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Power - Accuracy - Functionality: Tutorials
Power - Accuracy - Functionality: Tutorials
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8/21/00
11:52 AM
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V E R S I O N
6.0
T u t o r i a l s
1
Introduction
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Although you can begin with the tutorials, we recommend that you read the
COSMOS/Works Fundamentals, COSMOS/Works Interface, and Analysis
Background chapters of the COSMOS/Works Users Guide to familiarize yourself
with some of the fundamentals, including:
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1-1
1-2
COSMOS/Works Tutorial
2
Static Analysis Tutorial
This chapter presents step-by-step lessons for performing linear static analysis.
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2-1
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2-2
Start COSMOS/Works.
If you do not see the COSMOS/Works menu in the SolidWorks menu bar,
click Tools, Add-ins, then click the COSMOS/Works checkbox and click OK.
To set the unit options:
1
Click OK.
We recommend that you use File, Save As to save the part to a different name
before defining a study so that you can use the original file again.
2-3
COSMOS/Works Manager
on COSMOS/
Click the Add button. The Study Name dialog box opens.
In the New Study field, type in the name of the study, for example, Static-1.
Click OK.
2-4
Click OK.
Preprocessing
Assign Material
To assign a material from the COSMOS/M Library:
1
In the COSMOS/Works Manager tree, right-click the Tutor1 icon under Solids
folder and select Apply/Edit Material,
- or From COSMOS/Works menu, click Apply Material to All,
- or Click the Apply Material to All button
toolbar.
The Material dialog box opens with the COSMOS/M Library tab selected.
2
From the Material Type drop-down menu, verify that Steel is selected.
In the Material Name list box, verify that Alloy Steel is selected.
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2-6
To list the properties of the applied material, right-click the Tutor1 icon under
the Solids icon and click Details. The material information is listed in the
Details window.
Apply
pressure
normal to
this face
Fix these holes
Select the face of one hole. Press and hold down the Ctrl key and select the face
of the other hole. The two faces highlight as shown in the figure.
2-7
4 Optional:
To change the color of the restraint symbol, click the Color button.
The Color palette opens. Select the desired color and click OK.
2-8
Although the unit of length for the model is millimeters, you can choose to
specify pressure in any other system of units.
You can view the value of the applied pressure in other units by changing the
unit field.
7
You can edit the definition of any load or boundary condition by rightclicking the corresponding icon in the COSMOS/Works Manager tree.
2-9
Click OK.
In the COSMOS/Works Manager tree, right-click the Mesh icon and select
Create.
- or From COSMOS/Works menu, click Mesh, Create,
- or Click the Mesh button
The Mesh dialog box opens and an average element size is suggested. You can
change the element size by typing in its field or using the slider. A finer mesh
gives more accurate results but requires more computer resources and takes
more time to solve. In this example, however, we will use the default element
size.
2-10
Click OK. The Mesh Progress window opens and the program starts meshing.
After the mesh is completed, the Solid Mesh completed message appears.
Click OK. Notice the checkmark that appears on the Mesh icon.
2-11
Analysis starts. When the analysis is completed, you will get the Static
Analysis Completed message.
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Click OK.
2-12
To verify the results of the reaction force, multiply the area of the
circular face (2.8389 in 2 ) by the applied pressure (1000 psi) to get the
reaction force on the entire model.
To calculate the reaction forces on the vertical face:
In the Reaction Force dialog box, change the Units field to lb. The sum of the
reaction forces on the selected face will be listed. Note that the listed values
are all zeros as expected.
In the Reaction Force dialog box, change the Units field to lb. The reaction
force components will be listed. Note that the reaction force components in the
X, Y, and Z directions are not zeros. This is due to the fact that the edges of the
two holes are contributing to the reaction force on that face.
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If you select the edges of the two holes and calculate the reaction forces, you
should obtain the same values as those obtained when you select the bottom
face.
Click COSMOS/Works,
Preferences. The Preferences
setting box opens.
Click OK.
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In the COSMOS/Works Manager tree, click the (+) sign to the left of the Stress
folder. The Plot1 icon appears in the Stress folder.
In the COSMOS/Works Manager tree, right-click the Plot1 icon in the Stress
folder and select Edit Definition. The Stress Plot dialog box opens with the
Properties tab selected.
From the Stress Units menu, select the desired units and click OK.
to start the
to stop the animation.
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Click
. The Video Compression dialog
box opens.
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Deformation Plot
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Section Plot
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Click OK. The section plot is generated and a new icon (Plot2) appears in the
Stress folder of the study.
In the COSMOS/Works Manager, right-click the Plot2 and select Clipping. The
Section Clipping dialog box opens.
Drag the sliders to modify the distance and orientation of the section.
Click OK.
Right-click the Plot2 icon in the Stress folder and click Edit Definition.
Double-click the 0 Plane: in the cutting tool list box. The primitive selection
menu opens.
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Click OK.
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Click the Areas below factor of safety button and enter a value of 1 in the field
next to it.
Click Finish. Regions with a factor of safety less than 1 (unsafe regions) will
be shown in red.
Unsafe regions
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Printing Plots
To print a plot:
1
Right-click the plot icon and select Save As. The Save As dialog box opens.
In the Save in field, specify the folder where the plot is to be saved.
In the Save as type field, select VRML files (*.wrl), Bitmap files (*.bmp), XGL
files (*.xgl), or ZGL (*.zgl) files.
Click Save.
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Click OK.
Click OK.
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Crank Pulley,
Crank Arm Axle, and
Two Crank Arms.
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2-24
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Start SolidWorks.
Change the Look in folder to ...\Examples where ... refers to the COSMOS/
Works installation folder.
From the Files of type field, select Assembly Files (*.asm; *.sldasm).
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If you do not see the COSMOS/Works menu, click Tools, Add-ins, then
check the control box for COSMOS/Works and click OK.
Click OK.
We recommend that you click File, Save As to save the part to a different
name before defining a study so that you can use the original file again.
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Right-click the Crank icon and select Study. The Study dialog box opens.
In the New Study field, type in the name of the study, for example, Initial.
Click OK. The study name appears in the Studies list box.
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From the Material Type drop-down list make sure that Steel is selected.
From the Material Name list box, select Stainless Steel (ferritic).
Click OK. The selected material will be assigned to the CrankArm Axle part.
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Assign this material to all parts by right-clicking the Solids folder and
selecting Apply Material to All.
Edit the material definition for each part with a different material by rightclicking its icon and selecting Apply/Edit Material.
Select the outer cylindrical face of the pulley. The face highlights.
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Click OK.
Select the face of the pedal of CrankArm-2. The face highlights as shown.
Right-click the Load/Restraint folder and select Force. The Force dialog box
opens.
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Click OK.
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on COSMOS/
Right-click the Initial study icon and click Run. The analysis starts. When the
analysis is completed, you will get the Static Analysis Completed message.
Click OK.
Click OK.
Use the Standard option for very large models.
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In the COSMOS/Works Manager tree, click the (+) sign to the left of the Stress
folder. The plot1 icon appears.
Double-click the Plot1 icon. The von Mises stress plot is generated.
To change the display units of the stress, right click the Plot1 icon and select
Edit Definition. The Stress Plot dialog box opens.
On the Properties tab, select psi from the Stress Units menu.
.
.
Right-click the Plot1 icon and click Color Map. The Color Map dialog box
opens.
From the drop-down list select a color map. The available color maps are:
Default, Rainbow, Gray Scale.
Enter the desired number of chart colors you want to use in the plot.
After making your choice, click Apply to see the effect dynamically.
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Click OK.
Click OK.
Section Plots
To generate a section plot:
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Modify the sections as desired using the sliders. To modify a section, click its
tab and drag the Radius and Center sliders.
Click OK.
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Vector Plot
To generate a vector plot:
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In the COSMOS/Works Manager tree, right-click the Stress folder and select
Define. The Stress Plot dialog box opens.
In the Component list box, select P1: Normal stress (1st principal).
Click OK.
In the COSMOS/Works Manager, right-click the Initial study icon and select
Report. The Report dialog box opens.
Click a section in the Settings for list box to preview its contents.
For the result sections of the report, you may add AVI files, and image files as
desired.
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Click File,
Open. The
Open dialog
box opens.
Change the
Look in folder
to ...\Examples
where ...
refers to the
COSMOS/
Works
installation
folder.
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If you do not see the COSMOS/Works menu, click Tools, Add-Ins. Check the
COSMOS/Works checkbox and click OK.
To verify the units:
1
Make sure that Inches appears from the Linear units drop-down menu.
Click OK.
At this point, we recommend that you click File, Save As to save the part
with a different name before defining a study so that you can use the
original file again.
Before performing the analysis with COSMOS/Works, we will scale the part
down by a factor of 0.1.
To scale the part:
1
To restore the normal view of the model, click the Zoom to Fit tool
View toolbar.
on the
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Click OK.
Click OK.
FFE does not support
high-order shells. If you
choose FFE, the program
will automatically switch
to FFEPlus.
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Assign Material
To assign a material from the COSMOS/M Library:
1
Right-click the Sheet icon in the Solids folder and select Apply/Edit Material.
The Material dialog box opens with the COSMOS/M Library tab selected
From the Material Type drop-down list, verify that Steel is selected.
From the Material Name list box, verify that Alloy Steel is selected.
From the Unit System drop-down list, click the desired system of units to use it
in displaying the properties.
Click OK. The material is assigned to the part and a checkmark appears on the
Sheet icon in the Materials folder.
To verify the material assignment, right-click the Sheet icon and select Details.
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Notice that the Selected Entities box lists the number of selected faces,
edges and vertices. In this case, 3 faces are selected.
4
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From the Type box, verify that Fixed is selected to set all translations and
rotations to zero.
The Immovable option sets the translations to zero while the Fixed option
sets both translations and rotations to zero.
5 Optional:
To change the color of the restraint symbol, click the Color button.
The Color palette opens. Select the desired color and click OK.
Click OK.
Notice that the Selected Entities box lists one selected face.
3
In the Type box, click Normal to selected face to apply pressure normal to the
selected face.
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Right-click the Mesh icon and select Preferences. The Preferences dialog box
opens with the Mesh tab selected.
Click OK.
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Click OK. Notice that a check mark appears on the Mesh icon.
Right-click the Mesh icon and select Show Mesh. The mesh is displayed as
shown.
Right-click the Mesh icon again and select Hide Mesh to hide the mesh.
Right-click the Mesh icon and select Details to display the information about
the generated mesh.
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You may get different misaligned shells based on the version or service pack
of SolidWorks that you are using. ,
Flip these shell elements
In COSMOS/Works Manager, right-click the Mesh icon and select Flip shell
elements. The shell elements will be flipped.
In the COSMOS/Works Manager tree, right-click the Shell study icon and
select Run. Static analysis starts. When the analysis is completed, you will get
the Static Analysis completed message.
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In the COSMOS/Works Manager tree, click the (+) sign to the left of the Stress
icon. The Plot1 icon appears in the Stress folder.
Double-click the Plot1 icon. The von Mises stress fringe plot is generated.
The default plots are always generated on the top faces of the shell model.
Right-click the Plot1 icon and select Edit Definition. The Stress Plot dialog
box opens.
On the Properties tab, select psi from the Stress Units menu.
Click OK.
In the COSMOS/Works Manager, right-click the Plot1 icon and select Edit
Definition. The Stress Plot dialog box opens.
In the Plot Type box, select Bottom from the Shell Face drop-down menu.
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In the COSMOS/Works Manager tree, right-click the Plot1 icon in the Stress
folder and select Animate. The Animation dialog box opens.
You can save your animation as an AVI movie file by checking the Save
As AVI checkbox.
Equivalent Element Strain Plot
To plot equivalent element strain:
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In the COSMOS/Works
Manager tree, click the (+)
sign to the left of the
Strain icon. The Plot1 icon
appears in the Strain
folder.
Click the Animate in the COSMOS/Works Manager to animate the plot as was
described for the stress plot.
In the COSMOS/Works
Manager tree, click the (+) sign
to the left of the Displacement
icon. The Plot1 icon appears in
the Displacement folder.
Deformation Plot
To generate the deformed shape plot:
1
In the COSMOS/Works Manager tree, click the (+) sign to the left of the
Deformation icon. The Plot1 icon appears in the Deformation folder.
Click OK to print.
Right-click the desired plot and select Save As. The Save As dialog box opens.
From the Save As Type drop-down list, select VRML files (*.wrl), or Bitmap
files (*.bmp).
Click Save.
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COSMOS/Works Manager
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Click OK.
Assign Material
To Assign a Material from the COSMOS/M Library:
1
Right-click the Ibeam icon in the Solids folder and select Apply/Edit Material.
The Material dialog box opens with the COSMOS/M Library tab selected.
Click OK
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Right-click the Load/Restraint folder again and choose Hide All to hide load
and restraint symbols.
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Right-click the Mesh icon and select Preferences. The Preferences dialog box
opens with the Mesh tab selected.
Click OK.
Right-click the Mesh icon and select Create. The Mesh dialog box.
Right-click the Mesh icon again and click Hide Mesh to hide the mesh.
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Right-click the Shell Study icon and select Run. Analysis starts. When the
analysis is completed, you will get the Static Analysis completed message.
In the COSMOS/Works Manager tree, click the (+) sign to the left of the Stress
icon. The Plot1 icon appears in the Stress folder.
The default plots are always generated on the top faces of shell models.
By default, the stresses are plotted on the deformed shape.
To plot von Mises stresses on the bottom faces of the model:
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In the COSMOS/Works Manager, right-click the Plot1 icon in the Stress folder
and select Edit Definition. The Stress Plot dialog box opens.
Click OK.
In the COSMOS/Works
Manager tree, click the (+) sign
to the left of the Strain icon.
The plot1 icon appears in the
Strain folder.
In the COSMOS/Works
Manager tree, click the (+)
sign to the left of the
Displacement icon. The
Plot1 icon appears in the
Displacement folder.
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From the COSMOS/Works menu, click Study. The Study dialog box opens.
Click the Add button. The Study Name dialog box opens.
Click OK.
Right-click the Solids icon in Shell Study folder and select Copy.
Right-click the Solids Study folder and select Paste. The material will be
copied.
- or Drag the Solids icon from the Shell Study and drop it on the Solid Study folder.
The material is copied.
To apply loads/restraints:
1
Right-click the Load/Restraint folder in the Shell Study folder and select Copy.
Right-click the Solid Study folder and select Paste. The loads and restraints
will be copied.
- or Drag the Load/Restraint folder from the Shell Study and drop it on the Solid
Study. The restraints are copied.
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Right-click the Solid Study icon and select Run. Analysis starts. When the
analysis is completed, you will get the Static Analysis completed message.
Click OK.
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Click the (+) sign to the left of the Stress icon in the Solid study. The Plot1 icon
appears in the stress folder.
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In the COSMOS/Works Manager tree, click the (+) sign to the left of the Strain
folder in the Solid study.
Double-click Plot1.
In the COSMOS/Works Manager tree, click the (+) sign to the left of the
Displacement icon.
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From the File menu, click Open. The Open dialog box opens.
Click OK.
At this point, it is recommended that you click File, Save As to save the part
with a different name before defining a study so that you can use the
original file again.
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COSMOS/Works Manager
In the New Study field, type Shell Study (or any other
name) as the name of the new study.
From the Mesh Type box, click Shell using midsurfaces. A message window
opens.
Click OK.
Assign Material
To assign a material from the COSMOS/M Library:
1
Right-click the funnel icon in the Solids folder and select Apply/Edit. The
Material dialog box opens with the COSMOS/M Library tab selected.
From the Unit System drop-down list, click the desired system of units to use it
in displaying the properties.
Click OK.
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Select the inner face of the cylindrical base. The face highlights as shown.
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In the Selected Entities list box, notice that one face is selected.
Click OK.
FeatureManager
In the Selected Entities list box, notice that one face is selected.
In the Type box, verify that Use Reference plane or Axis is selected.
Click the checkbox of Axial Displacement and verify that 0 is entered in its
field.
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Click OK. The restraint is applied so that this face may not move in the axial
direction.
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Click OK. The restraint is applied so that this face cannot move in any
direction.
Immovable and Fixed are different for shells. Fixed sets all translations and
Rotations to zero while Immovable sets only the translations to zero.
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Right-click the Mesh icon and select Preferences. The Preferences dialog box
opens with the Mesh tab selected.
Click OK.
In the COSMOS/Works Manager tree, right-click the Mesh icon and select
Show Mesh. The mesh is displayed.
Right-click the Mesh icon again and select Hide Mesh to hide the mesh.
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Right-click the Mesh icon and select Details to display information about the
generated mesh.
Before flipping
After flipping
In COSMOS/Works Manager, right-click the Mesh icon and select Flip shell
elements. The shell elements will be flipped.
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Right-click the Shell Study icon and select Run. Analysis starts. When the
analysis is completed, you will get the Static Analysis completed message.
Click OK.
In the COSMOS/Works Manager tree, click the (+) sign to the left of the Stress
folder. The Plot1 icon appears in the Stress folder.
Global Coordinate
System
The default plots are displayed on the top faces of the model.
To plot von Mises stress on the bottom faces of the model:
1
Right-click the Plot1 icon in the Stress folder and select Edit Definition. The
Stress Plot dialog box opens.
In the Plot Type box, select Bottom from the Shell Face drop-down menu.
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Click OK.
To visualize extreme stresses, we recommend that you plot the stresses on top
and bottom faces for all shell models.
To change the display settings of the result axes:
1
Right-click Plot1 and select Axes. The Axes dialog box opens.
In the Axis box, move the size sliders to the positions shown in figure.
Click OK.
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In the COSMOS/Works Manager tree, right-click the Plot1 icon in the Stress
folder and select Edit Definition. The Stress Plot dialog box opens with the
Properties tab selected.
From the Stress Units menu, select the desired unit and click OK. The plot with
new units will be displayed.
Right-click the Plot1 icon in the Stress folder and select Animate. The
Animation dialog box opens.
You can save your animation as an AVI movie file by checking the Save As
AVI checkbox.
Equivalent Element Strain Plot
To plot the equivalent element strains:
1
In the COSMOS/Works Manager tree, click the (+) sign to the left of the Strain
icon. The Plot1 icon appears in the Strain folder.
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Density of Fuel is
0.029 lb/in3.
p(y) =y
Description
An aluminum storage tank is partially filled with a fuel of density = 0.029 lb/in3.
The fuel exerts a hydrostatic pressure that can be simulated by applying a varying
pressure. A linearly varying pressure (p(y) =y) will be applied to all inner faces
of the tank below the fuel surface, where y refers to the vertical distance measured
from the surface of the fuel.
In order to apply the pressure p(y) =y, the faces of the tank were split at the
surface of the fluid so that we can apply the pressure to the walls of the tank below
the surface of the fluid. We will also create a coordinate system at the fluid
surface with its y axis pointing downwards in order to be able to describe the
pressure variation in the y direction according to the above equation.
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In the Study dialog box, click the Add button. The Study Name dialog box
opens.
In the New Study field, enter variable pressure as the name of the study.
From the Analysis Type menu, make sure that Static is selected.
In the Mesh Type box, select Shell using midsurfaces. You will be prompted
with a message that the shell meshing works only for simple thin parts and is
being improved by both SRAC and SolidWorks. Close this information
window by clicking OK.
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Click OK.
Click inside the Origin box and select the vertex shown in the figure.
Click inside the Y Axis box, and select the edge shown in the figure.
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In the Selected Coord. System box, make sure that Coordinate System1 is
selected.
In the Equation for Variable Pressure fields, enter 0.029 in the field
corresponding to the y coefficient and 0 in all other fields.
Click OK.
Right-click the Mesh icon and select Preferences. Use the options shown in
figure below.
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Before Flipping
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After Flipping
Right-click the Plot1 icon in the Stress folder and select Edit Definition. The
Stress Plot dialog box opens.
In the Plot Type box, select Bottom from the Shell Face drop-down menu.
Click OK.
In the COSMOS/Works
Manager, click the (+) sign to
the left of the Displacement
folder.
Click OK.
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Description
COSMOS/Works lets you handle bearing problems in two ways:
You can model the assembly of the axle and the pulley. The forces are
transferred through the gap elements generated automatically by setting the
Contact/Gaps option on the faces of contact between the axle and the pulley.
You can model the pulley only and approximate the force intensity exerted by
the axle. The validity of the approximation depends on the validity of the
assumed force intensity for the problem at hand.
The second approach is used in this lessons force exerted by the axle on the pulley
is approximated by a 700 pound force acting normal to the lower face of the hole.
The intensity is assumed to be f() = Sin(), where is defined as shown in the
figure.
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The surface of central hole of the pulley was split into two faces. We will create a
coordinate system at the center of the hole as shown in the figure and use it to
specify a total normal force with given intensity.
Open the Pulley-Bearing part located in the Examples folder of the COSMOS/
Works installation folder.
We recommend that you click File, Save As to save the part to a different
name before defining a study so that you can use the original file again.
2
Create a Static analysis study. Make sure to select the Solid option while
defining the study.
Assign Steel Alloy from the COSMOS/M Material Library to the pulley.
Click OK.
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Click OK.
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In the COSMOS/Works
Manager, right-click the
Load/Restraint icon and
select Force. The Force
dialog box opens.
7In
8In
Click OK.
The summation of the magnitudes of the forces applied normal to the face will
be 700 pound force. The horizontal components over the face will cancel each
other.
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In the COSMOS/Works Manager, click the (+) sign to the left of the Stress
folder.
Click OK.
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In the COSMOS/Works
Manager, click the (+) sign
to the left of the
Displacement folder.
Click OK.
Right-click the Displacement folder and select Reaction Force . The Reaction
Force dialog box opens to list the reaction forces on the selected face as well as
on the entire model.
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Fo
X
Fn
Fosin()cos()
Fosin()
Fosin ()
2
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Description
In this problem, we will study the stress concentration around a hole at the center of a plate
subjected to in-plane pressure loading.
20
20
1 radius
10
10
1 in
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Open the Plate-with-hole part located in the Examples folder of the COSMOS/
Works installation folder.
We recommend that you click File, Save As to save the part to a different
name before defining a study so that you can use the original file again.
2
In the COSMOS/Works Manager, right-click the top icon and select Study.
Click the Add tab, enter a name for the study, select Static from the Analysis
Type menu (default), make sure to select Solid (default) in the Mesh Type box,
and click OK.
The p-adaptive method is not supported for shells.
Click the Properties button and then click the Adaptive tab.
From the Stop when drop-down menu, select Total Strain Energy (default) and
enter 0.02 in the change is % or less field.
In general, strain energy has a rapid convergence. This is why we entered a
small value for the allowable change in the strain energy.
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In the Update elements with strain energy error of % or more, enter 1.0.
10
Click OK.
Assign Material
To assign Material to the part:
1
Restrain this
edge normal
to Plane1
Face
B:
Restrain
this face in
direction 1
of Plane1
Click OK.
Repeat the above steps for face B (as shown in the figure) to restrain it in
direction 2 of Plane1.
Select the upper edge (as shown in the figure) of the plate.
In the Type box, select the Use Reference Plane or Axis , Plane1 appears in the
selected Reference field.
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Click OK.
Click OK.
1000 psi
Pressure
Click OK.
It is recommended to choose the At Nodes option from the Jacobian Check
drop-down menu when using the p-method.
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Click the Display tab and select the SX: Normal stress (X-dir.) component.
Click OK.
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In the COSMOS/Works Manager, right-click the study folder icon and select
Convergence Graph.
Click OK.
uncheck it.
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Click OK.
In the COSMOS/Works
Manager, right-click the study
folder icon and select
Convergence Graph.
Click OK.
Maximum
Normal
Stress Sx
Analytical
Solution
Using the
p-method
3024 psi
3059 psi
(1.16% error)
2539.5 psi
(16% error)
(obtained by deactivating the pmethod and re-running the analysis)
Reference
Roark and Young, Formulas for Stress and Strains, Fifth Edition, McGraw-Hill Book
Company, Chapter 15, pp-594.
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3
Contact Stress Analysis Tutorial
This chapter presents step-by-step lessons to show you how to use the Contact/
Gaps Options.
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Description
The imbalance in the motor causes a dynamic force of 5 pounds on the rotating shaft. The
worst scenario occurs when the shaft rotates at a frequency that is equal to one of the natural
frequencies of the assembly (resonance). Assuming a damping ratio () of 5%, the dynamic
force effect may be approximated by applying a static force of magnitude 1/(2) times the
magnitude of the dynamic force. We will, however, use a static force of 150 pounds (50
pounds times a factor of safety of 3) to evaluate the stresses caused by the imbalance at the
interface between the shaft and bearings. Note that the direction of the imbalance changes as
the shaft rotates. In this example, we will consider a force in the upward direction.
3-2
Start SolidWorks.
From the File menu, select Open. The Open dialog box opens.
If you do not see the COSMOS/Works menu, click Tools, Add-Ins, select
COSMOS/Works and click OK.
Lightweight components do not function properly with COSMOS/Works. To
turn off the automatic loading of components as lightweight, turn off the
option with Tools, Options, Performance.
It is recommended that you click File, Save As to save the assembly with a
different name before defining a study so that you or can use the original file
again.
3-3
3-4
Click the OK button. You will return to the Study dialog box.
10
Preprocessing
Assign Material
To assign material from the COSMOS/M Library:
1
Notice the checkmarks that appear on the icons in the Solids folder indicating
that a material has been assigned to each of them.
Insert Loads and Boundary Conditions
The imbalance in the motor-shaft assembly is estimated to cause a static force of
50 pounds. Since we want to perform static analysis, we will use a factor of safety
of 3 and apply 150 pounds. The force can be in any direction, however, in this
study, we apply the force in the vertical direction pointing upward.
To insert restraints:
1
Notice that the Selected Entities box lists the number of selected faces, edges
or vertices. In this case, two faces are selected.
3
3-5
With Plane2 selected from step 1, click the COSMOS/Works Manager tab
Press and hold the Ctrl key and select the lower face of the shaft connected to
the motor. The face highlights.
select Plane2
3-6
In the COSMOS/Works Manager tree, right-click the Mesh icon and click
Preferences. The Preferences dialog box opens with the Mesh tab selected.
Click OK.
3-7
In the COSMOS/Works Manager tree, right-click the Imbalance study icon and
click Run. Analysis starts. When the analysis is completed, you will get the
Static Analysis Completed message.
Click OK.
3-8
Double-click the Plot1 icon. Von Mises stresses are plotted as shown.
In the COSMOS/Works Manager tree, right-click the Plot1 icon under the
Stress tree and click Animate. The Animation dialog box opens.
You can save your animation as an AVI movie file by checking the Save As
AVI control box.
3-9
Click OK.
Notice that due to the applied upward force, stresses have developed at the
upper contact of the shaft with the bearing due to compression.
No stress concentration appears at the lower connection since a gap will
develop at the front end as will be illustrated by a section plot.
3-10
Section Plot
To generate a section plot of von Mises stress:
1
Click OK.
10
3-11
3-12
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Description
The Eyebar assembly is loaded and supported as shown. We will use a global Node to Node
contact condition on contacting faces to evaluate stress concentrations.
Due to symmetry, we will analyze one quarter of the model with the appropriate boundary
conditions. Since most of the steps are identical to the first example in this chapter, we will
describe them briefly.
Plane of symmetry
Plane of symmetry
No motion normal to the two planes of symmetry.
3-13
If you do not see the COSMOS/Works menu, click Tools, Add-Ins, select
COSMOS/Works and click OK.
We recommend that you click File, Save As to save the assembly with a
different name before defining a study so that you can use the original file
again.
3-14
No normal motion
Apply a tensile pressure of -300 psi to the end face of the eyebar part as shown
in the figure.
Immovable Face
300 psi
Right-click the Mesh icon and select Preferences. Use the options shown in
the figure.
3-15
On the Properties tab, select psi from the Stress Units drop-down menu.
Click the Display tab and select P1: Normal stress (1 st principal).
Click OK.
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Fixed
Description
The two cantilevers initially contact each other as shown in the figure. A pressure
is applied to the upper face of the upper cantilever. We will mesh this model with
a global Node to Node contact condition. The lower cantilever will deform under
the action of loads transferred through the contact. The program calculates friction
forces at the faces of contacting elements by multiplying the coefficient of friction
by the corresponding normal forces.
The lower face of the upper cantilever and the upper face of the lower
cantilever are contacting each other partially. COSMOS/Works automatically
takes care of this situation by generating compatible meshes on the contacting
portions of the two faces.
3-17
If you do not see the COSMOS/Works menu, click Tools, Add-Ins, select
COSMOS/Works and click OK.
We recommend that you click File, Save As to save the assembly with a
different name before defining a study so that you can use the original file
again.
2
3-18
Apply a normal pressure of 200 psi to the upper face of the upper cantilever.
Click OK.
3-19
Gap
Contact
3-20
Reaction Forces
Friction forces should develop reaction forces in the Z-direction at the supports.
To view the X, Y, and Z directions:
Click the FeatureManager tab.
2 Click Plane1. The global X, Y, and
Z directions are illustrated in the
figure.
1
3-21
Right-click the study icon and select Run. The stress and displacement results
without friction are shown below.
3-22
4
Importing Motion Loads
Introduction
Many products contain moving assemblies of components (mechanisms).
Mechanisms play a crucial role in the performance of such products. Dynamic
Designer/Motion is a design software produced by Mechanical Dynamics, Inc. for
the simulation of mechanical systems. Embedded in SolidWorks, it enables
designers to model 3D mechanisms as virtual prototypes.
After making sure that the mechanism is working properly in Dynamic Designer/
Motion, you naturally want to make sure that the parts of the assembly are safe
under the action of the loads generated by the specified motion. COSMOS/Works
can automatically import motion loads from the Dynamic Designer/Motion for
SolidWorks. This chapter presents a step-by-step lesson on how to define a
motion in Dynamic Designer/Motion and run static analysis based on importing
motion loads from Dynamic Designer /Motion.
This example is intended to provide you with a self-contained document for using
Dynamic Designer/Motion for the purpose of calculating motion loads to be used
by COSMOS/Works. For formal description of the capabilities of Dynamic
Designer /Motion, please refer to the Dynamic Designer/Motion for
SolidWorks User s Guide and the corresponding on-line help.
To be able to import motion loads to COSMOS/Works, you must install
Dynamic Designer/Motion on your system. For more information about
Dynamic Designer/Motion, please contact your sales representative at
Structural Research and Analysis Corporation.
4-1
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Description
In this tutorial, we will show you how to use Dynamic
Designer/Motion and COSMOS/Works to analyze a
landing gear assembly mechanism. The landing gear
mechanism is part of a retractable nose wheel of a
conceptual light aircraft. The main purpose of the
mechanism is to bring the gear down to a locked position.
The locked position is controlled by a diagonal bracing
which, when fully extended, has an electro-mechanical
latch to lock it in position. In real-life, the pilot activates a
switch to release this latch and a pre-loaded spring ensures
that the diagonal brace retracts to the initial position. The
actuator can retract the under carriage only when the
diagonal brace is free to move. Dynamic loads induced by
this motion will be automatically transferred to COSMOS/
Works to perform design analysis.
Link Arm
We will calculate the stresses that develop in the link arm due to motion loads. To
demonstrate the tight integration between Solid/Works, Dynamic Designer/
Motion, and COSMOS/Works, we will modify the part and repeat the motion and
design simulations after modifying the geometry.
4-2
The magnitudes of the loads generated by the moving mechanism may not be
significant compared to loads caused by the impact of landing. You can create
another study to simulate the impact of landing.
Start SolidWorks.
4-3
4-4
Click
Click
4-5
Click
. The Dynamic
Designer Options dialog box
opens with the Simulation tab
selected.
4-6
In the Results
Characteristics list box select Force.
Optional: Enter a name for the plot in the Title field, for example, Force.
4-7
Microsoft Excel is required for plotting the curve. However, you still can
transfer loads even if you dont have EXCEL.
4-8
Click the simulation button to delete the results and return to the initial
position.
Select the load information file generated in the previous step (i.e., the
landing_gear_16.txt file) and click Open.
Click
box.
Right-click the link_arm<1> icon and select Open link_arm.sldprt. The part
will be opened in the graphics area.
4-9
Click the COSMOS/Works Manager tab. You will see study Frame-16 with
gravity and centrifugal load already applied to the part. This study was created
automatically when you imported the motion load file to COSMOS/Works.
Define Materials
We will apply Plain Carbon Steel to the link arm part. Right-click the link_arm
material icon and select Apply/Edit Material. In the Material dialog box, select
Plain Carbon Steel from the Material Name list box and click OK.
Apply Restraints
We will fix the two cylindrical faces of
the link arm.
To fix the inner cylindrical faces:
4-10
Click OK.
Right-click the Mesh icon and select Preferences. The Preferences dialog box
opens with the Mesh tab selected.
From the Jacobian Check menu, make sure that 4 Points in selected.
Click OK.
4-11
Right-click the Plot1 icon under Stress folder and select Animate.
In the COSMOS/Works Manager, click the (+) sign next to the Displacement
folder.
4-12
Click OK.
On the SolidWorks menu bar click Motion, Toolbar. The Simulation toolbar
opens.
In the simulation toolbar, drag the slider to frame number 16 and click Motion,
Export Results to COSMOS/Works.
Click the simulation button to delete the results and return to the initial
position.
Click COSMOS/Works, Import Motion Loads. The Open dialog box opens.
Select the load file saved in the previous step and click Open.
In the Import Motion Loads dialog box, change the study name to Frame-16
Modified.
In the Available Loads list box, click the link_arm-1: Body Forces and move it
to the Selected Loads list box.
In the Selected Loads list box, click actu_pist-1:Body Forces and move it to
the Available Loads list box.
Click OK.
4-13
Right-click the link_arm<1> icon and select Open link_arm.sldprt. The part
will be opened in SolidWorks graphics area.
Click the COSMOS/Works Manager toggle icon. You will see the study
Frame-16-Modified with gravity and centrifugal loads already applied to the
part.
Open the Frame-16 study folder and select the Solids folder.
Apply Restraints
To fix the faces of the holes:
4-14
Click OK.
Click the (+) sign to the left of the Stress folder under the Frame-16-modified
study.
Double-click the Plot1 icon. Compare the results with respect to Frame-16
study.
4-15
5
Frequency Analysis Tutorial
5-1
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Start SolidWorks.
5-2
We recommend that you use File, Save As to save the part with a different
name before defining a study so that you can use the original file again.
COSMOS/Works Manager
Click OK.
5-3
In the COSMOS/Works Manager tree, right-click the Tutor1 icon under Solids
folder and select Apply/Edit Material. The Material dialog box opens with the
COSMOS/M Library tab selected.
From the Material Type drop-down menu, verify that Steel is selected.
In the Material Name list box, verify that Alloy Steel is selected.
Click OK.
Apply Restraints
To fix the two holes:
1
Select the face of one hole. Press and hold down the Ctrl key and select the face
of the other hole.
Click OK.
5-4
In the COSMOS/Works Manager tree, right-click the Mesh icon and click
Preferences. The Preferences dialog box opens with the Mesh tab selected.
Make sure that 4 Points is selected from the Jacobian Check menu.
Click OK.
Right-click the Mesh icon and select Create. The Mesh dialog box opens and
an average element size is suggested.
Click OK to accept the default element size. After meshing is completed, you
will get the Solid mesh completed message.
Right-click the Freq-1 study icon and click Run. The analysis starts. When the
analysis is completed, you will get the Frequency Analysis Completed
message.
Click OK.
5-5
5-6
Click OK.
5-7
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Change the Look in folder to ...\Examples where ... refers to the COSMOS/
Works installation directory.
If you do not see the COSMOS/Works menu, click Tools, Add-ins, then check
the control box for COSMOS/Works and click OK.
5-8
Right-click the Crank icon, and click Study. The Study dialog box opens.
In the New Study field, type in a name for the study, for example, Freq-2.
Click OK.
From the Material Name list box, select Gray Cast Iron.
Click OK.
Apply Restraints
To apply loads and restraints to the assembly:
1
Click OK.
Right-click the Mesh icon and select Preferences. The Preferences dialog box
opens with the Mesh tab selected.
Make sure that 4 Points is selected from the Jacobian Check menu.
Click OK.
5-9
Click OK.
5-10
Click COSMOS/Works, List Results, Mode Shape. The Mode Shape window
opens and lists the frequencies.
In the COSMOS/Works Manager tree, click the (+) sign to the left of the
Deformation folder of Freq-2 study.
5-11
6
Buckling Analysis Tutorial
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6-1
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0.4 thickness
0.2 thickness
6-2
6-3
Start COSMOS/Works.
Change the Look in folder to ...\Examples where ... refers to the COSMOS/
Works installation folder.
From the Files of type drop-down list, select Part Files (*.prt; *.sldprt).
6-4
Click OK.
Right-click the 3plates-midsurfaces icon in the Solids folder and select Apply/
Edit Material. The Material dialog box opens with the COSMOS/M Library tab
selected.
From the Material Name list box, verify that Alloy Steel is selected.
Click OK.
Click OK.
Right-click the Load/Restraint icon and select Force. The Force dialog box
opens.
6-5
Click OK.
Right-click the Mesh icon and select Preferences. The Preference dialog box
opens with the Mesh tab selected.
Make sure that 4 Points is selected from the Jacobian Check menu.
Click OK.
Right-click the Mesh icon and select Create. The Mesh dialog box opens and
an average element size of 0.37808 inches is suggested.
Click OK. After meshing is completed, you will get the Shell Mesh Completed
message.
Right-click the Mesh icon and select Show Mesh. The mesh is displayed in the
SolidWorks window.
After flipping
6-6
You may get different misaligned shells based on the version or service pack
of SolidWorks that you are using. You need to align all shells before running
the analysis.
4
Right-click the Mesh icon and select Hide Mesh to hide the mesh.
Click COSMOS/Works, List Results, Mode shape. The buckling load factor is
listed as 1.54
In the COSMOS/Works Manager tree, click the (+) sign to the left of the
Deformation icon.
Right-click the Plot1 icon under the Deformation folder and select Animate.
The Animation dialog box opens.
You can save the animation as an AVI file and view it with the Media Player
by checking the corresponding checkboxes.
6-7
Buckling Status
Notes
1 < BLF
COSMOS/Works does
not predict buckling.
BLF = 1
COSMOS/Works
predicts buckling to
occur.
BLF = -1
COSMOS/Works does
not predict buckling.
COSMOS/Works does
not predict buckling.
BLF < -1
COSMOS/Works does
not predict buckling.
= 1.54
6-8
Start COSMOS/Works.
Change the Look in folder to ...\Examples where ... refers to the COSMOS/
Works installation folder.
From the Files of type drop-down list, select Part Files (*.prt; *.sldprt).
Click OK. The new study name appears in the Studies list box.
Click OK.
6-9
Right-click the Shells folder icon in the COSMOS/Works Manager tree and
select Define by Selected Surfaces. The Define Shell dialog box opens.
Select these 3 faces
This dimension is
irrelevant
Click OK. The program creates an icon for each of the 3 faces in the Shells
folder.
In the Shells folder, click the Shell-2 icon. The middle shell highlights.
Click OK. The program changes the thickness of the middle shell from 0.2 to
0.4.
Right-click the Shells folder icon and select Apply Material to All. The
Material dialog box opens with the COSMOS/M Library tab selected.
From the Material Name list box, verify that Alloy Steel is selected.
Click OK.
You can assign a different material to each shell.
6-10
Click OK.
Select the right edge of the right shell face as shown in the
figure.
Click the Along plane Dir1 (of Plane 1) checkbox and enter -100 in its field.
Click OK.
Mesh the Part, Run the Analysis, and Visualize the Results
The rest of the steps are similar to the previous study:
1
To mesh the part, right-click the Mesh folder icon and select Create. Use the
default global element size of 0.74002.
Right-click the Mesh icon and select Show Mesh. If needed, align the shell
elements by selecting the misaligned face, right-clicking the Mesh icon, and
selecting Flip Shell Elements.
To run buckling analysis, right-click the study folder and select Run.
6-11
To list buckling results, click COSMOS/Works, List Results, Mode Shape. The
buckling load factor is listed as 1.54.
Start COSMOS/Works.
6-12
Click OK. The new study name appears in the Studies list box.
Click OK.
Right-click the Shells folder icon in the COSMOS/Works Manager tree and
select Define by All Ref Surfaces . The Define Shell dialog box opens.
Click OK. The program creates an icon for each of the 3 surfaces in the Shells
folder.
In the Shells folder, click the Shell-3 icon. The middle shell highlights.
6-13
Click OK. The program changes the thickness of the middle shell from 0.2 to
0.4.
Right-click the Shells folder icon and select Apply Material to All. The
Material dialog box opens with the COSMOS/M Library tab selected.
From the Material Name list box, verify that Alloy Steel is selected.
Click OK.
You can assign a different material to each shell.
Click OK.
6-14
Select the right edge of the right shell face as shown in the figure above.
Right-click the Load/Restraint icon and select Force. The Force dialog box
opens.
Click the Normal to plane (Plane 1) checkbox and enter -100 in its field.
Click OK.
Mesh the Part, Run the Analysis, and Visualize the Results
The rest of the steps are similar to the previous study:
1
To mesh the part, right-click the Mesh folder icon and select Create. Use the
default global element size of 0.23238.
Right-click the Mesh icon and select Show Mesh. If needed, align the shell
elements by selecting the misaligned surface, right-clicking the Mesh icon, and
selecting Flip Shell Elements.
You can specify a global element size larger than the default. We have seen
in the previous studies that element sizes of about 0.38 and 0.74 inches
gave similar results.
To run buckling analysis, right-click the study folder and select Run. When
analysis is completed, click OK.
To list buckling results, click COSMOS/Works, List Results, Mode shape. The
buckling load factor is listed as 1.5332.
6-15
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Fixed end
6-16
Start SolidWorks.
Click Open.
COSMOS/Works Users Guide
In the New Study field, type in the name of the study, for example, Buckling
Study.
Click OK. The new study name appears in the studies list box.
Click OK.
6-17
Assigning Material
To assign a material from the COSMOS/M Library:
1
In the COSMOS/Works Manager, right-click the Bar icon and select Apply/Edit
Material.
Click OK.
Notice the checkmark that appears on the part icon indicating that you have
assigned a material to the part successfully.
In the Value field, enter 1000 to apply a compressive 1,000 pound force.
Click OK.
6-18
Click OK.
Right-click the Mesh icon and select Preferences. The Preference dialog box
opens with the Mesh tab selected.
Make sure that 16 Points is selected in the Jacobian Check drop-down menu.
Click OK.
Right-click the Mesh icon and select Create. The Mesh dialog box opens and
an average element size is suggested.
Drag the slider to the extreme left to use an element size that is twice as the
suggested size.
6-19
= 20 inches
= Modulus of Elasticity = 30e7 psi
= moment of inertia of the cross section = 14/12 in4
= 1.67%
6-20
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Start COSMOS/Works.
Change the Look in folder to ...\Examples where ... refers to the COSMOS/
Works installation folder.
From the Files of type drop-down list, select Part Files (*.prt; *.sldprt).
6-21
Right-click the Tutor2 icon and select Study. The Study dialog box opens.
In the New Study field, type in a name for the study, for example, Buckling-1.
Click OK. The new study name appears in the Studies list box.
Click OK.
Preprocessing
Assign Material Properties
To assign a material from the COSMOS/M Library:
1
Right-click the Tutor2 icon in the Solids folder and select Apply/Edit Material.
The Material dialog box opens with the COSMOS/M Library tab selected.
From the Material Name list box, verify that Alloy Steel is selected.
Click OK.
Apply
pressure
normal to
this face
Notice that the Selected Entities box lists the number of selected faces,
edges and vertices. In this case, one face is selected.
6-22
4 Optional: To
change the color of the restraint symbol, click the Color button.
The Color palette opens. Select the desired color and click OK.
Click OK.
Click OK.
Click OK.
6-23
Right-click the Mesh icon and select Preferences. The Preference dialog box
opens with the Mesh tab selected.
Make sure that 4 Points is selected from the Jacobian Check menu.
Click OK.
Right-click the Mesh icon and select Create. The Mesh dialog box opens and
an average element size is suggested.
Click OK. After meshing is completed, you will get the Solid Mesh Completed
message.
Click OK.
6-24
Click OK.
Click COSMOS/Works, List Results, Mode Shape. The buckling load factor is
listed as 692.69.
to start the
to stop the
= 692.69
6-25
You can reduce the error by rebuilding the mesh using a smaller global
element size and rerunning the study again.
Right-click the Mesh icon, and select Preferences. The Preferences dialog box
opens with the Mesh tab selected.
Click OK.
Right-click the Mesh icon and select Create. A message window opens that
warns you of the deletion of the previous results when remeshing the model.
Click OK.
In the Mesh dialog box, enter 0.25 in the Global Size field.
Click OK.
6-26
6-27
7
Thermal Analysis Tutorial
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7-1
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Introduction
Electronic components very often become the hottest spots in many electronic
systems. The heat generated by electronic components transfers throughout the
electronic system and can cause potential problems. Thermal analysis, therefore,
provides you with valuable information for your electronic system designs.
Heat transfers by conduction, convection, and radiation. Most electronic systems
experience all these modes of heat transfer, though only one of them may
dominate a particular design condition. For example, radiation becomes
significant at high temperatures but may be negligible at low temperatures.
In this lesson, we will analyze the heat transfer in an electronic chip. Any such
chip has many electronic components-such as diodes, transistors, resistors, and
capacitors-all integrated in a single chip. A chip carrier or substrate, made of
ceramic, plastics, or glass, protects it from diverse environmental effects. The
carrier receives heat transferred from the chip and then transfers it to the chip
case. This process takes place, primarily, through a combination of conduction
and convection.
7-2
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The coefficient of thermal conductivity of the chip (k) = 130 W/m oC.
Due to the symmetry of the model, we will analyze one quarter of it and apply
symmetric boundary conditions at the physical boundaries of the model.
Start COSMOS/Works.
From the Files of type menu, select Assembly Files (*.asm, *.sldasm).
7-3
7-4
Right-click the COMPUTER_CHIP icon and select Study. The Study dialog box
opens.
In the New Study field, enter a name for the study, for example, Thermal-1.
Click OK.
Right-click the Substrate-1 icon under the Solids folder and select Apply/Edit
Material. The Materials dialog box opens with the COSMOS/M Library tab
selected.
Click OK.
Right-click the Chip-1 icon under the Materials folder and select Apply/Edit
Material.
From the Material Property Name list box, select KX Thermal conductivity.
In the Input Property Value field, enter 130 and click Set.
Repeat steps 3-5 to enter the numerical values for the elastic modulus
(EX=4.1e11) and specific heat (C=670).
Click OK.
Repeat steps 1-7 to input material properties for the other chips in the
assembly.
We will use the specific heat C when running transient analysis on the
assembly (lesson 19), and the elasticity modulus EX when running thermal
stress analysis (lesson 20) later in this tutorial.
7-5
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Right-click the Load/Restraint folder, and select Heat Flux. The Heat Flux
dialog box opens.
Click OK.
7-6
Select the opposite faces and the bottom face of the assembly.
Click OK.
To apply heat power boundary condition to the top faces of the chips:
1
Under the Solids folder, select Chip-1, Chip-2, Chip-3, and Chip-4. Press and
hold the Ctrl key while selecting these components.
Click OK.
Right-click the Mesh icon, and select Properties. The Preferences dialog box
opens with the Mesh tab selected.
Make sure that 4 Points is selected from the Jacobian Check menu.
Click OK.
Right-click the Mesh icon and select Create. The Mesh dialog box opens.
Click OK to accept the defaults. The meshing starts, when completed, a Solid
Mesh Completed message appears.
7-7
Right-click the Thermal-1 study icon and select Run. The analysis starts.
When completed, a Thermal Analysis Completed message appears.
7-8
This lesson is completed. The next lesson will use the same assembly.
7-9
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Introduction
Steady state analysis gives you thermal results when the model reaches thermal
equilibrium and the temperature of each particle remains constant afterwards.
Steady state analysis does not tell you how long it takes to reach this condition.
Transient analysis, on the other hand, answers questions such as: what will be the
temperature profile after a given period of time?.
In this lesson, you will learn how to perform transient thermal analysis on the
computer chip assembly. In this kind of analysis, the temperature changes with
time and we will be interested in calculating the temperature distribution in the
chip at different instances of time. Since the model and boundary conditions are
the same as those used during the steady state lesson (lesson 18), we will use drag
and drop procedure to ease the process of assigning the materials and applying the
loads and boundary conditions.
7-10
In the New Study field, enter a name for the study, for example, Thermal-2.
Click OK.
Click OK.
Click the (+) sign to the left of the Thermal-1 study icon to expand the study
items.
Drag the Solids folder from Thermal-1 study and drop it onto Thermal-2 study
icon. The materials will be copied from Thermal-1 to Thermal-2.
Click the plus sign to the left of the Thermal-1 study icon to expand the study
items.
Drag the Load/Restraint folder from Thermal-1 study and drop it onto
Thermal-2 study icon. The thermal loads and boundary conditions will be
copied from Thermal-1 to Thermal-2.
7-11
Right-click the Thermal-2 study icon and select Run. The analysis starts.
When completed, a Thermal Analysis Completed message appears.
7-12
Click the plus sign to the left of the Thermal folder. Plot1 icon appears.
Right-click the Plot1 icon, and select Edit Definition. The Thermal Plot dialog
box opens.
Click OK.
To plot the temperature profile after the third, ninth, and the last time step:
1
Right-click the Thermal folder under Thermal-2 study icon, and select Define.
The Thermal Plot dialog box opens.
Click OK.
Repeat steps 1-3 to plot temperature profiles at other times steps (by entering 9
and 12 respectively in the Time Step No. field in the corresponding dialog box).
This lesson is completed. The next lesson uses the same document.
7-13
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Create a static analysis study to find out the stresses generated by thermal
loading from thermal studies,
Define restraints,
Run the analysis, and
Visualize stress results due to thermal loading.
7-14
In the Reference
temperature at zero strain
field, enter
300 oK.
Face 2
Face1
Apply structural symmetry
boundary condition
on these faces.
Select the free faces of the chip assembly (shown as dotted lines in the figure).
Click OK.
Switch back to the COSMOS/Works Manager, and select Face 1 while pressing
the Ctrl key down.
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Select Use Reference Plane or Axis . make sure that Plane 1 appears in the
Selected Reference box.
Under Displacement, check Along plane Dir 1 and enter 0 in its field.
Click OK.
Select Face 2 of the chip and repeat steps (1-5) mentioned above except that in
step 4 check Along plane Dir 2.
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Click the plus sign to the left of the Stress folder. Plot1 icon appears.
Right-click Plot1 icon and select Edit Definition. The Stress Plot dialog box
opens.
Select psi from the Stress Units menu under the Properties tab.
Click the Settings tab, and enter 1 in the Scale Factor field.
Click OK.
This lesson is completed. You can close this document. The next lesson
uses different document.
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Use the Split Line function for the proper application of boundary conditions,
and
Specify thermal boundary conditions and run thermal analysis.
Introduction
Convection is the mode of energy transfer between a solid surface and an
adjacent moving fluid or gas. It involves the combined effects of conduction and
fluid motion. The rate of heat transfer from a surface at a temperature Ts to a
surrounding medium at T m is given by the simple law:
Q convection = hA ( Ts Tm )
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Pipe
Fins
Description
The assembly consists of the following components:
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An 8-mm long stainless steel pipe with an outer radius of 15 mm and an inner
radius of 13 mm.
A 2-mm thick aluminum fin (alloy # 2024) with an outer radius of 30 mm
attached to the surface of the pipe.
We will apply the following thermal loads and boundary conditions to the
assembly:
The inner face of the pipe is maintained at a fixed temperature of Ts=180 oC.
The ambient temperature far enough from the assembly is Tm= 25 oC.
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The heat transfer coefficient (h) of the outer face of the pipe (without fin) is 60
W/m2 oC.
The heat transfer coefficient (h) for the whole assembly (pipe + fin) is 50 W/m2
o
C
Start SolidWorks.
From the Files of type menu, select Assembly Files (*.asm; *.sldasm).
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Face 1
Face 2
Face 3
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Click the plus sign to the left of the Pipe<1> icon to expand its items.
to open a
10
11
12
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Right-click the Pipe icon at the top of the COSMOS/Works Manager and select
Study. The Study dialog box opens.
In the New Study field, enter a name for the study, for example, No Fin.
Click OK.
Click OK.
Apply fixed
temperature
to this face
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Click OK.
Apply convection
boundary conditions
to these faces
Make sure that 4 Points is selected from the Jacobian Check menu.
Click OK.
Right-click Plot1 icon and select Edit Definition. The Thermal Plot dialog box
opens.
From the Units menu under the Properties tab, select SI.
Click the Display tab and select Section in the Plot Type box.
Click the Settings tab and select None from the Boundary Options list.
Click OK.
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To view the section plot properly, click *Right from the Orientation box.
Close the Pipe part by clicking File, Close. You will get the following
message,
Click Yes.
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A temperature boundary condition on the inner face of the pipe in exact the
same way we did in the No Fin study (i.e., with Ts=180 oC).
Convection boundary conditions to the outer faces of the assembly (5 faces)
with an overall heat transfer coefficient of 50 W/m2 oC.
Select the outer faces of the assembly. This time the faces of the fin should be
included in the selection.
Click OK.
Click the plus sign to the left of the Thermal folder under the Fin study.
Right-click Plot1 icon and select Edit Definition. The Thermal Plot dialog box
opens.
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From the Units menu under the Properties tab, select SI.
Click the Display tab and select Section in the Plot Type box.
Click the Settings tab and select None from the Boundary Options list.
Click OK.
Conclusion
By looking at the resultant heat flux
values on the outer faces of the model
for both cases (with and without fin),
one can realize the effectiveness of the
fin in dissipating heat out of the model. By closer investigation of the values of
the resultant heat flux at the common face of the fin and the pipe, one can easily
realized that the fin has enhanced the heat transfer rate by over an order of
magnitude.
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8
Optimization Analysis Tutorial
8-1
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Introduction
The purpose of this lesson is to show you how to perform optimization analysis on
a given part. The fundamental ingredients of an optimization analysis study are:
an objective function, design variables, and behavior constraints. The objective
function usually defines the goal of the optimization process. In this release, you
can set the objective function to minimize/maximize the mass, volume, natural
frequency, and buckling load factor of a given design. The design variables, on
the other hand, are the changeable dimensions of the model that we are seeking to
optimize. The constraints define the conditions that the optimized design must
satisfy (please refer to Chapter 9 in the Users Guide book for more details).
In this lesson we will be seeking an optimum design of a cantilever bracket,
subjected to structural loading and boundary conditions, that will minimize its
volume. We will start the lesson by performing static analysis on the initial
design, then we will create an optimization study, and perform the optimization
analysis to find the optimum design of the part.
Description
The initial design of the cantilever
bracket has the following dimensions;
Fixed
face
Normal
pressure
DV1
8-2
DV3
DV2
We are seeking an optimum design of this part that minimizes its volume. The von
Mises stress resulting from the specified loading is not to exceed a certain value
(3x108 N/m2). The design variables (DV1, DV2, and DV3 in the graph) are to be
within some upper and lower bounds. The optimization problem that we are trying
to solve in this lesson has the following elements:
Objective Function
Minimize the volume of the cantilever part subject to the specified loading and
restraints.
Design Variables
The upper and lower bounds imposed on the design variables are:
Design Variable DV1 (in mm): 10 < DV1 < 25,
Design Variable DV2 (in mm): 10 < DV2 < 25, and
Design Variable DV3 (in mm): 20 < DV3 < 50.
Constraints
The von Mises stress on
the optimum design is
not to exceed 3x108 N/
m2, within 5%
tolerance.
Start SolidWorks.
Navigate to the
folder
...\Examples\Optimi
zation, where ...
refers to the
installation folder of
COSMOS/Works.
4
Make sure that the Files of type field is set to Part Files (*.prt, *.sldprt).
8-3
In the Study dialog box, click Add. The Study Name dialog box opens.
Click OK.
Right-click the Canilever_Bracket icon in the Solids folder and select Apply/
Edit Material.
In the Material dialog box, select Alloy Steel from the Material Name list box.
Click OK.
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Click OK.
Apply normal
pressure to
this face
Fix this
face
To apply normal uniform pressure to the upper horizontal face of the bracket:
1
Click OK.
Make sure the 4 Points is selected from the Jacobian Check menu.
Click OK.
Right-click the Mesh icon and select Create. The Mesh dialog box opens.
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8-6
Click OK.
Click OK.
Click OK.
Note the red checkmark that appears on the
Objective icon indicating that this item has been defined.
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8-8
Right-click the Design Variables icon and select Edit/Define. The Design
Variables dialog box opens.
In SolidWorks graphics area, select any dimension by clicking it once, for example, DV1 (=25
mm), and click Add. The corresponding Design
Variable dialog box opens. This dialog box
will help you assign upper and lower bounds of
the selected design variable.
Click OK. The dimension will listed in the Design Variables dialog box.
Right-click the Constraints icon and select Edit/Define. The Constraints dialog
box opens.
Click OK. The specified constraint will be listed in the Constraints dialog box.
Click OK.
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Final Design
Design after iteration No. 5
Final Design
8-10
Click OK.
Convergence of Graphs
To plot the convergence of the design
variables:
1
Right-click the Design History Graph folder and click Define. The Design
History Graph dialog box opens.
From the Graph Parameters menu, select the parameter you want to plot.
Move that data you want to plot from the Available Data box to the Plot Data
box.
Click OK.
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8-12
Click OK.
Click OK.
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Round Off the Final Design Dimensions and Rerun Your Analysis
The final dimensions of your design may or may not have decimal figures.
Typically, for fabrication purposes, these figures should be rounded off to the
closest number that can be measured within the precision of the fabrication
process. The changes in dimensions of the final design may lead to higher
stresses than those calculated by the program. In order to make sure that your
stress constraint is still satisfied on your final model, you need to rerun static
analysis on the finalized design and check the values of stresses throughout your
model.
8-14
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Introduction
The purpose of this lesson is to show you how to perform optimization analysis on
a given assembly subjected to constraints from multiple studies.
In this lesson we will be seeking an optimum design of a cylinder, subjected to
thermal and structural loading that minimizes its volume. We will start the lesson
by performing thermal and static analyses on the initial design, then we will create
an optimization study, and perform the optimization analysis to find the optimum
design that satisfies the constraints set by the user.
Description
The initial design of the cylinder has the following dimensions.
Heat Source
at the bottom
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The cylinder assembly consists of two parts; a heat source which is a circular disk
located at the bottom of the assembly, and a heat sink which constitutes the rest of
the cylinder. The heat source is made of Aluminum Alloy, and the heat sink is
made of a Alloy Steel. Due to the symmetry of the model, we will analyze only a
quarter of it. The model is subjected to the thermal loads shown in figure.
Convection and
radiation boundary
conditions on this face
Convection
boundary
condition
on these
faces.
Heat power to
the heat source
component
Convection boundary
condition on the bottom
face of the heat sink
Objective Function
Minimize the volume of the cylinder assembly subjected to the specified loading
and restraints.
Design Variables
The upper and lower bounds imposed on the design variables are:
The outer radius of the cylinder: 6 < R < 10 inches,
The thickness of the cylinder wall: 1.5 < T < 2 inches, and
The height of the cylinder: 8 < H < 10 inches.
Constraints
The following constraints are to be applied:
The temperature throughout the model is not to exceed 430 oK.
The von Mises stress on the model is not to exceed 8x108 Nm-2.
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Start SolidWorks.
Make sure that the Files of type field is set to Assembly Files (*.asm,
*.sldasm).
8-17
In the Study dialog box, click Add. The Study Name dialog box opens.
Click OK.
From the Material Name menu, select Aluminum Alloy (1060 alloy).
Click OK.
8-18
Right-click the Quarter_Heat_Sink-1 icon in the Solids folder and select Apply/
Edit Material. The Material dialog box opens.
Click OK.
Click OK.
Click OK.
8-19
Click OK.
Select the heat source part by clicking the Quarter_Heat_Source-1 icon in the
Solids folder. Make sure that the selected part is highlighted in the graphics
area.
Right-click the Load/Restraint folder and select Heat Power. The Heat Power
dialog box opens.
Click OK.
The program uses the heat power
loading when applied to components
as a uniformly distributed
volumetric heat source.
From the Jacobian Check menu, make sure that 4 Points is selected.
Click OK.
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Right-click the Mesh icon and select Create. The Mesh dialog box opens.
Click OK.
In the COSMOS/Works
Manager, right-click the
Quarter_Cylinder icon and
select Study.
In the Study dialog box, click Add. The Study Name dialog box opens.
In the New Study field, enter an name for your study, for example, Thermal
Stress.
Click OK.
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Click OK.
8-22
Click OK.
Restrain
these
two faces along
Dir 1 of Plane1
In the Displacement box, check Along Plane Dir 1 and enter 0 in its field.
Click OK.
Click OK.
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Click the Settings tab and enter 1 in the Scale Factor field.
Click OK.
Now, we will perform optimization analysis on the model, to find the optimum
design (dimensions) that will minimize its volume. We will apply constraints
from both Thermal Study and Thermal Stress studies.
Click OK.
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Click OK.
Right-click the Objective icon and select Edit/Define. The Objective dialog box
opens.
Click OK.
8-25
Right-click the Mesh icon and select Hide Mesh. The model displays in the
shaded view mode and its dimensions are visible and ready for user selection.
Hiding the mesh (or the results) is necessary for the next step of defining
the design variables of the study.
Right-click the Design Variables icon and select Edit/Define. The Design
Variables dialog box opens.
To add a design variable to the study select, for example, the radius dimension
(D2@Sketch1@Quarter_Heat_Sink.Part) and click the Add button in the
Design Variables dialog box. The Design Variable dialog box opens.
Click OK. The dimension will listed in the Design Variables dialog box.
To assign upper and lower bounds to the other dimensions (the wall thickness
and height), repeat steps (2-6) with the appropriate lower and upper bounds and
tolerance (as shown in the figure).
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Click OK. The specified constraint will be listed in the Constraints dialog box.
8-27
Initial Design
Click OK.
Final Design
8-28
Convergence Graphs
To plot the default design variable convergence graph:
1
Click the plus sign to the left of the Design History Graph folder.
Right-click the Design History Graph folder and click Define. The Design
History Graph dialog box opens.
8-29
Click the plus sign to the left of the Design local Trend Graph folder.
You can generate other graphs by right-clicking the Design Local Trend
Graph folder and selecting Define.
8-30