Simulation Professional - What each module can do for me

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1

Simulation Professional
What each Simulation module can do for me?

Gerry Kyle
Joe Galliera

DS SolidWorks Corp.
November 29, 2011

2

Your SolidWorks Simulation Team
 Your SolidWorks Value-Added Reseller (VAR)

 Gerry Kyle – Simulation Sales Manager
 20+ year’s in the CAE industry

 12+ years with COSMOS/M and SolidWorks

 Joe Galliera – Simulation Tech Manager
 Over 15 years of experience with CAE tools
 Helped hundreds of customers successfully
implement simulation solutions

3

SolidWorks Simulation customers
 SolidWorks has more simulation customers than any
other analysis company in the market

80% of our Simulation customers experienced an increase

in product quality
80% of your cost, quality, and performance is established
at the design phase, early detection of issues is critical.
57% report fewer field failures
100% showed time savings and advantages to using
simulation

4

Companies can Differentiate with Simulation

Survey of 620 companies.
 Use of Simulation remains a highly
differentiated strategy
 Perform more iterative assessments

of product performance

Recommendations for Action
 Perform more simulation of product
performance in the design phase.
 Provide CAD-embedded or CAD-
driven simulation capabilities to
engineers

The Aberdeen Group report
5

Sunrise Medical
 Company: Quickie P-222 Powered Wheelchair
 leading provider of rehabilitation products and
assistive technology devices for people with
disabilities, and patient care products used in
nursing homes, hospitals and homecare
settings

 Challenge:
 Find a reliable, easy-to-use, inexpensive &
feature rich CAD system
 Make the transition to 3D
 Run on NT workstations
 SolidWorks Benefits:
 Decreased design time by 45%
 Saved $40-50,000 in prototyping
 Reduced errors by 50% “SolidWorks won our CAD evaluation because it
was the one CAD software that did everything the
 Increased sales by over 50% sales representative promised it would”
Darin Trippensee,
Project Engineer

6

Windsave Glasgow, UK

 Company:
Founded in 2002 in Glasglow, Windsave is the largest micro wind turbine installer in
the UK and is at the forefront of a movement to bring green energy choices to
consumers.
 Challenge:
The company needed to standardise on a CAD system that would improve their
overall performance and efficiency, to refine the technology and accelerate

development of its wall mounted micro-wind turbine system to reduce the amount of
power a home or business draws from the national electricity grid.
 Key Benefits:
Windsave has reduced the number of prototypes to test new products or features
from four to one, saving up to £3,000, using SolidWorks and SolidWorks Simulation.
The company have reduced the prototype production and testing process from eight
weeks to two.
“With SolidWorks and SolidWorks Simulation, we’ve
As the company expands sales internationally in 2009, the team will explore the
been able to refine the action of the tailfin so that it is
possibility of mounting smaller versions of the micro turbines on street lights so
more efficient and aerodynamic.
municipalities can cut energy costs.
Additionally, prototyping costs and time kept adding up
with Pro/ENGINEER. SolidWorks and SolidWorks
Simulation allow us to produce and test a sample on
screen to see if we’ve over- or under-engineered it.
That’s a huge benefit when optimising a design.”

Mike Lumsdaine, mechanical engineer

7

Center Rock, Inc. - USA
 Company:
Center Rock, Inc, is a leading manufacturer of drilling supply
equipment. The company’s drill bits played a significant role in
the rescue of 33 Chilean miners, who were trapped 2,000 feet
underground for two months at the San José Mine in Chile.
 Challenge:

Efficiently increase the number of drilling products
offered, while maintaining the flexibility to resolve engineering
challenges and redesign drill bits on the fly in situations such as
the rescue of the trapped Chilean miners.
• Reached miners two months ahead of
projections
• Redesigned drill bit in three days “SolidWorks Flow Simulation allowed us
• Cut design cycles by 66 percent to reconfigure the tool and reach the
• Quadrupled product offering miners faster.”
Rudy Lyon
Senior Engineer and Product
Development Manager

8

Gaumer Process- USA
 Company:
 When companies in the process industries, including
oil, gas, food-processing, wastewater treatment, and
petrochemical companies, have electric process heating
needs, Gaumer Process often tops their list. That’s because
the Houston-based manufacturer helped to develop electric

process heater technology over the last 30 years, acquiring
several patents for its electric process heaters, systems, and
controls.
“With SolidWorks Simulation software, we were able to
 Challenge: study and test six different concepts and reach an
optimized design in less than three months. We
 Simulate the flow dynamics, heat transfer, and structural eliminated more than two years of costs, saved
characteristics of electric process heaters to trim material, cut $100,000 on prototyping, and produced a patented idea
costs, and accelerate development. for enhancing heat transfer. That’s the kind of advantage
that helps us beat our competition.”
Craig Tiras, P.E.
Vice President of Engineering and Design
 Cut development cycle from three years to three months
 Saved $100,000 in prototyping costs
 Reduced material costs by 75 percent
 Enhanced visualization of system performance

9

Your time, your companies reputation & your profits
Moving forward…
 Drawing board to 2D
 2D to 3D
 3D to parametric 3D
 To SolidWorks

 To virtual testing with SolidWorks simulation

 Each step keeps you ahead of the competition and in a
position to lower costs and improve sales

 Here are some examples of all the different industries
and application used by our simulation customers.

16

Consumer Products – Electronics
Frequency or Dynamics Buckling
• Tubular & angle frames are susceptible to
• Uncontrolled resonance due to speaker buckling.
frequencies can cause objectionable noise & • Consumer use is unpredictable so design
quality concerns must account for eccentric loading which
• Vibration from transportation or operation worsens buckling
must not cause electronics, fasteners, latches
or mechanisms to release or fail
Heat Transfer or Thermal
• Heat from batteries, lights or processors or

other high wattage components must be
Fatigue controlled.
• Hinge components and controls must • Thermal expansion can impact optics and
withstand hundreds of thousands of micro-drive performance. Correct temperature
operations. fields are important.
• Repetitive loading over life of product can
present fatigue concerns Nonlinear

• Contact between assembly components is
Drop Test required for realistic modeling
• Consumers drop products! Perception is • Accurate prediction of plastic or custom
usually lack of quality than misuse. materials requires nonlinear material modeling
• Rough handling of personal electronics is • As designers push the envelope, responses
normal and consumers expect performance to become increasingly nonlinear.
continue.

Motion Simulation

Optimization • Size motors for electric products
• Plastic prices track volatile oil prices. • Optimize mechanism paths and motor loads
Companies learned the hard way in 2005 that
sub-optimal plastic design can eliminate
Flow Simulation
profitability.
• Optimize cooling of critical parts
• Weight reduction for hand held devices is
always critical • Design and optimize heat sink
• Properly position fans and vents
17

Consumer Products – Tools
Frequency or Dynamics Optimization
• Plastic prices track volatile oil prices.
Companies learned the hard way in 2005 that
• Vibration from engines or motors must not
sub-optimal plastic design can eliminate
cause unnecessary fatigue to the consumer
profitability.
• Uncontrolled resonance can cause
• Weight reduction for hand held devices is
objectionable noise & quality concerns
always critical
• Vibration from transportation or operation
must not cause fasteners, to release or fail
Buckling
• Consumer use is unpredictable so design

must account for eccentric loading which
Fatigue worsens buckling

• Repetitive loading over life of product can
present fatigue concerns. Heat Transfer or Thermal
• Hardware products must be sustain peak
performance for a market-driven design life. • Temperatures from motors or engines must
not present danger to consumer.
• Cold weather and water products typically
Drop Test have complex and extreme temperature
distributions that can lead to expansion
related failure.
• Consumers drop products! Perception is
usually lack of quality than misuse.
• Today’s tool purchasers aren’t demanding Nonlinear
longevity as much as robust performance in
extreme use. Drop performance has become
a critical design consideration. • Contact between assembly components is
required for realistic modeling, friction
modeling may be required.
• Accurate prediction of plastic or custom
Motion Simulation
materials requires nonlinear material modeling
• Size motors for electric products • As designers push the envelope, responses
• Optimize mechanism paths and motor loads become increasingly nonlinear.

18

Medical Products
Frequency or Dynamics Drop Test
• Avoid failure of components if dropped during
• Avoid excessive shaking / rattling / vibration the assembly process.
by making sure that the natural frequency of • Minimize chances of product damage if
ultrasonic resonators or a CT scanners is dropped in a care facility.
different than the driving piezoelectric
components. Nonlinear
• Take into account vibration variation caused
by rotors in centrifuge systems • To study specialty materials such as the
• Minimize noise or perceived vibration and Nitinol shape alloy
• Improve the performance of catheters going

extend the life of machinery due to rotating
system imbalance through an artery which experience large
deformation.
• To study contact interactions between
assembly components
Heat Transfer or Thermal
• To predict buckling or collapse of tubing in
bending. Nonlinear buckling and material
• Avoid excessive heating on operator properties come into play for these scenarios.
accessible surfaces or components by
studying the temperature distribution of the
entire machine assembly Fatigue
• Isolating temperatures generated during • Avoid failure from repetitive or cyclic loads
normal operating conditions from affecting and temperatures
other components. • To estimate and/or optimize the lifespan of a
• Isolating temperatures generated during product
assembly processes such as welding from
affecting rest of the components of the Optimization
machine • To design lighter, smaller, cheaper parts
• Study thermal expansion/contraction of without compromising strength or
components and resulting thermal stress. performance
• Reduce shipping and transportation costs by
using lighter parts
Flow Simulation

• Optimize flow rate of valves and meters Buckling
• Study mixing in a drug delivery system to To avoid compressive buckling or collapse of
reduce variance slender needles or drug delivery systems
19

Manufacturing Equipment
Frequency or Dynamics Heat Transfer or Thermal

• Vibration from motors and spindles must not
• Temperatures from cutting/milling must not
impact precision
degrade bearings in spindles
• Vibration from surrounding environment must
• Temperature rise from operation and motor
not resonate in cabinet
must not impact milling precision due to
• Cantilevered work tables must not vibrate due thermal expansion of the system of the work
to operating cycles

Fatigue
• All structural members must be designed for Optimization
durability
• Weight reduction for spindles minimizes
• Repetitive loading of automatic tables can inertias and makes precision control of milling
present fatigue concerns more reliable
• Maximizing stiffness of components in load
path improves precision

Nonlinear

• Contact between assembly components is Drop Test
required for realistic modeling • Ensure that spindles or cutting tools can
handle reasonable drop heights without
damage

Flow Simulation Buckling

• Thermoformed packaging needs to be heated • Buckling on leveling & support legs is possible
and cooled failure mode to watch
• Product velocity can cause air flow related • Buckling of unsupported sections of
disturbances resulting in mishandling conveyors due to normal operation or misuse
• Design of an effective scrap removal system (operator weight) must be avoided.

20

SolidWorks Product Design & Simulation Tools
Flow Electronics HVAC

Flow Sustainability Sustainability

Non linear Dynamics Composites

Premium
Simulation

Thermal Fatigue Drop Test Optimize Frequency Buckling Pressure Motion Pro
Professional Vessel

Simulation Motion Routing ScanTo3D TolAnalyst CircuitWorks
Premium
SolidWorks

eDrawings Workgroup Task Design Feature
PhotoView Toolbox Utilities
Pro Scheduler Checker Works
Professional
PDM

Content
SolidWorks Rx Explorer
Standard Central

28

How do you know you have the best design?
 A few examples

Which angle?
Which material? 3 or 4 holes? What thickness?
Which tube size? 2 or 1 Ribs? Which ribs?

29

Cost of Prototyping

Physical Prototyping Virtual Prototyping
Labor Labor
Duration Cost HW Cost Duration Cost HW Cost
Initial Prototype 1 week $800 $2,000 4 hours $200 $0

1st Design Iteration 1 day $800 $500 2 hours $200 $0
2nd Design Iteration 1 day $800 $500 2 hours $200 $0
3rd Design Iteration 1 day $800 $500 2 hours $200 $0
4th Design Iteration 1 day $800 $500 2 hours $200 $0
Total 2 weeks $10,600 2 days $1,600

30

Physical v. Virtual Prototyping

 Finite discrete data points  Virtually unlimited data points
 Physically intrusive for maximum design insight
 Long lead times  Quick design changes with
 Expensive equipment CAD model
 Long setup and testing  Multiple what-if scenarios
 Inexpensive test equipment

31


Design A Better Frame

32



33
Which is stronger?


How much stronger? (Is it worth the extra
material, time, cost?)

34


Safety Factor 2.659 Safety Factor 13.08

Adding corner supports improves
the safety factor 5X

35


Which is Best?
Same Material Same Number of Cut, Same Number of Welds

30° 45° 60°

36


• 5 Minutes: Build Configurations
• 5 Minutes: Define Studies

• 6 Minutes: Run All Four Studies
• 1 Minute: Make Your Design
Decision

37


Better Good Best
Max Deflection: 0.181mm Max Deflection: 0.147mm Max Deflection: 0.118mm
Safety Factor: 13.19 Safety Factor: 13.08 Safety Factor: 14.21

30° 45° 60°

38


Frame Demo

39

Design a Better Guard

You know the 1100 RPM
speed of the blade (18.3 Hz)

Will the guard
excessively
vibrate?
?
40


Which Design is Better?

41


Initial Design Frequency Goal
SW Simulation
reports

>23.8 Hz 16.6
12.4
10.2 Hz
5.0 Hz Hz
18.8

Initial Design Will
Vibrate Excessively 
42


Design Change 1:
SW Simulation
Increase overall wall thickness from 3 to 4 mm Frequency Goal reports

(Increases weight 30% over initial design) >23.8 Hz 20.6
15.4
10.2 Hz
5.0 Hz Hz
25.2

Design Will Not
Vibrate Excessively 
43


Design Change 2:
SW Simulation
Use 3mm wall thickness and add external ribs Frequency Goal reports

9.8
5.6 Hz
2.0 Hz Hz
19.5

Design Will Vibrate
Excessively 
44


Design Change 3:
SW Simulation
Use 3mm wall thickness and added internal ribs Frequency Goal reports

9.8
5.6 Hz
2.0 Hz Hz
27.7

Design Will Not
Vibrate Excessively 
45


Best Design
• 30 minutes
• 4 design iterations
• 0 prototypes

46


Saw Guard Demo

47

Linear Static
 SolidWorks Simulation
 Providing stress, strain, and displacement analysis capabilities
for parts and assemblies, this design validation and
optimization tool enables you to identifies areas prone to
weakness and failure.

 This tool enables the engineer to determine if a product is over
or under designed. Also ensure that unique industry safety
factors are met.
 SolidWorks Simulation software helps improve quality by
indicating how product designs will behave before they are
built. Help your customers design better products.

48

SolidWorks Motion
 SolidWorks Motion is kinematic and dynamic simulation. It
provides all the resultant kinematic values, such as time-varying
displacement, velocity and acceleration, for all moving bodies and
resultant dynamics loads on all joints, such as force, torque and
power.

 This software enables you to study the physics of moving
assemblies. With SolidWorks Motion, you can estimate peak
motor torque, analyze robotic performance during operation, size
motors/actuators, and determine power consumption. In addition
to laying out linkages and developing cams, you can analyze gear
drives, size springs/dampers, determine how contacting parts
behave, and minimize force imbalances in rotating systems.

49

Natural Frequency and Resonance
 Avoid product failure due to excessive shaking or rattling or
vibration.
 Natural frequency is how quickly a system will move back and
forth (or oscillate).
 Can be used to compare the relative stiffness of design variations

(even if they are not interested in vibration).

50

Thermal
 Transient and Steady State Thermal problems solves the solid
Conduction problem and you can apply Convection and Radiation
conditions to the model.
 The outputs of a thermal study are temperature, temperature
gradient and heat flux distributions.

 Heat transfer effects due to:
 Conduction, convection, radiation (i.e. all types of heat transfer)
 Time-dependent conditions lead to Transient solutions
 Temperature-dependent material properties
 Use temperature results from a Thermal study to a Static loading:
 Thermal stresses
 Expansion and Contraction thermal displacements

51

Fatigue
 Help determine product life
 Predict if the product will be durable enough to withstand
repeated loading or usage
 Modify existing design to extend working life
 Identify critically damaged areas

 Life, percent total damage, load factor of safety
 Damage chart
 Input unique fatigue (S-N) material curves for different
material types

52

Buckling
 Buckling analysis is recommended:
 If structure has high compressive loads or
weight.
 If structure is long and slender
 Typically if structure has thin walls

 Buckling involves lack of stability in a structure
subject to compressive forces.
 Often a very sudden and unexpected failure!
 Standing on a empty can of soda that is propped
up on ground level will require Buckling Analysis

53

Optimization
 Reduce cost, weight
 Lightest possible design
 Automatically find the best design based on design intent
 Put constraints such that optimum design stay within

allowable stress limits
 The basic goal of optimization is to create a better and
more valuable product than those already exist.
Create 3D CAD Build Virtual Prototype Simulate Performance

Validate Simulation
Optimize Design

54

Steering Bracket Design

 Goals
– Design for strength – Keep stress below 2600 psi
– Design Optimization – Reduce weight of the part
– Design for life – One season of 10~20 rallies

– Frequency Check – Frequency range > 400Hz (24,000 RPM)

The part is from a Group N rally car (modified road cars)
58

SolidWorks Product Design & Simulation Tools
Flow Electronics HVAC

Flow Sustainability Sustainability

Non linear Dynamics Composites

Premium
Simulation

Thermal Fatigue Drop Test Optimize Frequency Buckling Pressure Motion Pro
Professional Vessel

Simulation Motion Routing ScanTo3D TolAnalyst CircuitWorks
Premium
SolidWorks

eDrawings Workgroup Task Design Feature
PhotoView Toolbox Utilities
Pro Scheduler Checker Works
Professional
PDM

Content
SolidWorks Rx Explorer
Standard Central

59

Thank you!

We would like to thank you for attending this
webinar on SolidWorks Simulation Pro!

 Gerry Kyle – Simulation Sales Manager
 Gerry.Kyle@3ds.com

 Joe Galliera – Simulation Tech Manager
 Joe.Galliera@3ds.com

60

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