Become An Fea Expert, Solidworks Simulation
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3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012
1
SolidWorks Simulation: Go from Novice to Expert in 32 Easy Slides
Joe Galliera DS SolidWorks Corp. Senior SIM Tech Mgr, EAST September 25, 2013
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012
Question of Accuracy
2
“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 Engineer’s official journal, The Structural Engineer
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012
Where you are now? Novice? Expert?
3
Everything you think you know is…
Wrong
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012
Only Difference between a Novice & Expert
4
The Expert knows…
What Questions to Ask. And how to go about answering them.
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012
What is FEA?
5
In the simplest terms, FEA answers complex questions about structural behavior...
Based on a Given Set of Assumptions!
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012
Problem Statement Y
10 in. X (0,0,0)
Problem Inputs: • Geometry: •Thickness •Length •Width
2 in.
1000 lbs. 1 in.
Z
• Load • End Restraint • Material Properties
What are the Assumptions? 6
Y
(0,0,0)
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012
What are the Assumptions?
7
Y
10 in. X (0,0,0)
Problem Inputs: • Geometry: •Thickness •Length •Width
X
Manufacturing Tolerances
Small1000 Displacement 2 in. Y 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
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012
Problem Statement
8
Y
10 in. X (0,0,0)
2 in.
1000 lbs. 1 in.
Z
What are the Assumptions?
Every Input is an Assumption!
Y
(0,0,0)
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012
Dilbert Knows
9
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012
10
What Does This All Mean? All FEA Solutions are wrong… Usually the Answers are right but the Questions are wrong!
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012
What is a “Question” in FEA Terms? The Assumption Set That Defines the Problem… • Geometry • Properties
• Material • Element • Interactions (Boundary Conditions) • Mathematical Representation (Mesh) • Idealization
• Convergence 11
…Controls the Accuracy!
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012
Steps to running an analysis
12
1. 2. 3. 4. 5. 6. 7. 8.
Objective? Expected Answer? Simplify Geometry Materials Restraints & Loads Mesh Solve Interpret Results
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012
What are Boundary Conditions?
13
Boundary Conditions… Loads & Constraints …Represent the Interactions of the Parts You Didn’t Model with the Parts You Did!
Your Boundary Conditions MUST NOT Impose Displacements, Stresses, Rigidity, or Other Behavior That the Parts You Didn’t Model Wouldn’t Have Imposed.
14
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012
Problems Simulating Real Life Conditions…
15
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
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012
Tension Spring Failure
16
Insufficient Knowledge of the System
Field Failure
Test & FEA Failure
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012
Tension Spring Failure
17
Insufficient Knowledge of the System
Threaded Rod
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012
Offset Shaft Bearing Model
18
Overly Constrained
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012
Offset Shaft Bearing Model
19
Overly Constrained
Fixed Bearing – 32 ksi Pinned Bearing – 98 ksi
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012
Torqued Frame
20
Improper Interpretation of Interaction
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012
Torqued Frame Improper Interpretation of Interaction
Enforced Displacement - Surface
Enforced Displacement – Pinned Tube 21
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012
Torqued Frame Improper Interpretation of Interaction
Enforced Displacement - Surface Enforced Displacement – Pinned Tube
22
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012
Railcar Floor Casting
23
Under-modeled System
Fully Constrained At Attachment Interfaces?
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012
Basketball Backboard Link
24
Incorrectly Calculated or Estimated Loads
5 6 7
3 4
2 1
1.80 1.125
24.0
N
8.00 2.35
1.45 R.
UL
UL
G1
N
P
P LL
LL
X 1,200 lbs.
G2
Y
+
25
Incorrectly Calculated or Estimated Loads 30,000.00
25,000.00
20,000.00
G1_X G1_Y
15,000.00
G1_Mag G2_X
10,000.00
Reaction (Lbs)
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012
Basketball Backboard Link
G2_Y G2_Mag UL_X
5,000.00
UL_Y UL_Mag
0.00 1
2
3
4
5
6
7
LL_X LL_Y
-5,000.00
LL_Mag P_X
-10,000.00
P_Y P_Mag
-15,000.00
N_X N_Y
-20,000.00
N_Mag
-25,000.00 Ratchet Position
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012
Wheelbarrow Handle
26
Incorrect Restraints
Should Z Rotations be released On Grip Portion of Handle?
Y
Z X
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012
Wheelbarrow Handle
27
Incorrect Restraints
Ty=0 Rz=0
Max. Disp. 0.070 in. VMS Exceeding 20,000 psi.
Rotations Freed on Grip
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012
Wheelbarrow Handle
28
Incorrect Restraints
Max. Disp. 0.315 in.
Pinned Connection Only Ty=0 VMS Exceeding 20,000 psi.
Grip “Pinned”
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012
Ball Valve CFD
29
Failure to Mimic Physical Test Conditions
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012
Ball Valve CFD
30
Failure to Mimic Physical Test Conditions
Upstream Static Pressure Gauge
Downstream Static Pressure Gauge
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012
Tips for Improved Simulations
31
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 Systèmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012
In Summary…
32
An Expert: 1. 2. 3. 4.
Understands the Physics Involved Can Manage Assumptions Knows How to Use Software Tools Properly Interprets Results
33
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012
THANK YOU!
Questions?
1
SolidWorks Simulation: Go from Novice to Expert in 32 Easy Slides
Joe Galliera DS SolidWorks Corp. Senior SIM Tech Mgr, EAST September 25, 2013
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012
Question of Accuracy
2
“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 Engineer’s official journal, The Structural Engineer
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012
Where you are now? Novice? Expert?
3
Everything you think you know is…
Wrong
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012
Only Difference between a Novice & Expert
4
The Expert knows…
What Questions to Ask. And how to go about answering them.
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012
What is FEA?
5
In the simplest terms, FEA answers complex questions about structural behavior...
Based on a Given Set of Assumptions!
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012
Problem Statement Y
10 in. X (0,0,0)
Problem Inputs: • Geometry: •Thickness •Length •Width
2 in.
1000 lbs. 1 in.
Z
• Load • End Restraint • Material Properties
What are the Assumptions? 6
Y
(0,0,0)
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012
What are the Assumptions?
7
Y
10 in. X (0,0,0)
Problem Inputs: • Geometry: •Thickness •Length •Width
X
Manufacturing Tolerances
Small1000 Displacement 2 in. Y 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
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012
Problem Statement
8
Y
10 in. X (0,0,0)
2 in.
1000 lbs. 1 in.
Z
What are the Assumptions?
Every Input is an Assumption!
Y
(0,0,0)
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012
Dilbert Knows
9
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012
10
What Does This All Mean? All FEA Solutions are wrong… Usually the Answers are right but the Questions are wrong!
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012
What is a “Question” in FEA Terms? The Assumption Set That Defines the Problem… • Geometry • Properties
• Material • Element • Interactions (Boundary Conditions) • Mathematical Representation (Mesh) • Idealization
• Convergence 11
…Controls the Accuracy!
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012
Steps to running an analysis
12
1. 2. 3. 4. 5. 6. 7. 8.
Objective? Expected Answer? Simplify Geometry Materials Restraints & Loads Mesh Solve Interpret Results
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012
What are Boundary Conditions?
13
Boundary Conditions… Loads & Constraints …Represent the Interactions of the Parts You Didn’t Model with the Parts You Did!
Your Boundary Conditions MUST NOT Impose Displacements, Stresses, Rigidity, or Other Behavior That the Parts You Didn’t Model Wouldn’t Have Imposed.
14
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012
Problems Simulating Real Life Conditions…
15
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
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012
Tension Spring Failure
16
Insufficient Knowledge of the System
Field Failure
Test & FEA Failure
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012
Tension Spring Failure
17
Insufficient Knowledge of the System
Threaded Rod
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012
Offset Shaft Bearing Model
18
Overly Constrained
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012
Offset Shaft Bearing Model
19
Overly Constrained
Fixed Bearing – 32 ksi Pinned Bearing – 98 ksi
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012
Torqued Frame
20
Improper Interpretation of Interaction
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012
Torqued Frame Improper Interpretation of Interaction
Enforced Displacement - Surface
Enforced Displacement – Pinned Tube 21
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012
Torqued Frame Improper Interpretation of Interaction
Enforced Displacement - Surface Enforced Displacement – Pinned Tube
22
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012
Railcar Floor Casting
23
Under-modeled System
Fully Constrained At Attachment Interfaces?
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012
Basketball Backboard Link
24
Incorrectly Calculated or Estimated Loads
5 6 7
3 4
2 1
1.80 1.125
24.0
N
8.00 2.35
1.45 R.
UL
UL
G1
N
P
P LL
LL
X 1,200 lbs.
G2
Y
+
25
Incorrectly Calculated or Estimated Loads 30,000.00
25,000.00
20,000.00
G1_X G1_Y
15,000.00
G1_Mag G2_X
10,000.00
Reaction (Lbs)
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012
Basketball Backboard Link
G2_Y G2_Mag UL_X
5,000.00
UL_Y UL_Mag
0.00 1
2
3
4
5
6
7
LL_X LL_Y
-5,000.00
LL_Mag P_X
-10,000.00
P_Y P_Mag
-15,000.00
N_X N_Y
-20,000.00
N_Mag
-25,000.00 Ratchet Position
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012
Wheelbarrow Handle
26
Incorrect Restraints
Should Z Rotations be released On Grip Portion of Handle?
Y
Z X
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012
Wheelbarrow Handle
27
Incorrect Restraints
Ty=0 Rz=0
Max. Disp. 0.070 in. VMS Exceeding 20,000 psi.
Rotations Freed on Grip
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012
Wheelbarrow Handle
28
Incorrect Restraints
Max. Disp. 0.315 in.
Pinned Connection Only Ty=0 VMS Exceeding 20,000 psi.
Grip “Pinned”
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012
Ball Valve CFD
29
Failure to Mimic Physical Test Conditions
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012
Ball Valve CFD
30
Failure to Mimic Physical Test Conditions
Upstream Static Pressure Gauge
Downstream Static Pressure Gauge
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012
Tips for Improved Simulations
31
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 Systèmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012
In Summary…
32
An Expert: 1. 2. 3. 4.
Understands the Physics Involved Can Manage Assumptions Knows How to Use Software Tools Properly Interprets Results
33
3DS.COM/SOLIDWORKS © Dassault Systèmes | Confidential Information | 9/25/2013 | ref.: 3DS_Document_2012
THANK YOU!
Questions?
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