APPLIED FINITE ELEMENT ANALYSIS WITH SOLIDWORKS SIMULATION 2015 Cyrus Raoufi, Ph.D., PEng. CERTIFIED Solution Partner ey ENGINEERING SERVICES INC, 5 www.cyraengineering.com PAS]Applied Finite Element Analysis with SolidWorks Simulation 2015 Cyrus Raoufi, Ph.D., P.Eng. British Columbia Institute of Technology ISBN 978-0-9919498-1-6 CYRA Engineering Services Inc. www.cyraengineering.comCYRA Engineering Services Inc. P.O. Box 30633 474 4567 Lougheed HWY Bumaby, BC VSC 2A0 CANADA Copyright © 2015 by Cyrus Raoufi All rights reserved, No part of this document may be reproduced, copied, photocopied, distributed, or translated in any form or by any means without the prior and express written permission of the publisher, CYRA Engineering Services Inc. Trademarks SolidWorks and SolidWorks Simulations are trademarks of Dassault Systemes, SolidWorks® Corporation. Microsoft Windows® and Excel® are trademarks of the Microsoft Corporation. Disclaimer ‘The author and publisher of this book have made their best efforts in preparing this document. ‘The author and publisher make no warranty of any kind, expressed or implied, related to the documentation presented in this book. The author and publisher shall not be liable for any products and parts designed, developed, and manufactured, in whole or part, from the reader's understanding of, or reliance upon, this document + The author and publisher made their best effort to identify and credit content of others but unintended errors or oversights may occur. Please contact CYRA Engineering Services Inc. with corrections which should be noted on this document.Table of Contents Chapter 1. Basic Background Mechanical Loading and Stresses. Axial Loading and Normal Stress... ‘Torsional Loading and Shear Stress Bending Moment and Normal Stress in Straight Beams «0 Direct Shear Loading and Shear Stress Transverse Shear Loading and Sheat Stress .. Linear Elastic Isotropie Model of Materials Determining the Area (A), Moment of Inertial, and Polar Moment (J) of a Cross Section using Solid Works 3-Dimensional Principle Stress 2-Dimensional Principle Stresses ..ummm Braiiple Ll ccrnnsnmammanumanmana ir Failure Theories. ‘Maximum von Mis Maximum Shear Stress Criterion Mohr-Coulomb Stress Criterion. Maximum Normal Stress Criterion Matrix Algebra Multiplication of a Addition of Matrices... Multiplication of Matrices. ‘Transpose of a Matrix Symmetric a Unit Matrix (or Identity Matrix)... Determinant of a Square Matrix, Inverse of Square Matrix. Orthogonal Mattix.ssmsessetestnsnnnnnen ssa Cramer's Rule for Solving Linear Algebraic Equations... Using Excel to Perform Matrix Manipulat Example 1.2 sone Example 13.rssssnonsne ‘ Example 14 Exercises. Chapter 2. Fundamentals of SolidWorks Simulatio ‘Types of Analysis Available in SolidWorks Simulation Premium SolidWorks Simulation Bundles... Basie Steps in FEA. FEA Pre-processing..onmFEA Proce — FEA Post-processing .... ‘Types of Elements in SolidWorks Simulation .. SolidWorks Simulation Options mene SolidWorks Simulation Working Environment Assigning Material(s) to a Part or an Assembly .. Fixed Geometry Fixture. Immovable Fixture. Roller/Slider Fixture... Fixed Hinge Advanced Fixture Symmetry FAXtUTE sons Circular Symmetry Fixture Use Reference Geometry Fixture On Flat F On Cylindri On Spherical Face Fixture Structural Loads. Fore nnn so Uniform Force Applied Normal to a Selected Entity... ‘Torque Uniform Force Applied along a Selected Direction .....snnnmnnnnnnennnninnnn rm Force Applied Normal to a Selected Entity rm Force Applied along a Selected Direction Post-processing in Solid Works Simulation... Options Available in a typical Stress Plot Edit Definition . 3 — Settings... Section Clipping Chart Options. Probing, Animating Define Factor of Safety Plot. Define Design Insight Plot Define Fatigue Check Plot... Generating FEA Reports.. Tutorial ExerciseChapter 3. Solid Element, Convergence Test and Adaptive Meshing. 3-Dimensional Tetrahedral Solid Element. se Element Size and Mesh Density. Element Aspect Ratio Jacobian Ratio Concave Element... Meshing with SolidWorks Simulation Mesh Quality Plots... se Convergence Check h-Adaptive Me p-Adaptive Mes! Mesh Contr ol.nnen Standard Mesh with Automatic tran: Curvature based mesh. Stress Singularity at Sharp Corners. Tutorial 3.1(Mesh Refinement) . Tutorial 3.2 (Stress Singularity and Mesh Control) Tutorial 3.3 (Curvature based mesh), Exercises. Chapter 4. Direct Stiffness Method and Truss Analysis Direct 88 Method for 1-Dimensional Element Shape Functions of a 1D Spring Element Example 4.1 : Pre-processing of a 1-Dimensional Structure in SolidWorks $i L-Dimensional Structure CAD Modeling in SolidWorks Defining a Beam Member in SolidWorks Simulation .... Assign the Materials to a L-Dimensional Structure in SolidWorks Simulation... Edit Joints of a 1-Dimensional Structure in SolidWorks Simulation ...cssneeees Apply Fixtures to the Joints of 1-Dimensional Stricture in SolidWorks Simulation Apply Extemal Loads to the Joints of a [Dimensional Beam Structure Post-processing of a 1-Dimensional Beam using the Displacement Plot Tutorial 4.1... so Direct Stiffness Method for 2D Truss Analysis... Example 4.2 ssesenenne . Pre-Processing a True Structure Analy Truss CAD Modeling in SolidWorks.. ss Truss 3D Modeling in SolidWorks: Custom Profile Approach ‘Truss 3D Modelin; lid Works: Structural Member Approach ‘Truss 3D Modeling in SolidWorks: Non-Structural Approach. ‘Truss Element in SolidWorks Simulation... Assign the Materials to the Truss Stucture in SolidWorks Edit Joints of a Truss Structure in SolidWorks Simulation... Apply Fixture to the Joints of a Truss Structure in SolidWorks Sin mulation, Lato ixApply External Loads to the Joints of a Truss Meshing of a Truss Structure in SolidWorks Simulation... Post-Processing of a Truss Structure Analysis in Solid Works Simulation. List Axial Porees and Stresses Produced in each Truss Member Generate the Beam Diagram of the Axial Forces Produced in each Truss Mi Determine the Displacements, Rotations and Reaction Forces/Moments using the Displacement Plot Tutorial 4,2 Direct Stiffness Method for 3D Truss Analysis: Tutorial 4.3.00 Exercises, Chapter 5. Beams and Frames Analysis ..ssssssssesseseese ‘The Direct Stiffness Method for the Beam Element Stress Components of a Beam under Axil Force, SI Normal Stress due to the Axial Loading... Shear Stress at outer Layers due to the Shear Force. Normal Stress due to the Bending Moment..... Equivalent Nodal Forces/Moments. 2D Planar Frames Analysis Direct Stiffness Method for 2D Planar Frame Analysis ww Example 5.1 Example 5.2. Example 5.3... rocessing of Beams and Frames Analysis in SolidWorks Simulation Beam/Frame CAD Modelin; SolidWorks. Beam Element in SolidWorks Simulation Defining the Beam Element for the Simple Beam... Defining the Beam Element for a Beam Structure Made of either multi Cross-sections or multi -28 Pi ing the Beam Element for a frame Structure Assign the Materials to the Beam and Prame Structure in SolidWorks Simulation... Edit Joints of a Beam or Frame Structure in SolidWorks Simulation Beam Member Ditection in SolidWorks Simulation Edit Beam Member Parameters in SolidWorks Simulation Beam Joint Conditions. Rigid Condition at Beam Joint. Hinge Condition at a Beam Joint... Slide Condition at a Beam Joint . Manually Specilying a Condition at a Beam Joint. Beam Cross-section Properties Apply Fixtures to the Joints of a beam of Frame Structure in SolidWorks Simulation Apply External Loads to the Joints, Points or Members of a Beam or Frame Structure Meshing of Beam or Frame Structures in SolidWorks Simulation.Post-Processing of a Beam or Frame Structure Analysis in SolidWork: List Forces and Stresses Produced in each Beam Member: Generate the Beam Diagrams... Determine the Displacement, Rotation and Reaction Forees/Moments using the Displacement Plot ‘Tutorial 5.1... Tutorial 5.2 Tutorial Exercises. Plane Stress Element sss Plane Strain Element ... Axisymmetric Element... Pre-Processing of 2D Model of a Part in Solid Works Simulation. Defining a 2D Simplified Study. sr Defining Fixtures for a 2D Simplified Study of a Par... Defining External Loads for a 2D Simplified Study of a Part Meshing of 2D Simplified Model of a Part in SolidWorks Simulatioy Post-Processing of 2D Simplified Model of a Part in SolidWorks Simulation.. 3D Shell Element in SolidWorks Simulation... Modeling the Thin Parts in SolidWorks Simulation Defining the Shell Model for a Surfacebody Part usi Defining the Shell Model for a Solidbody Part using S Defining the Shell Model for a Sheet Metal Part Pre-Processing of 3D Shell Models of Parts in SolidWorks Simulation. Pre-Processing of 3D Shell Models of Sheet Metal Parts - Pre-Processing of 3D Shell Models of Surface Geometry Parts ‘Thin versus Thick Shell Modeling in SolidWorks Simulation .. Thick Shell Modeling Option for the Cylindrical Portion ofthe Pressure Vessel ‘Thin Shell Modeling Option for the Cylindrical Portion of the Pressure Vessel ‘Thick Shell Modeling Option for the Spherical Portion of the Pressure Vessel... ‘Thin Shell Modeling Option for the Spherical Portion of the Pressure Vessel Post-Processing of 3D Shell Models of Parts in SolidWorks Simulation Shell Manager Tutorial 6.1 senmmnnnmnnane Tutorial 6.2 smmumnnne Tutorial 6.3 Exercises se surface Modeling Tools. lid Modeling Tools...Chapter 7. Assembly Analysis with Contact Set Centrifugal Force... Bearing Load enn Remote Loads/Restrai Remote Mass (Rigid Connection) Remote Loads (Rigid Connection) .. Remote Loads (Direct Transfer) Remote Displacement (Rigid Connection) Distributed Mass Load Case Manager... Mixed Meshing. Contact Sets Contact Set Level. Defining a Bonded Contact Set (Manually select contact sets) 116 Compatible versus Incompatible Mixed Meshing Contact Rigid Parts Excluding Part Fix/Float Parts Incremental Meshing Exercises Chapter 8. Assembly Analysis with Connectors... Edge Weld Connector Terminology .. Local Weld Coordinate System (WJC) Introduction to Weld Sizing Using the Elastic Vector Method Example 8.1. Example 8.2 Example 8.3 . se Edge Weld Connector in SolidWorks Edge Weld Connector Post-Proce: Spot Weld Connector in SolidWorks Simulation. Tutorial 8.1 cscs Bolt Connector in Solid Works Simulation.. Pin/Bolt safety check in SolidWorks Simulation.. Pin Connectors Terminology in SolidWorks Sim Bearing Connectors Terminology in SolidWorks Simulation... Effect of self-alignment option a Flexible versus Rigid Bearing connector... xiSpring Connectors Terminology in SolidWorks Simulation Elastic Support Connectors Terminology in SolidWorks Simulation Tutorial 8.2 EXerCI8€S sasssssee Chapter 9. Frequency Analysis of Parts... Mass-Spring-Damper Syste ‘Mass-Spring-Damper Syste Frequency Analysis using SolidWorks Simulation . Opening a New Frequency Analysis Study Frequency Analysis Pre-Processing..n..usnnnunmnesnannnss Frequency Analysis Processing (Meshing and Solving). Frequency Analysis Post-Processing... List the Natural Frequencies .. Plot the Mode Shapes. Rigid Body Mode: List Mass Participation Frequency analysis of assemblies Tutorial 9.1 Tutorial 9.2... EXCrCI8€S ssnsessnnnnnts xiiiNote that the numerical result values that you see on your computer screen for the tutorials, examples, and exercises may be slightly different form the ones shown in this text due to the different hardware and software configurations.Chapter 1: Basic Background Chapter 1 Basic Background ‘The Finite Element Method, also called Finite Element Analysis (FEA), is a numerical approach used to solvea wide variety of engineering problems in such diverse areas as heat transfer, fluid mechanics, clectro-magnetism, and mechanical structure analysis. In many engineering problems, we have to deal with complicated geometries, loadings, and material properties which makes it very difficult, if not impossible, to solve the problem using analytic mathematical methods. Generally speaking, analyti methods require solving ordinary or partial differential equations. Closed form analytic solutions (© those types of problems are not easily available or in some cases, are not available at all. Thus, we need to use numerical methods to obtain the desired parameters (unknowns) at points of interest. In FEA, we discretize a part into smaller parts (finite elements) and implement the governing equations to those elements to solve for unknowns. We then combine the solutions of the elements to obiain the solution for the entire part. In this chapter, the fundamentals of the mechanical loading will be presented, 3-Dimensional and 2- Dimensional stress states will be reviewed briefly. In addition, four failure theories used in the SolidWorks Simulation will be introduced and the definition of the factor of safety in each criterion will be addressed. Finally, the basics of matrix algebra and Cramer's rule for solving linear algebraic equations as well as matrix manipulation using Microsofi Excel will be presented. a4Chapter ‘asic Background Mechanical Loading and Stresses Axial Loading and Normal Stress Consider an extemal force P is applied to a bar as shown below. The load direction is exactly along the centroidal axis of the bar. ET ‘The average stress in any cross section along the bar is obtained by: ©) P ora Where: P: Axi Joad (Tension ot Compression) [N] A: Cross-section of the bar before applying the load [mm"] co; Normal Stress [MPa] or [N/mm | Nim?]; [MPaJ=10° x[Pa]= 10° x[N/m"] In order to use the above equation, the following assumptions are made: * Force Pis uniformly distributed over the cross section. In the case of the concentrated external load applied at the end of the bar, the assumption is valid as long as the location of the eross section is far from the loaded ene. ‘The bar is ideally straight in terms of geometry and there are no features such as holes, notches, cracks/scratches, or threads along the bar, The bar is considered homogenous and perfectly elastic in terms of material, * No buckling occurs during the loading, A very small block (ele induced stress and its dir t) of paterial, located arbitrarily in the bar, is shown below to illustrate MGR HEChapter 1: Basic Background Torsional Loading and Shear Stress Consider an extemal torque T is applied to a round bar as shown below. The torque is applied about v (\ at radius r is given by the following equation: ‘The shear stres Where: T: Applied torque [N.mm] rr Radius [mm] J: Polar moment of inertia of the eross section [mm'] t Shear stress [MPa] or [N/mm?] In order to use the above equation, the following assumptions are made: © The torque mu: be applied about the longitudinal axis, ‘+ The bar is ideally straight and round in terms of geometry and there are no features such as holes, notches, cracks/seratches, of threads along the bar: ‘+ The bar is considered homogenous and perfectly elasti n terms of material. ‘+ The equation is valid as long as the location of the eross section is far from the loaded end, A very small block (clement) of material, located arbitrarily in the bar, is shown below to illustrate induced stress and its direction. yl i A 13Chapter 1: Basic Background Bending Moment and Normal Stress in Straight Beams Consider an extemal moment M is applied to a beam as shown below. The moment M is applied about the axis normal to the paper. mM C mM € ‘The normal stress at distance y from the neutral surface is given by the following equation: My ~T e Where: M: Applied moment [N.mm] y: Distance from the neutral axis [mm] 1: Moment of inertia of the cross section [mm*] o: Normal stress [MPa] or [N/mm?] In order to use the above equation, the following assumptions are made: ‘+The moment must be applied about the axis normal to the paper. ‘* The beam is ideally straight in terms of geometry and there are no features such as holes, notches, efacks/scratches, or threads along the beam. ‘+ The beam is considered homogenous and perfectly elastic in terms of material, * The equation is valid as long as the location of the cro where the loads are applied ection is not close to the regions 14Chapter 1: Basic Background Direct Shear Loading and Shear Stress In a typical direct shear loading, two equal and opposite forces apply to a part such that the material experiences shear stress. If the distance between the two forces is very small, the bending moment and resultant bending can be ignored. Consider a typical bolt and nut fastener used to prevent relative motion of two links as shown below, External load P is applied to each fink, Link 1 — “ Nut P Area of direct shear <_ ° Bolt — ——* CU Link 2 ‘The direct shear stress is obtained by: Where: P: Axial load (N] A; Direct shear area [mm?] Shear stress [MPa] or [N/mm] ‘Transverse Shear Loading and Shear Stress Beams are structural members that can support both shear and bending moments. Assume V represents a transverse shear force applied to a eross section of a beam as shown on the next page. 15Chapter 1: Basic Background Vv If the distribution of the shear stress along the width t is considered constant, the shear stress at any point located on t is calculated as follows: VQr It Qy = Arhy Where: V: Internal shear force J; Moment of inertia of the entire cross section area obtained about the neutral axis £ Thickness of the cross section area where the shear stress is to be calculated Ap: Portion of the area of the cross section located above t hy: Distance from the center of Ay to the neutral axis Qp: Moment of inertia of Ay obtained about the neutral axis 16Chapter 1: Basic Background Linear Elastic Isotropic Model of Materials Inthis text, all materials are assumed to behave according to a linear elastic isotropic model. A material is called isotropic if its properties do not vary with direction, The material is assumed to be perfectly weaning that it returns to its original shape when the loads are released. Using the linear isotropic i is assumed that the material follows Hooke’s law when the loading is either increased or model decreased. In the Figure shown below, the relationship between the stress and strain is illustrated. (Stress) Fyield | T € (Strain) 17Chapter 1: jasic Background Determining the Area (A), Moment of Inertia (1), and Polar Moment (J) of a Cross Section using SolidWorks Mechanical designers frequently need to use geometric properties such as area, moment of inertia of the cross sections, and polar moment of the cross s ctions in engineering analysis. In this section, we will investigate the tools available in SolidWorks to calculate and specify the above properties. We will describe the tool using an example of a beam with a rectangular cross section as shown below. On yout own, create a 3D model of the beam, All dimensions are in mm. First, we g rate a Point reference geometry located at the center of A. To do so, click on the Features CommandManager tab and click on Reference Geometry and then Select Point. The Point PropertyManager will he displayed. Set up the parameters as shown below. Click OK. Wrap a uv > oo fees bes ar to . Pine ORS Me 3. | coordinate sytem = Pom s¥ Mate Rcence [@lare center A [Bicemer ot ace (lrmscon {lojcen ® (i000 18Chapter 1: Basic Background ‘Then, we generate a Coordinate System reference geometry located at point A. To do so, click on the Features CommandManager tab and click on Reference Geometry and then Select Coordinate System, The Coordinate System PropertyManager will be displayed. Set up the parameters as shown on the next page. Click OK. operant TS TTD — Coondinat - S Ss e System | To obtain the section properties, click on Evaluate CommandManager and then click on Section Properties. The Section Properties PropertyManager will be displayed. Select Coordinate System 1 for Output coordinate system and select face A for Selected Items. Click Recalculate. Note a triad IAL will be automatically located at the centre of the area to specify the coordinate system used to calculate the Principal moment of inertia of the area. ‘The orientation of this triad may be different from the Output coordinate system. sets |e a ss = [poe=tss) SS ‘SIS Sevan ol et cede ne: cmt Ses : “raed face ac ktches that Bein ab ones. ati i we! canteen ng (es) Monet tna fea, a attr * ira uh oon Pt ont nati tee, ah ctl = 4080.00 rine 4 pd ete ie er px = 98.09 gen naps moran nerd er, eens (rites 4)Chapter 1: Basic Background 3-Dimensional Principal Stresses The nine stress components acting on the faces of an element are shown in Figure below. ‘The magnitudes of the normal stresses (6,,0,,, and G,) and shear stresses (tyy, Tyz» and Tx) are expressed in the xyz coordinate system. These values vary with direction in any arbitrary coordinate system. However, there are always planes on which the components of shear stress are zero. The normal stresses acting on those planes are called the principal normal stresses and the planes are called the principal planes. Also, the directions of the vectors which are normal to the principal planes are called the principal axes. There are also planes on which the shear stresses are maximum. Those shear stresses are called the principal shear stresses. ‘We need to determine both the principal normal stresses and the principal shear stresses based on given loading and geometry to ensure that the material will not fail. The failure theories and the effect of the factor of safety will be discussed in upcoming sections. As mechanical designers, we are most concerned with the magnitudes of the normal and shear stresses rather than the directions of these stresses as long as we can assume that the materials are isotropic. This assumption is acceptable for many engineering materials. Regarding the six shear stress components, the following relationships are always correct: tet xy = Tye 1-10Chapter 1: Basic Background It can be shown that the three normal principal stresses (¢,,02, and ¢) are the roots of the following cubic polynomial equation: Ot Oy +0, 2 ch, +12, Ah, +B, + th. -0,0y — 050, — 00 2g, 120,12, Og = 055 y0g + ByyTyzT gy — Fe Te Dy Tey OgT hy ‘The principal shear stresses can be determined as: lles~orh 2 Tag are 45° from the direction of the Note that the direct planes of the princi als can be written as: a [CG - vey + vey + vez] — Gna) [ver +(1—v) ey + vee] z Oy Tamera ee Fey + Wes] Yay = altChapter 1: Basic Background Where: E: Modulus of elasticity vy: Poisson's ratio G: Modules of elasticity in shear € : Strain y: Shear strain. 2-Dimensional Principal Stresses Some engineering problems can be analyzed using the 2-Dimensional stress (plane stress) state, In this section, the 2-Dimensional stress state will be discussed and the principal stresses will be presented. Four stress components acting on the faces of an element are shown in Figure below.Chapter 1: Basic Background ‘The normal and shear stresses acting on a plane with an arbitrary angle a are given by: (G, — 6) sin 2a — Ty cos2a As mentioned, in design and stress analysis, we need to determine the principal normal stresses. The angle locating the maximum principal normal stress («) and its magnitude (0,) is given by the following equations: ‘The magnitude of the minimum principal normal stress (62) is determined by: (e+ 4;)- || -65)) +2 Note that on the plane on which the principal normal stresses act, the shear stresses are zero. The angle locating the principal shear stress ()) and magnitude of the principal shear stress ( determined by the following equati 1 7e- papa Try mae = # [[5e- oy] +22 Note that on the clement on which the maximum shear stress occurs, the normal stres by the following equation: is determined 1 Save = 5 (0x + 9) 1-13‘Chapter 1: Example 1.1 A beam is subjected to three forces P, R, and Q as shown below. Beam is welded at its end to a structure and has a radius of r, Determine the state of stress at elements A and B. ‘The cross section of the beam and all internal loading at the area of interest are shown below. Element A y Element B Moment about the yeaxis: Mj= Qg-Rd Shear force along. yeatnis : Vs Element A. Normal force Shoar fore along axis: Ve=R A Moment about the x-axis: My = Pg Moment about the z-axis: M. = Pd 1-14Chapter 1: Basic Background ‘The properties of the cross section of interest can be determined as follows: Asa =f,4 Jar Atpoint At m2 (4),= 5 (hy), (4), = (F) Gr) 3" y Point A (4), =0 (4p hy), = 0 At point Br = Od,=ér (ay), =r), = (FY Gr) 34 (4), =0 , (phy), = 0 Point B 1-15Chapter 1: Basic Background ‘The state of stress at point A is determined as follows: _Normal force Mzr_Q (Pd)r__Q_—(Pd)r nT TT Gr es) Y(Q,), PCO) _ nt (Gy), = V0), Mer _ 837) Par CTT Gee Ge) (2), =9 (),=0 (@)4=0 ‘The state of stress at point B is determined as follows: Normal force Myr __@ __ (Qq—Ra)r A Tr) Gr) (a = WG), RO _ 4 Gade = t= (2), = 0 (%), =9 (2a =0 1-16Chapter 1: Basic Background Failure Theories Failure criteria predict the failure of the material under combined stresses. In SolidWorks Simulation, four failure criteria are available: © Maximum von Mises stress criterion ‘© Maximum shear stress criterion © Mohr-Coulomb stress criterion © Maximum normal stress criterion Maximum von Mises Stress Criterion This criterion predicts the failure of ductile materials at the point where the von Mises stress becom equal to the stress limit, Most designers prefer to set the stress limit (Srnce) 10 the yield strength, However, in SolidWorks Simulation, you are able to set the stress limit to the ultimate tensile strength, or you can set it to your own stress limit, Factor of safety (08) is defined as Stam ros = Sumit S von von Mises stress is defined based on the normal and shear stress expressed in the global coordinate system as Bon = J05[(a, oy)” + (05 — 92)” + (02 ~ 95)?] + 3( ty + tHe + 1) von Mises stress can be defined by three principal stre es as Foon = ¥O.5[(G1 — 42)? + (G2 — G5)? + (3 — 04)*] ing, von Mises stress is obtained by i ‘When the state of stress is pure she: von And failure occurs at the location where 0.5775, Tmax ‘yield 117Chapter 1: Basic Background Maximum Shear Stress Criterion This criterion predicts the failure of ductile materials at the point where the maximum shear stress (Zina) becomes equal to the stress that causes the material to yield in the simple tension test, Based on this criterion, the factor of safety is defined as Stimie Fos = 2 max Where Tinax is considered as the highest value of tas SE T= Where: 0, > 02 > 03 Mohr-Coulomb Stress Criterion ‘This criterion predicts the failure of brittle materials, ones with different tensile and compressive properties. It occurs at the point where © 1 2Sn, Ifo, > 0 anda, >0 ‘The factor of safety is Fos = 2 © lo) 2 Se Ifo, <0 anda, <0 The factor of safety is Fos = 7% 0 ay lel sy Ifo, > 0 anda, <0 Ste -Seu 1-18Chapter 1: Basic Background ‘The factor of safety is, FOS Sync Bly eo Ifa, <0 ando3>0 ‘The factor of safety is, Where: |9;| > [621 > |oal Sr1= The limit stress is equal to the tensile strength and has a positive sign. Scx= The limit stress is equal to the compressive strength and ha a negative sign. Maximum Normal Stress Criterion criterion predicts the failure of brittle materials, ones with the s material in tension and compression. It occurs at the point where me ultimate strength of the 1 2 Sumit Based on this criterion, the factor of safety is a Fos = 1-19Chapter 1: Basic Background Matrix Algebra "Gin ~ el ¢ If +m, the matrix is called a rectangular matrix. * [fm =n, the matrix is called a square matrix. © Ifm= 1 and n> 1, the matrix is called a row matrix. = If =1 and m > 1, the matrix is called a column matrix. Examples: 3.2 0 4 [433] =]1 6 8 [Bai] = |8} [Cis]=[0 3 10] 20 3 0 The size of a matrix is given by its order which is defined as the number of its rows and columns. For example, the above matrix A and B are described as having order 3 by 3 and 3 by 1. respectively. Multiplication of a Matrix by a Scalar If we multiply a matrix by a scalar, every element of the matrix is multiplied by the scalar. Example: Ic 2 4 aq fe 3 5 ol s=[t5 ol Addition of Matrices Matrices with the same order can be added together by algebraically adding corresponding elements of the matrices. Example: mi=B ol ME aol + I=B alls aol=le 20 1-20Chapter 1: Basic Background Multiplication of Matrices In order to multiply two matrices [4] and [B], the number of columns in [A] must equal the number of rows in [B]. Assume [A] is an m x n matrix and [B] is ann x k matrix: (cl = 1108) ‘Then [C] will be a m x k matrix. Using subscript notation, the matrix multiplication can be written as follows: (cul = Yaa By) Example: i=[} 3): @i=(B 3] ste=tel=[; _ (2) + 2(0) 120) B 7] 0 3. 31 (2)+90) 44) +9(3)] 7 Is Note that in general, matrix multiplication is not commutative: [BI[A] + [4][B] Transpose of a Matrix e transpose of a matrix is obtained by interchanging rows and columns such that the first row becomes the first column; the second row becomes the second column, and so on. The transpose of matrix [A] is denoted by [4]" Example: “jl 5 2 wi=[t gal Symmetric Matrix ‘The symmetric matrix is a square matrix where its transpose is equal to itself. 1-21Chapter 1: Basic Background Example: Unit Matrix (or Identity Matrix) ‘The identity or unit matrix is always a square matrix of any order in which each diagonal ele! equal to 1 and all other elements are equal to zero. Example: 10 0 wi=[o 1 4 001 Note that the function of the unit matrix in matrix algebra is the same as the function of the number | in conventional multiplication, {Al = [AJL] = [A] Determinant of a Square Matrix ‘A square array of elements of matrix [A] is called the determinant and denoted by lal = |4y| ‘The determinant is a single numerical value when the array is evaluated. To calculate the determinant ‘of matrix [A], we need to calculate the cofactors of [4;;] as shown below: [c,] = (a) Im] Where [C),] is the cofactors and |m| is called the first minor of [yj]. ‘The determinant of a matrix is obtained by Al = Yay Cy 7 Where ‘is any row number (1 | M4» bi Sheott ‘Sheet? ‘Sheets Dal +L | dy | eG so 3. Enter [A] + [B] =in cell BB as shown on the next page. 4, Select cell C7 and drag the mouse to cell E9, Cell C7 through E9 will be selected. 5. -E9+H12:J4 in the formula bar as shown on the next page. Note that you can pick the cell ranges (C7:E9 and H2:J4) inste: of typing them. 1-27displayed on the screen. 6. Hold down both the Ctrl and the Shift keys and then press the Enter key. The result will be Bao: ook Miso cl Esa ome [Rae Pope poet Ramer Daa near Ver are s@oeR X clit -fh = SBF eed | (cinmeraemanig> Gores | a= | coe | wa” Bevin Bhima On re fan Ce i = 7 Za ° (oe 1s | al aoa rl a ‘ » W) Sheeti ‘Sheet? Sheet? _€4. pal ¥iT 1-28Chapter 1: Basic Background Example 1.3 Given matrices [A] , [B] and [C] in Example 1.2, determine [A][B] and [A][C]. 1. Using the same procedure in steps | and 2 in example 1.2, enter the values for matrices[A] , [B] and [c). Buse ook Masa ee Fe om uae se 2 noe 2 Bh us Ele ae 6 ze wee 7 eT i] 3 7 ee 2 5 0 es 3| nat » 2. ‘Type [A][B] = in cell B8 as shown below. 3. Select cell C7 and drag the mouse to cell E9. Cell C7 through E9 will be selected, 4. Type sMMULT(C2:E4,H2:J4) in the formula bar as shown below. Note that you can pick the cell ranges (C2:F4 and H12:J4) instead of typing them. Bido- es toot cst a FEI om fe cert tre om ae aes o@can ‘ (i. eae +e > zy ¢ |B-ik-A- |e ein |S Biroma-| > Sate fete sun SKK cwmnricrtsye 5] y 4A | 8 ET FT Tn 1 ake Tw Te 2 “t 7 2 7727 ar || 3 te 13 he) a oie 4 | Bi oi pong 1 $ 6 co te n FI M4)» Sheett Sheet? Sheets #3 a) = yo cm ED com i 1-29Chapter 1: Hold down both the Ctrl and the Shift keys and then press the Enter key. The result will display on the sereen, i ok Waoeek bad =/SLe Soe o@oRa x a Gount = Elwdntemaig= Fetes E- eg Ee aA em Oe Beemer roma > St EA wie wT] € > a. # 1 y Tere, | a | 4 i er ee! > 3 wu é i zi ‘ put | Shots /Shaed shea ty ‘ n » Similarly, you can calculate [A][C]. ‘The final result is shown below. sasic Background ry 3 ae 6 wt tater: 5 4 4 Bebo > Toad okcosst ba EEL PIER one et tcctnee ormie Oen ten Vow Al 2@oe8 2 Gtk SI Gow iin romigs goes | E> FDa-proee $2 on “iar a aa ae) Botsv: 1-30Chapter 1: Basic Background Example 1.4. Use Excel to solve a set of linear equations with three unknowns. x, +2x,+x3=4 x, + 3x, =3 2x, — x3 =0 ‘We can re-write above equations in matrix form as follows: 12 1774) 14 1 3° 0})%2)=]3) — or [AJLX] = [c] o 2 -ilbs! lo 1 Ix] = fs x3, = [4)*[C] In order to determine[A]-*[C] , the following procedure should be used in Excel. 1. Open a new file in Excel. 2. Enter the values and characters as shown below. You may want to use the Font and Format Cell tools to adjust the cell parameters to present the data as shown below, Sido-¢-\. Bookl - Microsoft Excel ies PEI ers | rice rcetyon torts on noiew view Addins 9 Qe wh ES X Gib in cowl = wy ame BIU AK Mr | 8% 9 ce ~ 9 Bm Ae De et s Cipboo Font =| Alignment Dai ~@ & A 8 c > EL Fiis 1 2 1 2 7 4 3 [ae 4 3 ode 3 4 2 a ° 5 7 i _« > Wi| Sheet1 “Sheet? ‘Sheet3_23. 4 oy ro) Reedy 100% (-) © oY) 131Chapter 1: Basic Background 3. Enter inv [A]= in cell B9. 4. Select cell C8 and drag the mouse to cell E10. Cell C8 through E10 will be selected as shown below. 5. Type =MINVERSE(C2:E4) in the formula bar as shown below. Note that you can pick the cell range (C2:B4) instead of typing it. Bao ect a ea er rere aos 1 a ee Da sru cc eeae wee" Se Oa Been =o 6, Hold down both the Ctrl and the Shift keys and then press the Enter key. The result will be displayed on the sereen. tate or Tots wars ad FE rere cots tome cas heey ver an OQ ORT 7 x-te away “2 1-32Chapter 1: Basic Background 7. Enter [X] =inv[A][C] in cell B9. 8. Enter xf, x2, and x3 in cells C14, C15, and C16. You may want to use the Font and Format Cell tools to adjust the cell parameters to present the data as shown below, 9. Select cell D14 and drag the mouse to cell D16. Cell D14 through D16 will be selected as shown below. 10. Type =MMULT(C8:E10,H2:H4) in the formula bar, Note that you can pick the cell ranges (C8:E10 and H2:H4) instead of typing it Bido-es teat = c oo (EN ee es ees ta er ats OO 2 me ABruae s a Boe. ; deme so Ra Sum > ROR snares ti00 na) 2 | Tr 4 5 We re . as smi a 0 a a | 3 a= Bem sina fe= 11, Hold down both the Ctrl and the Shift keys and then press the Enter key. The result will be displayed on the screen. Base ott aon Be =e wey aru B86 ae 4 eek eB os aia oe = FE cumuicssionanay Smee aa 15 Dsnwtaiel z= 2 ce, aves lenChapter 1: Basic Background Exercises 1.1 Given matrices 21 =«*5) 0 -5 2 2 taj=|4 o 1] (wl=|1 6 4) tcl=|-4 3.0 2. 2 0 5 3 Determine the result of the following operations. ° [Al +[B] ° [Al -[B] + [Al[B] + [BIA] ° [Alc] « —5S[A] > ([8) 1.2 Use Microsoft Excel to solve a set of linear algebraic equations with four unknowns. X1+2x3— 44 =3 Xp tx =1 2x, — 2x, +23 + 10x, = -14 x, +x%2 +43 +2, =0 1.3 A shaft is subjected to a torque of 100 N.m, bending moment of 400 N.m, and a shear force of 900 N as shown below. Determine the principal stresses at point A and B. Shaft is welded at P and has a diameter of 30 mm at segment QR.Chapter 1: Basic Background 14 A beam is subjected to a force R and a moment P as shown below. Determine the principal stresses at point A and B, Beam is welded at its end to a structure and has a radius of r, Determine the state of stress at elements A and B Element A. Element B 15 A supporting bracket is subjected to a force F= 5 kip as shown below. Determine the principal stress and maximum shear stress developed at points A and B. All dimensions shown on the next page are in inches. NA 1:35Chapter 1: Basic Background 425 F Poim Ag, 136Chapter 2: Fundamentals of SolidWorks Simulation Chapter 2 Fundamentals of SolidWorks Simulation SolidWorks Simulation is a Computer Aided Engineering (CAB) tool based on Finite Element Analysis (FEA). SolidWorks Simulation was originally developed by SRAC (established in 1982) and is now part of SolidWorks Corporation. SRAC joined with SolidWorks and created COSMOS Works in 1995. In 2001, SRAC was acquired by Dassualt Systemes, the parent company of SolidWorks Corporation. SRAC eventually merged with SolidWorks Corporation in 2003. In 2009, COSMOSWorks was renamed to SolidWorks Simulation, In this chapter, we will present a general overview of SolidWorks Simulation and address the main tools and options requited in a typical FEA study. The types of analysis available in SolidWorks Simulation and four commercially available SolidWorks Simulation packages will be introduced, The three SolidWorks Simulation working environment are pre-processing, ain steps in FEA used in th processing, and post-processing; these steps will be discussed in detail. Related tools available in this, software will be presented as well, Both standard and advanced Fixtures will be demonstrated using appropriate examples. The External Loads available in SolidWorks Simulation will be introduced. Three standard External Loads including Force, Moment, and Gravity will be discussed in more detail. Types of elements available in this software will be introduced. Several important tools that are needed in a typical design process such as Factor of Safety Plot, Fatigue Check Plot, Design Insight Plot, and FEA Report will also be presented. The meshing process and its key parameters using the Solid Element will be discussed in Chapter 3, Types of Analysis available in SolidWorks Simulation Premium ‘Types of analysis available with SolidWorks Simulation Premium are summarized on the next page. 24Chapter 2: Fundamentals of SolidWorks Simulation Static Analysis Static Analysis provides tools to perform static analysis of parts and a loads are applied very slowly and can be considered constant. Frequency Analysis Frequency Analysis provides tools to perform frequency analysis to determine the natural frequencies and mode shapes of paris and assemblies. Buckling Analysis Buckling Analysis provides tools to perform buckling analysis to determine both buckling modes and critical buekling loads. Thermal Analysis ‘Thermal Analysis includes tools to perform thermal analysis to determine the distribution of temperature in bodies due to heat transfer. Drop Test Drop Test_provides tools to_perform_drop_test_analysis_to investigate the results_of collision of parts and assemblies with rigid or flexible flat surfaces, Fatigue Analysis Fatigue Analysis provides tools to perform fatigue analysis to investigate the fatigue parameters while the cyclic loadings are applied to the bodies. Pressure Vessel Design Analysis Pressure Vessel Design Analysis provides tools to perform pressure vessel design analysis to investigate the design parameters in the pressure vessel design process. Linear Dynamic Linear Dynamic provides tools to perform linear dynamic analysis to study the effect of applying time or frequency dependent. loads to the bodies. Nonlinear Analysis Nonlinear Analysis provides. tools to perform nonlinear analysis to study the nonlinear behaviour of bodies under applied loading. 22Chapter 2: Fundamentals of SolidWorks Simulation SolidWorks Simulation Bundles SolidWorks Simulation is available in four different packages as shown below. Simulation Xpress SimulationXpress includes tools to perform static analysis of parts with very limited kinds of loads and fixtures, SolidWorks Simulation SolidWorks Simulation includes tools to perform static analysis of parts and assemblies. SolidWorks Simulation Professional SolidWorks Simulation Professional includes tools to perform static, thermal, buckling, frequency, drop test, optimization, and fatigue analysis of parts and assemblies. SolidWorks Simulation Premium SolidWorks Simulation. Premium. includes tools to_ perform all_analysis feasible by SolidWorks Simulation Professional plus nonlineat and dynamic analysis. Basic Steps in FEA A typical FEA procedure can be categorized into three major sub-procedures as follows © Pre-processing © Processing © Post-processing FEA Pre-processing FEA pre-processing includes accomplishing required tasks and/or determining all required parameters before the FEA model can be solved, In general, pre-processing can be divided into two groups: (i) the geometric modeling pre-processing; and (ii) the mathematical modeling pre-processing, ‘Major geometric modeling pre-processing tasks include: 23Chapter 2: Fundamentals of SolidWorks Simulation © De-feaiuring. This involves eliminating or suppressing the features that are not affecting parameters of interest significantly. It meaningfully improves the FEA processing time. Two examples of de-featuring include removing chamfers and text from a typical 3D CAD model. * Simplifying. This involves simplifying or even destructively changing the geometry of a 3D CAD model, One example of simplifying is to represent a thin-walled container only by surfaces, Important mathematical modeling pre-processing tasks include ‘* Perform the appropriate type anailysis based on the objective of FEA ‘* Select the proper types of element( ‘© Select and implementing the right fixture(s) + Assign the material(s) ‘+ Apply the correct loading FEA Processing FEA processing involves discretization, often called meshing, and converting the model into diserete finite elements and simultaneously solving a set of algebraic equations to determine some parameters of interest such as stress, strain, and displacement of the elements. FEA Post-processing ‘Some of the commonly used tools of FEA post-processing include: ‘+ Verifying the results to ensure that FEA model represent the mathematical model acceptably * Validating the results to assure that FEA results are acceptable and characterize the real world ‘* Documenting FEA procedure in proper format/report that includes results, assumptions, simplifications, errors and so on ‘© Plotting and printing the results © Creating the animation, ‘The major steps in a typi ss are illustrated in Figure shown on the next page FEA proChapter 2: Fundamentals of SolidWorks Simulation CAD geometry FEA geometry 8 Simplifying Type of Analysis. ———> Properties Fixtures. =< Mathematical Model Meshing ef Engine FEA model FEA results “Major steps in FEA process 25Chapter 2: Fundamentals of SolidWorks Simulation Types of Elements in SolidWorks Simulation The different types of elements available in SolidWorks Simulation are shown below. The elements can be categorized into two major sub-groups: (i) 3 Dimensional (3D) elements; and (ii) 2 Dimensional (2D) elements. More details will be presented in later chapters. Beam ‘Truss Element Element Ry Beam Element a 3D Elements Shell Element cS Solid Element [F% Plane Stress Element | (i | 2D Elements Plane Strain Element | Axisymmetric Element | SolidWorks Simulation Options Parameters such as units, result plots, reports and mesh can be customized by adjusting them in the SolidWorks Simulation Options dialog box. To access the SolidWorks Simulation Options dialog box, select the Simulation menu and choose Options as shown on the next page. 2-6image not availableimage not availableimage not availableChapter 2: Fundamentals of SolidWorks Simulation In this text, we mostly use the SolidWorks CommandManager to invoke a tool. However, we sometimes use Wo alternatives as well. As shown on the next page, we can access the SolidWorks Modeling Environment by clicking the SolidWorks Modeling Environment Tab (o allow modifications the model. The changes will be implemented seamlessly in the SolidWorks Simulation Environment. [chsouonons | Fo lt Ym Int Tele Sraion Wow tip] + + i - 9 FoR ns este bE, Bent Betin min QPtoe 5, oe, Sane Sit ae Mat odor crm acre Qf nn me rma RQSAE Te ORE: _| fink (efout< D + a (Sensors a a CommandManager ulation CommandManager_ | 5 Toolbars Tab 2 Det Birk ‘corctions shure Bote Ls “nen SolidWorks Design Tree Simulation Study Tree Graphics area SolidWorks Modeling, Environment Tab SolidWorks Simulation Environment Tab 2-10image not availableimage not availableimage not availableChapter 2: Fundamentals of SolidWorks Simulation Standard Fixtures Fixed Geometry Fixture It constrains all translational and rotational degrees of freedom to veto. The Fixed Geometry Fixture can be applied to the verti edges, faces, and beam joints. As shown in the 3D symbol representing this Fixture, arrows represent the constraints applied for translation and disks represent the constraints applied for rotations, A Fixed Geometry Fixture Immovable Fixture It constrains only translation degrees of freedom while rotational => degrees of freedom remain unconstrained. As shown in the 3D symbol representing this Fixture, arrows represent the constraints applied for translation, Roller/Slider Fixture Immovable Fixture It constrains the planar motion of a planar face. The planar face A ‘can move freely on its plane but cannot move in the direction normal to itself, However, note that the face can shrink or expand under loading. Fixed Hinge Roller/Slider Fixture It is applied to a cylindrical face such that the face can rotate about its axis, Note that the length and radius of the eylindrical face remain fixed under loading. Fixed Hinge Fixture 214image not availableimage not availableimage not availableChapter 2: Fundamentals of SolidWorks Simulation On Cylindrical Face Fixture It applies constraints to a cylindrical face along three directions including axial, radial and circumferential directions as shown below. The Figure on the right illustrates the three directions and the Figure on the left shows an example where only the radial and circumference constraints are applied to the external face of the cylinder. eel Cc» me Axial Direction Radial’ m ¢ Diretpn € Circumferentia | € | Direction ‘Advanced(On Cylindrical Faces) @ Sime (@) cater Symetry (i) use Retrence Geometry (@ onriet Feces @_ on crinerica Faces (@) On spherial oces Select a cylindrical face. Select an appropriate unit of ‘measurement, Enter each of the value of translation along the three directions. Note that the rotational options are also available if shell elements are used in. the modelimage not availableimage not availableimage not availableChapter 2: Fundamentals of SolidWorks Simulation Torque ‘Torques or moments can be applied to faces (typically circular or cylindrical faces) and beams. An example is shown below. Select the face(s) to apply the Torque. Select a reference axis, an edge, or cylindrical face to determine the direction of the Torque. Select the unit Torque. Select the direction of the Torque. Select Per item to apply the Torque per selected, face or edge. and enter the magnitude of the Select Total to apply the Torque to the selected es. This option is available when more than one entity is selected, cetit 2-22image not availableimage not availableimage not availableChapter 2: Fundamentals of SolidWorks Simulation ‘Nonuniform Force Applied Normal to a Selected Entity A nonuniform normal force ean be applied to the face of solid(s) and shell(s). It ean also be applied to the edge(s) of a shell(s). To specify a nonuniform force applied normal to an entity, we need to cetermine the magnitude of the force and the distribution function, © Nor Distbaton Fe foxes | cmon oats | ses 4 Select face(s) of « solid(s), shells), or edge(s) of the shell() nate System} ata, Sa eh Select a Reference Coordinate System to specify the distribution of the nonuniform force, Enter the coefficients for the nonuniform force distribution function; fuQuy) = at bx t ox + dxy + ex? + fy? Where: © fa(.y) is the magnitude of the force applied at a point with coordinates x and y expressed in the selected coordinate system. © x and y are coordinates of the point relative to the selected coordinate system. © @,b,c,d,e and f are the second order polynomial function coefficients. 2:26image not availableimage not available