Professional Documents
Culture Documents
SolidWorks Simulation
Professional
Introduction
About This Course . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Course Design Philosophy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Using this Book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Laboratory Exercises . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
About the Training Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Windows® 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Conventions Used in this Book . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Use of Color . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
What is SolidWorks Simulation? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Limitations of SolidWorks Simulation Professional. . . . . . . . . . . . . . . 5
Lesson 1:
Frequency Analysis of Parts
Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Modal Analysis Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Required Material Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Frequencies and Mode Shapes . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Fundamental Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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 . . . . . . . . . . . . . . . . . . . . . . . . 14
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Contents SolidWorks 2012
ii
SolidWorks 2012 Contents
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Exercise 5: Buckling Analysis of a Stool . . . . . . . . . . . . . . . . . . . . . . 51
Exercise 6: Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Lesson 4:
Thermal Analysis
Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Thermal Analysis Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Mechanisms of Heat Transfer. . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Conduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Convection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Radiation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Material Properties for Thermal Analysis . . . . . . . . . . . . . . . . . . 69
Case Study: Microchip Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Project Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Stages in the Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Steady-State Thermal Analysis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Interfacial Conductance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Initial Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Thermal Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Heat Flux. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Heat Flux Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Heat Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Transient Thermal Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Importing Convective Effect from SolidWorks Flow Simulation 80
Results Comparison . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Transient Analysis with Time Varying Load . . . . . . . . . . . . . . . . . . . 83
Time Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Temperature Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Transient Thermal Analysis using a Thermostat . . . . . . . . . . . . . . . . 85
Symmetry Boundary Condition in Thermal Analysis . . . . . . . . . 87
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Exercise 7: Thermal Analysis of a Cup . . . . . . . . . . . . . . . . . . . . . . . 89
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Lesson 5:
Thermal Analysis with Radiation
Case Study: Spot Light Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Project Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Stages in the Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Steady State Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Review of Analysis Parameters . . . . . . . . . . . . . . . . . . . . . . . . . 101
Heat Flux Singularities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
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Contents SolidWorks 2012
Lesson 6:
Advanced Thermal Stress
2D Simplification
Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Thermal Stress Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Case Study: Metal Expansion Joint . . . . . . . . . . . . . . . . . . . . . . . . . 106
Project Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Stages in the Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Thermal Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
2D Simplification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Prescribed Temperature Condition . . . . . . . . . . . . . . . . . . . . . . . 112
Meshing Considerations in Thermal Analysis . . . . . . . . . . . . . . 112
Thermal Stress Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Importing Temperatures and Pressures from
SolidWorks Flow Simulation . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Reference Temperature at Zero Strains . . . . . . . . . . . . . . . . . . . 115
3D model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Exercise 8: Thermal Stress Analysis of a
Microchip Testing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Thermal Stress Study . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Change in Thermal Boundary Conditions . . . . . . . . . . . . . . . . . 129
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Exercise 9: Thermal Stress Analysis of a Gas Tank . . . . . . . . . . . . . 132
Exercise 10: Thermal Stress Analysis of a Thermoelectric Cooler . 137
Problem Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Loading Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Goal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Lesson 7:
Fatigue Analysis
Fatigue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Stages of Failure due to Fatigue . . . . . . . . . . . . . . . . . . . . . . . . . 142
High vs. Low Cycle Fatigue . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Stress-life (S-N) Based Fatigue . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Fatigue Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Case Study: Pressure Vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Project Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Stages in the Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Thermal Study. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Thermal Stress Study . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Static Pressure Study . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Fatigue Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
S-N Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
iv
SolidWorks 2012 Contents
v
Contents SolidWorks 2012
vi
Introduction
1
Introduction SolidWorks 2012
2
SolidWorks 2012 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.
Click on the link for Support, then Training, then Training Files, then
SolidWorks Simulation Training Files. Select the link for the desired
file set. There may be more than one version of each file set available.
Direct URL:
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
required for doing the laboratory exercises.
Windows® 7 The screen shots in this manual were made using SolidWorks 2012 and
SolidWorks Simulation 2012 running on Windows® 7. If you are
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.
Conventions Used This manual uses the following typographic conventions:
in this Book
Convention Meaning
Bold Sans Serif SolidWorks Simulation commands and
options appear in this style. For example,
“Right-click External Loads and select
Force” means right-click the External
Loads icon in the SolidWorks Simulation
study tree and select Force from the shortcut
menu.
Typewriter Feature names and file names appear in this
style. For example, Fixed Geometry-1.
Double lines precede and follow sections of
17 Do this step the procedures. This provides separation
between the steps of the procedure and large
blocks of explanatory text. The steps
themselves are numbered in sans serif bold.
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 2012
4
SolidWorks 2012 Introduction
5
Introduction SolidWorks 2012
6
Lesson 1
Frequency Analysis of Parts
Objectives Upon successful completion of this lesson, you will be able to:
Perform a frequency analysis with and without supports.
Investigate rigid body modes.
Discuss the role of supports in a frequency analysis.
Perform a frequency analysis with a prestress condition.
Use design scenarios to conduct design sensitivity studies
(optional).
7
Lesson 1 SolidWorks 2012
Frequency Analysis of Parts
Modal Analysis Every structure has its preferred frequencies of vibration called
Basics resonant frequencies. Each such frequency is characterized by a
specific shape of vibration.
When excited with a resonant frequency, a structure vibrates in a shape.
This is called a mode of vibration.
Recall that structural static analysis calculates nodal displacements as
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].
·· ·
M d + C d + K d = Ft
8
SolidWorks 2012 Lesson 1
Frequency Analysis of Parts
For example, the figure below shows the natural modes (shapes) of
vibration for an unsupported plate with a hole model, used in Lesson 1
of the SolidWorks Simulation training manual. Each mode corresponds
to a specific natural frequency.
UNSUPPORTED PLATE
MODE 1 MODE 2
MODE 3 MODE 4
MODE 5 MODE 6
9
Lesson 1 SolidWorks 2012
Frequency Analysis of Parts
Required Material The following material properties are required in a frequency analysis:
Properties Modulus of elasticity (also called Young’s modulus)
Poisson’s ratio
Mass density
10
SolidWorks 2012 Lesson 1
Frequency Analysis of Parts
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
concept of rigid body modes and presents their corresponding
frequencies.
The model is first run with a fixed boundary condition simulating the
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
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
applied to the end of the fork, and its effects will be investigated.
Project A tuning fork, shown in the
Description figure, is designed to emit a
lower A tone at the
fundamental frequency of
440 Hz. First, perform a
frequency analysis to confirm
that the tuning fork vibrates at
the correct frequency.
In addition, determine the
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
Process list:
Apply Fixtures
The end of the tuning fork will be fixed, attempting to simulate
being held in a person’s hand.
Mesh the model
Postprocess Results
The results of the initial analysis will be post-processed to properly
investigate their meaning.
No Fixed Geometry
The fixture will be removed to reveal additional modes of vibration.
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.
11
Lesson 1 SolidWorks 2012
Frequency Analysis of Parts
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
Supports frequency is indeed 440 Hz (lower A tone).
12
SolidWorks 2012 Lesson 1
Frequency Analysis of Parts
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.
13
Lesson 1 SolidWorks 2012
Frequency Analysis of Parts
Animate the plot and observe that in the first natural frequency, both
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.
14
SolidWorks 2012 Lesson 1
Frequency Analysis of Parts
MODE 1 MODE 2
229 Hz 232 Hz
MODE 3 MODE 4
423 Hz 443 Hz
15
Lesson 1 SolidWorks 2012
Frequency Analysis of Parts
Frequency Looking at the first three modes of this analysis, it is revealed that if the
Analysis tuning fork was unsupported, these mode shapes would not occur.
Without Furthermore, the human hands are simply incapable of creating a
completely rigid support as in the model. Let us try modeling the fork
Supports
without the rigid support.
16
SolidWorks 2012 Lesson 1
Frequency Analysis of Parts
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
(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
six degrees-of-freedom as a rigid body: three translations and three
rotations.
Fundamental The first elastic mode of vibration where the tuning fork experiences
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?
If we closely examine the first three modes of vibration of the
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
any of these three modes.
Because human fingers cannot generate a rigid support used in this first
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
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
Analysis with stiffening. This type of analysis is called a frequency analysis with
Load pre-load or frequency analysis with prestress.
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
frequency analyses because it affects the resultant stiffness of a
structure and therefore changes its vibration properties and its response
to a load.
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
Lesson 1 SolidWorks 2012
Frequency Analysis of Parts
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
governed by the actual geometry of the model and will not change with
an applied prestress.
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.
Tensile stresses have the opposite effect. For example, when tuning a
guitar string, the tension in the string is increased to produce a higher
frequency, which corresponds to a higher note.
18
SolidWorks 2012 Lesson 1
Frequency Analysis of Parts
Summary Using the model of a tuning fork, we can see how SolidWorks
Simulation can be used to calculate natural frequencies and mode
shapes of a structure.
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 important information about the vibration properties of a
structure, it does not, by itself, calculate vibration amplitudes or
stresses.
We demonstrated the effect of stress softening on the natural
frequencies of the tuning fork due to a compressive force. Stress
softening and stiffening effects are automatically taken into account if
there is a load present. These effects are very common in rotating parts
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.
19
Lesson 1 SolidWorks 2012
Frequency Analysis of Parts
20
SolidWorks 2012 Exercise 1
Frequency Analysis of a Car Suspension Bulkhead
21
Exercise 1 SolidWorks 2012
Frequency Analysis of a Car Suspension Bulkhead
22
SolidWorks 2012 Exercise 2
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.
Analysis of a This exercise reinforces the following skills:
Blower Fan Frequency Analysis with Load on page 17.
Postprocessing Frequency Results on page 14.
Design Scenarios from SolidWorks Simulation manual.
Axis of
Rotation
23
Exercise 2 SolidWorks 2012
Frequency Analysis of a Blower Fan
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.
Duplicate the study named section into a new study named section
preload.
24
SolidWorks 2012 Exercise 2
Frequency Analysis of a Blower Fan
Note The FFEPlus solver cannot be used while including the effects of
loading in frequency analysis.
13 List the natural frequencies.
Prestress has the biggest effect on the first frequency, also called the
fundamental or natural frequency. It has increased from 75 Hz to
95 Hz. The other four frequencies have increased as well.
With Prestress
The results show that the natural frequencies of the turbine blade differ
significantly if a centrifugal load causing tensile stresses is considered
in analysis.
25
Exercise 2 SolidWorks 2012
Frequency Analysis of a Blower Fan
The result of the design study lists frequencies of all five modes for the
five scenarios.
26
SolidWorks 2012 Exercise 2
Frequency Analysis of a Blower Fan
Note A design scenario can be run for other parameters. You are encouraged
to use the design scenario feature to investigate the effect of element
size on natural frequencies, or in other words, to perform a convergence
analysis of frequencies. The 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 to investigate as a learning tool.
Summary In this exercise we extracted natural frequencies of a cooling fan blade.
In the first part we assumed stationary fan. As the fan begins to rotate,
centrifugal load results in stress stiffening and subsequent increase in
the natural frequencies of the blade. This was subject of the second part
of this exercise. The last section utilized the design study to establish
the variation of the natural frequencies on the speed of rotation.
At the fan velocity of 3000 rpm (50 Hz), the first natural frequency of
the blade is close to 96 Hz. This represents nearly double of the fan
velocity and the resonance due to some imperfection or unbalance is
therefore unlikely. Because at higher speeds the fan rpm surpasses the
lower natural frequencies of the blades, resonance may develop. This
frequency interval therefore may warrant more attention.
27
Exercise 3 SolidWorks 2012
Frequency Analysis of an Impeller
5 Apply Restraints.
To simulate shaft support, select the
cylindrical face of the hole at the bottom
and make it Fixed Geometry.
6 Apply an angular velocity of 20,000 rpm.
Select Axis1 as the reference.
28
SolidWorks 2012 Exercise 3
Frequency Analysis of an Impeller
8 Create Mesh.
Create a High quality mesh using the
Maximum element size of 10.5 mm. Use
Standard mesh.
9 Set study properties.
Request 5 frequencies.
10 Run the analysis.
Note Since there are loads present in this analysis, their effect on the
frequency results will be automatically accounted for.
11 Review results.
f1 = 1182.1 Hz f2 = 1182.2 Hz
f3 = 1182.3 Hz f4 = 1185 Hz
Notice that the first modes of vibration are reserved for blades only and
the corresponding frequencies are very close.
29
Exercise 3 SolidWorks 2012
Frequency Analysis of an Impeller
30
Lesson 2
Frequency Analysis of
Assemblies
Objectives Upon successful completion of this lesson, you will be able to:
Understand the concepts of natural frequencies in assemblies.
Approximate the real contacts and connectors with the appropriate
contact entities.
31
Lesson 2 SolidWorks 2012
Frequency Analysis of Assemblies
Case Study: In this analysis, we will investigate the natural frequencies and
The Engine corresponding mode shapes of an assembly. This model introduces the
Mount concept of a frequency analysis of an assembly. Various contact
conditions can exist within an assembly and we will develop a way to
properly model them in a frequency analysis.
Project The engine frame supports a heavy
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
rigid structure at the four locations
depicted in the figure.
The engine itself is not the focus of this
analysis, so it can be treated as a remote
mass.
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.
Stages in the Some key stages in the analysis of this assembly are shown in the
Process following list:
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.
Set up Connections
Connections, contacts, and boundary conditions must be applied to
the model.
Mesh the assembly
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
SolidWorks 2012 Lesson 2
Frequency Analysis of Assemblies
Remote Mass Whenever a mass of a body is significant and the stresses and
deformations are not important, the object can be conveniently treated
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.
Note We assume that the suppressed sub-assembly is rigid and its mass is
small in relation to the rest of the structure.
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
Lesson 2 SolidWorks 2012
Frequency Analysis of Assemblies
3 Define fixtures.
Define Fixed Geometry fixtures for the four faces shown in the figure.
Connecting the Because frequency analysis requires constant stiffness and mass of the
Assembly Parts structure, we cannot define No Penetration contacts. Consequently, we
also cannot use bolted connections, for example.
When a No Penetration contact is specified, the structure may change
its configuration multiple times as the loads are applied to it.
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
No Penetration conditions
between the respective
components will need to be
approximated. In this part of the
lesson, we will assume that all
contacts are bonded.
34
SolidWorks 2012 Lesson 2
Frequency Analysis of Assemblies
Animate each of the modes to see what the direction the structure
oscillates as it freely vibrates at the corresponding natural frequency.
35
Lesson 2 SolidWorks 2012
Frequency Analysis of Assemblies
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
Penetration of the No Penetration contacts between the respective assembly
components. Because No Penetration contacts are not allowed in
Contacts
frequency studies, we chose to approximate all contacts as bonded. As
will be concluded later in this lesson, such an approach makes the
assembly stiffer.
36
SolidWorks 2012 Lesson 2
Frequency Analysis of Assemblies
Orient the assembly as shown in the figure and define the remaining
three pins.
Use the exploded view for easier definition.
Note that the pin connectors in the other three corners have already
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.
5 Mesh the assembly.
Create a Draft quality mesh with the default mesh parameters. Use the
default Curvature based mesh.
6 Run the analysis.
37
Lesson 2 SolidWorks 2012
Frequency Analysis of Assemblies
The frequency results have changed, and the design could be modified
to avoid these frequency ranges.
8 Plot modal shapes for first four modes.
38
SolidWorks 2012 Lesson 2
Frequency Analysis of Assemblies
Discussion The frequency results show that the model in the second part of the
lesson, with a combination of bonded and allow penetration contact
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
remains the same - this, however, does not always need to be the case.
The above two studies do not provide perfectly accurate answers, but
may serve as insight into what could be the boundaries for the
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
must compare the modes whose shapes are the same, not necessarily
the mode number.
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,
No Penetration contacts are not allowed in the frequency analysis and
an alternate approximated approach is required. For example, various
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
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
structural response (displacements, velocities, etc). This is the subject
of the SolidWorks Simulation Premium: Dynamics training manual.
The range of the lowest four natural frequencies from both studies is 90
Hz - 670 Hz (5400 rpm - 40,200 rpm). This would fall below the range
of operating rpm’s for most conventional engines. If resilient mounts
were used the results would be considerably different.
39
Lesson 2 SolidWorks 2012
Frequency Analysis of Assemblies
40
SolidWorks 2012 Exercise 4
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
Analysis of a skills:
Particle Frequencies and Mode Shapes on page 10.
Separator All Bonded Contact Conditions on page 32.
Postprocessing Frequency Results on page 14.
41
Exercise 4 SolidWorks 2012
Frequency Analysis of a Particle Separator
Discussion Even though the model was made up of numerous different parts and
element types, all of the contact conditions were bonded. This means
that although being an assembly, all of the parts are perfectly connected
and it behaves as if it were modeled as a single part.
42
Lesson 3
Buckling Analysis
Objectives Upon successful completion of this lesson, you will be able to:
Perform buckling analysis.
Understand buckling load factors and decide whether the product
fails in strength or stability.
43
Lesson 3 SolidWorks 2012
Buckling Analysis
KE + i KS i = 0
44
SolidWorks 2012 Lesson 3
Buckling Analysis
Buckled Arch
Buckled Strut
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 .
P cr
BLF = -----------
P app
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
displacements.
Buckling Analysis As previously mentioned, linear buckling analysis typically
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
Lesson 3 SolidWorks 2012
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
Separator as the model featured in Lesson 10 of the SolidWorks Simulation
training manual. We will calculate the bucking load factor of the model
and learn to properly interpret the buckling results.
Project The loads on the support frame consist of the
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
the separator. Finally, on the intake of the
particle separator, a 75 N normal and 45 N
along direction 1 loads will be applied to
simulate additional loading that the separator
might experience during installation.
46
SolidWorks 2012 Lesson 3
Buckling Analysis
47
Lesson 3 SolidWorks 2012
Buckling Analysis
Conclusion The factor of safety in buckling (21.6) is significantly larger than the
factor of safety in strength (7.3). Buckling is therefore not the
governing phenomenon. In general, it must always be considered
during the design.
Calculating To calculate the buckling load(s) for a particular mode, multiply all the
Buckling Loads applied loads by the BLF for that mode.
The second buckling mode is mostly of academic importance. If the
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.
48
SolidWorks 2012 Lesson 3
Buckling Analysis
Buckling
BLF Value Interpretation of Results
Status
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.
- 1 < BLF < 0 No buckling Buckling occurs if you reverse all load directions.
BLF < - 1 No buckling Buckling does not occur, even if you reverse all load directions.
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
yield strength factor.
Imagine a slender beam under a compressive load. A small load offset
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
resist the compressive load partly in axial compression, partly in
bending.
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.
49
Lesson 3 SolidWorks 2012
Buckling Analysis
Will the structure The stress factor of safety of 35 is higher than the buckling factor of
Buckle or Yield safety of 21.6. The structure would therefore buckle before it would
First? yield.
In many instances yielding changes geometry which in turn reduces the
buckling load factors and a structure collapses by a combination of
material yielding and buckling.
A nonlinear analysis, available in SolidWorks Simulation Premium, is
required to describe these complex problems.
Summary In this lesson we conducted buckling analyses and made use of the
stress analysis results from the SolidWorks Simulation course. While
the stress analysis assesses the performance of the design in strength
(yielding is the criterion), buckling analysis evaluates the stability of
the structure.
Safety factors related to material yield strength and to buckling load
factors were explained.
As is seen, buckling, rather than excessive stress, is often the
predominant mode of failure for slender structures under compressive
loads.
Questions 1. Onset of buckling implies that the total stiffness of the structure
(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
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.
50
SolidWorks 2012 Exercise 5
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:
Analysis of a Buckling Analysis on page 44.
Stool Calculating Buckling Loads on page 48.
51
Exercise 5 SolidWorks 2012
Buckling Analysis of a Stool
52
SolidWorks 2012 Exercise 5
Buckling Analysis of a Stool
The results of the stool 01 study show a maximum von Mises stress of
approximately 187 MPa [27,122 psi].
The yield strength of AISI Steel is 207 MPa [30,000 psi], as stated in
the material property definition.
53
Exercise 5 SolidWorks 2012
Buckling Analysis of a Stool
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.
11 Create buckling study named stool buckling.
54
SolidWorks 2012 Exercise 5
Buckling Analysis of a Stool
Animate both of the above plots to understand how the stool buckles in
each mode.
55
Exercise 5 SolidWorks 2012
Buckling Analysis of a Stool
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.
Most likely, one of the legs will yield before it buckles. Yielding
changes the geometry and reduces the buckling load so that finally the
stool collapses in a combination of material yielding and buckling.
To analyze this, we require the nonlinear analysis available in
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:
Create a frequency study and calculate the fundamental frequency of
stool for different load magnitudes.
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
SolidWorks 2012 Exercise 6
Cabinet
Exercise 6: In this exercise, you will perform a buckling analysis on a stool. This
Cabinet exercise reinforces the following skills:
Buckling Analysis on page 44.
Calculating Buckling Loads on page 48.
57
Exercise 6 SolidWorks 2012
Cabinet
We can see that the maximum stress of 43.3 MPa is located at the lower
front joint. This translates into a factor of safety in yielding in beams of
4.5.
5 Review stress results in shells and solids.
Note that the stress reaches values of approximately 132.5 MPa. This
translates into a factor of safety in yielding of only 1.5.
58
SolidWorks 2012 Exercise 6
Cabinet
The image above is derived from the von mises stress result plots (steps
4 and 5). A low value for the factor of safety is caused by the edge
bond. We will ignore this low value as unrealistic and conclude that 4.5
represents the factor of safety in yielding.
In the next part of this exercise, we will assess the performance of the
cabinet in stability.
8 Create buckling study.
Create a Buckling study named buckling analysis.
59
Exercise 6 SolidWorks 2012
Cabinet
9 Copy folders.
Copy the Parts, Joint Group and External Loads folders from the
stress analysis study to the buckling analysis study.
Do not copy the Fixtures and Connections folders.
Note Due to the nature of the buckling solution, buckling study setup will
somewhat differ from that of the stress analysis study. Similarly to
frequency analysis, No penetration contacts and some connectors
(bolts for example) are not permitted in buckling analysis. In such
situations, only the estimates or the lower and upper limits of the
buckling loads can be extracted. In our case, we will simulate the No
Penetration contact by excluding the Base and adding two additional
fixtures.
10 Exclude Base from analysis.
11 Add fixtures.
Define a Fixed Geometry
fixture on the four edges of the
bolt holes previously bonded
to the Base.
Note Step 11 and 13 above assume infinite stiffness of the excluded Base in
the vertical direction and ignore any friction between the Base and the
Cabinet. Can you comment on whether the current model for the
buckling study is stiffer or softer than the model used in the stress
analysis study? What is the consequence on the critical buckling load
that we will obtain from this study?
14 Define Contacts.
Copy eight bonded beam contacts from static study to the buckling
study.
60
SolidWorks 2012 Exercise 6
Cabinet
Note This mesh control is specified in order to improve bonding with the
side faces of the solid bodies.
16 Create mesh.
Create mesh with the parameters identical to those in step step 2 on
page 57.
17 Set buckling analysis study properties.
Request 5 buckling modes.
18 Run buckling analysis.
61
Exercise 6 SolidWorks 2012
Cabinet
62
Lesson 4
Thermal Analysis
63
Lesson 4 SolidWorks 2012
Thermal Analysis
64
SolidWorks 2012 Lesson 4
Thermal Analysis
Structural Thermal
Displacement Temperature
Strain Temperature gradient
Stress Heat flux
Load Heat source/Heat sink
Prescribed displacements Prescribed temperatures
Convection coefficients
Elastic supports
(film coefficients)
Elastic modulus Thermal conductivity
65
Lesson 4 SolidWorks 2012
Thermal Analysis
66
SolidWorks 2012 Lesson 4
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
density of the fluid due to differences in temperature between the solid
and the fluid.
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
density decreases. Hence, they move upward.
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.
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
heat transfer in a vacuum.
Heat transfer by radiation becomes
more significant at higher
temperatures. Note that the amount
of radiated heat is proportional to
the fourth power of absolute
temperature.
67
Lesson 4 SolidWorks 2012
Thermal Analysis
68
SolidWorks 2012 Lesson 4
Thermal Analysis
Material Properties We conclude this theoretical section with a review of the material
for Thermal properties required in a thermal analysis.
Analysis The following material properties are specifically required as input to
various types of thermal analyses:
Type of Thermal
Material Property Definition
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
of heat needed to raise the temperature of only
a unit mass of the material by one degree
of temperature.
Mass Density Although not directly used in thermal Transient analysis
analysis, mass density is required to only
provide information on mass because
specific heat is defined as heat per unit of
mass
69
Lesson 4 SolidWorks 2012
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
Assembly model the glue between the microchip and heat sink. We will learn to
properly apply thermal boundary conditions as well as thermal loads.
In addition, several transient thermal analyses (analyses of heat flow,
which changes with time) will be performed to show how the
microchip assembly will respond to changing heat loads.
Project The CAD model of a Connectors
Description microchip assembly consists Microchip
of five components:
Copper heat sink
Ceramic microchip
Three copper terminals
(connectors)
Heat Sink
The ceramic microchip
generates heat, which
dissipates to the environment by convection through all external faces
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].
The ceramic microchip and copper heat sink are connected by a layer
of Arctic Silver 5 high conductance glue, 25 m thick. It would be very
difficult to mesh this layer if we modeled it as an assembly component.
Instead of explicitly modeling this glue layer, we will account for it by
defining a thermal resistance between the bonded faces of the
microchip and the heat sink.
Stages in the 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.
Transient analysis (step heat load)
The temperature time history is calculated for 300 seconds, starting
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.
70
SolidWorks 2012 Lesson 4
Thermal Analysis
Where to Find It Right-click Thermal Loads in the Simulation Study tree and
select Heat Power.
In the Simulation menu, select Loads/Fixture, then Heat Power.
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
surfaces, and its effect will be modeled as a thermal resistance.
71
Lesson 4 SolidWorks 2012
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
surfaces due to their roughness.
Through the interface between the two contacting faces, two modes of
heat transfer exist. The first is conduction through points of solid-to-
solid contact, which is very effective. The second is conduction through
the gas-filled gaps, which can be poor due to their low thermal
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.
Introducing: Thermal contact resistance is the inverse of hc (conductance) and is
Thermal Resistance equal to L/KA (A is the area of contact). Typical values of interfacial
conductance are summarized in the table below:
Iron/aluminum 45,000
72
SolidWorks 2012 Lesson 4
Thermal Analysis
Where to Find It In the Simulation Study tree, right-click Thermal Loads and
select Convection.
In the Simulation menu, select Loads/Fixture, then Convection.
73
Lesson 4 SolidWorks 2012
Thermal Analysis
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.
74
SolidWorks 2012 Lesson 4
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
the situation where the temperature field has stabilized under the
defined conditions.
The initial temperature may only shorten or lengthen the time required
to obtain thermal equilibrium, but does not affect the steady-state
conditions. Therefore, initial temperature is irrelevant for a steady-state
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.
Note that temperature (TEMP), as a scalar
entity, is available for display only as a fringe
plot. Temperature gradients and heat flux (both
resultants and components), are vector
quantities and can be displayed in fringe or
vector format.
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.
75
Lesson 4 SolidWorks 2012
Thermal Analysis
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, -----
m
2
=
sm
-
2 , represent the fact that every second
76
SolidWorks 2012 Lesson 4
Thermal Analysis
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
meshes are recommended if the heat flux results are of importance to
the designer.
77
Lesson 4 SolidWorks 2012
Thermal Analysis
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
power for a specific entity, List selected command has to be used.
The basic unit for the hear power is Watt, W = J-- in the SI system
s
Btu
of units, and ----------
s in the English system of units.
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.
The results only display what the stabilized state will look like. The
amount of time depends on the initial temperature conditions, which
are not defined in a steady-state thermal analysis.
To analyze temperature changes in time, a transient thermal analysis is
required.
We assume that prior to turning on the power, all model components
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.
78
SolidWorks 2012 Lesson 4
Thermal Analysis
Note 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.
The second required modification is the definition of initial
temperatures for the model.
2 Set analysis type to Transient.
Right-click transient 01 and select Properties. This opens the
Thermal window.
Select Transient as the Solution type.
To set initial conditions and time increment, enter 300 sec for the Total
time and 10 sec for the Time increment.
Select the Direct Sparse solver.
Click OK.
The will be run for 300 seconds and the results are saved every 10
seconds.
79
Lesson 4 SolidWorks 2012
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
from SolidWorks convection coefficients directly into the thermal study in SolidWorks
Flow Simulation Simulation. (See the SolidWorks Flow Simulation tutorial titled
Conjugate heat transfer for an example of the analysis of heat transfer
within an air-cooled electronic package.) This option is very useful for
simulations with forced convection in which the convection coefficient
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.
Where to Find It In the Simulation Study tree, right-click Thermal Loads and
select Temperature.
In the Simulation menu, select Loads/Fixture, then Temperature.
80
SolidWorks 2012 Lesson 4
Thermal Analysis
81
Lesson 4 SolidWorks 2012
Thermal Analysis
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.
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.
82
SolidWorks 2012 Lesson 4
Thermal Analysis
Transient Now, we will add more complexity to the transient thermal analysis.
Analysis with We still want to monitor what happens during the first 300 seconds
Time Varying using 10-second intervals, but heat power will now vary with time.
Load
1 Create new thermal study.
Duplicate the transient 01 study into a new study named
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.
In the Thermal Loads folder, right-click Heat Power-1 and select
Edit Definition to open the Heat Power PropertyManager.
In the Heat Power PropertyManager, click the
Use Time curve button and select Edit to
open the Time curve window.
Enter three points to define the time curve: (0,0),
(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.
Click OK.
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Lesson 4 SolidWorks 2012
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
seconds. Then power is gradually decreased to 0 over the next 30
seconds. After 60 seconds, no power is generated.
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
also be made time or temperature dependent.
Having defined heat power as a function of time, we are ready to run
the study transient 02.
Temperature Similarly to time dependence of the load using time curves, any
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.
Note that solutions with temperature curves are significantly more time
demanding as convergence iterations are required.
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SolidWorks 2012 Lesson 4
Thermal Analysis
Transient Having analyzed the results for the transient 01 study (the study with
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
simulated by the thermostat feature available in SolidWorks
Simulation.
Introducing: The Thermostat (Transient) feature allows the temperature of a given
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. When defining a Heat Power select the check box next to
Thermostat (Temperature).
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Lesson 4 SolidWorks 2012
Thermal Analysis
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SolidWorks 2012 Lesson 4
Thermal Analysis
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
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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Lesson 4 SolidWorks 2012
Thermal Analysis
88
SolidWorks 2012 Exercise 7
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.
Analysis of a This exercise reinforces the following skills:
Cup Steady-State Thermal Analysis on page 71.
Convection on page 66.
Vector Plots from the SolidWorks Simulation training manual.
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.
Procedure Follow the procedure below:
1 Open part file.
Open the part named Cup.
2 Create thermal analysis study.
Create a study named thermal study one. Select Thermal as the
Analysis type.
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/
in2].
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Exercise 7 SolidWorks 2012
Thermal Analysis of a Cup
10 Evaluate results.
To examine the accuracy of your results, define a new study and repeat
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.
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SolidWorks 2012 Exercise 7
Thermal Analysis of a Cup
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Exercise 7 SolidWorks 2012
Thermal Analysis of a Cup
92
Lesson 5
Thermal Analysis with
Radiation
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Lesson 5 SolidWorks 2012
Thermal Analysis with Radiation
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
Assembly heat transfer mechanism and how it works. The properties that define
heat transfer will be discussed. We will also comment on when
radiation will become a dominant mode of heat transfer and when it can
be ignored.
Project 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
Glass Aluminum
Glass Bulb
Cover Housing
Glass Cover
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.
Our objective is to find the steady state temperature distribution of the
reflector housing and the glass cover due to the heat produced by the
light bulb. Certain assumptions on the environment as well as the
geometry were made.
Let’s review the heat transfer mechanism in the model. What happens
to the heat generated by the light bulb?
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
by convection to the ambient air. Similar mechanism applies also in the
case of the glass cover.
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SolidWorks 2012 Lesson 5
Thermal Analysis with Radiation
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Lesson 5 SolidWorks 2012
Thermal Analysis with Radiation
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
temperature of the surroundings.
Where to Find It In the Simulation Study tree, right-click Thermal Loads and
select Radiation.
In the Simulation menu, select Loads/Fixture, then Radiation.
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SolidWorks 2012 Lesson 5
Thermal Analysis with Radiation
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
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
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.
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
material property that depends on the surface temperature and the
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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Lesson 5 SolidWorks 2012
Thermal Analysis with Radiation
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SolidWorks 2012 Lesson 5
Thermal Analysis with Radiation
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Lesson 5 SolidWorks 2012
Thermal Analysis with Radiation
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SolidWorks 2012 Lesson 5
Thermal Analysis with Radiation
Review of Analysis The mechanism for heat transfer has been fully defined. This completes
Parameters the model setup for the thermal analysis.
In preparation for this steady-state thermal analysis, we have defined
the coefficient of convection, heat power, and emissivity. The only
thermal quantity we do not use in this lesson is a heat flux load (heat
power per unit of area).
If a transient thermal analysis was required, then all three quantities
could have been defined as functions of time using time curves.
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Lesson 5 SolidWorks 2012
Thermal Analysis with Radiation
14 Temperature of glass
cover.
Set the upper limit of
the legend to the
maximum value of
200°C, the maximum
design temperature on
the outside surfaces.
Using the Probe
function we can see
that the maximum
temperature on the
external face of the
glass cover is 310°C,
well above the design limit of 200°C.
It can be seen, that the design temperature of the glass cover external
surface was not met and is of a serious concern. The result indicates
that substantial design changes, including those of using less powerful
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.
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-
entrant corner.
To conceptualize the singularity of heat flux in a sharp re-entrant edge,
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
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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SolidWorks 2012 Lesson 5
Thermal Analysis with Radiation
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).
Summary In this lesson, we have analyzed a steady state heat transfer problem
with conduction, convection, and radiation.
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 5 SolidWorks 2012
Thermal Analysis with Radiation
104
Lesson 6
Advanced Thermal Stress
2D Simplification
Objectives Upon successful completion of this lesson, you will be able to:
Perform thermal stress analysis of assemblies.
Utilize 2D simplification to reduce the problem size.
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Lesson 6 SolidWorks 2012
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
type of static analysis, which is a subgroup of the structural class of
problems. Thermal analysis does not belong to this group.
In addition to all regular structural loads, such as forces and
displacements, thermal stress analysis enables the inclusion of loads
due to the constrained thermal expansion or contraction.
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
Analysis Type SolidWorks
Classification
Simulation
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SolidWorks 2012 Lesson 6
Advanced Thermal Stress 2D Simplification
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Lesson 6 SolidWorks 2012
Advanced Thermal Stress 2D Simplification
3D model 2D Simplification
3D model 2D Simplification
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SolidWorks 2012 Lesson 6
Advanced Thermal Stress 2D Simplification
3D model 2D Simplification
2 Symmetry.
Activate Symmetry configuration to reduce the model size.
3 Create thermal analysis study.
Create a new Thermal study named t distribution.
Click the Use 2D Simplification checkbox located
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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Lesson 6 SolidWorks 2012
Advanced Thermal Stress 2D Simplification
4 2D Simplification
options.
In the 2D Simplification
property manager, specify
Axi-symmetric, select
Front Plane as Section
plane and Axis1 as Axis
of symmetry.
Click OK.
Note Use the Use other side checkbox to switch the side of the cut.
The 2D cut on the new
plane named t
distribution will be
generated. The simulation
model will be built on this
geometry.
5 Materials.
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
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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SolidWorks 2012 Lesson 6
Advanced Thermal Stress 2D Simplification
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].
Flange detail
Flange detail
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Lesson 6 SolidWorks 2012
Advanced Thermal Stress 2D Simplification
8 Mesh assembly.
Mesh the assembly with High quality elements. Move the Mesh Factor
all the way to the Fine position to set the Maximum element size to
0.97428mm [0.038357 in]. Use Curvature based mesh.
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.
9 Run the analysis.
The simulation completes in a couple of seconds.
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SolidWorks 2012 Lesson 6
Advanced Thermal Stress 2D Simplification
10 Resulting temperatures.
We can see that the temperature in the bellow wall is nearly constant.
Probing on the outside walls shows that the temperature drop is no
more than 2° to 3°C.
11 3D plot.
Right-click the resulting temperature plot and select Show as 3D Plot.
The temperatures shown in 3D adds realism to the way the results can
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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Lesson 6 SolidWorks 2012
Advanced Thermal Stress 2D Simplification
The arrows clearly indicate the direction of the heat flow through the
walls of the bellow and through the flange.
Note To change the arrow size, right-click the plot and select Vector Plot
Options.
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.
Thermal Stress Having calculated the temperature distribution, we can now proceed
Analysis with the static stress study.
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SolidWorks 2012 Lesson 6
Advanced Thermal Stress 2D Simplification
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Lesson 6 SolidWorks 2012
Advanced Thermal Stress 2D Simplification
4 Symmetry.
At the beginning of this lesson we specified Symmetry configuration.
This condition must now be defined in the simulation study.
Specify Symmetry
fixture on the
exposed edge of the
Bellow.
5 Flange condition.
The expansion joint flanges
are bolted to the flanges of
the connecting pipes. While
significant deformations and
stresses of the Bellow are
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
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.
Right-click the Fixtures and select Advanced Fixtures.
Select the indicated edge of the Flange and specify 4mm in the Along
Plane Dir 1 field.
Click OK.
Note The Front Plane is the default choice for the reference entity in 2D
model and can not be changed.
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SolidWorks 2012 Lesson 6
Advanced Thermal Stress 2D Simplification
6 Pressure.
The low pressure steam is transported
at a pressure of 3 bars [0.3 MPa,
43.51 psi].
Right-click the External Loads
folder and select Pressure.
Select the three edges indicated in the figure. Additionally, select the
remaining internal faces of the Bellow. Enter 0.3 N/mm^2 (MPa).
Click OK.
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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Lesson 6 SolidWorks 2012
Advanced Thermal Stress 2D Simplification
9 Mesh assembly.
Mesh the assembly with High quality elements. Move the Mesh Factor
all the way to the Fine position to set the Maximum element size to
0.97428mm [0.038357 in]. Use Curvature based mesh.
Note With the above mesh density we were able to fit 4 elements in the
Bellow.
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.
It takes a couple of seconds to complete the study.
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SolidWorks 2012 Lesson 6
Advanced Thermal Stress 2D Simplification
119
Lesson 6 SolidWorks 2012
Advanced Thermal Stress 2D Simplification
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
the SolidWorks Simulation training manual for the definition of nodal
and elemental stresses). Although it provides a measure of the error in
energy norm, not in stress, it can still be viewed to represent the relative
distribution of stress errors in homogeneous meshes. High values at the
regions with sharp re-entrant corners should, therefore, be ignored.
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 Right-click the Results folder and select Define Stress Plot.
Under Display, select ERR: Energy Norm Error as the
Component.
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
contribution of the pressure load is minimal.
3D model We mentioned that 2D simplification leads to a dramatic reduction in
the model size. To demonstrate this fact, we will now attempt the
solution with the traditional 3D approach.
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SolidWorks 2012 Lesson 6
Advanced Thermal Stress 2D Simplification
15 Model Configuration.
Change the configuration to 3D
symmetry.
18 Mesh details.
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.
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Lesson 6 SolidWorks 2012
Advanced Thermal Stress 2D Simplification
It can be observed that the stress solution is very close to that obtained
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 simulation of the expansion joint, a part of the
piping system transporting low pressure hot steam. The solution was
obtained in two steps.
First, a thermal study was conducted with the primary objective of
calculating temperatures for the thermal stress study. Then, a thermal
stress study was conducted with a model that was properly restrained
and loaded by the temperatures obtained in the thermal study. In
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.
The maximum stress in the model reached approximately 377 MPa in
the bellow. Because this magnitude significantly exceeds the material
yield strength, the below design has to be modified. Because the bellow
is loaded cyclically, the next step in the validation of the design would
be fatigue simulation.
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SolidWorks 2012 Lesson 6
Advanced Thermal Stress 2D Simplification
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
magnitude varies along the longitudinal direction of the pipe.
Which of the following 2D simplifications could be applied to
reduce the size of this problem? (plane strain / plane stress / axi-
symmetry / none)
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Lesson 6 SolidWorks 2012
Advanced Thermal Stress 2D Simplification
124
SolidWorks 2012 Exercise 8
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.
Analysis of a This exercise reinforces the following skills:
Microchip Convection on page 66.
Testing Heat Flux on page 76.
Assembly Thermal Stress Analysis on page 114.
positioned on a platform
inside the testing chamber; it
is not connected to any other
secondary structure. Housing
125
Exercise 8 SolidWorks 2012
Thermal Stress Analysis of a Microchip Testing Assembly
4 Heat power.
Define 5 W [0.004739 BTU/s]
Heat power on the microchip
part.
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.
5 Convection on assembly outside faces.
Apply Convection to the outside faces, as shown in the figures below.
Specify 300 W/m2K [0.0001 BTU/s in2°F] as the Convection
Coefficient and 298K [25°C, 77°F] for the Bulk temperature.
Note The top face is not selected for the convection because it is not exposed
to the air flow. instead, a constant temperature is assigned to it in the
next step.
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.
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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SolidWorks 2012 Exercise 8
Thermal Stress Analysis of a Microchip Testing Assembly
8 Mesh assembly.
Mesh the assembly with Draft quality elements and the Maximum
element size of 3.07mm [0.121 in]. Use Curvature based mesh.
Note The gasket part was hidden in the above figure to see the details of the
housing geometry.
9 Run the analysis.
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Exercise 8 SolidWorks 2012
Thermal Stress Analysis of a Microchip Testing Assembly
6 Mesh control.
Apply identical mesh control to microchip.
7 Mesh assembly.
Mesh the assembly with Draft quality elements and the Maximum
element size of 3.07mm [0.121 in]. Use Curvature based mesh.
8 Run the th stress study.
If a message appears about excessive displacements, click No. Because
there are no restraints, rigid body displacements are possible but will
not affect the solution.
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SolidWorks 2012 Exercise 8
Thermal Stress Analysis of a Microchip Testing Assembly
We notice that, as expected, the gasket has slightly separated from the
housing.
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
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.
Heat was allowed to pass through the interface perfectly. A zero
thermal resistance condition between the gasket and the housing
becomes invalid as soon as the gasket separates from the housing. A
nonlinear analysis would be required to capture this effect.
129
Exercise 8 SolidWorks 2012
Thermal Stress Analysis of a Microchip Testing Assembly
The energy norm error confirms our conclusions on the mesh quality in
the vicinity of the microchip component and around the bolt holes.
Finer mesh would be needed in this region in order to obtain more
reliable stress data.
130
SolidWorks 2012 Exercise 8
Thermal Stress Analysis of a Microchip Testing Assembly
131
Exercise 9 SolidWorks 2012
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.
Analysis of a This exercise reinforces the following skills:
Gas Tank Convection on page 66.
Heat Flux on page 76.
Thermal Stress Analysis on page 114.
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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SolidWorks 2012 Exercise 9
Thermal Stress Analysis of a Gas Tank
133
Exercise 9 SolidWorks 2012
Thermal Stress Analysis of a Gas Tank
While the outside face temperature should not pose any problems, the
maximum temperature on the inside face may be controlled to limit the
expansion of the gas.
10 Evaluate and graph thermal results on a section plot.
Direction of point
selection for
Probe feature
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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SolidWorks 2012 Exercise 9
Thermal Stress Analysis of a Gas Tank
11 Graph temperatures.
In the Probe Results window, under Report Options, click the Plot
button to generate a path plot of the variation of the temperature along
the specified trajectory.
Thermal Stress The results from the thermal analysis will now be used to perform a
Analysis thermal stress analysis.
1 Create a thermal stress analysis.
Create a new Static study named static study to determine 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 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.
3 Setup thermal stress analysis.
Right-click on the static study and
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].
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Exercise 9 SolidWorks 2012
Thermal Stress Analysis of a Gas Tank
6 Plot displacement.
We can see that the tank expanded on the sunny side of the face.
7 Plot von Mises stress.
The stress of 64 MPa is well below the Yield strength of the material
(620 MPa). We can see, however, that the stresses are rather localized
at the location of the fixture. 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.
136
SolidWorks 2012 Exercise 10
Thermal Stress Analysis of a Thermoelectric Cooler
137
Exercise 10 SolidWorks 2012
Thermal Stress Analysis of a Thermoelectric Cooler
Solder Bismuth
Alumina
Sn-40Bi- Telluride
(Al2O3)
0.1Cu (Bi2Te3)
138
SolidWorks 2012 Exercise 10
Thermal Stress Analysis of a Thermoelectric Cooler
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.
Convection 5 W/(m^2.K)
on all exposed TEC faces
Convection 20 W/(m^2.K) on
specimen channel (outside faces only)
and the heat sink No convection on inside
faces of specimen channel
Theat sink=60°C
(surface temperature)
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.
The assembly file Device for this exercise is located in the
Lesson06\Exercises folder.
As you are building the simulation study, consider the following points:
Can I simplify the geometry and use smaller model to solve the
problem?
How fine mesh and in what regions of the model do I need to solve
the problem reliably?
How do I efficiently apply convective conditions on all exposed
faces?
139
Exercise 10 SolidWorks 2012
Thermal Stress Analysis of a Thermoelectric Cooler
140
Lesson 7
Fatigue Analysis
Objective Upon successful completion of this lesson, you will be able to:
Understand the basic concepts in fatigue.
Understand the required information to proceed with fatigue
analysis.
Understand the concept of S-N curves.
Setup a fatigue analysis with multiple constant amplitude events.
Evaluate results of a fatigue analysis.
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Lesson 7 SolidWorks 2012
Fatigue Analysis
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SolidWorks 2012 Lesson 7
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
two basic groups:
High Cycle Fatigue, where the magnitudes of alternating stresses
are moderate and cause none or small levels of plastic deformations
in the material. The parts loaded in this manner are assumed to
resist a high number of loading cycles (from 1000 to 1e6 cycles)
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
required to cause fatigue failure. The fatigue analysis available in
SolidWorks Simulation is based on this approach and is the subject
of further discussion in the remainder of the training manual.
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
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
Based Fatigue the accompanying training lessons) treats the stress-life (S-N) based
approach to high cycle fatigue in detail.
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
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:
constant amplitude loading
variable amplitude loading
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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
alternating stress, mean stress, stress ratio, and the number of cycles.
The terms characterizing the constant amplitude event are described as
follows:
Stress
Time
Smax and Smin are the maximum and minimum stress magnitudes in
a stress cycle.
Salt is the alternating stress.
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.
Stress ratio R = Smin / Smax. Two typical loading histories, zero
based and fully reversed, are shown in the figures below with the
corresponding values for R and Smean.
Stress
Stress
Time
Time
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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
and thermal loading cycle. We will learn how to define the S-N curve
that governs fatigue failure. The interaction of multiple loading events
will be discussed. In addition, we will learn how to properly interpret
fatigue results. Finally, we will see the effect of a constant, unchanging
load on the fatigue study.
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
[200 psi] (-1.38 MPa [-200 psi]) and
6.89 MPa [1000 psi]; the thermal stress is
due to a heat flux oscillation between 0 and
1471.8 W/m^2 [0.0009 Btu/(s-in^2)].
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.
Our objective is to determine whether or not the vessel will fail after
2,000,000 thermal and 500,000 pressure 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:
Thermal study
The thermal study applies a heat flux to the inside of the vessel as
well as convection on the outside.
Thermal stress study
A static study will be needed to see the thermal expansion effects of
the thermal study.
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.
Fatigue study
The fatigue study will take into account all of the loading
conditions and run them on the model for a specified number of
cycles.
Postprocess the results
Once the fatigue study is run, the results must be analyzed to decide
if failure has occurred.
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Thermal Study We will first run the thermal study so that the temperature results can be
exported to the thermal stress study.
4 Mesh Thermal study.
Create a Draft quality mesh with the following parameters:
Maximum element size:101.5784mm,
Minimum El element size: 5mm,
Thermal Stress Having completed the Thermal study, we can proceed and compute
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.
7 Mesh Thermal stress study.
Create mesh with the same parameters as in the step 4.
8 Define material for Thermal stress study.
Verify that 7075-T6 (SN) Aluminum alloy is assigned to both parts.
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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11 Stress results.
We can see that the pressure vessel stress is very high with the
maximum magnitude close to 966 MPa, well above the yield strength
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.
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.
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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
failure.
13 Define material for Static Pressure study.
Assign the same Aluminum 7075-T6 Alloy (SN) to both parts.
14 Mesh pressure study.
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.
Each analysis should take less than 5 minutes to completely run
through. You may review the results if you wish. The stresses from
these studies will serve as basic input for the fatigue analysis.
16 Stress results.
We can see that the pressure vessel stress is very high with the
maximum magnitude close to 1361 MPa, well above the yield strength
of the material, 505 MPa.
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We can observe that the stress 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. Detailed simulation of the bolted connection would be
required.
18 Stress results - detail.
Zoom onto the areas of high stress and probe the critical regions.
It can be seen that the stresses distant from the stresses concentrations
are below the yield strength of the material.
Note For high cycle fatigue, the stresses must remain below the yield
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.
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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.
S-N Curve The behavior of the material in the high cycle fatigue is characterized
by the relation between the alternating stresses (Salt) and the
corresponding number of cycles (N) to failure. A typical S-N curve is
shown in the figure below.
Stress (ksi)
Fatigue strength at
106 cycles
Endurance limit
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
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
infinite). The endurance limit is usually defined for fully reversed
alternating stresses. The endurance limit is also called the fatigue limit.
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,
only fully reversed (R=-1) fatigue test data is available, and the
influence of the mean stress is accounted for approximately with the
Goodman, Gerber, or Soderberg mean stress correction algorithms; all
three are described later in this lesson.
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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
overestimated.
The most accurate data can be obtained from fatigue testing of the
actual product, or a typical product of the same type and material. As
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
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
scatter, especially at higher cycles. For this reason, most design
handbooks suggest a reliability factor of 0.52, reducing the fatigue
strength. It is always the responsibility of the analyst to verify the
trustworthiness of the material data source.
S-N Curve The interpolation between the S-N data points can be done using the
Interpolation following three schemes:
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
number of cycles. Use this option when the defined S-N curves has
a relatively small stress range compared to the variation in number
of cycles.
Linear - A linear interpolation for both stress and number of cycles
is used. Use this option when the defined S-N curves have many
data points.
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Example Suppose that you defined an S-N curve that has the following two data
points (in addition to others):
For a stress of 45,000 psi, the program reads the number of cycles
based on the S-N interpolation scheme as follows:
103.944 = 8,790.
Semi-Log S-N Curve - The X-axis S
represents the logarithm of the
number of cycles and the Y-axis 50,000
represents the stress. At stress
45,000
value of 45,000 psi, the program
performs linear interpolation and 40,000
calculates the number of cycles as
104=10,000. 3 4 5 Log N
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.
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Where to Find It In the Simulation Study tree, right-click Loading and select Add
Event.
Select Fatigue, Add Event from the Simulation menu.
2 Add Event.
Right-click on Loading and choose Add Event.
Enter 2,000,000, for the Cycles.
Select Zero based (LR=0) for the Loading
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)].
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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.
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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
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
alternating stress values from these known S-N curves are multiplied
by the Young’s Modulus of the unknown material and divided by the
Young’s Modulus of the known material.
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:
Amplitude Events No interaction: The software assumes that events occur
Interaction
sequentially, one after the other, without any interaction.
Random interaction: The software considers the possibility of
mixing the stress peaks from different events. This option is more
conservative and is recommended by ASME Boiler and Pressure
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
available:
Stress intensity (P1 - P3), which is identical to twice the magnitude
of the maximum shear stress at a given material point
Von Mises stress
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:
Goodman - recommended for brittle materials
Gerber - experimentally shown to be good for ductile materials
Soderberg - yields conservative results in tension
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The following graph illustrates the effect of all three criteria together.
The horizontal axis represents the magnitude of the mean stress Smean
scaled by the value of the material ultimate tensile strength Sultimate.
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
materials increases as the mean stress Smean becomes compressive.
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Note We selected Gerber mean stress correction to account for the fact that
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.
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
(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
states that each cycle causes a damage factor D1 that consumes 1/N1 of
the life of the structure.
Moreover, if a structure is subjected to n1 cycles at S1 alternating stress
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
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
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
percentage.
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7 Damage plot.
Change the Max limit of the legend to 100 and review the resulting
Damage plot.
Some regions in red color have damage greater than 100%. This result
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.
Note the bolt region which is all in red color. As we used theoretical
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.
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.
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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
the other contributor (thermal event) is relatively small. The alternating
von Mises stress due to the fluctuating pressure is approximately
201 MPa [29.2 ksi] (see the stress results for Static Pressure study).
The analyses of the S-N curve suggests that 7075-T6 alloy should be
able to resist the specified oscillations at this stress level. The mean
stress correction, however, reduces the stress values in the SN curve
considerably. Because the pressure event features significant mean
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.
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
this location.
This assessment represents a considerable inaccuracy brought into our
fatigue computation by completely ignoring the detrimental effects of
the mean stress.
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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.
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
substantially increase/decrease the mean stress magnitudes and thus
considerably change fatigue damage results.
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)
fatigue events.
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Note Since the thermal load fluctuates between 0 and 1471.8 W/m^2 [0.0009
Btu/(s-in^2)], for the lower extreme thermal fatigue event definition we
only need to disable the thermal loading.
16 Run Thermal Stress 0 study.
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Find Cycle Peaks If dead loads are present or more complex fatigue events are expected
Find Cycle Peaks event type option may be utilized.
If two studies are selected the fatigue event stresses fluctuate between
the two extremes defined by the two static studies.
Sometime, however, a single fatigue event may fluctuate between three
or more extremes when various loads peak at different times. In such
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.
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Lesson 7 SolidWorks 2012
Fatigue Analysis
Summary In this lesson we simulated the fatigue resistance of the pressure vessel
subjected to a combination of the thermal and pressure loading cycles.
It was found that the vessel fails at the critical location in the bent
below the bolted connection and a use of different material would be
recommended. Addition of the dead load resulted in a significant
reduction in the fatigue damage. This effect, however, should be
considered as additional safety only. The region adjacent to the bolted
connection was strongly affected by the theoretical bolt connection and
was excluded from the conclusions of this simulation. A detailed
dedicated simulation would be required here.
The 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
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.
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.
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
two fatigue events. Was it, however, true that no dead load was
present in the analysis? If no, how would you then define the
fatigue events correctly?
2. Damage result discussion on page 161 states that the alternating
stress in the pressure fatigue event is approximately 201 MPa [29.2
ksi]. Verify this statement.
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SolidWorks 2012 Exercise 11
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:
Analysis of a Constant Amplitude Loading on page 144.
Basketball Rim S-N Curve on page 151.
Mean Stress Correction on page 156.
Damage Factor Plot on page 159.
5 Apply a fixture.
Fix the back face, as shown in the figure.
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Exercise 11 SolidWorks 2012
Fatigue Analysis of a Basketball Rim
Geometrically nonlinear
Linear solution
solution (large displacements)
Note We observe that both linear and nonlinear results are nearly identical.
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
rim appears to yield. This can be a concern, because in high cycle
fatigue simulation stresses must be limited by the yield strength. A
more careful stress results analysis would be required.
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SolidWorks 2012 Exercise 11
Fatigue Analysis of a Basketball Rim
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.
We can see that the yielding occurs at the location of the stress
singularity. More geometry realism would be needed to eliminate
singularity and capture realistic stress distribution. The rest of the
model shows stresses below the yield limit.
10 Fatigue curve stress limit.
Review the stress plot in greater detail with the upper limit of the
legend set to the highest stress value in the 7075-T6 (SN) material S-N
curve (318 MPa).
Notice the five locations depicted in the figure. Aside from the stress
singularity identified in the previous step, the four indicated locations
exhibit stresses above the highest stress data point in the 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 mind when
drawing conclusions from the results of the fatigue simulation.
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Exercise 11 SolidWorks 2012
Fatigue Analysis of a Basketball Rim
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.
11 Create fatigue study.
Create a constant amplitude event Fatigue study named rim fatigue.
12 Add event.
Right-click on Loading and choose Add Event.
Enter 10000 for the No. of cycles.
Select Zero based (LR=0) for the Loading Type.
Select rim static as the Study Association name, and make sure the
Scale value is 1.
Click OK.
13 Material Properties.
Right-click the solid body in the Simulation study tree and select
Apply/Edit Fatigue Data.
This aluminum alloy already has the fatigue data defined.
Select Log-Log for the Interpolate field.
Click Apply and Close.
14 Review and change Fatigue study properties.
Right-click on the Fatigue study name, and choose Properties.
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).
Select the Gerber method for the Mean stress correction.
The Fatigue strength reduction factor (Kf) should be set to 1.
Click OK.
15 Run the fatigue analysis.
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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SolidWorks 2012 Exercise 11
Fatigue Analysis of a Basketball Rim
16 Review results.
The resulting Damage and Life plots are shown below.
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.
The above results show very high values of damage, 142%, (low values
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
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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Exercise 11 SolidWorks 2012
Fatigue Analysis of a Basketball Rim
The fatigue results at the four critical locations are well below 100%
with the highest value of approximately 81%. Under normal
circumstances these results would be satisfactory. However, due to the
insufficient data in the material S-N data we know that results here are
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
Advanced Fatigue Analysis
Objectives Upon successful completion of this lesson, you will be able to:
Understand a variable amplitude loading history and its setup in the
fatigue study.
Postprocess results and analyze the composition of the variable
amplitude loading.
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Lesson 8 SolidWorks 2012
Advanced Fatigue Analysis
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
defining a variable amplitude event as well as how the software
computes its result. In addition, we will learn how to properly post-
process these results.
Project A simple scaled model of a suspension
Description (shown in the figure) was analyzed in
the Design Scenarios lesson of the
SolidWorks Simulation training manual
on the loads caused by:
A stationary vehicle.
A vehicle moving at a constant
acceleration on a smooth road.
A vehicle moving on a bumpy
road.
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
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.
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
setup and can be seen in the figure below.
Stress
Time
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SolidWorks 2012 Lesson 8
Advanced Fatigue Analysis
The graph in the figure is scaled, and the extreme values (1,-1)
correspond to the static load used in the linear static analysis.
Each of the loading cycles inflict a corresponding incremental damage
on the assembly material. The goal of this analysis is to assess the
performance of the previously optimized design in fatigue (after the
suspension has been subjected to the prescribed number of loading
cycles).
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 Static study
Process The static study that was setup in Lesson 10 of the SolidWorks
Simulation training manual will be run.
Variable amplitude fatigue study
A variable loading amplitude history curve will be input into the
study and the properties of the fatigue study will be setup.
Postprocess the results
Once the study is run, we will review the relevant results.
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Lesson 8 SolidWorks 2012
Advanced Fatigue Analysis
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SolidWorks 2012 Lesson 8
Advanced Fatigue Analysis
Fatigue Study Now that the static study is complete, we can proceed with the fatigue
study.
7 Define Fatigue study.
Define a new Fatigue study named suspension-
Fatigue.
Select Variable amplitude history data under
Options as the type of fatigue study.
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.
Rainflow Cycle In the Rainflow counting method, the stress history is decomposed into
Counting Method cycles, as demonstrated in the figure below.
Time
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Lesson 8 SolidWorks 2012
Advanced Fatigue Analysis
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.
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
this lesson.
8 Add event.
Right-click on the Loading folder and select
Add Event.
In the Add Event dialog window, click the Get
Curve button.
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
Curve forms:
Amplitude only, where the X column represents an index and the 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.
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
specified as well. Start time for each event must be specified.
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Block
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Note The data for the above S-N curve is for the purpose of the training
lesson only. It is the responsibility of the analyst to obtain the most
relevant material fatigue resistance data.
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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
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
accurate result, but take longer to run. However, 32 bins are usually
enough to accurately represent the loading.
Stress
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.
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
operates can greatly differ from the conditions of the test.
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:
Corrosion (Kc) Temperature (Kt)
Loading mode (Km) Reliability (Kr)
Frequency (Kfreq) Notch Effects (Kn)
Size Factor (K1) Fretting (Kfret)
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 .
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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.
We observe that, after approximately 3389 blocks of the loading
history, the fillet on the Shock Plunger fails. If the required number of
loading blocks was 3389, a redesign would be required.
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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
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.
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
the node corresponding to the worst damage location. You will notice
that for all of these Rainflow charts, most of the counted cycles have
positive mean stress.
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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
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.
Fatigue Literature The following literature is suggested for further study of this subject:
Stephens, R. I., Fatemi, A., Stephens, R. R., and Fuchs, M. O., Metal
Fatigue in Engineering, 2001.
Suresh, S., Fatigue of Metals, 2004.
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Summary In this lesson, we used the model of suspension that was already
analyzed and optimized, using linear static analysis, in the SolidWorks
Simulation training course. The fatigue analysis investigated the
performance of this design when subjected to a variable amplitude
loading history obtained from the test data.
This lesson demonstrated the definition of the variable amplitude event
and introduced the concept of the Rainflow counting method, bins,
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
definitions are important to correlate the occurrence of the cycles if the
multiple events are defined.
Matrix plots used to analyze the composition of the load were shown
and discussed as well.
Lastly, it was shown that the assembly passing the yield strength
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.
Questions 1. Fatigue analysis is computed from the stress results obtained in the
static analysis. The fatigue failure ( Damage 1 ) therefore (does /
does not) imply the onset of yielding.
2. Because components loaded by fluctuating loading typically fail
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 module of SolidWorks Simulation.
4. A loading history for the above case would fit the (constant
amplitude / variable amplitude) event.
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190
Lesson 9
Drop Test Analysis
Objectives Upon successful completion of this lesson, you will be able to:
Perform a drop test analysis.
Use an elasto-plastic material model.
Analyze results of a dynamic analysis.
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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
analysis is not fully nonlinear as in complete dynamic analysis, drop
test analysis can prove very useful in obtaining a benchmark
simulation.
Case Study: In this study, we will perform a drop test analysis on a camera
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
in a fully dynamic simulation.
Project The structural integrity of a Bottom Cover
Description camera is tested by dropping it on
a rigid floor. The testing includes
different drop heights and floor
types.
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 Lens
Zoom Top Cover
camera in one position from a
height of 2m [78.7in].
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
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 Apply materials.
Process Linear-elastic or elasto-plastic material can be defined for the drop
test.
Drop test setup.
A height or impact velocity can be chosen for the drop test. In
addition, gravity is defined.
Define results options.
Decide how long the simulation will be run and what options will
be saved.
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1 Open Assembly.
Open the assembly named Camera.
A magnesium-cased camera with a steel zoom and glass lens is
represented in a simplified form, which features all components
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.
3 Review material properties.
The material properties transfer automatically from SolidWorks.
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.
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.
Where to Find It Connections can be found in either the Simulation Study tree or
the Simulation CommandManager.
Setup can be found in the Simulation menu as well as the
Simulation Study tree.
Result Options can be found in the Simulation menu as well as
the Simulation Study tree.
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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.
Note In this problem the drop height of 2m [78.7in] is measured from the
camera centroid.
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6 Define gravity.
The direction of gravity is normal
to the horizontal reference
plane. If necessary, use the arrow
button to control the orientation of
gravity.
Enter one of the following as the
magnitude of gravitational
acceleration:
9.81 and select m/s2
386 and select in/s2
7 Set impact plane orientation.
Under Target, for the Target orientation, select Normal to gravity.
Leave the Friction Coefficient set to 0.
Click Rigid target.
Select OK.
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.
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.
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
we will see later in the lesson).
In this study, we do not define friction and we use a linear material.
Therefore, the impact causes no energy 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
technique for small time steps when solving problems in a dynamic
analysis.
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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.
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.
Then select the four vertices shown below. Simulation data will be
logged for these locations.
Select OK.
Vertex 1
Vertex 2
Vertex 4
Vertex 3
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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
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
magnesium. E - modulus of elasticity
- density of material
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The default solution time is based on the time 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 wave from the wave that
starts propagating in the model at the moment of impact.
Assuming that the length of the model is L, the wave takes a time
period approximately equal to 2L/v to travel to the farthest boundary
(where it is reflected) and back to the originating area.
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.
Because the impact period is usually very small, the program measures
it in microseconds. The maximum response may occur during impact or
after impact while the body is rebounding. The study can evaluate
multiple impacts and rebounds if you specify an adequate solution time.
While there is no limit on Solution Time After Impact, a longer
solution time requires a longer time to run the analysis.
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?
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
solution.
The relation between the number of plots and the number of time
instances where the data is saved for graphing at selected vertices is
shown in the next figure.
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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:
1. Identify the surface that will first hit the wall during the drop test
study.
2. Create a static study.
3. Apply some G-loading (i.e. 10g).
4. Apply a fixed restraint to the surface identified in step 1.
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
fair results.
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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
structure, the model may exhibit large structural deformations; in such
case a nonlinear solution is required.
In impact analysis, the structural deformations are almost always
nonlinear. SolidWorks Simulation therefore uses Large displacement
nonlinear solution as a default option. If it is observed that no
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
Drop Test module allows for the specification of full elasto-plastic
material model required to correctly model these situations. The
description of this material model goes beyond the scope of this
training and the students are referred to SolidWorks Simulation
Premium: Nonlinear training course.
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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 (1193 MPa [173 ksi]) is likely
to damage the magnesium case.
Create and review plots corresponding to other time steps.
16 Animate results.
The most interesting way of reviewing the drop test results is through
animation.
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
one of the twenty-five plots can be used.
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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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Comparing the maximum von Mises stresses between the studies with
the rigid and flexible target we observe that the maximum value has
reduced from 1403 MPa (203.5 ksi) to approximately 425.7 MPa (62
ksi).
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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
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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We can see that even with the maximum von Mises stress dropped from
1403 MPa (203.5 ksi) to 201 MPa (29.1 ksi).
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.
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).
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Lesson 9 SolidWorks 2012
Drop Test Analysis
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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Tabs
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From this plot, we can see that the contact condition is no longer
bonded.
The model also indicates severe stresses (2700 MPa) at the corners of
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
shift along each other.
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SolidWorks 2012 Exercise 12
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:
Clip
Rigid Floor Drop Test on page 193.
Drop Test Parameters on page 194.
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Exercise 12 SolidWorks 2012
Drop Test of a Clip
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SolidWorks 2012 Exercise 12
Drop Test of a Clip
10 Animate results.
Before Impact
Animate the resultant displacement plot to observe how the two faces
collide during impact and then slide after impact.
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Exercise 12 SolidWorks 2012
Drop Test of a Clip
214
Lesson 10
Optimization Analysis
Objectives Upon successful completion of this lesson, you will be able to:
Perform an optimization analysis based on static and frequency
analyses.
Properly post-process optimization results.
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Lesson 10 SolidWorks 2012
Optimization Analysis
Optimization Design optimization determines the optimum design with respect to the
Analysis selected objective by finding the best combination of allowable values
in the design variables.
The optimum design is subject to imposed constraints.
The optimized design can be further optimized according to a new
objective and new constraints.
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
an optimization study. The optimization results will then be processed
and we will learn exactly how much better our design will get as a
result of the study.
Project A press frame assembly consists Top Plate
Description of a top plate where a 22,250 N
[5,000 lb.] upward force is
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
of the assembly by modifying the
frame geometry. Side Plate
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Optimization Analysis
1 Open Assembly.
Open the assembly named press.
2 Create static study.
Create a Static study named press static.
3 Review material properties.
The material, Plain Carbon Steel, has been defined for all components
and transfers automatically to SolidWorks Simulation.
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Optimization Analysis
Load 22,250N
Supports
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Optimization Analysis
Optimization All design constraints are satisfied in the original design configuration.
Analysis We now try to reduce the mass of the press frame assembly while still
satisfying the design constraints.
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
information about the loading and
constraints.
Before proceeding, let us review some terminology used in an
optimization analysis.
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.
The visible dimensions are design variables in our optimization study.
Constraints Constraints define allowable ranges of stress, deflection, frequency,
and so on. Both minimum and maximum values can be specified.
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.
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Optimization Analysis
The second possible outcome is that the constraint has been reached.
The optimum design then lies on the critical constraint boundary. The
critical constraint refers to the restraint that has been activated; for
example, stress has reached its limit.
Up to 60 constraints can be defined. The constraints can be: stresses,
strains, displacements, buckling load factors, frequencies,
temperatures, temperature gradients, and/or heat fluxes.
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).
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
on how the constraints are set up.
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.
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.
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Optimization Analysis
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Optimization Analysis
Design Variable The definition of the three design variables that we use in this study is
Summary complete. The SolidWorks Simulation design study displays three
design variables under the Variables list.
Define Constraints The last step in the setup of the optimization study is the definition of
constraints.
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Lesson 10 SolidWorks 2012
Optimization Analysis
Select Is less than, and then enter 0.5mm as the Max limit.
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Optimization Analysis
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.
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Optimization Analysis
23 Final design.
The Results View tab of the design study is activated. The final design
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
plots allows us to compare the model before, after, and during the
optimization procedure.
BEFORE AFTER
Postprocessing The side plate height has decreased from 100mm to 64.236mm.
Optimization The length of the back plate has been reduced from 375mm to
Results 208.643mm, and the size of cut-out has increased from 100mm to
248.656mm.
In the next paragraphs, we discover that the maximum allowed stress
and the minimum allowed frequency constraints were activated and the
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.
An optimization analysis should be conducted using local copies of
parts or assemblies.
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Optimization Analysis
The maximum von Mises stress is 99.8 MPa. It did not exceed the
maximum allowed stress of 100 MPa.
This result indicates that the constraint defined on stress has been met.
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The first natural frequency is 81.16 Hz, which is within the allowed
frequency range of 80-150 Hz.
The frequency constraint has also been met.
25 Examine mass properties of optimized design.
Under Results View, we have a summary of each iteration. We have
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
iteration did not satisfy all of the design constraints.
It can be seen that the mass of the optimized design dropped from
73.953 kg to 59.36 kg. This translates to approximately 19% reduction
in the material mass.
Note Detailed information about the mass before and after optimization can
also be determined using SolidWorks tools (Tools, Mass Properties).
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Optimization Analysis
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Lesson 10 SolidWorks 2012
Optimization Analysis
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
stresses, displacements, and frequencies. The optimization too fifteen
steps to complete and the final design satisfied all constraints.
Design Local Trend Graphs show the optimization objective and
optimization constraints as functions of the design variables.
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SolidWorks 2012 Exercise 13
Optimization Analysis of a Cantilever Bracket
9 Define a goal.
The goal here is to minimize the mass.
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Exercise 13 SolidWorks 2012
Optimization Analysis of a Cantilever Bracket
Design variable 2
Design variable 3
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.
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
bracket as the last design variable. 2Set the lower bound to 20 mm and
upper bound to 50 mm.
11 Apply constraint.
Select Stress as the Data Quantity and VON: von Mises stress as the
stress Component.
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.
13 Run optimization analysis.
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SolidWorks 2012 Exercise 13
Optimization Analysis of a Cantilever Bracket
We find that the mass has been significantly reduced from the initial
value of 105.251g to approximately 83.9g.
16 Plot stress results in the optimized design.
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Exercise 13 SolidWorks 2012
Optimization Analysis of a Cantilever Bracket
234
Lesson 11
Pressure Vessel
Analysis
Objectives Upon successful completion of this lesson, you will be able to:
Apply SolidWorks Simulation Pressure Vessel Design module to
the design of the pressure vessels.
Create linear and SRSS combinations of the load cases.
Evaluate stress results.
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Lesson 11 SolidWorks 2012
Pressure Vessel Analysis
Case Study: The objective of this lesson is to show the functionality of the
Pressure Vessel Pressure Vessel Design module and its application to the vessel
design in accordance with ASME Boiler and Pressure Vessel Code,
Section VIII, Division 2. Other codes and requirements may be
followed as well. We will analyze the same pressure vessel that was
discussed in the Mixed Meshing (Shells and Solids) lesson of the
SolidWorks Simulation training manual.
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
other loading conditions such as elevated
temperature, free nozzle end forces,
moments, and additional stresses due to
the support conditions. Wind and
earthquake conditions are not considered
in this example even though a real life
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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Pressure Vessel Analysis
3 Review supports.
The pressure vessel is supported by four
symmetrically orientated lugs with
slotted bolt holes allowing for the radial
expansion of the vessel.
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
here. You will notice, however that some
parts (manway nozzle) are meshed with
significantly finer mesh.
To reduce the computational time, other
parts of the vessel are meshed with coarser
draft quality mesh.
Note All of the studies participate in a pressure vessel analysis and must
have identical mesh properties.
5 Review study results.
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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Lesson 11 SolidWorks 2012
Pressure Vessel Analysis
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
and Pressure Vessel Code therefore relies on the Tresca yield criterion
which is more conservative than the von Mises criterion. The
maximum difference between these two criteria is 13%.
Membrane and ASME Boiler and Pressure Vessel Code states possible limiting values
Bending Stresses 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
and a stress linearization along a selected trajectory is required. This
lesson demonstrates the linearization procedure towards its end.
Basic Stress ASME Boiler and Pressure Vessel Code defines five stress intensity
Intensity Limits limits which must be satisfied (Section VIII, Division 2, Appendix 4,
Article 4-130)
General Primary Stress Intensity Pm
Local Membrane Stress Intensity PL
Primary Membrane (General or Local) Plus Primary Bending Stress
Intensity PL + Pb
Primary Plus Secondary Stress Intensity PL + Pb + Q
Peak Stress Intensity PL + Pb + Q + F
Nozzle piping transition is then the subject of yet another Article 4-138
of the same Appendix 4.
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.
1 Pressure vessel study.
Define a new study. Specify Pressure Vessel Design as a study Type
and name it vessel 1.
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SolidWorks 2012 Lesson 11
Pressure Vessel Analysis
Note The temperature load is not included in this combination. In this lesson
the vessel shell will be subjected to the General Primary Membrane
Stress Intensity criterion only. Temperature load is not considered in
this criterion.
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Lesson 11 SolidWorks 2012
Pressure Vessel Analysis
Load Case Pressure vessel module features two methods for the load case
Combinations combinations:
Linear combination. Where the resulting quantity X
(displacement, stress etc.) is computed from:
N
X = x
=1
x
2
X =
=1
Note An SRSS combination of the loads can also be included in a linear
combination as a separate load case. Such combination may be required
if the pressure vessel is subjected to the seismic load.
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SolidWorks 2012 Lesson 11
Pressure Vessel Analysis
General Primary The ASME Boiler and Pressure Vessel Code defines General Primary
Membrane Stress Membrane Stress Intensity as:
Intensity not self- limiting.
resulting in failure or gross distortion if above a yield strength
magnitude.
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;
Primary Membrane (General or Local) plus Primary Bending Stress
Intensity or Peak Stress Intensity criteria include the temperature loads.
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
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
at this location. These regions are covered by the Local Membrane
Stress Intensity and the Peak Stress Intensity criteria.
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Lesson 11 SolidWorks 2012
Pressure Vessel Analysis
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,
radial and tangential stresses as 1.5 Sm, Sm and Sm, respectively. (For
the simplicity we assume that flanges are manufactured from the same
material as the pressure vessel body and nozzles.)
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SolidWorks 2012 Lesson 11
Pressure Vessel Analysis
Stress Even though the ASME Boiler and Pressure Vessel Code does not
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.
Note The stress limits are indicated for shown parts only.
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Lesson 11 SolidWorks 2012
Pressure Vessel Analysis
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.
The Linearize stress dialog shows the summary of the membrane and
bending components.
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SolidWorks 2012 Lesson 11
Pressure Vessel Analysis
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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Lesson 11 SolidWorks 2012
Pressure Vessel Analysis
The above six graphs show the variations of all stress components
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
and green, correspondingly).
12 Save and close the assembly.
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Index
B O
Buckling Load Factor 45, 49 Optimization Analysis
Bulk Temperature 74 Constraints 222
Define 219
C Local Trend Graph 229
Centrifugal Load 25 Objective 220
Conduction 65 Results 226
Convection 66
Convection Coefficient 100 P
Define 100 Plot Heat Flux 103
Forced Convection 67 Plot Temperature 101
Free Convection 67
R
D Radiation 67
Damping 8 Define 97
Drop Test Parameters 97
Define 193 Stefan-Boltzmann Law 68
Drop Height. 194, 211 Surface to Surface 97
Impact Plane 195 Type 97
Parameters 194 Reference Temperature at Zero
Response Graph 202 Strain. 115, 128
Resonant Frequencies 8
E Response Graph 82
Eigenvectors 44
Elastic Stiffness Matrix 44 S
SolidWorks 4
F
Fatigue Analysis Theory 142 T
Fundamental Frequency 10 Temperature Curves 84
Thermal Contact Resistance 71
H Define 73
Heat Flux Singularities 102 Thermal Resistance 72, 109
Heat Power 71 Thermostat 85
Define 96 Time Curves 83–84
Transient Thermal Analysis 79
I
Include Thermal Effects 115, 128 V
Initial Temperature 80 Vector Plot 114
Interfacial Conductance 72, 107
L
Linear vs. Nonlinear Buckling 44
List Resonant Frequencies 13
M
Material Properties for Thermal
Analysis 69
Mode Shapes 10
247
Index SolidWorks 2012
248