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2. Simulation Professional What each Simulation module can do for me? Dassault Systmes Confidential Information Gerry Kyle Joe GallieraDS SolidWorks Corp. November 29, 2011 2 3. Your SolidWorks Simulation Team Your SolidWorks Value-Added Reseller (VAR) Gerry Kyle Simulation Sales Manager 20+ years in the CAE industry Dassault Systmes Confidential Information 12+ years with COSMOS/M and SolidWorks Joe Galliera Simulation Tech Manager Over 15 years of experience with CAE tools Helped hundreds of customers successfullyimplement simulation solutions3 4. SolidWorks Simulation customers SolidWorks has more simulation customers than anyother analysis company in the market80% of our Simulation customers experienced an increase Dassault Systmes Confidential Information in product quality80% of your cost, quality, and performance is establishedat the design phase, early detection of issues is critical.57% report fewer field failures100% showed time savings and advantages to usingsimulation4 5. Companies can Differentiate with Simulation Survey of 620 companies. Use of Simulation remains a highlydifferentiated strategy Perform more iterative assessments Dassault Systmes Confidential Information 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 6. Sunrise Medical Company:Quickie P-222 Powered Wheelchair leading provider of rehabilitation products andassistive technology devices for people withdisabilities, and patient care products used innursing homes, hospitals and homecaresettings Dassault Systmes Confidential Information 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 itwas the one CAD software that did everything the Increased sales by over 50% sales representative promised it wouldDarin Trippensee,Project Engineer6 7. Windsave Glasgow, UK Company:Founded in 2002 in Glasglow, Windsave is the largest micro wind turbine installer inthe UK and is at the forefront of a movement to bring green energy choices toconsumers. Challenge:The company needed to standardise on a CAD system that would improve theiroverall performance and efficiency, to refine the technology and accelerate Dassault Systmes Confidential Information development of its wall mounted micro-wind turbine system to reduce the amount ofpower 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, weve 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 weve over- or under-engineered it. Thats a huge benefit when optimising a design. Mike Lumsdaine, mechanical engineer7 8. Center Rock, Inc. - USA Company: Center Rock, Inc, is a leading manufacturer of drilling supply equipment. The companys 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 Jos Mine in Chile. Challenge: Dassault Systmes Confidential Information 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. SolidWorks Benefits: Reached miners two months ahead of projections Redesigned drill bit in three daysSolidWorks Flow Simulation allowed us Cut design cycles by 66 percent to reconfigure the tool and reach the Quadrupled product offering miners faster.Rudy LyonSenior Engineer and Product Development Manager8 9. 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. Thats because the Houston-based manufacturer helped to develop electric Dassault Systmes Confidential Information 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. Thats the kind of advantage that helps us beat our competition. SolidWorks Benefits: 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 10. Your time, your companies reputation & your profits Moving forward Drawing board to 2D 2D to 3D 3D to parametric 3D To SolidWorks Dassault Systmes Confidential Information To virtual testing with SolidWorks simulation Each step keeps you ahead of the competition and in aposition to lower costs and improve sales Here are some examples of all the different industriesand application used by our simulation customers.16 11. 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 concernsmust account for eccentric loading which Vibration from transportation or operationworsens buckling must not cause electronics, fasteners, latches or mechanisms to release or fail Heat Transfer or Thermal Heat from batteries, lights or processors or Dassault Systmes Confidential Information other high wattage components must be Fatigue controlled. Hinge components and controls must Thermal expansion can impact optics and withstand hundreds of thousands ofmicro-drive performance. Correct temperature operations. fields are important. Repetitive loading over life of product can present fatigue concernsNonlinear 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 tobecome 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 vents17 12. 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 Dassault Systmes Confidential Information 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. Todays tool purchasers arent demandingNonlinear 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 loadsbecome increasingly nonlinear.18 13. Medical Products Frequency or Dynamics Drop Test Avoid failure of components if dropped during Avoid excessive shaking / rattling / vibrationthe 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 Dassault Systmes Confidential Information extend the life of machinery due to rotating system imbalancethrough 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 affectingand 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 ofwithout 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 systems19 14. Manufacturing Equipment Frequency or DynamicsHeat Transfer or Thermal Vibration from motors and spindles must not Temperatures from cutting/milling must not impact precisiondegrade bearings in spindles Vibration from surrounding environment must Temperature rise from operation and motor not resonate in cabinetmust not impact milling precision due to Cantilevered work tables must not vibrate duethermal expansion of the system of the work to operating cycles Dassault Systmes Confidential Information Fatigue All structural members must be designed forOptimization 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 loadpath improves precision Nonlinear Contact between assembly components is Drop Test required for realistic modeling Ensure that spindles or cutting tools canhandle reasonable drop heights withoutdamage Flow SimulationBuckling 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 mishandlingconveyors due to normal operation or misuse Design of an effective scrap removal system(operator weight) must be avoided. 20 15. SolidWorks Product Design & Simulation ToolsFlowElectronicsHVAC FlowSustainabilitySustainability Non linear DynamicsComposites Premium Simulation Dassault Systmes Confidential Information Thermal Fatigue Drop Test Optimize Frequency Buckling PressureMotion Pro ProfessionalVessel Simulation MotionRoutingScanTo3DTolAnalystCircuitWorks Premium SolidWorkseDrawingsWorkgroup Task Design FeaturePhotoView Toolbox Utilities Pro SchedulerCheckerWorks Professional PDMContentSolidWorks Rx Explorer Standard Central 28 16. How do you know you have the best design? A few examples Dassault Systmes Confidential Information Which angle? Which material? 3 or 4 holes? What thickness? Which tube size?2 or 1 Ribs?Which ribs? 29 17. Cost of Prototyping Physical Prototyping Virtual Prototyping Labor LaborDuration CostHW Cost DurationCostHW Cost Initial Prototype1 week $800 $2,000 4 hours$200$0 Dassault Systmes Confidential Information 1st Design Iteration1 day $800 $500 2 hours$200$0 2nd Design Iteration1 day $800 $500 2 hours$200$0 3rd Design Iteration1 day $800 $500 2 hours$200$0 4th Design Iteration1 day $800 $500 2 hours$200$0 5th Design Iteration1 day $800 $500 2 hours$200$0 6th Design Iteration1 day $800 $500 2 hours$200$0 Total2 weeks$10,600 2 days$1,600 30 18. Physical v. Virtual Prototyping Dassault Systmes Confidential Information Finite discrete data points Virtually unlimited data points Physically intrusive for maximum design insight Long lead times Quick design changes with Expensive equipmentCAD model Long setup and testing Multiple what-if scenarios Inexpensive test equipment 31 19. Dassault Systmes Confidential Information Design A Better Frame32 20. Dassault Systmes Confidential Information Design A Better Frame33 Which is stronger? 21. Design A Better Frame Dassault Systmes Confidential Information How much stronger? (Is it worth the extramaterial, time, cost?) 34 22. Design A Better FrameSafety Factor 2.659Safety Factor 13.08 Dassault Systmes Confidential Information Adding corner supports improves the safety factor 5X 35 23. Design A Better Frame Which is Best? Same Material Same Number of Cut, Same Number of Welds Dassault Systmes Confidential Information 304560 36 24. Design A Better Frame 5 Minutes: Build Configurations 5 Minutes: Define Studies Dassault Systmes Confidential Information 6 Minutes: Run All Four Studies 1 Minute: Make Your DesignDecision 37 25. Design A Better FrameBetterGoodBest Max Deflection: 0.181mm Max Deflection: 0.147mm Max Deflection: 0.118mm Safety Factor: 13.19Safety Factor: 13.08Safety Factor: 14.21 3045 60 Dassault Systmes Confidential Information 38 26. Dassault Systmes Confidential Information Frame Demo39 27. Design a Better Guard Dassault Systmes Confidential Information You know the 1100 RPMspeed of the blade(18.3 Hz)Will the guardexcessivelyvibrate?? 40 28. Dassault Systmes Confidential Information Which Design is Better?41 29. Design a Better Guard Initial DesignFrequency Goal SW Simulationreports>23.8 Hz 16.6 12.4 10.2 Hz 5.0 Hz Hz 18.8 Dassault Systmes Confidential Information Initial Design Will Vibrate Excessively 42 30. Design a Better Guard Design Change 1: SW Simulation Increase overall wall thickness from 3 to 4 mm Frequency Goalreports (Increases weight 30% over initial design) >23.8 Hz 20.6 15.4 10.2 Hz 5.0 Hz Hz 25.2 Dassault Systmes Confidential Information Design Will Not Vibrate Excessively 43 31. Design a Better Guard Design Change 2:SW Simulation Use 3mm wall thickness and add external ribsFrequency Goalreports (Increases weight 1% over initial design) >23.8 Hz 13.99.85.6 Hz2.0 Hz Hz19.5 Dassault Systmes Confidential Information Design Will VibrateExcessively 44 32. Design a Better Guard Design Change 3:SW Simulation Use 3mm wall thickness and added internal ribsFrequency Goalreports (Increases weight 1% over initial design) >23.8 Hz 13.99.85.6 Hz2.0 Hz Hz27.7 Dassault Systmes Confidential Information Design Will NotVibrate Excessively 45 33. Design a Better Guard Dassault Systmes Confidential Information Best Design 30 minutes 4 design iterations 0 prototypes 46 34. Dassault Systmes Confidential Information Saw Guard Demo47 35. Linear Static SolidWorks Simulation Providing stress, strain, and displacement analysis capabilitiesfor parts and assemblies, this design validation andoptimization tool enables you to identifies areas prone toweakness and failure. Dassault Systmes Confidential Information This tool enables the engineer to determine if a product is overor under designed. Also ensure that unique industry safetyfactors are met. SolidWorks Simulation software helps improve quality byindicating how product designs will behave before they arebuilt. Help your customers design better products. 48 36. SolidWorks Motion SolidWorks Motion is kinematic and dynamic simulation. Itprovides all the resultant kinematic values, such as time-varyingdisplacement, velocity and acceleration, for all moving bodies andresultant dynamics loads on all joints, such as force, torque andpower. Dassault Systmes Confidential Information This software enables you to study the physics of movingassemblies. With SolidWorks Motion, you can estimate peakmotor torque, analyze robotic performance during operation, sizemotors/actuators, and determine power consumption. In additionto laying out linkages and developing cams, you can analyze geardrives, size springs/dampers, determine how contacting partsbehave, and minimize force imbalances in rotating systems.49 37. Natural Frequency and Resonance Avoid product failure due to excessive shaking or rattling orvibration. Natural frequency is how quickly a system will move back andforth (or oscillate). Can be used to compare the relative stiffness of design variations Dassault Systmes Confidential Information (even if they are not interested in vibration). 50 38. Thermal Transient and Steady State Thermal problems solves the solidConduction problem and you can apply Convection and Radiationconditions to the model. The outputs of a thermal study are temperature, temperaturegradient and heat flux distributions. Dassault Systmes Confidential Information 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 displacements51 39. Fatigue Help determine product life Predict if the product will be durable enough to withstandrepeated loading or usage Modify existing design to extend working life Identify critically damaged areas Dassault Systmes Confidential Information Life, percent total damage, load factor of safety Damage chart Input unique fatigue (S-N) material curves for differentmaterial types 52 40. Buckling Buckling analysis is recommended: If structure has high compressive loads orweight. If structure is long and slender Typically if structure has thin walls Dassault Systmes Confidential Information 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 Analysis53 41. Optimization Reduce cost, weight Lightest possible design Automatically find the best design based on design intent Put constraints such that optimum design stay within Dassault Systmes Confidential Information 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 PerformanceValidate Simulation Optimize Design 54 42. 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 Dassault Systmes Confidential Information Frequency Check Frequency range > 400Hz (24,000 RPM) The part is from a Group N rally car (modified road cars)58 43. SolidWorks Product Design & Simulation ToolsFlowElectronicsHVAC FlowSustainabilitySustainability Non linear DynamicsComposites Premium Simulation Dassault Systmes Confidential Information Thermal Fatigue Drop Test Optimize Frequency Buckling PressureMotion Pro ProfessionalVessel Simulation MotionRoutingScanTo3DTolAnalystCircuitWorks Premium SolidWorkseDrawingsWorkgroup Task Design FeaturePhotoView Toolbox Utilities Pro SchedulerCheckerWorks Professional PDMContentSolidWorks Rx Explorer Standard Central 59 44. Thank you! We would like to thank you for attending this webinar on SolidWorks Simulation Pro! Dassault Systmes Confidential Information Gerry Kyle Simulation Sales Manager Gerry.Kyle@3ds.com Joe Galliera Simulation Tech Manager Joe.Galliera@3ds.com 60