Introduction to Finite Element Analysis Using SOLIDWORKS Simulation 2023

Introduction to Finite Element Analysis Using SOLIDWORKS Simulation 2023
Randy H. Shih
Oregon Institute of Technology
Table of Contents
Preface i
Acknowledgments ii
Introduction
Introduction Intro-2
Development of Finite Element Analysis Intro-2
FEA Modeling Considerations Intro-3
Types of Finite Elements Intro-4
Finite Element Analysis Procedure Intro-6
Matrix Definitions Intro-6
Getting Started with SOLIDWORKS Intro-9
Starting SOLIDWORKS Intro-9
SOLIDWORKS Screen Layout Intro-12
x Menu Bar Intro-12
x Menu Bar Pull-down Menus Intro-13
x Heads-up View Toolbar Intro-13
x Features Toolbar Intro-13
x Sketch Toolbar Intro-13
x Feature Manager Design Tree Intro-14
x Graphics Area Intro-15
x Reference Triad Intro-15
x Origin Intro-15
x Confirmation Corner Intro-15
x Graphics Cursor or Crosshairs Intro-15
x Message and Status Bar Intro-15
Using the SOLIDWORKS Command Manager Intro-16
Mouse Buttons Intro-17
[Esc] – Canceling Commands Intro-17
SOLIDWORKS Help System Intro-18
Leaving SOLIDWORKS Intro-18
Create a CAD Files Folder Intro-19
Chapter 1
The Direct Stiffness Method
Introduction 1-2
One-dimensional Truss Element 1-3
Example 1.1 1-5
Example 1.2 1-7
Basic Solid Modeling Using SOLIDWORKS 1-10
The Adjuster Design 1-10iv Introduction to Finite Element Analysis
Starting SOLIDWORKS 1-10
Step 1: Create a Rough Sketch 1-12
Graphics Cursors 1-12
Geometric Relation Symbols 1-14
Step 2: Apply/Modify Relations and Dimensions 1-15
Viewing Functions – Zoom and Pan 1-17
Delete an Existing Geometry of the Sketch 1-18
Modify the Dimensions of the Sketch 1-19
Step 3: Complete the Base Solid Feature 1-20
Isometric View 1-21
Rotation of the 3D Model – Rotate View 1-21
Rotation and Panning – Arrow Keys 1-23
Dynamic Viewing – Quick Keys 1-24
3D Rotation 1-26
Viewing Tools – Heads-up View Toolbar 1-26
View Orientation 1-27
Display Style 1-28
Orthographic vs. Perspective 1-28
Customize the Heads-up View Toolbar 1-28
Step 4-1: Adding an Extruded Boss Feature 1-29
Step 4-2: Adding an Extruded Cut Feature 1-33
Step 4-3: Adding another Cut Feature 1-35
Save the Model 1-37
Questions 1-38
Exercises 1-39
Chapter 2
Truss Elements in Two-Dimensional Spaces
Introduction 2-2
Truss Elements in Two-Dimensional Spaces 2-2
Coordinate Transformation 2-5
Example 2.1 2-9
Solution 2-10
Global Stiffness Matrix 2-10
Example 2.2 2-13
Solution 2-13
Questions 2-19
Exercises 2-20
Chapter 3
2D Trusses in MS Excel and Truss Solver
Direct Stiffness Matrix Method using Excel 3-2
Example 3.1 3-2Table of Contents v
Establish the Global K Matrix for each Member 3-3
Assembly of the Overall Global Stiffness Matrix 3-8
Solving the Global Displacements 3-10
Calculating Reaction Forces 3-16
Determining the Stresses in Elements 3-18
The Truss Solver and the Truss View Programs 3-23
The Truss View Program 3-30
Questions 3-32
Exercises 3-33
Chapter 4
Truss Elements in SOLIDWORKS Simulation
One-dimensional Line Elements 4-2
Starting SOLIDWORKS 4-4
Units Setup 4-5
Creating the CAD Model – Solid Modeling Approach 4-6
A CAD Model is NOT an FEA Model 4-15
The SOLIDWORKS Simulation Module 4-16
Creating an FEA Model 4-17
Assign the Element Material Property 4-19
Apply Boundary Conditions – Constraints 4-20
Apply External Loads 4-23
Create the FEA Mesh and Run the Solver 4-25
Viewing the Stress Results 4-26
Viewing the Displacement Results 4-28
Questions 4-29
Exercises 4-30
Chapter 5
SOLIDWORKS Simulation Two-Dimensional Truss Analysis
Finite Element Analysis Procedure 5-2
Preliminary Analysis 5-3
Starting SOLIDWORKS 5-4
Units Setup 5-5
Creating the CAD Model – Structural Member Approach 5-6
Creating Structural Members in SOLIDWORKS 5-8
Weldment Profiles 5-9
Activate the SOLIDWORKS Simulation Module 5-12
Setting Up Truss Elements 5-14
Assign the Element Material Property 5-15
Applying Boundary Conditions – Constraints 5-16
Applying External Loads 5-21
Create the FEA Mesh and Run the Solver 5-23vi Introduction to Finite Element Analysis
Viewing the Stress results 5-24
Viewing the Internal Loads of All members 5-26
Viewing the Reaction Forces at the supports 5-27
Questions 5-28
Exercises 5-29
Chapter 6
Three-Dimensional Truss Analysis
Three-Dimensional Coordinate Transformation Matrix 6-2
Stiffness Matrix 6-3
Degrees of Freedom 6-3
Problem Statement 6-5
Preliminary Analysis 6-5
Start SOLIDWORKS 6-7
Units Setup 6-8
Create the CAD Model – Structural Member Approach 6-9
Create a New Weldment Profile in SOLIDWORKS 6-12
Create Structural Members using the New Profile 6-17
Editing the Dimensions of the New Profile 6-19
Activate the SOLIDWORKS Simulation Module 6-20
Setting Up the Truss Elements 6-22
Assign the Element Material Property 6-23
Applying Boundary Conditions – Constraints 6-24
Applying the External Load 6-25
Create the FEA Mesh and Run the Solver 6-27
Using the Probe Option to View Individual Stress 6-28
Viewing the Internal Loads of All Members 6-29
Questions 6-30
Exercises 6-31
Chapter 7
Basic Beam Analysis
Introduction 7-2
Modeling Considerations 7-2
Problem Statement 7-3
Preliminary Analysis 7-3
Start SOLIDWORKS 7-6
Units Setup 7-7
Create the CAD Model – Structural Member Approach 7-8
Create a Rectangular Weldment Profile 7-10
Create Structural Members Using the New Profile 7-14
Adjust the Orientation of the Profile 7-15Table of Contents vii
Add a Datum Point for the Concentrated Load 7-16
Activate the SOLIDWORKS Simulation Module 7-18
Assign the Element Material Property 7-20
Apply Boundary Conditions – Constraints 7-21
Apply the Concentrated Point Load 7-24
Apply the Distributed Load 7-26
Create the FEA Mesh and Run the Solver 7-28
What Went Wrong? 7-29
Directions 1 and 2 in Shear and Moment Diagrams 7-32
Questions 7-34
Exercises 7-35
Chapter 8
Beam Analysis Tools
Introduction 8-2
Problem Statement 8-2
Preliminary Analysis 8-3
Stress Components 8-4
Start SOLIDWORKS 8-6
Create the CAD Model – Structural Member Approach 8-7
Create a Rectangular Weldment Profile 8-9
Create Structural Members Using the New Profile 8-13
Adjust the Orientation of the Profile 8-14
Add a Datum Point for the 1.5m Location 8-15
Activate the SOLIDWORKS Simulation Module 8-17
Assign the Element Material Property 8-19
Apply Boundary Conditions – Constraints 8-20
Apply the Distributed Load 8-23
Create the FEA Mesh and Run the Solver 8-25
Shear and Moment Diagrams 8-26
Using the Probe Option to Examine Stress at Point1 8-28
Questions 8-29
Exercises 8-30
Chapter 9
Statically Indeterminate Structures
Introduction 9-2
Problem Statement 9-3
Preliminary Analysis 9-3
Start SOLIDWORKS 9-6
Create the CAD Model 9-7
Create a Circular Weldment Profile 9-9viii Introduction to Finite Element Analysis
Create Structural Members using the New Profile 9-13
Add a Datum Point for the Concentrated Load 9-14
Activate the SOLIDWORKS Simulation Module 9-16
Assign the Element Material Property 9-18
Apply Boundary Conditions – Constraints 9-19
Apply the Concentrated Point Load 9-22
Create the FEA Mesh and Run the Solver 9-24
Viewing the Internal Loads of All members 9-25
Shear and Moment Diagrams 9-26
Questions 9-28
Exercises 9-29
Chapter 10
Two-Dimensional Surface Analysis
Introduction 10-2
Problem Statement 10-3
Preliminary Analysis 10-3
x Maximum Normal Stress 10-3
x Maximum Displacement 10-4
Geometric Considerations of Finite Elements 10-5
Start SOLIDWORKS 10-6
Create the CAD Model 10-7
Activate the SOLIDWORKS Simulation Module 10-10
Assign the Element Material Property 10-13
Apply Boundary Conditions – Constraints 10-14
Apply the External Load 10-17
H-Element versus P-Element 10-18
Create the first FEA Mesh –Coarse Mesh 10-19
Run the Solver 10-21
Refinement of the FEA Mesh– Global Element Size 0.10 10-23
Refinement of the FEA Mesh– Global Element Size 0.05 10-25
Refinement of the FEA Mesh– Global Element Size 0.03 10-27
Refinement of the FEA Mesh– Global Element Size 0.02 10-28
Comparison of Results 10-29
Questions 10-30
Exercises 10-31
Chapter 11
Three-Dimensional Solid Elements
Introduction 11-2
Problem Statement 11-3
Preliminary Analysis 11-4Table of Contents ix
Start SOLIDWORKS 11-7
Create a CAD Model in SOLIDWORKS 11-8
¾ Define the Sweep Path 11-8
¾ Define the Sweep Section 11-10
¾ Create the Swept Feature 11-12
¾ Create a Cut Feature 11-13
Activate the SOLIDWORKS Simulation Module 11-15
Assign the Element Material Property 11-17
Apply Boundary Conditions – Constraints 11-18
Apply the External Load to the system 11-19
Create the first FEA Mesh – Coarse Mesh 11-20
Run the Solver 11-22
Refinement of the FEA Mesh – Global Element Size 0.10 11-24
Refinement of the FEA Mesh – Mesh Control Option 11-26
Refinement of the FEA Mesh – Automatic Transition 11-29
Comparison of Results 11-31
Questions 11-32
Exercises 11-33
Chapter 12
2D Axisymmetric and 3D Thin Shell Analyses
Introduction 12-2
Problem Statement 12-4
Preliminary Analysis 12-4
Start SOLIDWORKS 12-6
Create a 3D Solid Model in SOLIDWORKS 12-7
Activate the SOLIDWORKS Simulation Module 12-9
Assign the Element Material Property 12-12
Apply Boundary Conditions – Constraints 12-13
Apply the Pressure to the System 12-14
Create the first FEA Mesh – Coarse Mesh 12-15
Run the Solver and View the Results 12-16
Refinement of the FEA Mesh – Global Element Size 5.0 12-17
Start a New 3D Surface Model 12-18
Start a New FEA Study 12-21
Completing the Definition of the Surface Model 12-22
Assign the Element Material Property 12-23
Apply Boundary Conditions – Constraints 12-24
Apply the Pressure to the System 12-28
Create the first FEA Mesh – Coarse Mesh 12-29
Run the Solver and View the Results 12-30
Refinement of the FEA Mesh– Global Element Size 10.0 12-31
Create a 3D Solid Model in SOLIDWORKS 12-32
Activate the SOLIDWORKS Simulation Module 12-34x Introduction to Finite Element Analysis
Assign the Element Material Property 12-36
Apply Boundary Conditions – Constraints 12-37
Apply the Pressure to the System 12-39
Create the first FEA Mesh – Coarse Mesh 12-40
Run the Solver and View the Results 12-41
Refinement of the FEA Mesh – Global Element Size 12.5 12-42
Notes on FEA Linear Static Analyses 12-43
Questions 12-44
Exercises 12-45
Chapter 13
FEA Static Contact Analysis
Introduction 13-2
Problem Statement 13-3
Parts 13-4
(1) Pliers-Jaw 13-4
(2) Pin 13-6
(3) Fork 13-6
Start SOLIDWORKS 13-8
Document Properties 13-8
Insert the First Component 13-9
Insert the Second Component 13-10
Assembly Mates 13-11
Insert the Third Component 13-14
Insert the Upper Jaw Component 13-16
Identifying Coincident Surfaces in the Model 13-19
Activate the SOLIDWORKS Simulation Module 13-20
Assign the Element Material Property 13-22
Apply Boundary Conditions – Constraints 13-23
Apply the External Load on the Handles 13-24
Global Contact Settings 13-25
Set up Specific Local Surfaces Interaction 13-26
Set up another Surface Interaction set on the PIN part 13-28
SOLIDWORKS Curvature-Based Mesh 13-30
Create the FEA Mesh 13-31
Run the Solver and View the Results 13-32
Use the Animate Option 13-34
Refinement of the FEA Mesh – Apply Mesh Control 13-35
Use the Section Clipping Option 13-37
Use the Iso Clipping Option 13-38
Set up a Contact Pressure Plot 13-39
Questions 13-42
Exercises 13-43Table of Contents xi
Chapter 14
Dynamic Modal Analysis
Introduction 14-2
Problem Statement 14-3
Preliminary Analysis 14-3
The Cantilever Beam Modal Analysis Program 14-6
Start SOLIDWORKS 14-9
Create the CAD Model 14-10
Activate the SOLIDWORKS Simulation Module 14-12
Assign the Element Material Property 14-14
Apply Boundary Conditions – Constraints 14-15
Create the first FEA Mesh 14-16
Viewing the Results 14-18
Refinement of the FEA Mesh – Global Element Size 0.15 14-21
Add an Additional Mass to the System 14-23
One-Dimensional Beam Frequency Analysis 14-27
Conclusions 14-28
Questions 14-29
Exercises 14-30
Appendix
Index
INDEX
AAn
alysis Procedure, Intro-6
Animate, 4-27, 13-34
Apply Materials, 4-19
Apply Mesh Control, 13-35
Assembly, 13-8
ATAN2, Excel, 3-4
Automatic Transition, 11-29
Axisymmetric, 10-2, 12-2, 12-10
BBe
am Bending, 8-3
Beam elements, 7-2
Bending Stress, 8-4
Bonded, 13-2
Buttons, Mouse, Intro-17
CCA
D Model, 4-15
Cancel, [Esc], Intro-17
Centroid, 4-2
Circle, 1-33
Coarse Mesh, 10-19
Command manager, 4-4
Contact analysis, 13-2
Constraints, Fixture, 4-20
Considerations, Modeling, Intro-3
Contact Pressure Plot, 13-39
Contact Set, 13-26
Convergence study, 10-29
Coordinates transformation, 2-5
Create Mesh, 4-25
Create Shell Mesh, 12-29
Create Solid Mesh, 11-20
Curved beam, 11-5
Customize Heads-up View Tools, 1-28
Cut, Extrude, 1-35
DDa
tum Planes, 4-8
Datum Points, 7-16
Degrees of freedom, 6-3
Dimension, Smart, 1-15
Displacement Constraint, 4-22
Displacement Results, 4-28
Display Style, 1-27
Direct Stiffness Method, 2-2
Direction Cosines, 2-8
Direction Reference, 4-23
Display Modes, 1-28
Display Options, 1-28
Distributed Load, 8-23
Dynamic, Modal, 14-2
Dynamic Orientation, 1-27
Dynamic Pan, 1-17
Dynamic Rotation, 1-21
Dynamic Viewing, 1-24
Dynamic Zoom, 1-17
EEd
it Definition, 4-18
ELEMENT, Intro-4
Element types, Intro-4
Excel, MS, 3-2
EXIT, Intro-18
External Loads, 4-23
Extrude, 1-20
Extruded Cut, 1-33
FFa
ilure Criteria, 11-2
FEA Elements, Intro-4
File Folder, Intro-19
Finite elements, types of, Intro-4
Finite element analysis, Intro-2
Finite element procedure, 5-2
Fixed Geometry, 4-20
Fixture, Constraints, 4-20
Force/torque, 6-25
GGe
ometric Considerations, 10-5
Geometric Constraints, 1-14
Geometric Factor, 10-3I-2 Introduction to Finite Element Analysis
Global Contact, 13-25
Global Matrix, 1-6
Global stiffness matrix, 1-7
Global stiffness matrix, 2D, 2-10
Graphics Cursors, 1-12
Graphics Window, Intro-12
HH
-method, 10-18
Heads-up View Toolbar, 1-26
Heads-up View Tools, Customize, 1-28
Help, On-Line, Intro-18
Hide/Show Items, 1-27
Hidden-lines Removed, 1-28
History, FEA development, Intro-2
II
nsert Columns, 3-16
Insert Component, 13-9
Insert Function, Excel, 3-11
Interference Detection, 13-19
IPS (inch, pound, second), 4-5
Iso Clipping, 13-38
Isometric View, 1-21
LLi
ne, 1-29
Linear Statics Analysis, 1-2
List Beam Forces, 5-26
Local coordinate system, 1-29
Longitudinal stress, 12-4
MM
aterial Properties, 4-19
Mates, Assembly, 13-11
Matrix
Addition, Intro-7
Column Matrix, Intro-7
Definitions, Intro-6
Diagonal Matrix, Intro-7
Identity Matrix, Intro-8
Inverse of a Square Matrix, Intro-8
Multiplication by a constant, Intro-7
Multiplication of Two Matrices, Intro-8
Row Matrix, Intro-7
Square Matrix, Intro-7
Transpose of a Matrix, Intro-8
Merge Result, 1-32, 4-13
Mesh Control, 11-26
Mesh, Shell, 12-29
MINVERSE, 3-12
MMULT, 3-14
Modal analysis, 14-2
Modal Analysis program, 14-6
Mode Shapes, 14-20
Modeling considerations, Intro-3
Modify Dimensions, 1-19
Modulus of Elasticity, 1-3
Moment in Dir 2, 7-32
Moment Diagram, 7-5, 8-27
Mouse Buttons, Intro-17
NN
atural frequency, 14-2
Neutral axis, 8-4, 11-4
New Part, 4-4
New Study, 4-17
No Penetration, 13-2
NODE, Intro-4
Normal To, 1-27
OOr
ient, Beam Section, 7-15
Orthographic, 1-28
PPmethod, 10-18
Pan, 1-17
Perspective, 1-28
Plane Strain, 10-2
Plane Stress, 10-2
Plane Stress element, 10-2
Pressure Load, 12-14
Principle of Superposition, 9-3
Probe, 6-28
Procedure, Analysis, Intro-6
QQu
ick keys, 1-24Index I-3
RRe
dundant, 9-2
Reference Geometry, 4-8
Refinement, 10-23
Relative Motion Analysis, 1-4
Results, 4-26
Resonance, 14-2
Revolved Boss/Base, 12-7
Rotate, 1-21
Rough Sketches, 1-12
Run, 4-25
SSc
reen Layout, Intro-12
Section Clipping, 13-34
Shaded Solid, 1-28
Shear & Moment, 7-5
Shear Diagram, 7-5, 8-26
Shear Force in Dir 1, 7-32
Shell, 12-29
Shell Mesh, 12-29
Sketch, 1-33
Sketch plane, 1-29
Smart Dimension, 1-15
Solid Modeling, 1-10
SOLIDWORKS Simulation, 4-16
Solver, 4-25
Spring Constant, 1-3
Starting SOLIDWORKS, Intro-9
Statically Indeterminate system, 9-2
Stiffness, 1-2
Stress Concentration Factor, 10-3
Stress-Strain Diagram, 1-2
Structural Member, 5-6
Study, Simulation, 4-16
Superposition, Principle, 9-3
Surface Mesh, 12-29
Sweep, 11-8
Sweep Path, 11-8
Sweep Section, 11-10
Symmetrical features, 12-3
TTa
ngential stress, 12-5
Thickness, Shell, 12-29
Thin-Shell, 3D, 12-3
Treat selected bodies as beams, 4-17
Tresca Yield Criterion, 11-2
Through All, 1-34
Truss Element, 1-D, 1-3
Truss Element, 2-D, 2-2
Truss Solver Program, 3-23
Truss Viewer Program, 3-23
UUn
its Setup, 1-11
User Coordinate system, 1-29
VVi
ewing functions, 1-17
View Orientation, 1-27
Von Mises Stress, 11-2
Von Mises Yield Criterion, 11-2
WWe
ldments, 5-8
Weldment Profile, 5-9
YYo
ung’s Modulus, 2-14, 2-15
ZZe
ro force members, 4-29
ZOOM, dynamic, 1-17

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