield
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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.
146
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.
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S-N Curve The behavior of the material in the high cycle fatigue is characterized
e
by the relation between the alternating stresses (Salt) and the
F
corresponding number of cycles (N) to failure. A typical S-N curve is
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shown in the figure below.
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Stress (ksi)
Fatigue strength at
106 cycles
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Endurance limit
E Number of cycles to failure

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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
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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
y
infinite). The endurance limit is usually defined for fully reversed
alternating stresses. The endurance limit is also called the fatigue limit.
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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,
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only fully reversed (R=0) fatigue test data is available, and the
influence of the mean stress is accounted for approximately with the
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Goodman, Gerber, or Soderberg mean stress correction algorithms; all

three are described later in this lesson.
147
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
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overestimated.
e
The most accurate data can be obtained from fatigue testing of the
F
actual product, or a typical product of the same type and material. As
ut
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
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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
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scatter, especially at higher cycles. For this reason, most design
handbooks suggest a reliability factor of 0.52, reducing the fatigue
st
strength. It is always the responsibility of the analyst to verify the
trustworthiness of the material data source.
S-N Curve
InterpolationE The interpolation between the S-N data points can be done using the
following three schemes:
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I 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
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I
number of cycles. Use this option when the defined S-N curves has
a relatively small stress range compared to the variation in number
y
of cycles.
I Linear - A linear interpolation for both stress and number of cycles
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is used. Use this option when the defined S-N curves have many
data points.
-
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148
Fatigue Analysis
Example Suppose that you defined an S-N curve that has the following two data
points (in addition to others):
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No. of Cycles (N) Alternating Stress (S)
F
1000 (= 103) 50,000 psi
ut
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100,000 (= 105) 40,000 psi
For a stress of 45,000 psi, the program reads the number of cycles
based on the S-N interpolation scheme as follows:
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Log-Log S-N Curve - The X and Y Log S
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axes represent the logarithm of the
number of cycles and the stress 4.699
E respectively. The program takes 4.653

the logarithm of the stress value
4.602
45,000 and performs linear
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interpolation. Using this
procedure, the number of cycles is 3 3.944 5 Log N
103.944 = 8,790.
Semi-Log S-N Curve - The X-axis S
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represents the logarithm of the

number of cycles and the Y-axis 50,000
represents the stress. At stress
45,000
y
value of 45,000 psi, the program
performs linear interpolation and 40,000
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calculates the number of cycles as

104=10,000. 3 4 5 Log N
Linear S-N Curve - The X and Y S

axes represent the number of
-
cycles and the stress respectively.

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At a stress value of 45,000 psi, the 50,000

program performs linear 45,000
interpolation and calculates the 40,000
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number of cycles as 50,500.

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.
149
Fatigue Analysis
Fatigue Study Proceed with the fatigue study as follows:
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1 Create Fatigue Study.
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Create a new study named Fatigue. Select
F
Fatigue as the analysis type.
ut
Under Options select Constant amplitude
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events with defined cycles.
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E
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Introducing: A fatigue loading event is defined by an alternating and mean stress

Loading Events levels and a number of cycles. You can define multiple fatigue events
for a study. Each fatigue event refers to one specific static study, or a set
y
of static studies.
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Where to Find It I In the Simulation Study tree, right-click Loading and select Add
Event.
I Select Fatigue, Add Event from the Simulation menu.
2 Add Event.
-
Right-click on Loading and choose Add Event.

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Enter 2,000,000, for the Cycles.

Select Zero based (LR=0) for the Loading
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Type.
Select Thermal stress as the Study
Association name, and make sure the Scale
value is 1.
Click OK.
Note Zero based event type is used because the thermal load oscillates
between 0 and 1471.8 W/m^2 [0.0009 Btu/(s-in^2)].
150
Fatigue Analysis
3 Define Second Event.

Add a second event.
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Enter 500,000, for the Cycles.
e
Select Loading ratio for the Loading Type and
F
enter -0.2 as Loading Ratio.
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Select Static Pressure as the Study
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Association name and make sure the Scale
value is 1.
Click OK.
Note The pressure load oscillates between negative 0.78 MPa and 3.9 MPa.
The loading ratio, identical to the stress ratio R=Smin/Smax, is then
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computed as LR=Pmin/Pmax = -0.78/3.9= -0.2.
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4 Apply material.
The material properties chosen in the static studies will be transferred
E to the fatigue study. If the existing material data does not have a fatigue
curve, you need to enter an appropriate curve.
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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.
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y
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-
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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.
151
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
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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
e
alternating stress values from these known S-N curves are multiplied
F
by the Young’s Modulus of the unknown material and divided by the
ut
Young’s Modulus of the known material.
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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:
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Amplitude Events I No interaction: The software assumes that events occur
Interaction
st
sequentially, one after the other, without any interaction.
I Random interaction: The software considers the possibility of
E mixing the stress peaks from different events. This option is more
conservative and is recommended by ASME Boiler and Pressure
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Vessel Code.
The selected option should reflect the real situation.
Salt Computation Alternating stress Salt was defined as Salt = (Smax - Smin) / 2. It was not
specified, however, which component of stress should be used for its
calculation. In SolidWorks Simulation, the following options are
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available:
I Stress intensity (P1 - P3), which is identical to twice the magnitude
y
of the maximum shear stress at a given material point
I Von Mises stress
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I Maximum absolute principle stress P1

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:
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I Goodman - recommended for brittle materials

I Gerber - experimentally shown to be good for ductile materials
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I Soderberg - yields conservative results in tension
152
Fatigue Analysis
The following graph illustrates the effect of all three criteria together.
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e
F
ut
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E The horizontal axis represents the magnitude of the mean stress Smean
scaled by the value of the material ultimate tensile strength Sultimate.
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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
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materials increases as the mean stress Smean becomes compressive.

y
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-
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153
Fatigue Analysis
5 Review and change Fatigue Study properties.

Right-click the Fatigue study, and select Properties.
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In the Fatigue properties window, make sure Constant Amplitude
e
Event Interaction is set to Random interaction.
F
Change the Computing alternating stress using to Equivalent
ut
Stress (von Mises).
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In the Mean stress correction dialog, select Gerber.
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st
E
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Note We selected Gerber mean stress correction to account for the fact that
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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.
-
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Click OK.
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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
154
Fatigue Analysis
(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
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states that each cycle causes a damage factor D1 that consumes 1/N1 of
the life of the structure.
e
F
Moreover, if a structure is subjected to n1 cycles at S1 alternating stress
ut
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
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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
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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
st
percentage.
E 6 Run the analysis.

The software will display the following message indicating that some
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data point in the S-N curve may be missing:
Stresses in the model exceed the maximum stress value in
an associated S-N curve.
If you would like to modify the S-N curves or other data and
try again, press No to stop.
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Otherwise if you want to use the smallest number of cycles

from the associated S-N curves and continue calculation
y
press Yes.
Note This message indicates that some stresses in the model exceed the
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highest stress data point in the S-N curve. Depending on the situation,
you may need to add more data points in the S-N curve, or click Yes
and use the last data point in the S-N curve for all high stress locations.
This, however, can be dangerous because the solution will not be
conservative.
-
In the present case, however, this message is invoked due to the

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presence of stress singularities. Because we are ignoring these locations

in this simulation, we can dismiss this message.
PR
Click Yes to complete the calculation with the current S-N curve
155
Fatigue Analysis
7 Damage plot.
Change the Max limit of the legend to 100 and review the resulting
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Damage plot.
e
F
ut
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st
E Some regions in red color have damage greater than 100%. This result
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is suggesting a potential fatigue failure.
8 Probe damage plot.
Zoom onto the detail of the bolt and Probe the high damage location at
the bent section below the bolt.
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y
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-
Note the bolt region which is all in red color. As we used theoretical
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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.
PR
The bent section below the bolt gives an accurate result. The value of
nearly 125% confirms that also this bent region suffers from severe
fatigue failure. This result confirms that the design is inadequate.
Damage result The majority of the damage was caused by the pressure fluctuations
discussion between -0.78 MPa and 3.9 MPa [-113.1 and 565.6 psi]. The effect of
156
Fatigue Analysis
the other contributor (thermal event) is relatively small. The alternating

von Mises stress due to the fluctuating pressure is approximately
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201 MPa [29.2 ksi] (see the stress results for Static Pressure study).
e
The analyses of the S-N curve suggests that 7075-T6 alloy should be
F
able to resist the specified oscillations at this stress level. The mean
ut
stress correction, however, reduces the stress values in the SN curve
considerably. Because the pressure event features significant mean
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stress, it is significantly impacted by this correction so that 201 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.
or D
9 Modify study properties.
st
In the Fatigue study properties, change the Mean/stress correction
method to None. We will ignore the increased mean stress due to the
E zero based fatigue events.

Again, the dialog window informing you about the maximum stress
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exceeding the last data point in the SN curve will show. Click Yes to
complete the calculation with the current S-N curve.
11 Damage plot.
Show the detail of the damage plot and probe the bent region below the
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bolt connector.
y
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-
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Ignoring the region of the bolt connector, we observe that the total
accumulated damage decreased significantly from 125% to 86%. This
result incorrectly indicates that the vessel is safe from fatigue failure at
PR
this location.
This assessment represents a considerable inaccuracy brought into our
fatigue computation by completely ignoring the detrimental effects of
the mean stress.
This exercise demonstrates the importance of entering multiple S-N
curves for various stress ratios (R) or the application of the mean stress
correction algorithms available in SolidWorks Simulation.
157
Fatigue Analysis
Fatigue study In the second portion of this lesson the pressure vessel will be loaded,
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with dead load in addition to the fluctuating thermal and pressure loads, with a
e
(optional) 66,725 N [15,000 lb] dead load on the top of the lid.
F
ut
12 Apply dead load in both Thermal
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stress and Static Pressure studies.
Apply 6672.5 N [1500 lb] Normal force
on to top of the lid.
13 Run updated Thermal stress and

Static Pressure studies.
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st
E
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Note Due to the symmetry we only apply 66,725/10= 6,672.5 N. The dead
load must be applied in both stress studies as it is present when both the
pressure and thermal loads fluctuate.
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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
y
substantially increase/decrease the mean stress magnitudes and thus

considerably change fatigue damage results.
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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 (-0.78 MPa)
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fatigue events.
14 Duplicate Thermal stress study into a new study Thermal

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stress 0.
158
Fatigue Analysis
15 Change study properties.

In the study properties under Flow/Thermal Effects select Input
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temperature (and deselect Temperature from thermal study).
e
F
ut
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Note Since the thermal load fluctuates between 0 and 1471.8 W/m^2 [0.0009
or D
Btu/(s-in^2)], for the lower extreme thermal fatigue event definition we
only need to disable the thermal loading.
st
16 Run Thermal Stress 0 study.
E 17 Duplicate Static Pressure study into a new study Static

Pressure Low.
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18 Modify pressure loading.
Modify the pressure load from 3.9 MPa [565.6 psi] to -0.78 MPa
[-113.1 psi].
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19 Run Static Pressure Low study.
20 Define a new fatigue study Fatigue - with dead load.

y
21 Define the thermal fatigue event.

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Right-click on Loading and choose Add

Event.
Enter 2,000,000 for the No. of cycles.
Select Find Cycle Peaks for the Loading
-
Type.
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Select Thermal stress 0 and Thermal

stress as the extremes between which the
thermal event fluctuates.
PR
Click OK.
159
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.
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If two studies are selected the fatigue event stresses fluctuate between
e
the two extremes defined by the two static studies.
F
Sometime, however, a single fatigue event may fluctuate between three
ut
or more extremes when various loads peak at different times. In such
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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.
22 Define the pressure fatigue event.
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Similarly to the thermal fatigue event define the 500,000 cycle pressure
st
fatigue event fluctuating between the results of Static Pressure Low
and Static Pressure studies.
E 23 Review and change the study properties.

In the study properties set Random Interaction for the two specified
events, Equivalent stress (von Mises) for the computation of the
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alternating stress, Gerber mean stress correction and the default
Fatigue strength reduction factor of 1.
24 Run Fatigue - with dead load study.
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y
Show the detail of the damage plot.
Set the Max legend limit to 100 and probe the bent region below the
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bolt connector.
-
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PR
We observe that the maximum damage in the bolt region is unaffected

by the additional dead load. This suggests that the bolt preload has
major impact on the fatigue result at this location. As before, we are
going to ignore result at this location since more detailed simulation
would be required.
160
Fatigue Analysis
The damage result in the bent region below the bolt is, however,
considerably different. The fatigue damage dropped from 160% (step
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8) to approximately 29%. The dead load therefore has positive effect on
the fatigue resistance of this vessel. Can you explain why?
e
F
To evaluate the effect of the mean stress we will rerun the study without
ut
the mean stress correction.
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26 Disable the mean stress correction.
In the study properties change the Mean stress correction method to
None.
27 Re-run Fatigue - with dead loads study.
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st
E
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The solution is incorrect as the mean stress correction or multiple SN

curves for various mean stress values were ignored in this study.
y
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Summary This 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

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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.
PR
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.
161
Fatigue Analysis
Questions 1. In part one of this lesson the dead load was not applied and we used
Loading Ratio and Zero Based (LR=0) event types to define the
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two fatigue events. Was it, however, true that no dead load was
present in the analysis? If no, how would you then define the
e
fatigue events correctly?
F
ut
2. Damage result discussion on page 156 states that the alternating
stress in the pressure fatigue event is approximately 259.6 MPa
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[37.6 ksi]. Verify this statement.
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st
E
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-
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PR
162
Fatigue Analysis of a Basketball Rim
Exercise 11: In this exercise, you will analyze a basketball rim for fatigue life using
Fatigue linear analysis. This exercise reinforces the following skills:
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Analysis of a I Constant Amplitude Loading on page 140.
e
Basketball Rim I S-N Curve on page 147.
F
I Mean Stress Correction on page 152.
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I Damage Factor Plot on page 154.
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Problem The rim is loaded with a 1000 N
Statement [225 lb] force and the back face of the
rim is fixed to the backboard. Use these
conditions to determine if the rim will
fail after 10,000 cycles.
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1 Open the part file.
Open the part named Basketball_rim.
E 2 Create a static study.

Create a Static study named rim static.
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3 Edit material properties.
Aluminum alloy 7075-T6 (SN) should already be defined for the
material.
4 Apply a load on the rim.
Apply a 1000 N [225 lb] downward force
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on the split face in the front of the ring.

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5 Apply a fixture.
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Fix the back face, as shown in the figure.

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6 Mesh the model.

Create a mesh with High quality elements and the Maximum element
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size of 8.99mm [0.344in]. Use Curvature based mesh.

7 Run the analysis.
The large displacement warning appears. Obtain both the linear (small
displacement) and nonlinear (large displacement) solutions.
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8 Plot both linear and nonlinear responses.

Plot the RES: Resultant displacement and the VON: Von Mises
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stress contour plots.
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Geometrically nonlinear
Linear solution
solution (large displacements)
Note We observe that both linear and nonlinear results are nearly identical.
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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
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rim appears to yield. This can be a concern, because in high cycle
fatigue simulation stresses must be limited by the yield strength. A
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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.
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164
We can see that the yielding occurs at the location of the stress
singularity. More geometry realism would be needed to eliminate
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singularity and capture realistic stress distribution. The rest of the
model shows stresses below the yield limit.
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10 Fatigue curve stress limit.
Review the stress plot in greater detail with the upper limit of the
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legend set to the highest stress value in the 7075-T6 (SN) material S-N
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curve (318 MPa).
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Notice the five locations depicted in the figure above. Aside from the
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stress singularity identified in the previous step, the four indicated

locations exhibit stresses above the highest stress data point in the
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fatigue S-N curve. This is of a concern, as the fatigue results at this
location will underestimate the real situation. We have to keep this in
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mind when drawing conclusions from the results of the fatigue

simulation.
Note The highest stress of 420 MPa is fairly close to the Yield strength of the
material, 505 MPa. It may be wise to strengthen the bracket regions
somewhat to bring stresses down more and achieve higher factor of
-
safety, especially knowing that fatigue results will be underestimated at

these locations.
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11 Create fatigue study.

Create a constant amplitude event Fatigue study named rim fatigue.
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12 Add event.
Right-click on Loading and choose Add Event.
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Enter 10000 for the No. of cycles.
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Select Zero based (LR=0) for the Loading Type.
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Select rim static as the Study Association name, and make sure the
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Scale value is 1.
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Click OK.
13 Material Properties.
Right-click the solid body in the Simulation study tree and select
Apply/Edit Fatigue Data.
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This aluminum alloy already has the fatigue data defined.
Select Log-Log for the Interpolate field.
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Click Apply and Close.
E 14 Review and change Fatigue study properties.

Right-click on the Fatigue study name, and choose Properties.
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Constant Amplitude Event Interaction is irrelevant in this case
because only a single event is defined.
Change Computing alternating stress using to Equivalent stress
(von Mises).
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Select the Gerber method for the Mean stress correction.

The Fatigue strength reduction factor (Kf) should be set to 1.
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Click OK.
15 Run the fatigue analysis.
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As in the main lesson, the software will display a message indicating

that stresses in the model exceed the highest stress data point in the S-N
curve. This was expected, as discussed in step 10. Click Yes to
complete the study with the current S-N curve data.
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16 Review results.
The resulting Damage and Life plots are shown below.
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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 479 MPa), the minimum
life plot value can be directly obtained from the material SN curve.
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The above results show very high values of damage, 142%, (low values
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for the life plot, 7000 cycles) at the location of the stress singularity. We
will exclude this location from our conclusions as more realism in our
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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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17 Fatigue results - details.

Probe the damage plot at the four critical location on the bracket.
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The fatigue results at the four critical locations are well below 100%
with the highest value of approximately 22%. Under normal
E circumstances these results would be satisfactory. However, due to the

insufficient data in the material S-N data we know that results here are
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underestimated. It is up to the designer to decide, whether to accept the
current results and factor of safety, or whether to strengthen the
structure somewhat to bring stresses below the highest stress data point
in the S-N curve, 318 MPa. Alternatively, S-N curve with more data
points may be obtained and used in an updated fatigue simulation.
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Lesson 8
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I Understand a variable amplitude loading history and its setup in the
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fatigue study.
I Postprocess results and analyze the composition of the variable
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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
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defining a variable amplitude event as well as how the software
computes its result. In addition, we will learn how to properly post-
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process these results.
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Project A simple scaled model of a suspension
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Description (shown in the figure) was analyzed in
the Design Scenarios lesson of the
SolidWorks Simulation training manual
on the loads caused by:
I A stationary vehicle.
I A vehicle moving at a constant
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acceleration on a smooth road.
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I A vehicle moving on a bumpy
road.
E I 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
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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.
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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
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setup and can be seen in the figure below.
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Stress
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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.
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Each of the loading cycles inflict a corresponding incremental damage
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on the assembly material. The goal of this analysis is to assess the
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performance of the previously optimized design in fatigue (after the
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suspension has been subjected to the prescribed number of loading
cycles).
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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 I Static study
Process The static study that was setup in Lesson 10 of the SolidWorks
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Simulation training manual will be run.
I Variable amplitude fatigue study
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A variable loading amplitude history curve will be input into the
study and the properties of the fatigue study will be setup.
E I Postprocess the results

Once the study is run, we will review the relevant results.
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1 Open the assembly named suspension.sldasm.
Notice that the static study with the loading corresponding to the worst
vehicle travel condition is already defined.
2 Review the loading.
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Review the loading forces. The horizontal and vertical forces are equal
to 115 N [25.8 lb] and 900 N [202.3 lb], correspondingly. This load
represents the amplitudes (the maximum magnitude) obtained during
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the test.
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3 Review the restraints and the connectors.

Create a High quality mesh with the default mesh parameters. Use
Curvature Based Mesher.
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5 Run static study.

Two large displacements warning message will pop up. One is about
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displacements, and the other about rotations. As shown on the next
page, the effect of large displacements on stress is fairly significant.
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However, to reduce time we will complete the simulation as linear.
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Click No in both of the dialog windows.
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6 Review the stress and displacement results.
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Linear Solution Geometrically nonlinear

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solution (large displacements)
Discussion The above figures indicate a substantial increase in stresses when

comparing the linear ( σ vm, max = 481 MPa) and nonlinear results
( σ vm, max = 584 MPa). We would normally choose the nonlinear
-
results as a base for our fatigue analysis. Because of the time required
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to complete the geometrically nonlinear problem (large displacements

analysis), we will utilize linear results in the remainder of this lesson.
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Note The stress results indicate stresses below the yield strength of the
material. We can therefore proceed with the high cycle fatigue analysis.
172
Fatigue Study Now that the static study is complete, we can proceed with the fatigue
study.
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7 Define Fatigue study.
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Define a new Fatigue study named suspension-
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Fatigue.
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Select Variable amplitude history data under
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Options as the type of fatigue study.
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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.
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Rainflow Cycle In the Rainflow counting method, the stress history is decomposed into
Counting Method cycles, as demonstrated in the figure below.
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Stress history Rainflow counted cycles
Stress
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Time
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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.
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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
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this lesson.
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8 Add event.
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Right-click on the Loading folder and select
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Add Event.
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In the Add Event dialog window, click the Get
Curve button.
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Note The Start times field is required to specify the start time
for each variable amplitude event (if multiple variable amplitude events
are specified). If only one event is specified, this parameter is not used.
Variable Loading The variable loading history curve can be entered in three different
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Curve forms:
I Amplitude only, where the X column represents an index and the Y
y
column is the dimensionless loading amplitude that will be used to
scale the stresses in the associated static study. Start time is
assumed to be equal to 0.
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I Sampling rate & amplitude, where the X column represents an

index and the Y column contains the dimensionless loading
amplitude scaling the associated static study. The sampling rate
corresponding to the intervals at which the data is recorded must be
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specified as well. Start time for each event must be specified.

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I Time and amplitude, where the X and Y columns represent the

time and the loading amplitude scaling the associated study. Start
time for each event must be specified.
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The time variable in the latter two forms listed above is used only to
relate the signal peak magnitudes when multiple events are specified. If
only one event is specified, the Amplitude only type should be used.
174
9 Input the curve.

In the Load History Curve
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dialog window, under Type,
select Amplitude only.
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Data has previously been taken
to model the characteristic
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loading that the suspension
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undergoes. We will use this data
in defining our Load History
Curve.
To define the curve, copy the
data from the SAE suspension-
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modified.xls file located in the
lesson directory into the data
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area of the Load History Curve dialog window.
E 10 View the graph.

Click View to graph the loading history.
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Block
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The random loading sequence in the figure above is defined as Block.

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Click OK in the Load History Curve dialog window, and close the
graph window.
Under Options, enter 1 in the Number of repeats field.
Click OK in the Add Event dialog window to complete the definition
of this event.
Note The number of repeats is equal to 1 because we wish to analyze the
damage caused by fatigue due to one block of the loading sequence.
175
11 Modify material information.

All of the components have their material already defined (Alloy
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Steel). Because we intend to run a fatigue analysis, we have to input a
material S-N curve.
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Right-click on the Parts folder and select Apply Fatigue Data to All
Bodies.
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The Fatigue SN Curves tab should be active; you will see that the S-N
curve information is missing.
Enter the S-N curve data points in N/m^2, as shown in the figure.
Make sure that Stress Ratio R is set to -1 (implying that the S-N curve
was obtained from a fully reversed fatigue test) and that Interpolate is
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set to Log-log.
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Click Apply and Close.
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Note The data for the above S-N curve is for the purpose of the training
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lesson only. It is the responsibility of the analyst to obtain the most

relevant material fatigue resistance data.
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176
12 Set result locations.

SolidWorks Simulation allows the
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user to specify points on the model
to monitor the counted stress
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cycle’s magnitudes and damage as
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functions of the variable loading
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history parameters. Right-click on
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the Result Options folder and
select Define/Edit.
Select the four vertices on the
lower arm indicated in the figure to monitor the damage computations.
Under Fatigue calculations, select Whole model.
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Click OK.
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Note The frame labeled Fatigue calculations allows you to define the
locations for damage calculations to be either at all nodes or only at
E surface nodes. In general for an assembly, cracks can occur inside the
model at the interface of two parts with different materials. In most
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other cases, cracks occur at the model boundary. Using the option
Surface only saves time since less calculations are needed. The
savings are substantial for large problems with multiple variable
amplitude fatigue loading.
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177

In the Variable amplitude event options dialog, enter 32 for the No.
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of Bins for rainflow counting.
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Enter 1% in the Filter load cycles below field.
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In the Computing alternating stress using dialog, select Equivalent

stress (von Mises).
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Set the Mean stress correction method to Gerber.
In the Fatigue strength reduction factor (Kf) field, enter 0.75.
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Click OK.
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178
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
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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
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accurate result, but take longer to run. However, 32 bins are usually
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enough to accurately represent the loading.
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Stress
with constant amplitude

Equally spaced bins
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E Time
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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.
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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
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operates can greatly differ from the conditions of the test.

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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:
I Corrosion (Kc) I Temperature (Kt)
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I Loading mode (Km) I Reliability (Kr)

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I Frequency (Kfreq) I Notch Effects (Kn)

I Size Factor (K1) I Fretting (Kfret)
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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 .
179
14 Run the study.
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15 Review the damage plot.
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We can observe that the maximum damage has accumulated at the
Shock Plunger, where the long slender body meets with the cap.
The rather small numerical results can be misleading without further
discussion. The maximum damage of approximately 2.79e-2 is very
small. It corresponds, however, to one block of the loading history
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specified in the fatigue event definition. In reality, the components may

be subjected to tens of thousands of such loading blocks.
16 Review the life plot.
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The life plot is the inverse of the damage plot. It identifies how many
loading blocks the assembly can be subjected to before the fatigue
failure occurs.
180
We observe that, after approximately 3590 blocks of the loading

history, the fillet on the Shock Plunger fails. If the required number of
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loading blocks was 3590, a redesign would be required.
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17 Define Rainflow matrix chart.
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Right-click on the Results folder and
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select Define Matrix Chart.
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Under Location, specify Predefined
location and select the vertex shown
in the figure.
Under Type, select Rainflow matrix
and specify units of N/mm^2.
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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
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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.
181
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
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the node corresponding to the worst damage location. You will notice
that for all of these Rainflow charts, most of the counted cycles have
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positive mean stress.
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18 Define Damage matrix chart.
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Follow the procedure in the previous step and define a Damage matrix
chart at the same vertex as the previous step.
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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
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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:
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Stephens, R. I., Fatemi, A., Stephens, R. R., and Fuchs, M. O., Metal
Fatigue in Engineering, 2001.
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Suresh, S., Fatigue of Metals, 2004.
182
Summary In this lesson, we used the model of suspension that was already
analyzed and optimized, using linear static analysis, in the SolidWorks
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Simulation training course. The fatigue analysis investigated the
performance of this design when subjected to a variable amplitude
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loading history obtained from the test data.
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This lesson demonstrated the definition of the variable amplitude event
and introduced the concept of the Rainflow counting method, bins,
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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
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definitions are important to correlate the occurrence of the cycles if the
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multiple events are defined.
Matrix plots used to analyze the composition of the load were shown
E and discussed as well.

Lastly, it was shown that the assembly passing the yield strength
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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.
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Questions 1. Fatigue analysis is computed from the stress results obtained in the
-
static analysis. The fatigue failure ( Damage ≥ 1 ) therefore (does /

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does not) imply the onset of yielding.

2. Because components loaded by fluctuating loading typically fail
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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 modulus of SolidWorks Simulation.
4. A loading history for the above case would fit the (constant
amplitude / variable amplitude) event.
183
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184
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Lesson 9
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Drop Test Analysis
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I Perform a drop test analysis.
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I Use an elasto-plastic material model.

I Analyze results of a dynamic analysis.
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185
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
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analysis is not fully nonlinear as in complete dynamic analysis, drop
test analysis can prove very useful in obtaining a benchmark
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simulation.
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Case Study: In this study, we will perform a drop test analysis on a camera
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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
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in a fully dynamic simulation.
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Project The structural integrity of a
Bottom Cover
Description camera is tested by dropping it on
E a rigid floor. The testing includes

different drop heights and floor
types.
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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
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Lens
camera in one position from a Zoom Top Cover
height of 2m [78.7in].
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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
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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 I Apply materials.
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Process Linear-elastic or elasto-plastic material can be defined for the drop

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test.
I Drop test setup.
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A height or impact velocity can be chosen for the drop test. In

addition, gravity is defined.
I Define results options.
Decide how long the simulation will be run and what options will
be saved.
186
Drop Test Analysis
I Mesh the model.

Create an appropriate mesh that will obtain accurate results for the
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simulation.
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I Run the analysis.
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I Postprocess the results.
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Properly analyze the results from the drop test analysis.
I Apply study refinements.
Refinements to the study, such as an elasto-plastic material model
or contact can be applied to make the simulation more realistic.
Rigid Floor In the first analysis, we will drop the camera on a rigid floor. In the
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Drop Test second analysis, we will consider the floor to be partially elastic.
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1 Open Assembly.
Open the assembly named Camera.
E A magnesium-cased camera with a steel zoom and glass lens is

represented in a simplified form, which features all components
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essential for modeling its behavior under a dynamic impact.
2 Create drop test study.
Create a study named free fall 01. Select Drop Test as the Type.
Note that the drop test analysis only supports solid meshes.
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The material properties transfer automatically from SolidWorks.
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The magnesium and glass are both elastic material models. Later in the
lesson, you will have the option to use an elasto-plastic material model.
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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.
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Where to Find It I Connections can be found in either the Simulation Study tree or
the Simulation CommandManager.
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I Setup can be found in the Simulation menu as well as the

Simulation Study tree.
I Result Options can be found in the Simulation menu as well as
the Simulation Study tree.
187
Drop Test Analysis
4 Open drop test setup window.

Right-click Setup and select Define/Edit to open the Drop Test Setup
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PropertyManager.
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In this PropertyManager, we define the drop height (h), the acceleration
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(g), and the orientation of the impact plane.
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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.
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The velocity at impact ( v ) is calculated as v = 2gh .
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As an alternative to the drop height, we can define the velocity at
impact.
E No rotations are considered until initial impact occurs.

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5 Define drop height.
Select Drop height under Specify, From
centroid under Height, and enter 2m [78.7in].
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Note In this problem the drop height of 2m [78.7in] is measured from the
camera centroid.
188
Drop Test Analysis
6 Define gravity.
The direction of gravity is normal
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to the horizontal reference
plane. If necessary, use the arrow
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button to control the orientation of
F
gravity.
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Enter one of the following as the
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magnitude of gravitational
acceleration:
I 9.81 and select m/s2
I 386 and select in/s2
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7 Set impact plane orientation.
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Under Target, for the Target orientation, select Normal to gravity.
Leave the Friction Coefficient set to 0.
E Click Rigid target.

Select OK.
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The setup of the drop test study is complete.
Note The position of the impact plane is normal to gravity, that is, horizontal.
You can experiment with other floor positions after you complete this
study.
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8 Review drop test setup details.

To review the details of the drop test setup, right-click Setup and select
Details to display the Setup Details window.
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189
Drop Test Analysis
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
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we will see later in the lesson).
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However, SolidWorks Simulation Professional does not support
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damping in a drop test analysis. This feature is available in the
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Simulation Premium package. In this study, we do not define friction
and we use a linear material. Therefore, the impact causes no energy
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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
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technique for small time steps when solving problems in a dynamic
analysis.
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E 9 Define sensors.
When we set up our Results Options, we may want to log data from
the simulation at certain predefined points on the model.
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In the SolidWorks FeatureManager design tree, right click Sensors
and select Add Sensor.
Under Sensor Type select Simulation Data.
Under Data Quantity select Workflow Sensitive.
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Then select the four vertices shown below. Simulation data will be
logged for these locations.
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Select OK.
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Vertex 1
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Vertex 2
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Vertex 4
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Vertex 3
190
Drop Test Analysis
Note We selected these locations based on previous experience with physical

drop tests that produced cracks around the lens base.
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Split lines are used to define the locations of the four vertices. The time
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history data (stresses, displacements, velocities, accelerations) will be
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available in the form of graphs only for these locations.
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10 Set solution time after impact.
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Right-click Result Options and select
Define/Edit.
Enter 50 microsec as the Solution Time After
Impact.
In the Save Results dialog, enter 0 microsec
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under Save Results Starting From. SolidWorks
Simulation starts saving results immediately after
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the impact.
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Enter 25 for No. of plots. The solution time is divided into twenty-five
intervals, and the full results (available as plots) are saved only for
those intervals.
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In the Sensor List field, select the Workflow Sensitive1 sensors that
you defined in the previous step. These are used as reference points for
the time history graph.
Enter 20 as the No. of Graph Steps Per Plot. The total number of data
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points for each graph is equal to the number of plots times the number
of graph steps per plot.
Select OK.
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Note Full results (in the form of contour plots) are saved for twenty-five
plots evenly spaced out over fifty microseconds, as we defined under
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the Solution Time After Impact.

However, for graphing the time history results at the requested 4
vertices more data points may be required. We define how many of
these partial results are saved in the No. of Graph Steps Per Plot field.
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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
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the period of free fall of the body.

The program estimates a value for the
solution time based on the model geometry v ELASTIC WAVE = E
---
and the default material properties for ρ
magnesium. E - modulus of elasticity
The default solution time is based on the time ρ - density of material
191
Drop Test Analysis
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
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wave from the wave that starts propagating in the model at the moment
of impact.
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Assuming that the length of the model is L, the wave takes a time
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period approximately equal to 2L/v to travel to the farthest boundary
(where it is reflected) and back to the originating area.
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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.
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Because the impact period is usually very small, the program measures
it in microseconds. The maximum response may occur during impact or
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after impact while the body is rebounding. The study can evaluate
multiple impacts and rebounds if you specify an adequate solution time.
E While there is no limit on Solution Time After Impact, a longer

solution time requires a longer time to run the analysis.
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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?
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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
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solution.
The relation between the number of plots and the number of time
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instances where the data is saved for graphing at selected vertices is

shown in the next figure.
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192
Drop Test Analysis
11 Apply mesh controls.

Because we are interested in Fillets
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stress results at the four sensors
that we selected in the Result
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Options window, we must
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ensure that the finite element
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mesh correctly meshes these
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locations.
Right-click Mesh, select Apply
Mesh Control and select the
fillet on the TopCover assembly
component.
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Accept the default mesh control parameters.
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12 Mesh the model.
Mesh the assembly with High quality elements. Set Maximum
E element size to 10mm, Minimum element size to 2mm, Min number

of elements in a circle to 8 and Element size growth ratio to 1.6.
Use Curvature based mesh.
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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:
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1. Identify the surface that will first hit the wall during the drop test
study.
2. Create a static study.
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3. Apply some G-loading (i.e. 10g).
4. Apply a fixed restraint to the surface identified in step 1.
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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
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fair results.
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Right-click the free fall 01 study and select Properties.
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Make sure that the Large displacement option is checked.
193
Drop Test Analysis
Linear vs. At the end of the SolidWorks Simulation course it was explained that
Nonlinear Solution depending on the magnitude of the loads and the stiffness of the
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structure, the model may exhibit large structural deformations; in such
case a nonlinear solution is required.
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In impact analysis, the structural deformations are almost always
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nonlinear. SolidWorks Simulation therefore uses Large displacement
nonlinear solution as a default option. If it is observed that no
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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
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Drop Test modulus allows for the specification of full elasto-plastic
material model required to correctly model these situations. The
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description of this material model goes beyond the scope of this
training and the students are referred to SolidWorks Simulation
E Premium: Nonlinear training course.

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The drop test solution may experience unbalance in energy. If this
occurs, the solver displays the following message and attempts the
solution again.
Large unbalance energy is detected. Solve is going to switch
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the element type from default to composite tetrahedron and

rerun the analysis.
Click OK and continue with the solution.
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Note Solution with composite tetrahedron make take significantly more

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computational time as compared to the conventional tetrahedron. It

takes approximately 5 minutes to complete this simulation.
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Drop Test Analysis
15 Plot von Mises stresses.

After the first solution is complete, review the automatically created
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stress plot in the Results folder. The default plot is generated for the
last saved time step.
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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 (1580 MPa [229 ksi]) is likely
to damage the magnesium case.
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Create and review plots corresponding to other time steps.

16 Animate results.
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The most interesting way of reviewing the drop test results is through
animation.
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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
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one of the twenty-five plots can be used.

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195
Drop Test Analysis
17 Plot time history response.

To review the time history response, right-click
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the Results folder and select Define Time
History Plot. The Time History Graph
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PropertyManager opens.
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To create a time history plot for all four selected
locations, select Predefined locations and
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choose the vertices to include in the graph.
Select the von Mises stress to be plotted in the
graph.
Click OK.
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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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196
Drop Test Analysis
18 Bound plot for von Mises stresses.

Edit the stress plot.
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Click the Plot Bounds across All Steps button
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to see the maximum stress plot over the duration
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of the entire event.
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The maximum stress increased to 1780 MPa (258 ksi).
Elastic Floor The camera will now be dropped on an elastic floor. Let us say that the
Drop Test floor is a 0.4 in thick layer of Nylon 6/10 material.
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1 Create new study.

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Duplicate the study free fall 01 into free fall 01 soft.
2 Edit Drop Test setup to add elastic floor.
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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.
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Under Stiffness and thickness, in the Units list, select SI .

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For the Normal stiffness, enter 1.05e12 (N/m)/m2

[3.868e6 (lb/in)in^2].
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For the Tangential stiffness, enter 3.2384e8 (N/m)/m2

[1193 (lb/in)/in^2].
For the Mass density, enter 1400.6 kg/m3 [0.0506 lb/in^3].

For the Target thickness, enter 10.16mm [0.4in].
Click OK.
197
Drop Test Analysis
3 Set results options.

Right-click Result Options and select Workflow Sensitive1 under
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the Sensor List.
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Make sure that Large displacement (geometrically nonlinear)
solutions is specified.
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5 Run the analysis.
As in the step 14, click OK when you receive a message regarding the
energy unbalance.
6 Bound for stress results.
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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
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reduced from 1780 MPa [258 ksi] to approximately 503 MPa [73 ksi].
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7 Compare results for vertex 1.

For a better comparison between the impacts on a rigid and an elastic
floor, plot the resultant translational acceleration versus time for
vertex 1 for studies free fall 01 and free fall 01 soft.
RESULTANT ACCELERATION TIME HISTORY
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RIGID FLOOR ELASTIC FLOOR
198
Drop Test Analysis
The maximum resultant acceleration, as measured at vertex 1, is

58.8e3g when the camera falls on a rigid floor. When the camera falls
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on the Nylon base this value drops to 28.1e3.
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Elasto-Plastic As we mentioned before, loss of energy in a drop test normally occurs
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Material Model due to damping, friction, or plastic deformation. A fully dynamic
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simulation would be needed to include all of these variables.
Using drop test analysis, we are able to include plastic deformation to
make our model a little more realistic. In all of the previous analyses,
we used a linear elastic material model. Without any energy loss, the
camera would continue to bounce forever. In the next simulation, we
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will use an elasto-plastic material model. For a more detailed
explanation of material models, please refer to the SolidWorks
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Simulation Premium: Nonlinear course.
E 1 Create new study.

Duplicate the study free fall 01 into free fall elasto-plastic.
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2 Edit material properties.
Right-click the BottomCover, TopCover, and Zoom parts and select
Apply/Edit Material.
Right-click the Magnesium Alloy under Other Alloys, then select
Copy.
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Paste the material under a folder in Custom Materials.

With the new Magnesium Alloy custom material selected, under the
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Model Type, select Plasticity - von Mises.
Enter the Yield stress as 155e6 N/m^2.
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Enter the Tangent modulus as 4.5e9 N/m^2, then Apply and Close.
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199
Drop Test Analysis
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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
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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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3 Edit results options.
Make sure that the Workflow Sensitive1 sensor is selected.
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4 Run the analysis.

energy unbalance.
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200
Drop Test Analysis
5 Bound for stress results.
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We can see that even with the maximum von Mises stress dropped from
E 1780 MPa (258 ksi) to 231 MPa (34 ksi).

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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.
6 Compare the results.

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Plot a time history response of the free fall elasto-plastic study and
compare it to free fall 01. We can see that the stresses in the elastic
model continue to rise whereas for the elasto-plastic model, the rise in
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stresses seems to have slowed considerably.
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VON MISES STRESS TIME HISTORY

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ELASTIC MODEL ELASTO PLASTIC MODEL
Furthermore, we can see that the maximum stress at the four sensor
location (approximately 133 MPa) is now below the material yield
strength of 155 MPa (22 ksi).
201
Drop Test Analysis
Discussion Will the model break?

The study indicates that localized yielding does occur at the impact
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location for a short time during the impact. While this would cause
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some level of permanent damage in the cover, it does not imply
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immediately that the camera would be destroyed. Provided the optical,
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electronic and other mechanical components remain functional, the
camera could still be used.
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The study also indicates that while the localized yielding was detected
at the impact locations, the magnesium cover was stressed below the
yield strength in the vicinity of the lens.
Often times, maximum acceleration is used as a means of predicting
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whether or not something will fail in a drop test, so these results are
useful to evaluate such cases as well.
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You are encouraged to repeat both studies using a longer solution time,
for example 500 microseconds. If a long enough solution time is used
E for the analysis, you will see the camera bouncing off the floor and
hitting it in different locations.
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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.
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1 Create new study.

Duplicate the study free fall 01 (rigid floor) into free fall with
contact.
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202
Drop Test Analysis
2 Create contact conditions.

Edit the camera model by adding a No penetration contact condition
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between the TopCover and BottomCover. This way the camera will
be held together only by the two tabs.
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Tabs
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3 Apply mesh controls.
Right-click Mesh, select Apply Control, and select the face on the
TopCover and BottomCover assembly component with contact
conditions.
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Accept the default mesh control parameters.

4 Mesh the model.
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Mesh the assembly with the default mesh parameters. Use Curvature
based mesh.
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Make sure that Large displacement (geometrically nonlinear)
solutions is specified.
6 Run the analysis.
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energy unbalance.
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203
Drop Test Analysis
7 Bound for von Mises stress.
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From this plot, we can see that the contact condition is no longer
E bonded.
The model also indicates severe stresses (2760 MPa) at the corners of
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the clip. To better understand the stresses at these regions, more
realistic geometry and elasto-plastic material model would have to be
utilized.
8 Animate displacement plot.
When viewing animated results, observe how the top and bottom cover
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shift along each other.

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Summary A drop test analysis is a dynamic analysis intended to model the
dynamic impact force of a very short duration event. It considers
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inertial effects, but not damping. The only mechanism of energy loss is
material yielding, if an elasto-plastic material model is specified.
A drop test analysis uses a numerically intensive, but stable, direct time
integration method, and its analysis time is generally limited to within a
short time after the impact, which is when damage is most likely to
-
occur.
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A drop test analysis can process a large amount of result data at the
expense of solution time and storage space. Therefore, only selected
results should be requested.
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A drop test analysis does not directly provide pass/fail results. It is best
used to compare the severity of impact for different drop scenarios.
In the case of the camera drop test, we find that all of the studies will
most likely result in permanent damage to the camera body.
204
Drop Test of a Clip
Exercise 12: In this lab exercise, you will perform a drop test analysis of a clip.
Drop Test of a This exercise reinforces the following skills:
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Clip
I Rigid Floor Drop Test on page 187.
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I Drop Test Parameters on page 188.
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Problem A plastic clip is dropped from a height
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Statement of 2m [79in] onto a rigid floor. Arm<1>
Calculate the stresses and
displacements of the clip. Note that
there is a gap where the arms of the
clip meet. A no penetration contact
will be used to address this.
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Arm<2>
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E 1 Open the Assembly model.

Open the assembly named clip. This model has been specifically
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prepared for an easy illustration of how a drop test analysis can account
for relative contact or sliding between parts.
2 Create drop test study.
Create a study named drop test. Select Drop Test as the Type.
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Material Nylon 6/10 has been assigned to the parts from SolidWorks.
4 Define drop height.
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Define an 2m [79in] drop test measured
From centroid of the assembly.
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Specify 9.81 m/s^2 [386.22 in/s^2] for

Gravity in the direction normal to the
Top Plane.
Face Hitting Rigid Target
Specify Rigid target orientated Normal
to gravity. Select OK.
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5 Set solution time after impact.

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Right-click Result Options and select Define/Edit.

In the Solution Time After Impact box, enter 350 microsec.
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Specify 25 full data storage points with Save Results Starting From
set to 0 microsec.
205
Drop Test of a Clip
6 Define contact conditions.

Define a No penetration contact
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condition between the gap created by
arm<1> and arm<2>.
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Leave the Global contact condition as
Bonded. This is required to keep the
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assembly components firmly connected
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at one end.
7 Mesh the model.
Mesh the assembly with the High quality elements and the default
element size. Use Curvature based mesh.
8 Run the analysis.
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9 Plot resultant displacement results.
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206
Drop Test of a Clip
10 Animate results.
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Before Impact
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250 Microseconds after
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the first impact
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E Animate the resultant displacement plot to observe how the two faces
collide during impact and then slide after impact.
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207
Drop Test of a Clip
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208
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Lesson 10
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I Perform an optimization analysis based on static and frequency
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analyses.
I Properly post-process optimization results.
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209
Optimization Design optimization determines the optimum design with respect to the
Analysis selected objective by finding the best combination of allowable values
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in the design variables.
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The optimum design is subject to imposed constraints.
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The optimized design can be further optimized according to a new
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objective and new constraints.
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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
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an optimization study. The optimization results will then be processed
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and we will learn exactly how much better our design will get as a
result of the study.
Project
Description
E A press frame assembly consists
of a top plate where a 22,250 N
[5,000 lb.] upward force is
Top Plate
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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
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of the assembly by modifying the

frame geometry. Side Plate
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We wish to consider the
following changes, provided, of Back Plate
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course, that they are beneficial to

our goal of mass reduction:
I The height of the side plate (where it supports the top plate) may
be decreased within a range varying from the current 100mm down
to a minimum of 50mm.
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I The cut-out forming legs of the side plate may be increased within
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a range varying from the current 100mm up to a maximum of

250mm.
I The back plate may be shortened within a range varying from the
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current 375mm down to a minimum of 150mm.
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Design We also must comply with the following design requirements:

Requirements I The von Mises stresses in the model must not exceed 100 MPa
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[15,000 psi].
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I The maximum deflection must not exceed 1mm.
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I The first natural (resonant) frequency must not be less than 80 Hz.
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The optimized design will meet all of these criterion.
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Stages in the I Run static study.
Process Results from the static study will be used in the optimization
analysis.
I Run frequency study.
Results from the frequency study will be used in the optimization
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analysis.
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I Create optimization study and define parameters.
Define what needs to be optimized as well as the boundaries on the
E I
variable parameters for the simulation to perform it’s optimization.
Postprocess the results.
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Determine whether or not the design changes that get made meet
your needs.
Static and Before starting the optimization analysis, we should verify that the
Frequency design “as is” does not violate any of the above constraints. Therefore,
Analyses we need to conduct static and frequency analyses of the frame
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assembly in its initial configuration prior to optimization.
1 Open Assembly.
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Open the assembly named press.
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2 Create static study.

Create a Static study named press static.
The material, Plain Carbon Steel, has been defined for all components
and transfers automatically to SolidWorks Simulation.
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211
4 Apply loads and restraints.

Apply a 22,250 N [5,000 lb.] upward vertical force to the top plate, and
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apply Fixed Geometry to bottom faces of all four legs.
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Load 22,250N
Supports
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5 Mesh the model.
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Mesh the model with the High quality elements and the default
Maximum element size. Use Curvature based mesh.
E 6 Run the analysis.

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7 Create frequency study.
Create study named press frequency.
8 Define study parameters.
Copy fixture, mesh, and load from the static study.
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Specify for the computation of the first natural frequency only, and
select Direct Sparse Solver.
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Remember, we have to use the Direct Sparse solver because we wish to
include the effect of the load in the frequency analysis.
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11 Show displacement, stress and frequency results.

The illustrations present the resultant displacement, von Mises stresses,
and frequency results in the model prior to optimization.
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212
The maximum displacement is 0.34mm and the maximum von mises

stress is 63.5 MPa.
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The first natural frequency is 129.08 Hz.
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Optimization All design constraints are satisfied in the original design configuration.
Analysis
E We now try to reduce the mass of the press frame assembly while still
satisfying the design constraints.
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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
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information about the loading and

constraints.
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Before proceeding, let us review some terminology used in an
optimization analysis.
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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.
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The visible dimensions are design variables in our optimization study.

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Constraints Constraints define allowable ranges of stress, deflection, frequency,

and so on. Both minimum and maximum values can be specified.
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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.
213
The second possible outcome is that the constraint has been reached.
The optimum design then lies on the critical constraint boundary. The
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critical constraint refers to the restraint that has been activated; for
example, stress has reached its limit.
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Up to 60 constraints can be defined. The constraints can be: stresses,
strains, displacements, buckling load factors, frequencies,
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temperatures, temperature gradients, and/or heat fluxes.
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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).
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12 Create optimization study.
Create a new design study called press
E optimization.
13 Define goal.
Select the Goals drop down menu and click Add
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sensor. The Sensor PropertyManager opens.
The goal here is to minimize the mass of the press
assembly.
Select Mass Properties under Sensor Type.
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Select Mass under Properties. Make sure that the press assembly is
also selected.
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Click OK.
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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
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on how the constraints are set up.

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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.
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In this case, the optimization study is based on both the press static
and press frequency studies due to the desired constraints.
In general, the prerequisite studies required for optimization analysis
not only depend on the type of constraints, but also on the goals. For
example, we can have constraints defined in terms of stresses while the
goal is defined in terms of frequency. In this case, both prerequisite
static and frequency studies would be required.
214
14 Define first design variable.

Select the Variables drop down menu and click
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Add parameter. The Parameters and Add
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Parameters dialog windows open.
F
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In the model view window, select
the 100mm dimension (near the
yellow top plate). This will assign
the dimension value
D2@Sketch1@press side plate
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to the new parameter.
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Click OK in the Add Parameter
dialog.
E Click OK in the Parameters window.

The parameter is now added to the Variables list in the design study.
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Next to the Parameter1 in the Variables list, select Range from the
drop down menu.
Enter 100mm as the Max and 50mm as the Min.
Click OK.
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Tip Considering that the Initial value is 100mm., we do not allow it to

increase because this would increase the mass. We allow it to decrease
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to a possible minimum of 50mm.
Note Optimization analysis requires the parametric formulation of
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SolidWorks. In order to be used as a design variable, a dimension must

be explicitly defined in SolidWorks. It is not possible to optimize a
model, which consists of only imported features.
Often times, it may not be possible to create your design to the exact
specifications calculated in the design study. In this case, you can select
-
Range with step so that the variables can only change in increments
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defined by the Step.

15 Define second design variable.
PR
Add another parameter from the Parameters dialog.

In the model view window, select the 100mm
dimension (at the support locations). This will assign
the dimension value to Bounds. Clic100k OK.
In the Variables list, add the parameter to the list.
Select Range from the drop down menu. Enter 100mm and 250mm as
the Min and Max limits respectively.
215
Click OK.
16 Define last design variable.
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Repeat the same procedure for the back plate
e
dimension of 375mm. Select Range from the drop
F
down menu. Enter 150mm and 375mm as the Min
and Max limits, respectively.
ut
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Design Variable The definition of the three design variables that we use in this study is
Summary complete.
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The SolidWorks Simulation design study displays three design
variables under the Variables list.
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Define Constraints The last step in the setup of the optimization study is the definition of
E constraints.
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17 Define global stress constraint.
Select the Constraints drop down menu and click
Add sensor. The Sensor PropertyManager
opens.
Select Simulation Data as the Sensor Type.
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Under Data Quantity, select Stress and

VON: von Mises Stress.
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Under Properties, select N/mm^2 (MPa) as the
Unit, Model Max as the Criterion. and Across all
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Steps as the Step Criterion.

Click OK.
Select Is less than, and then enter 100 N/mm^2
(MPa) as the Max limit.
-
This constraint prevents model changes that result in von Mises

stresses higher than 100 MPa anywhere in the model.
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Note The static type of response is based only on the press static study.
PR
216
18 Define global displacement constraint.

Select the Constraints drop down menu and click
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Add sensor. The Sensor PropertyManager
opens.
e
F
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Under Data Quantity, select Displacement and
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URES: Resultant Displacement.
Under Properties, select mm as the Unit, Model
Max as the Criterion and Across all Steps as the
Step Criterion.
Click OK.
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Select Is less than, and then enter 1mm as the
st
Max limit.
19 Define frequency constraint.
E Repeat the same steps used previously to define

another Constraint sensor.
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Under Data Quantity, select Frequency and
Under Properties, select Hz as the Unit and
Model Max as the Criterion. Also, enter 1 as the
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Mode Shape.
Click OK.
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Select Is between, and then enter 80 Hz as the
Min and 150 Hz as the Max limits.
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-
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217
20 Define local displacement constraint.

Select the Constraints drop down menu and click Add sensor. The
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Sensor PropertyManager opens.
e
F
Under Data Quantity, select Displacement and URES: Resultant
ut
Displacement.
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Under Properties, select mm as the Unit
Select Max over Selected Entities as the Criterion. Clear the
selection field and select the edge of the yellow plate as shown in the
figure.
Click OK.
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E
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Select Is less than, and then enter 0.5mm as the Max limit.
Note With sensors defined anywhere, you can monitor any quantity at that
particular location and ensure that your design meets your specific
criterion in that area.
-
Constraint In the constraints definition, tolerance pertains to the range of allowed

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Tolerance changes. Here we allow the frequency to change within the range of
150 Hz - 80 Hz = 70 Hz.
PR
Constraint Constraint definition proceeds in the following order:

Definition 1. Definition of sensor type.
Procedure
2. Definition of response quantity (stress, displacement, frequency, etc.)
3. Definition of the particular measure of the response quantity (von
Mises stress, resultant displacement, first mode of vibration, etc.)
4. Definition of the allowed range of variation.
218
21 Set optimization properties.

Before running the optimization analysis, select Properties.
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Under Design Study Quality, select Fast Results.
E Click OK.
22 Run optimization analysis.
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Select Run from the design study.
The analysis takes 15 steps for the design objective (minimizing mass)
to converge.
23 Final design.
The Results View tab of the design study is activated. The final design
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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
y
plots allows us to compare the model before, after, and during the
optimization procedure.
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-
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BEFORE AFTER
219
Postprocessing The side plate height has decreased from 100mm to 65.005mm.
Optimization The length of the back plate has been reduced from 375mm to
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Results 206.044mm, and the size of cut-out has increased from 100mm to
e
245.596mm.
F
In the next paragraphs, we discover that the maximum allowed stress
ut
and the minimum allowed frequency constraints were activated and the
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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.
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An optimization analysis should be conducted using local copies of
parts or assemblies.
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24 Plot optimized design results.
E Let us review the stress, displacement, and frequency results

corresponding to the optimized design.
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The results are accessible in the corresponding studies: press static
and press frequency.
These studies have been updated to reflect the new model
configuration.
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-
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The maximum von Mises stress is 98.2 MPa. It did not exceed the
maximum allowed stress of 100 MPa.
220
This result indicates that the constraint defined on stress has been met.
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e
F
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E The maximum resultant displacement is 0.55mm. This result did not
exceed its allowed maximum magnitude of 1mm, meaning that the
displacement constraint has also been met.
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-
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The first natural frequency is 80.9 Hz, which is within the allowed
frequency range of 80-150 Hz.
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The frequency constraint has also been met.
221
25 Examine mass properties of optimized design.

Under Results View, we have a summary of each iteration. We have
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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
e
iteration did not satisfy all of the design constraints.
F
ut
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It can be seen that the mass of the optimized design dropped from
st
73.953 kg to 59.487 kg. This translates to approximately 19%
reduction in the material mass.
Note
E Detailed information about the mass before and after optimization can
also be determined using SolidWorks tools (Tools, Mass Properties).
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26 Define a design local trend graph.
Right-click the Results and Graphs folder and
select Define Local Trend Graph.
Select the variable Parameter3 to be plotted on
the X-axis.
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This design variable controls the length of the

back plate.
y
Select the Objective to be plotted on the Y-axis.
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This variable defines the Local Trend Graph showing mass as a

function of back plate length as it changes within the specified range of
150mm to 375mm.
222
27 Define second design local trend graph.

Create one more plot in the Results folder.
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Right-click the Results folder and select Define
Local Trend Graph.
e
F
Select the same design variable, Parameter3, as
ut
before (back plate length) to be plotted on the X-
axis, and select Constraint to be plotted on the
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Y-axis.
Of the three available constraints, select
Frequency1. This is the frequency constraint.
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E
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These selections create a graph showing the first natural frequency as a

function of the back plate length.
y
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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

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stresses, displacements, and frequencies. The optimization too fifteen

steps to complete and the final design satisfied all constraints.
PR
Design Local Trend Graphs show the optimization objective and

optimization constraints as functions of the design variables.
223
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F
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E
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-
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PR
224
Optimization Analysis of a Cantilever Bracket
Exercise 13: In this exercise, you will perform an optimization analysis on a

Optimization cantilever bracket based on its stress analysis.
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e
Cantilever I Optimization Goal on page 214.
F
Bracket I Postprocessing Optimization Results on page 220.
ut
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Problem In this exercise we will perform an
Statement optimization of a cantilever
bracket based on its stress analysis.
The bracket is supported by two
rods mounted through the two
circular holes. The goal is to
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minimize volume by varying the
st
dimensions of the triangular
cutout.
E 1 Open part file.

Open the part named Cantilever_Bracket.
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2 Create static analysis study.
Create a study named bracket static. Select Static as the Analysis
type.
Create a custom material with an Elastic modulus of 2E11 N/m^2
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(Pa) and a Poisson’s ratio of 0.3. Also, enter 7800 kg/m^3 for the
Mass density and 350E6 N/m^2 for the Yield strength.
4 Apply load.
y
Apply a Pressure of 5E6 N/m^2 (Pa)
to the top face of the bracket.
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5 Apply restraint.
Apply Fixed Hinge restraints to the
two cylindrical holes.
-
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6 Mesh the model.

PR
element size. Use Curvature based mesh.

7 Run the analysis.
8 Create an design study.
9 Define a goal.
The goal here is to minimize the mass.
225
10 Define design variables.

We will now select the dimensions defining the bracket cutout as the
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design variable.
e
Design variable 1
F
ut
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Design variable 2
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st
Design variable 3
E 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.
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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
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bracket as the last design variable. 2Set the lower bound to 20 mm and
upper bound to 50 mm.
11 Apply constraint.
y
Select Stress as the Data Quantity and VON: von Mises stress as the
stress Component.
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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 Fast Results in the Design Study properties
-
window.
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13 Run optimization analysis.

PR
226
14 Plot optimized design.
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F
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E 15 Show details of the optimized design.
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We find that the mass has been significantly reduced from the initial
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value of 105.251g to approximately 83.9g.

16 Plot stress results in the optimized design.
y
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-
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The maximum von Mises stress of 202.6 MPa translates to a factor of

safety of 1.7 (Yield strength is 350 MPa). The optimization study
allowed us to create economical, yet still safe design.
227
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F
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E
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228
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Lesson 11
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Pressure Vessel
st
Analysis
E
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I Apply SolidWorks Simulation Pressure Vessel Design modulus to
the design of the pressure vessels.
y
I Create linear and SRSS combinations of the load cases.

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I Evaluate stress results.

-
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PR
229
Case Study: The objective of this lesson is to show the functionality of the
Pressure Vessel Pressure Vessel Design modulus and its application to the vessel
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design in accordance with ASME Boiler and Pressure Vessel Code,
Section VIII, Division 2. Other codes and requirements may be
e
followed as well. We will analyze the same pressure vessel that was
F
discussed in the Mixed Meshing (Shells and Solids) lesson of the
ut
SolidWorks Simulation training manual.
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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
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other loading conditions such as elevated
temperature, free nozzle end forces,
st
moments, and additional stresses due to
the support conditions. Wind and
E earthquake conditions are not considered

in this example even though a real life
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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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Stages in the I Static studies.

Process We will run a different study for each loading condition and
y
evaluate the results.

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I Pressure vessel study.

The pressure vessel study will combine the loading conditions
defined in the static studies. The results can then be evaluated.

-
Open the assembly named Pressure vessel.SLDASM.

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2 Review the studies.

Four studies have been completed before hand:
pressure: pressure vessel shell as well as nozzles are subjected to
PR
I
a 165 psi internal pressure,
I inlet nozzle loads: external bending moments and forces exerted
on the vessel due to the connection to the piping system,
I temperature: temperature load of 700° F applied to all the
components,
I self weight: weight of the pressure vessel.
230
3 Review supports.
The pressure vessel is supported by four
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symmetrically orientated lugs with
slotted bolt holes allowing for the radial
e
expansion of the vessel.
F
ut
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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
or D
here. You will notice, however that some
parts (manway nozzle) are meshed with
st
significantly finer mesh.
E To reduce the computational time, other

parts of the vessel are meshed with coarser
draft quality mesh.
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Note All of the studies participate in a pressure vessel analysis and must
y
have identical mesh properties.
5 Review study results.
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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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231
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
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and Pressure Vessel Code therefore relies on the Tresca yield criterion
which is more conservative than the von Mises criterion. The
e
maximum difference between these two criteria is 13%.
F
ut
Membrane and ASME Boiler and Pressure Vessel Code states possible limiting values
Bending Stresses
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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
or D
and a stress linearization along a selected trajectory is required. This
st
lesson demonstrates the linearization procedure towards its end.
Basic Stress ASME Boiler and Pressure Vessel Code defines five stress intensity
E
Intensity Limits limits which must be satisfied (Section VIII, Division 2, Appendix 4,
Article 4-130)
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I General Primary Stress Intensity Pm
I Local Membrane Stress Intensity PL
I Primary Membrane (General or Local) Plus Primary Bending Stress
Intensity PL + Pb
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I Primary Plus Secondary Stress Intensity PL + Pb + Q

I Peak Stress Intensity PL + Pb + Q + F
y
Nozzle piping transition is then the subject of yet another Article 4-138
of the same Appendix 4.
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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.
-
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1 Pressure vessel study.

Define a new study. Specify Pressure Vessel Design as a study Type
and name it vessel 1.
PR
232
2 Isolate the vessel shell.

Hide all components but the vessel shell
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with the bottom and top head.
e
F
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E 3 Define load configuration.
Right-click on the Setup icon and select Define/
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Edit. Under Option select Linear combination
and specify pressure, inlet nozzle loads and
self weight, all with the scaling factor of 1.
Click OK.
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Note The temperature load is not included in this combination. In this lesson
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the vessel shell will be subjected to the General Primary Membrane

Stress Intensity criterion only. Temperature load is not considered in
this criterion.
Load Case Pressure vessel modulus features two methods for the load case
-
Combinations combinations:
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I Linear combination. Where the resulting quantity X

(displacement, stress etc.) is computed from
PR
X = ∑ xι
ι=1
In the equation above, N is the number of studies included in the

combination, and x ι is the quantity (displacement, stress etc.) from
study ι .
233
I SRSS (Square Root Sum of Squares). In this method the resulting

quantity is obtained using the equation
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N
e
2
X = ∑ ( xι )
F
ι=1
ut
Note An SRSS combination of the loads can also be included in a linear
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combination as a separate load case. Such combination may be required
if the pressure vessel is subjected to the seismic load.
4 Run study vessel 1.
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5 General Primary Membrane Stress
Intensity.
st
Plot the Membrane component of the
INT: Stress Intensity (P1-P3). Make
E sure that the legend limits show the

minimum and maximum values for
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shown parts only.
Note that the maximum value in the plot
is 28.7 ksi which exceeds the limiting
stress intensity for this category Sm =
15.3 ksi. This maximum is however
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highly localized and does not fit the

definition of the General Primary
Membrane Stress Intensity as per the
y
ASME Boiler and Pressure Vessel Code.
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General Primary The ASME Boiler and Pressure Vessel Code defines General Primary
Membrane Stress Membrane Stress Intensity as:
Intensity
I not self- limiting.
I resulting in failure or gross distortion if above a yield strength
-
magnitude.
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I 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;
PR
Primary Membrane (General or Local) plus Primary Bending Stress

Intensity or Peak Stress Intensity criteria include the temperature loads.
234
The above definition does not fit the location of our maximum values.
The maximum membrane stress intensity of 28.7 ksi is at the junction
rib T
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
e
at this location. These regions are covered by the Local Membrane
F
Stress Intensity and the Peak Stress Intensity criteria.
ut
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6 Modify the limit of the plot.
Set the upper limit in the plot to
Sm = 15.3 ksi, a limit for the General
Primary Membrane Stress Intensity.
Notice how the plot changes with areas
or D
close to and above the limit value of Sm
st
= 15.3 ksi in red color. Any region away
from the nozzle reinforcement should be
E below this limiting value for the design

to pass this criterion.
You can verify that the values are below
op AS
15.3 ksi in all shell regions except in the
vicinities of the nozzle openings and lug
supports. The shell design therefore
passes the General Primary Membrane Stress Intensity criterion.
The remaining components must satisfy the General Primary
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Note
Membrane Stress Intensity limit criterion as well (nozzles are covered
by its own special provision).
y
Also, the remaining Basic Stress Intensity Limits as listed on page 232
must be satisfied.
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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,
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radial and tangential stresses as 1.5 Sm, Sm and Sm, respectively. (For
the simplicity we assume that flanges are manufactured from the same
PR
material as the pressure vessel body and nozzles.)
235
7 Plot longitudinal, radial and tangential stresses in the Manhole

nozzle flange.
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Define plots of SZ: Z Normal Stress, SY: Y Normal Stress and SX: X
Normal Stress. For all stress plots request the axis of the Manhole
e
nozzle as a reference to specify the cylindrical coordinate system.
F
ut
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E
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Ignoring the longitudinal stress concentrations in the vicinity of the bolt

-
openings, the stress values are well below the limits for all three cases.
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Stress Even though the ASME Boiler and Pressure Vessel Code does not
PR
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.
236
8 Isolate components, stress intensity plot.

Isolate Manhole nozzle flange and Manhole cover components.
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Create an INT: Stress
e
Intensity (P1-P3) plot.
F
Specify the Section
ut
clipping feature using the
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Right plane as a reference.
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Note E The stress limits are indicated for shown parts only.
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9 Linearize stress results.
Right-click on the stress plot created in the
previous step and select Linearize.
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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.
237
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E The Linearize stress dialog shows the summary of the membrane and
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bending components.
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238
10 Save the data.

Click the Save button. Save the information into a *.csv file.
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Open the above *.csv file with Microsoft Excel, for example. The file
e
contains additional informations required for the comparison with the
F
ASME Boiler and Pressure Vessel Code.
ut
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st
E
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y
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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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239
11 Plot stress graphs.

Click the Plot button in the linear stress dialog (step 9) to generate
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graphs of the stress components variations.
e
F
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E
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The above six graphs show the variations of all stress components
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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
y
and green, correspondingly).
12 Save and close the assembly.
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240
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e
Index
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B O
Buckling Load Factor 45, 48 Optimization Analysis
Bulk Temperature 70 Constraints 216
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Define 213
C Local Trend Graph 222
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Centrifugal Load 25 Objective 214
Conduction 61 Results 219
Convection 62
E
Convection Coefficient 96 P
Define 96 Plot Heat Flux 99
Forced Convection 63 Plot Temperature 97
Free Convection 63
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R
D Radiation 63
Damping 8 Define 93
Drop Test Parameters 93
Define 187 Stefan-Boltzmann Law 64
Drop Height. 188, 205 Surface to Surface 93
Impact Plane 189 Type 93
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Parameters 188 Reference Temperature at Zero

Response Graph 196 Strain. 111, 123
Resonant Frequencies 8
E Response Graph 79
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Eigenvectors 44
Elastic Stiffness Matrix 44 S
SolidWorks 4
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F
Fatigue Analysis Theory 138 T
Fundamental Frequency 10 Temperature Curves 81
Thermal Contact Resistance 67
H Define 69
Heat Flux Singularities 98 Thermal Resistance 68, 105
Heat Power 67 Thermostat 82
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Define 92 Time Curves 80–81

Transient Thermal Analysis 76
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I
Include Thermal Effects 111, 123 V
Initial Temperature 77 Vector Plot 110
Interfacial Conductance 68, 103
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L
Linear vs. Nonlinear Buckling 44
List Resonant Frequencies 13
M
Material Properties for Thermal
Analysis 65
Mode Shapes 10
241
242
Index
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SolidWorks 2011
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ut
e

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Dassault Systèmes SolidWorks Corporation

trademarks and FeatureManager is a jointly owned registered

Simulation, SolidWorks Flow Simulation, and eDrawings

Copyright Notices for eDrawings Products

Portions of this software © 2000-2010 Tech Soft 3D.

Portions of this software © 1998-2001 3Dconnexion.

Document Number: PMT1141-ENG_DRAFT

What is SolidWorks Simulation? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Modal Analysis Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Required Material Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Case Study: The Tuning Fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Frequency Analysis Without Supports . . . . . . . . . . . . . . . . . . . . . . . . 16

All Bonded Contact Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Linear vs. Nonlinear Buckling Analysis. . . . . . . . . . . . . . . . . . . . 44

Transient Thermal Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Transient Thermal Analysis using a Thermostat . . . . . . . . . . . . . . . . 82

Symmetry Boundary Condition in Thermal Analysis . . . . . . . . . 84

Steady State Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Thermal Stress Analysis of a Microchip Testing Assembly. . . . . . . 121

Thermal Stress Analysis of a Gas Tank . . . . . . . . . . . . . . . . . . . . . . 128

Thermal Study. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

Project Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

Rainflow Cycle Counting Method . . . . . . . . . . . . . . . . . . . . . . . 173

Fatigue Literature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

Rigid Floor Drop Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

Optimization Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213

Constraint Tolerance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

Optimization Analysis of a Cantilever Bracket . . . . . . . . . . . . . . . . 225

Load Case Combinations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233

About This The SolidWorks Simulation Professional training course is a direct

I Completed the introductory SolidWorks Simulation (or similar)

process-based training course emphasizes processes and procedures

under the guidance of an experienced SolidWorks Simulation

and case studies are designed to be demonstrated “live” by the

E running on a different version of Windows, you may notice differences

options appear in this style. For example,

Loads icon in the SolidWorks Simulation

17 Do this step the procedures. This provides separation

between the steps of the procedure and large

Also, in many cases, we have Radius 50mm

software for SolidWorks Corporation. The commercial success of

Windows operating system. SolidWorks Simulation has also been

integration between SolidWorks and SolidWorks Simulation is possible

SolidWorks Simulation comes in different “bundles”, or applications,

E In this volume, we introduce SolidWorks Simulation Professional

Each subsequent lesson assumes familiarity with software functions

With any FEA software, we need to take advantage of its strengths as

I loads are static

successfully within these limitations. For a detailed discussion of each,

I Investigate rigid body modes.

I Perform a frequency analysis with a prestress condition.

I Use design scenarios to conduct design sensitivity studies

E motion for damped forced vibration. In the absence of damping and

frequencies and modes. The maximum number of modes that can be

In resonance, inertial and elastic stiffness cancel. In effect, the structure

resonance is damping. If damping is low, and most often it is low, the

of vibration, the more complex the mode shape.