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3DS.COM/SOLIDWORKS Dassault Systmes | Confidential Information | 9/25/2013 | ref.

: 3DS_Document_2012

SolidWorks Simulation: Go from Novice to Expert in 32 Easy Slides

Joe Galliera DS SolidWorks Corp. Senior SIM Tech Mgr, EAST September 25, 2013

Question of Accuracy
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Structural Engineering is the Art of moulding materials we do not wholly understand into shapes we cannot precisely analyse, so as to withstand forces we cannot really assess, in such a way that the community at large has no reason to suspect the extent of our ignorance.
Dr. A. R. Dykes, in the May 1978 issue of the Institution of Structural Engineers official journal, The Structural Engineer

3DS.COM/SOLIDWORKS Dassault Systmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012

Where you are now? Novice? Expert?

Everything you think you know is

Wrong

Only Difference between a Novice & Expert


3DS.COM/SOLIDWORKS Dassault Systmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012

The Expert knows

What Questions to Ask. And how to go about answering them.

What is FEA?
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In the simplest terms, FEA answers complex questions about structural behavior...

Based on a Given Set of Assumptions!

Problem Statement
3DS.COM/SOLIDWORKS Dassault Systmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012

10 in.
X (0,0,0)

1000 lbs. 1 in.


Z

2 in.

(0,0,0)

Problem Inputs: Geometry: Thickness Length Width

Load End Restraint Material Properties

What are the Assumptions?


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What are the Assumptions?


3DS.COM/SOLIDWORKS Dassault Systmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012

10 in.
X (0,0,0)

Small Displacement 2 in. Y 1000 lbs. Linear Elastic Stress-Strain 1 in. (0,0,0) Gravity? Z
Load Magnitude & Direction End Restraint Unobtainium? Material Properties
Actual material values from supplier

Problem Inputs: Geometry: Thickness Length Width


Manufacturing Tolerances

Problem Statement
3DS.COM/SOLIDWORKS Dassault Systmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012

10 in.
X (0,0,0)

1000 lbs. 1 in.


Z

2 in.

(0,0,0)

What are the Assumptions?

Every Input is an Assumption!

3DS.COM/SOLIDWORKS Dassault Systmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012

Dilbert Knows

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What Does This All Mean?


All FEA Solutions are wrong
Usually the Answers are right but the Questions are wrong!

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What is a Question in FEA Terms?


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The Assumption Set That Defines the Problem Geometry


Properties

Material
Element Interactions (Boundary Conditions) Mathematical Representation (Mesh) Idealization

Convergence
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Controls the Accuracy!

Steps to running an analysis


1. 2. 3. 4. 5. 6. 7. 8. Objective? Expected Answer? Simplify Geometry Materials Restraints & Loads Mesh Solve Interpret Results
3DS.COM/SOLIDWORKS Dassault Systmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012

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What are Boundary Conditions?


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Boundary Conditions
Loads & Constraints Represent the Interactions of the Parts You Didnt Model with the Parts You Did!

Your Boundary Conditions MUST NOT Impose Displacements, Stresses, Rigidity, or Other Behavior That the Parts You Didnt Model Wouldnt Have Imposed.

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3DS.COM/SOLIDWORKS Dassault Systmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012

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Problems Simulating Real Life Conditions


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1. 2. 3. 4. 5. 6. 7.

Tension Spring Failure Offset Shaft Bearing Model Torqued Frame Railcar Floor Casting Backboard Linkage Wheelbarrow Handle Ball Valve CFD

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Tension Spring Failure


Insufficient Knowledge of the System

Test & FEA Failure

Field Failure

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17

Tension Spring Failure

Threaded Rod

Insufficient Knowledge of the System

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18

Offset Shaft Bearing Model


Overly Constrained

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Overly Constrained

Offset Shaft Bearing Model

Fixed Bearing 32 ksi


Pinned Bearing 98 ksi

3DS.COM/SOLIDWORKS Dassault Systmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012

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Torqued Frame
Improper Interpretation of Interaction

Torqued Frame
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Improper Interpretation of Interaction

Enforced Displacement - Surface

Enforced Displacement Pinned Tube


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Torqued Frame
3DS.COM/SOLIDWORKS Dassault Systmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012

Improper Interpretation of Interaction

Enforced Displacement - Surface Enforced Displacement Pinned Tube

22

3DS.COM/SOLIDWORKS Dassault Systmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012

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Railcar Floor Casting


Under-modeled System

Fully Constrained At Attachment Interfaces?

Basketball Backboard Link


3DS.COM/SOLIDWORKS Dassault Systmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012

Incorrectly Calculated or Estimated Loads

5 6 7 4

3 2 1

24.0

1.80 1.125

UL N P LL LL

UL P

8.00 2.35

G1

1.45 R.

X
1,200 lbs.

G2

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Basketball Backboard Link


3DS.COM/SOLIDWORKS Dassault Systmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012

Incorrectly Calculated or Estimated Loads


30,000.00 25,000.00

20,000.00

G1_X G1_Y G1_Mag G2_X G2_Y G2_Mag UL_X UL_Y UL_Mag 1 2 3 4 5 6 7 LL_X LL_Y LL_Mag P_X P_Y P_Mag N_X N_Y N_Mag

15,000.00

10,000.00

Reaction (Lbs)

5,000.00

0.00

-5,000.00

-10,000.00

-15,000.00

-20,000.00

-25,000.00 Ratchet Position

25

3DS.COM/SOLIDWORKS Dassault Systmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012

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Wheelbarrow Handle

Incorrect Restraints

Should Z Rotations be released On Grip Portion of Handle?

Wheelbarrow Handle
3DS.COM/SOLIDWORKS Dassault Systmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012

Incorrect Restraints

Max. Disp. 0.070 in. VMS Exceeding 20,000 psi.

Ty=0 Rz=0

Rotations Freed on Grip

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Wheelbarrow Handle
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Incorrect Restraints

Max. Disp. 0.315 in.

Pinned Connection Only Ty=0


VMS Exceeding 20,000 psi.

Grip Pinned

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3DS.COM/SOLIDWORKS Dassault Systmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012

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Ball Valve CFD


Failure to Mimic Physical Test Conditions

Ball Valve CFD


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Failure to Mimic Physical Test Conditions

Downstream Static Pressure Gauge

Upstream Static Pressure Gauge

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Tips for Improved Simulations


1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Anticipate Behavior Use Common Sense Build Free Body Diagrams Identify Stiffness Differentials Determine Model Sensitivity Utilize Hand Calculations Beware of Over-Constraining Watch out for Rigid Body Motion Utilize Force Summations Review Historical Data Utilize Outside/Inside Support for Sanity Check Build Test Models Correlate to Appropriate Constructed Tests Generate Reports / Document Sources Build up Models Slowly Use Simplified Techniques First
3DS.COM/SOLIDWORKS Dassault Systmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012

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In Summary
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An Expert:
1. 2. 3. 4. Understands the Physics Involved Can Manage Assumptions Knows How to Use Software Tools Properly Interprets Results

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THANK YOU!

Questions?

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