VAR logo here

Position: Horizontal VAR logo

5.86” & Vertical .46”,
both from top left corner

SolidWorks Simulation Professional Training

SolidWorks 2010

Confidential
Information
Six types of analysis
VAR logo

Frequency
Frequency Buckling Thermal
Thermal

Fatigue Optimization Drop Test

Optimization

Confidential
Information
 VAR logo here
Position: Horizontal VAR logo
5.86” & Vertical .46”,
both from top left corner

Lesson 1
Frequency Analysis

Confidential
Information
Modal Analysis Basics
VAR logo

Every structure has its preferred frequencies of vibration called resonant

frequencies. Each such frequency is characterized by a specific shape of
vibration.

When excited with a resonant frequency, a structure vibrates in a shape. This

is called a mode of vibration.

Recall that structural static analysis calculates nodal displacements as the

primary unknowns: [K]d = F where [K] is known as the stiffness matrix, d is
the unknown vector of nodal displacements, and F is the known vector of
nodal loads.

In dynamic analysis, we additionally consider damping [C] and mass [M].

Confidential
Information
 Frequency Analysis
VAR logo

The equation above is traditionally referred to as the equation of motion for

damped forced vibration.
In the absence of damping and external forces the equation below equation is for
motion for free vibration

What if loads are changing very slowly with time ? Can we still use the assumption
of Static analysis ?
Yes, if the frequency of the applied load is significantly lower than the first natural
frequency of the structure. If not, a dynamic analysis is required to check if the
structure is likely to resonate.

Confidential
Information
 Structural Characteristics
VAR logo

Natural Frequencies:- Frequencies at which the structure prefers to oscillate (if

excited). Often these values are referred to as resonant frequencies.

(Natural) modes of vibration:- Unique shapes of vibrations corresponding to

specific natural frequencies.

Note that any real structure has an infinite number of natural frequencies and
modes. The maximum number of modes that can be extracted is limited to the
number of degrees-of-freedom.

In resonance, inertial stiffness subtracts from elastic stiffness and, in effect, the
structure loses its stiffness. The only factor controlling the vibration amplitude in
resonance is damping. If damping is low, and most often it is low, the amplitude
may reach dangerous levels.

Confidential
Information
 Frequency Analysis
VAR logo

Can we use symmetry in frequency analysis?

When you analyze the results of a frequency
analysis of a symmetric model, the modes of
vibration are either symmetric or anti symmetric.
Observe that the higher the mode of vibration,
the more complex the mode shape is.
Note that a frequency analysis can be conducted
on both parts and assemblies. If an assembly is
analyzed, all parts must be bonded; no
contact/gap conditions are allowed. If assembly
parts interfere, as with assemblies intended for
shrink fit analysis, this interference must be
eliminated prior to performing a frequency
analysis.
What do we get from Frequency analysis ?
Frequency values and deformation mode-shapes
Cannot get actual values of displacements – only
obtained deformation mode. Actual values of
displacements depends on amplitude of imposed
loads and damping

Confidential
Information
Frequency Analysis
VAR logo

Required Material Properties :- The following material properties are required in a

frequency analysis: Modulus of elasticity (also called Young’s modulus),
Poisson’s ratio, Mass density
Important! In order to model inertial stiffness, material properties specified for a
frequency analysis model must include material density (not specific gravity).
Frequencies and Mode Shapes:- While every real life structure has an infinite
number of natural frequencies and associated modes of vibration, only a few of
the lowest modes are important in the response of a structure to dynamic loading.
The frequencies of these first few modes are usually well-spaced apart;
frequencies of higher modes are spaced closer.
A frequency analysis calculates those resonant frequencies and their associated
modes of vibration. It is important to understand that resonant frequencies and
the associated modes of vibrations are all that a frequency analysis calculates.

Confidential
Information
Frequency Analysis
VAR logo

Important! A frequency analysis does not calculate displacements or stresses.

While mechanical resonance is avoided in mechanical systems, resonance is not
always a “bad” thing. Indeed, some devices are designed to work in resonance.
Some obvious examples are musical instruments, machines like soil compactors,
pneumatic hammers, and so on.
In most cases, though, we avoid resonance. Knowing what excitation frequencies
our product will be exposed to, we design the product in such a way that its
natural frequencies do not coincide with the excitation frequencies.
To bring the natural frequency of a structure out of the critical range, we can
change its geometry, materials, or characteristics of the shock isolators, or we
can appropriately place mass elements. The effect of these actions can be
analyzed with a frequency analysis.

Confidential
Information
Lesson 1 Description
VAR logo

Problem statement
Tuning fork designed to emit a lower A tone (440 Hz). The design of the this
tuning fork is to be confirmed using the frequency analysis.

What are the boundary conditions?

How will loading effect the natural frequencies?

Confidential
Information
 Lesson 1 Description
VAR logo

Fundamental Frequency:-
The fundamental frequency is the lowest resonant frequency. The natural
frequency value is proportional to the level of energy required to excite the
structure at a particular mode. A structure oscillating at its fundamental frequency
would, therefore, require the least amount of energy when compared to all of the
higher natural frequencies. We can expect that 440 Hz is the fundamental
frequency for our tuning fork.


Analysis Type:- Frequency Analysis

Mesh Type:- Solid Mesh

No. of Frequencies:- 4

Solver:- Automatic

Material Properties:- Chrome Stainless Steel

Restraints:- Face of ball as fixed

Mesh:- High – 0.058in

Confidential
Information
Lesson 1 Results
VAR logo

Confidential
Information
 Lesson 1 Displacement
VAR logo

Displacement Results in Frequency Analysis:-

The magnitude of the displacement results is meaningless in a frequency analysis.

Displacement results can be used only to compare relative displacements between
different portions of the model and only within the same mode of vibration.
Meaningful displacement results require the execution of a dynamic analysis, where
time-dependent force excitation of the initial impetus causing the model to vibrate
exists.

As explained previously, a frequency analysis only calculates the natural (resonant)

frequencies and associated modes (shapes) of vibrations. It extracts these important
structural properties by analyzing the equation of motion of free vibrations without
any initial conditions causing the actual motion (i.e. no motion exists).

Confidential
Information
Lesson 1 Description
VAR logo

Frequency Analysis Without Supports

Rigid Body Modes:- 6 RB modes for 6 DOF
The first elastic mode of vibration where the tuning fork experiences elastic
deformation is Mode 7. Mode 7 has a frequency of 444 Hz, very close to what we
expected as the fundamental mode of vibration for the tuning fork.

Effect of Restraints
Why didn’t the frequency analysis with supports produce the first mode with a
frequency close to the operating frequency of 440 Hz?
If we closely examine the first three modes of vibration of the supported tuning
fork, we notice that the first three modes need the support in order to exist.
Without it, the tuning fork cannot vibrate in any of these three modes.
Because human fingers cannot generate a rigid support used in this first study,
none of the first three modes are likely to occur. If any signs of these three modes
do occur, they are quickly damped by the flexible support of the human “grip”.
In effect, the tuning fork, with or without supports, ends up vibrating the way it
was designed to, with a frequency of 440 Hz: mode 4 as calculated in the analysis
with supports, or mode 7 as calculated in the analysis without supports. These
two modes are identical.

Confidential
Information
Lesson 1 – with loading
VAR logo

 Frequency analysis with loads

– Loads affect the natural frequency
– Compressive loads decrease resonant
frequencies and tensile loads increase.
Example: changing the tension on a violin
string the increasing the tension will
increase frequency.

 Use the Direct Sparse solver

– If Solver option is set to Automatic, then
Direct Sparse solver will be used when
loads are defined for a frequency study

Confidential
Information
Exercise 1: Car Suspension Bulkhead
VAR logo

Perform a frequency analysis on the front bulkhead of

an automobile suspension system.

The bulkhead shown is used as part of the front

suspension system of a dirt-road racing car. It is built
from Cast Alloy Steel.

The following features will be used in the lab

exercise: Perform frequency analysis of a part,
Investigate rigid body modes

Run two analysis one with no restraints and the other

with hinge restraints on the four bolt holes

Confidential
Information
Exercise 1: Car Suspension Bulkhead
VAR logo

Confidential
Information
 Exercise 2: Blower Fan
VAR logo

A blower fan is subjected to a centrifugal force causing tensile stresses in its blades.
These stresses increase blade stiffness. The additional stiffness is called stress
stiffness; it adds to the elastic stiffness (also called shape stiffness) of the blade.

In effect, rotating blades are stiffer than stationary blades, and this increased
stiffness affects the resonant frequencies of the blades. In this exercise, we
investigate the effect of the increase in stiffness, caused by the centrifugal force, on
the natural frequencies of the rotating fan blade.

To demonstrate the effect of stress stiffening, we perform the frequency analysis

twice:

The first analysis does not account for the increase in stiffness.
The second analysis accounts for the increase of stiffness.

Confidential
Information
 Exercise 2: Blower Fan
VAR logo

Frequency Analysis Without An Applied Load

Frequency analysis with loads

– Loads affect the natural frequency
– Compressive loads decrease resonant frequencies and tensile loads increase.
Example: changing the tension on a violin string the increasing the tension will
increase frequency.

 Use the Direct Sparse solver. If Solver option is set to Automatic, then Direct
Sparse solver will be used when loads are defined for a frequency study

 Three studies
– Frequency of blade when there is no rotation
– Frequency of blade when rotating at 3000 rpm
– Using Design Scenarios to get frequencies of blade when rotating at various
speeds

Material:- 1060 Aluminum Alloy

Restraints:- Fixed at center hole

Confidential
Information
 Exercise 2: Blower Fan
VAR logo

No rotation Rotation Speed 300 rpm

Pre-Stress has the biggest effect on the first frequency, also called the fundamental or
natural frequency. It has increased from 75 Hz to 95 Hz. The other four frequencies have
increased as well. The results show that the natural frequencies of the turbine blade
differ significantly if a centrifugal load causing tensile stresses is considered in
analysis.

Confidential
Information
 Exercise 2: Blower Fan
VAR logo

Sensitivity Study – Design Scenarios

With increasing rpm the blades

become stiffer.

The effect of stress stiffening due to a centrifugal load on the natural frequencies of a
cooling fan blade. Stress softening and stiffening effects are automatically taken into
account if there is a load present. This same effect must be accounted for in a
frequency analysis of rotating parts, such as turbines, motor rotors, and wind turbines.
Using the design scenario feature, we established the relation between natural
frequencies and the speed of rotation of the fan. Confidential
Information
 Exercise 2: Blower Fan
VAR logo

In plane Stresses:- We can generalize our findings by saying that predominantly

tensile stresses increase natural frequencies, as these examples of the rotating fan
blade illustrate. Fast rotating machinery typically requires consideration of the effect
of pre-stress. Tuning a guitar string is another example; to produce a higher note, we
increase tension in the string.

Compressive stresses have the opposite effect. They decrease natural frequencies.
For example, the analysis of the natural frequencies of a compressed column
demonstrate that natural frequencies decrease with an increased load. Note that a
load magnitude corresponding to a zero frequency equals a buckling load.

Effects of Loads in Frequency Analysis:- Compressive and tensile loads change the
capacity of a structure to resist bending. Compressive loads decrease resistance to
bending; this phenomenon is called stress softening. Tensile forces increase
bending stiffness; this phenomenon is called stress stiffening.

Stress softening or stiffening can be important both in static and frequency analyses
because it affects the resultant stiffness of a structure and therefore changes its
vibration properties and its response to a load.

In a static analysis, an accurate solution that considers the effect of loads on the
stiffness requires nonlinear analysis. In frequency analysis, the stress stiffening or
softening effect changes the natural frequencies.
Confidential
Information
Exercise 3: Impeller
VAR logo

Frequency Analysis of an impeller rotating at 20000 rpm

Perform a frequency analysis on the Impeller part and study the effect
of stress stiffening on the natural frequencies of the model.
• Mixed Meshing
• Bonded contact sets between Solid and Shell

Confidential
Information
Exercise 3: Impeller
VAR logo

Shell Thickness – 1 mm
Material – Alloy Steel
Centrifugal Load – 20000 rpm
Contact – Bonded
Source – Shell, Target – Solid

Confidential
Information
 VAR logo here
Position: Horizontal VAR logo
5.86” & Vertical .46”,
both from top left corner

Lesson 2
Frequency Analysis of Assemblies

Confidential
Information
 Lesson 2 Topics
VAR logo

Project Description

The engine frame supports a heavy engine in the configuration shown in the figure to
the right. The frame is connected to a secondary rigid structure at the four
locations depicted in the figure.

In this analysis, we will investigate the natural frequencies of the assembly. To

simplify the simulation, we will assume that the intermediate components directly
connected to the engine are very stiff and light in comparison to the engine mass.
This will allow us to suppress them from the analysis.

Remote Mass

Whenever a mass of a body is significant and the stresses and deformations are not
important, the object can be conveniently treated as remote mass rigidly
connected to the load bearing faces.

Confidential
Information
Lesson 2 Topics
VAR logo

Remote Mass to represent certain components

Frequency of assembly depends on exact masses of components
Geometry of some components may not be exactly represented in SW
model
Engine Component is modeled as “point mass” with appropriate mass and
inertia characteristics
Contact-sets for frequency analysis
Bonded or Free

Confidential
Information
Lesson 2 Topics
VAR logo

We cannot define No Penetration contact for Frequency Analysis

Frequency Analysis requires constant mass and stiffness
For No Penetration Contact model, Stiffness depends on deformation (not
constant)
See example below:

Confidential
Information
Lesson 2 Topics
VAR logo

No of Frequencies – 5
Solver – Direct Sparse
Material – Alloy Steel
Engine – Remote Mass, Connected to four holes
Restraints – Fixed on bottom four faces
Contacts – All Bonded
– Allow penetration with pin connectors

The analysis with allow penetration is more softer than the analysis with global
bonded.

It is shown that due to the requirement of a constant stiffness matrix, No

Penetration contacts are not allowed in the frequency analysis and an alternate
approximated approach is required.

Confidential
Information
Lesson 2 Topics
VAR logo

For example, various contacts and connectors in the assemblies have to be

approximated with the help of bonded and free contacts, pins, spot welds, etc.
Based on combinations of these features, we typically create a model that exhibits
a stiffer/softer response, providing us with good information on the bounds of the
vibrational characteristics of the original assembly.

Note that the true vibration characteristics of such an assembly can be obtained by
subjecting the assembly to a shock load and by studying the structural response
(displacements, velocities, etc). This is the subject of the Advanced Dynamics
training manual.

Confidential
Information
Exercise 4: Particle Separator
VAR logo

No. of Modes – 5

Solver – Direct Sparse

Material – AISI 1020

Remote Mass for Cyclone to 8 faces of Supporting

Structure

Contact – Global Contact

Other Local Bonded Contact – Supporting Frame to

contact face

Fixture – Bottom face of structure is fixed

Confidential
Information
Exercise 4: Particle Separator
VAR logo

Confidential
Information
 VAR logo here
Position: Horizontal VAR logo
5.86” & Vertical .46”,
both from top left corner

Lesson 3

Buckling Analysis

Confidential
Information
Lesson 3 Topics
VAR logo

 A small increase in load causes an abrupt large

increase in deformation
 Large compressive force
 Associated with slender components subjected to
axial compressive force
 Buckling Load Factor =

Confidential
Information
 Lesson 3 Topics
VAR logo

Buckling Analysis Basics

Buckling refers to sudden large displacements due to compressive loads. Slender

structures, subject to axial loads, can fail due to buckling at load levels lower than
those required to cause material failure.

Buckling can occur in different modes under the effect of different load levels. In
most cases, only the lowest buckling load is of interest.

To grasp the concept of buckling, note that any structural load affects structural
stiffness by adding a component commonly referred to as stress stiffness. Tensile
loads induce a positive stress stiffness, which adds to the elastic stiffness of the
structure. Compressive loads induce a negative stress stiffness, which is
subtracted from the elastic structural stiffness causing the structure to soften.

Buckling takes place when the resultant structure stiffness (a result of subtracting
the stress stiffness induced by compressive load from elastic stiffness) drops to
zero.

The first mode and its associated magnitude of buckling force is most important
because buckling most often causes catastrophic failure or renders the structure
unusable, even if the structure can withstand the load in its buckled shape.

Confidential
Information
 Lesson 3 Topics
VAR logo

Linear vs. Nonlinear Buckling Analysis

Buckling can be thought of as a situation where a very small increase in the load
causes the structure to lose its stability and collapse.
A linear buckling analysis determines the eigenvalues of the structure for given
loads and restraints, disregarding any imperfections and nonlinear effects that
always exist in real structures. Those imperfections and nonlinear effects
significantly lower the real buckling loads as compared to the buckling loads
predicted by a linear buckling analysis. For this reason, the results of a linear
buckling analysis must be interpreted with caution. Nonlinear buckling analysis
must be used to find accurate values of the buckling load in many cases and to
study post-buckling effects. Some buckling problems that always require nonlinear
buckling analysis and cannot even be approximated by linear buckling analysis
include:
� Inelastic or nonlinear material behavior prior to instability
� Re-alignment of applied pressure during deformation
� Large displacements prior to buckling
Buckling should always be considered as a potential mode of failure in structures
that consist of slender members in compression. In fact, many structural disasters
are initiated by buckling, and only the final destruction is caused by excessive
stresses in the post-buckling stage.
In SolidWorks Simulation, a buckling analysis can be conducted on parts and
assemblies. If an assembly is analyzed, all parts must be bonded; no contact/gaps
conditions are allowed.
Confidential
Information
Lesson 3 Topics
VAR logo

Buckling load factor (BLF)

The buckling load factor (BLF) is a number by which the applied load Papp must be
multiplied in order to obtain the buckling load magnitude Pcr .

Note that the buckling mode presents the shape of the structure at the onset of
buckling and provides insight into the post-buckled shape. However, it says
nothing about the actual magnitude of deformation. This is analogous to a modal
analysis, which provides qualitative information on modes of vibration, but not on
the actual magnitude of displacements.

Buckling Analysis Considerations

Linear buckling analysis typically overestimates the buckling load. Loads and
supports are applied with perfect accuracy with no misalignment. In reality, the load
is always applied with some misalignment; walls are never perfectly flat, supports
are never perfectly rigid, and so on. To conclude this issue, we repeat that
considering the combined effects of discretization error (minor effect) and modeling
error (major effect), the results of a buckling analysis must be interpreted with
caution.

Confidential
Information
Lesson 3 Topics
VAR logo

Mixed Mesh with Shells, Beams, &

Solids
Bonded Contact for Mixed Mesh
Static Study – Review Stresses
Buckling Study
Linear vs Nonlinear Buckling

No. of Modes – 5
Solver – Direct Sparse
Material – AISI 1020
Shell, Solid and Beam Combination
Contact – Global Bonded
Fixture – Bottom Face of Support
Loads – Gravity
Weight – 50 Kgs Downward
Force – Laterally Applied

Confidential
Information
Lesson 3
VAR logo

Confidential
Information
 Lesson 3 Results
VAR logo

The lowest positive value of the buckling load factor is the

factor of safety in buckling which can be used to determine
the buckling load.

If the Factor of Safety in Buckling is lower than the Factor of

Safety in strength, then Buckling is therefore the governing
phenomenon and must be considered during the design.

Confidential
Information
Exercise 5: Stool
VAR logo

Buckling Analysis of a Stool

In preparation for destructive testing of a steel stool, we would like to predict its
mode of failure and approximate the highest magnitude load it can sustain without
failing. In particular, we would like to find out if the stool can withstand a 2,000 lb.
vertical load, and,
when it eventually collapses, is it due to excessive stress or due to buckling?
Note that buckling is always a possibility when slender members, like stool legs,
are under compressive loads.

To answer these questions we need to perform both static and buckling analyses.

Material Properties – AISI 304 Steel

Force – 2000 lbs

Confidential
Information
Exercise 5: Stool
VAR logo

What are the boundary conditions and Loads?

Confidential
Information
Exercise 5 Results
VAR logo

Confidential
Information
Exercise 5 Results
VAR logo

Buckling shapes

Buckling modal shape #1 Buckling modal shape #2

Look at the values of the displacements. Why are these values so large?
Confidential
Information
 Exercise 5 Results
VAR logo

Will the Stool Buckle or Yield First?

The stress factor of safety is lower than the buckling factor of safety. However,
while the stress factor of safety is conservative, it describes the load causing the
first instance of yielding in the structure; the buckling factor is non-conservative.
Most likely, one of the legs will yield before it buckles. Yielding changes the
geometry and reduces the buckling load so that finally the stool collapses in a
combination of material yielding and buckling.

Relationship Between Buckling and Frequency Analyses

We have already stated that a compressive load induces a stress stiffness that is
subtracted from the elastic stiffness. Buckling takes place when this resultant
stiffness drops to zero. How does that relate to frequency analysis?

Try This!
Create a frequency study and calculate the fundamental frequency of stool for
different load magnitudes. Observe that the fundamental frequency (as well as
higher frequencies) drops with the increase of the compressive load magnitude.
Find the load magnitude for which the fundamental frequency drops to zero. This
will be the buckling load.

Confidential
Information
 Exercise 6: Cabinet
VAR logo
A cabinet manufactured from Aluminum 5052 H32 is
loaded by an isolated 1,000 lb force and two 1,000 lb
loads distributed along the two corner beams of the
cabinet, as shown in the figure. All other loads and
masses, such as shelf loads etc., are not included in
this analysis to keep the model simple. The bottom of
the cabinet, along with the pedestal, are bolted to the
floor (represented through the Solidworks feature
PLANE1) using four 1/2 - 11 foundation bolts.

The objective of this analysis is to asses the

performance of the cabinet using the stress and
buckling analyses.

Specify a combination of Solid, Shell and Beam

Elements

Confidential
Information
 VAR logo here
Position: Horizontal VAR logo
5.86” & Vertical .46”,
both from top left corner

Lesson 4
Thermal Analysis

Confidential
Information
 Thermal analysis Basics
VAR logo

Thermal analysis deals with heat transfer in solid bodies. Although thermal
analysis seems less intuitive than structural analysis, it is much simpler in terms
of the computational effort.

The primary unknown in a thermal analysis is temperature, which is a scalar

entity. Therefore, only one degree of freedom needs to be assigned to the nodes
of a thermal FE model, regardless of the type of element.

The important conceptual difference between structural and thermal analysis is

that while structural static analysis deals with the state of equilibrium under an
applied load, the analogous thermal analysis does not describe the state of
equilibrium.

Instead, it models the steady state condition where heat flow continues, but does
not change over time. Therefore, the thermal analogy of a linear static analysis is
a steady state thermal analysis, while a dynamic structural analysis is analogous
to a transient thermal analysis.

Temperature is the primary unknown in a thermal analysis and is analogous to

displacements in a structural analysis. There are other similarities, which are
summarized in the following table. Because of these analogous behaviors,
experience in performing a structural analysis is directly transferable to
performing a thermal analysis.
Confidential
Information
Thermal analysis – analogy to stress analysis
VAR logo

Confidential
Information
 Thermal analysis Conduction
VAR logo
Mechanisms of Heat Transfer – Conduction, Convection and Radiation

Conduction:- Conduction is the most important heat transfer mechanism in solid

bodies. It does not involve any bulk motion of matter. Fluids transfer heat by direct
collisions between molecules.

Non-metallic solids transfer heat by lattice vibrations so there is no motion of the

media as heat propagates through them.

Metals are better conductors than nonmetals at normal temperatures because they
have free electrons that carry thermal energy.

Thermal conductivity is a material property that indicates the effectiveness of a

material in transferring heat energy by conduction. It is defined as the rate of heat
transfer through a unit thickness of the material per a unit temperature difference.
Thermal conductivity is
usually denoted as K.

Heat transferred by conduction moves from a hot region to a cooler region. The
magnitude of heat transferred by conduction is proportional to the following:
Thermal conductivity, K, of the medium in which heat transfer takes place
Temperature gradient: THOT - TCOLD
Area, A, through which heat transfer takes place
The magnitude is inversely proportional to the thickness, L, of the medium.
Confidential
Information
Thermal analysis - Conduction
VAR logo

Heat Flux = - Thermal_Conductivity * Area * Temperature_gradient

Thot Tcold

The units of thermal conductivity are W/m in the SI system and BTU/s
in the IPS system.
Confidential
Information
Thermal conductivity of materials
VAR logo

Confidential
Information
 Thermal Analysis - Convection
VAR logo

Convection is the heat transfer mode by which heat transfers between a solid face
and an adjacent moving fluid (liquid or gas). The magnitude of heat transferred by
convection between a solid body surface and the ambient fluid is proportional to
the convection coefficient h, surface area A, and the temperature difference
between the surface and ambient gas:

Q CONVECTION = h A (Ts - Tf)

Generally, there are two modes of convection heat transfer:

Natural (free) convection
Forced convection

Free Convection:- In free convection, the motion of the fluid adjacent to a solid
face is caused by buoyancy forces. These forces are induced by changes in the
density of the fluid due to differences in temperature between the solid and the
fluid. For example, when a hot plate is left to cool down in the air, the particles of
air adjacent to the face of the plate get warmer and their density decreases.
Hence, they move upward.

Forced Convection:- In forced convection, a fan or a pump is used to accelerate

the flow of the fluid over the face of the solid. The rapid motion of the fluid over
the face of the solid maximizes the temperature gradient and increases the rate of
heat exchange.
Confidential
Information
 Thermal Analysis - Convection
VAR logo

Heat flux = Convection_coefficient * Area * Difference in Temperature

Confidential
Information
Convection coefficient
VAR logo

Confidential
Information
 Thermal Analysis - Radiation
VAR logo

Thermal energy emitted by bodies in the form of

electromagnetic waves because of their temperature

Confidential
Information
 Thermal Analysis - Radiation
VAR logo

Radiation:- Thermal radiation is the thermal energy emitted by bodies, due to their
temperature, in the form of electromagnetic waves. All bodies with a temperature
above absolute zero emit thermal energy.

Because radiation does not require a medium, radiation is the only form of heat
transfer in a vacuum.

Heat transfer by radiation becomes more significant at higher temperatures. Note

that the amount of radiated heat is proportional to the fourth power of absolute
temperature.

Thermal radiation occupies a narrow range in the radiation spectrum.

Confidential
Information
 Types of Radiation – Surface to ambient
VAR logo

Surface- Ambient-
temperature temperature
Stefan-Boltzmann constant
= 5.67E-8 W/m2K4

Emissivity of the radiating surface (between 0 and 1)

Aluminum (polished) 0.04-0.06
Copper (commercial) 0.07
Steel (polished) 0.52-0.56
Steel (rough) 0.95-0.98
Porcelain 0.92
Confidential
Information
 Types of Radiation – Surface to surface
VAR logo

Radiation heat transfer between two surfaces also

depends on:
• shape of faces
• relative orientation of faces
• distance between the faces

Radiation View Factor –The fraction of thermal energy leaving the surface of object 1 and
reaching the surface of object 2, determined entirely from geometrical considerations. It is
the fraction of object 2 visible from the surface of object 1.
A multiplier to the previous equation that takes above factors into account and calculated
internally by SolidWorks Simulation. It is unitless and ranges between 0 and 1.
A concave face can radiate to itself; Planar and convex faces do not radiate to themselves.
Such effects are automatically considered.

Confidential
Information
 Material Properties for Thermal Analysis
VAR logo

The following material properties are specifically required as input to various types of
thermal analyses:

Material Definition Type of Thermal

Property Analysis
Conductivity Thermal conductivity indicates the effectiveness Steady state and
of a material in transferring heat energy by transient
conduction. analysis

Specific Heat Specific heat of a material is the quantity of heat Transient

needed to raise the temperature of a unit mass of analysis only
the material by one degree of temperature.
Mass Density Although not directly used in thermal analysis, Transient
mass density is required to provide information analysis only
on mass because specific heat is defined as heat
per unit of mass

Confidential
Information
 Lesson 4 Topics
VAR logo

Microchip generates 25 Watts of heat power

Connectors are insulated
Four studies –
– STUDY 1: Steady state heat transfer
– STUDY 2: Transient thermal analysis –
 Study how the temperature increases in the first 300 seconds after power
is first turned on
– STUDY 3: Transient thermal analysis –
 Heat-power is increased gradually in the first 30 seconds and then slowly
turned off in the next 30 seconds
– STUDY 4: Transient thermal analysis with thermostat
 Heat-power is controlled (turned on and off) by a thermostat in order to
prevent the microchip from overheating

Confidential
Information
 Thermal Resistance
VAR logo

Resistance to heat flow at the junction of two

components - Tiny air gaps will always exist
between the two contacting surfaces due to their
roughness

Thermal Resistance depends on:

1. Surface Flatness
2. Roughness of surfaces
3. Contact-force between surfaces
4. Thermal interface material (e.g., thermal
grease, elastomer, adhesive, etc.) Typical Thermal resistance values

Dry Joint 2.9 C/W

Thermal grease (0.003 in gap)

Confidential 0.9 C/W
Information
 Lesson 4
VAR logo

STUDY 1: Steady state thermal analysis

Thermal Resistance between the two faces in SI Units as Distributed - 2.857e-6
m2K/W Surface to Surface Contact

The conductance (hc) of the 25 μm layer of Actic Silver 5 material is

approximately 350,000 m2K/W. The distributed value of thermal resistance is
the inverse of the intertacial conductance; 1/350,000 = 2.857e-6 m2K/W.

In thermal analysis, the Node to Node option results in bonded contact modeling
the ideal conduction between two components. The thermal resistance value
field is not accessible. Node to Surface and Surface to Surface thermal
resistance contacts are identical.

Define Convection on external faces of the heat sink with convection co-efficient
of 250 W/m2K, 300 K as the bulk Temperature (Ambient Temperature)

Repeat the same procedure for the micro-chip part as 100 W/m2K and 300 K as
Bulk Temperature

Define heat power of 25 W for microchip part

No Initial temperature is required for steady state analysis

Confidential
Information
Lesson 4 Results
VAR logo

STUDY 1: Steady state thermal analysis

Confidential
Information
Transient Thermal Analysis
VAR logo

Transient Thermal Analysis:- The results of the steady-state thermal analysis, which
we have just completed, describe the situation where sufficient time has elapsed and
the heat flow has stabilized so that the temperature field reaches equilibrium.
Note that we do not know at what time this stabilized situation occurs. The amount of
time depends on the initial temperature conditions, which are not defined in a steady-
state thermal analysis.
To analyze temperature changes in time, a transient thermal analysis is required.
We assume that prior to turning on the power, all model components are at a room
temperature of 25°C. At time t = 0 s, the power is turned on and the microchip starts
generating 25 W of heat power (25 Jouls every second). Our objective is to monitor
the temperature changes during the first 300 seconds of operation, with particular
attention to the temperature of the middle connector.

Create a Transient Study, with total time as 300 Sec and increment as 10 Sec with
Direct Sparse Solver.

Set the Initial Temperature for all components as 25 Deg C

Probe the middle terminal and create a response graph as a function of time

Comparing the steady and transient analysis, both show the same result at the last
time step

Confidential
Information
Lesson 4 Results
VAR logo

STUDY 2: Transient thermal analysis

Confidential
Information
 Transient Analysis with Time Varying Load
VAR logo

Now, we will add more complexity to the transient thermal analysis. We still want
to monitor what happens during the first 300 seconds using 10-second intervals,
but heat power will now become variable with time.

Create a new transient study with time curve for heat power.
Specify heat power of 25 W with time curve as (0,0), (30,1), (60,0).

Run the analysis and probe the result

Confidential
Information
 Lesson 4 Results
VAR logo

STUDY 3: Transient thermal analysis after heat-power is turned on and

then turned off

Confidential
Information
 Transient Thermal analysis using Thermostat
VAR logo

Having analyzed the results for the transient 01 study (the study with constant
heat power), we decided that the microchip is overheating. Recall that the steady-
state temperature measured at the tip of the middle terminal reached 166oC.

We would like to keep the maximum operating temperature at the middle terminal
below 120oC. To achieve this, the heat power generated by the microchip needs
to be controlled. This can be simulated by the thermostat feature available.

In the Heat power option, select the thermostat option and select the vertex for
the sensor of thermostat location. Specify the lower bound and upper bound
temperature as 100 and 120 deg C.

The temperature in the selected location is now monitored. If the temperature

raises above 120oC, the heat power is turned off. If it drops below 100oC, the heat
power is turned on again. The Thermostat feature is available only for transient
thermal analysis.

Modify the tiem increment as 5 Sec and run the analysis.

Probe the results on the sensor location

Confidential
Information
Thermostat
VAR logo

Heat-power or flux condition is turned on or off

based on the temperature at the specified vertex
Obtained results will slightly overshoot the target
temperature

Confidential
Information
Lesson 4 Results
VAR logo

STUDY 4: Transient thermal analysis with thermostat

Confidential
Information
Lesson 4 Results
VAR logo

The graph clearly illustrates how microchip heat power is controlled by the
thermostat. Because of the heat inertia, the temperature oscillates between 95oC and
128oC, even though we specified the operating range between 100oC and 120oC.
To keep the microchip temperature below 120oC, as we originally intended, we would
have to define the upper bound temperature in Thermostat definition to be below
120oC. The actual upper bound temperature could be found by trial and error.

Symmetry Boundary Condition in Thermal Analysis

Thermal boundary conditions are easier to use than structural boundary conditions
because nothing needs to be defined on the faces that fall on the plane of symmetry.
The absence of convection coefficients means that the faces are insulated; there is
no heat flowing through them (heat flux in the direction normal to the symmetry face
is zero). This is exactly what happens in the absence of any thermal conditions.

Confidential
Information
 Exercise 7: Cup
VAR logo

Thermal Analysis of a Cup

Objective:- Our objective is to find the steady state temperature of the cup housing
due to the heat produced by the rotating shaft which is in contact with the cup.

Study:- Thermal Anlaysis

Material:- Maganese Bronze
Define heat flux on the inner face :- 0.005 BTU/s/in2
Convection Co-efficient on outer face:- 1.0e-5 (IPS) and 70 degF as bulk temperature

Confidential
Information
Exercise 7: Cup
VAR logo

Confidential
Information
 VAR logo here
Position: Horizontal VAR logo
5.86” & Vertical .46”,
both from top left corner

Lesson 5

Thermal Analysis with Radiation

Confidential
Information
 Lesson 5 Topics
VAR logo

• Steady state heat transfer including conduction, convection

and radiation
• Conductivity of materials applied by materials properties of
solids
• Convection is applied to the surfaces exposed to the
atmosphere
• Radiation between the bulb
and lamp-surfaces
• Bulb generates 100 Watts of
heat power

Confidential
Information
 Lesson 5 Topics
VAR logo

Project Description:- An aluminum reflector houses a light bulb producing 100 W

(0.095 BTU/s) of heat power.

The reflector side of the housing is exposed to a vacuum. The back side is exposed
to air. Our objective is to find the steady state temperature of the reflector housing
due to the heat produced by the light bulb.

Apply Material Properties on reflector as aluminium and bulb as glass.

Apply Heat Power on the bulb as 100 W (0.095 BTU/s). This heat power is generated
in the entire volume of the bulb.

Define the first radiation condition:- Select Surface to Surface Radiation on the
surface of the bulb. Select Open system under Radiation Parameters. This selection
accounts for the fact that some heat may be radiated out directly into space rather
than to the reflector. Also under Radiation Parameters, enter the Ambient
Temperature of 25°C (76.7°F), the assumed temperature of the vacuum. Enter 0.7 as
the emissivity for the bulb material.

Define the second radiation condition:- Select Surface to Surface Radiation on the
surface of the casing. Under Radiation Parameters, select Open system and enter
25°C (76.7°F) as the Ambient Temperature. This is the assumed temperature of the
vacuum. Enter 0.1 as the emissivity. Note that the reflector is designed to reflect
radiation, which is why the value of the emissivity coefficient is low. Confidential
Information
 Lesson 5 Topics
VAR logo

Define convection on the back external face of the reflector in contact with air. Enter a
Convection Coefficient of 50 W/ m2°K (1.7x10-5 BTU/s in2 F) and a Bulk Temperature
(ambient temperature) of 315 °K (41.85 °C or 107.3 °F), which is the temperature of the air
surrounding the back of the reflector housing.

Review of loads:- Some of the heat produced by the light bulb is radiated out directly into
space. Heat that is not directly radiated out is transferred to the reflector through radiation. A
small portion of it enters the reflector directly through the base of the bulb by conduction.
Heat that has reached the reflector either by radiation or conduction is partially radiated out
and partially transferred by conduction through the aluminum material to the air side of the
reflector. It is then dissipated by convection to the ambient air.

Review of Results:- Note that the bulb reaches 2,171 °C. This temperature is attained
because heat removal by radiation becomes effective only at higher temperatures. Therefore,
the bulb must reach this high temperature in order to dissipate 100 W (0.095 BTU/s) by
radiation.

Confidential
Information
Lesson 5 Results
VAR logo

Results – temperature distribution

Notice small effect on the temperature of the reflector.

Confidential
Information
Lesson 5 Results
VAR logo

Heat flux distribution

Notice heat flux concentrations near the corners.

Confidential
Information
 VAR logo here
Position: Horizontal VAR logo
5.86” & Vertical .46”,
both from top left corner

Lesson 6
Advanced Thermal Stress Analysis

Confidential
Information
 Lesson 6 Topics
VAR logo

• Study 1 – Steady state thermal analysis

• Study 2 – Static study to get deformation due thermal
effects
• Microchip generates heat power of 5.26 W
• Face of acrylic gasket is kept at 336.5 K
• Ambient temperature is 298K

Confidential
Information
 Lesson 6 Topics
VAR logo

Project Description
In this lesson, we analyze an assembly consisting of a ceramic insert, a nylon
housing, and an acrylic gasket. This assembly is part of a microchip testing device.
The gasket and the nylon housing are connected by two bolts, which will not be
included in the analysis. The assembly is then freely positioned on a platform inside
the testing chamber; it is not connected to any other secondary structure.
The initial temperature of the assembly is 77 °F. During testing, a microchip housed
inside a pocket in the nylon housing generates a heat power of 0.005 BTU/s while
the face of the acrylic gasket is kept at a constant temperature of 200 °F.
Our objective is to find the thermal stresses in the assembly. This requires a two
step procedure:
1. Perform a thermal analysis to calculate the temperature distribution in the model.
Because the stress analysis is requested after the flow of the heat stabilizes, we will
run a steady state thermal analysis.
2. Use the temperature results from the thermal study, perform a static analysis to
find the thermal stresses.
We are looking for the steady state solution, meaning the state after which enough
time has elapsed for the temperature field to stabilize itself. Therefore, the initial
temperature is irrelevant for a steady state analysis because the initial temperature
does not affect the steady state condition itself, only the time to reach steady state.
However, the initial assembly temperature is important for calculating thermal
stresses as it is used as a reference temperature.

Confidential
Information
 Lesson 6 Topics
VAR logo

Create a thermal study

Specify heat power for the microchip as 0.005 BTU/s

The sign of heat power distinguishes between heat entering and heat leaving the
model. “+” denotes heat power (or heat flux) entering the model, “-” denotes heat
power (or heat flux) leaving the model. Negative heat power is called a heat sink.

Define convection on outside faces of assembly as heat is disipated from that face.
Specify Convection Co-efficient as 0.0001 BTU/s and bulk temperature as 77 drg F.

Define prescribed temperature on face of acrylic gasket as 200 deg F

Prescribed Temperature Condition:- The temperature can be kept constant at 200 °F

by means of either heating or cooling. We do not know if the face is heated or
cooled until we examine the results and determine in which direction the heat is
flowing through the face in question.

Meshing Considerations: If a model is intended only for calculating temperatures,

there are no special meshing considerations. Meshing with the default element size
and no mesh controls usually produces a mesh that yields correct results. For
calculating heat flux, mesh refinement is necessary. Excessive curvatures of
element faces and excessively sharp corners may cause artificial heat flux
concentration.
Confidential
Information
 Lesson 6 Topics
VAR logo

Create a thermal study

Specify heat power for the microchip as 0.005 BTU/s

The sign of heat power distinguishes between heat entering and heat leaving the
model. “+” denotes heat power (or heat flux) entering the model, “-” denotes heat
power (or heat flux) leaving the model. Negative heat power is called a heat sink.

Define convection on outside faces of assembly as heat is disipated from that face.
Specify Convection Co-efficient as 0.0001 BTU/s and bulk temperature as 77 drg F.

Define prescribed temperature on face of acrylic gasket as 200 deg F

Prescribed Temperature Condition:- The temperature can be kept constant at 200 °F

by means of either heating or cooling. We do not know if the face is heated or
cooled until we examine the results and determine in which direction the heat is
flowing through the face in question.

After Thermal Analysis Export Results to Simulation with ref temperature as 77

degF.
Use Soft Springs with Direct Sparse Solver.
Define Bolt Connectors and node to surface contact between gasket and housing.

Confidential
Information
Lesson 6 Results
VAR logo

Thermal analysis - results

Temperature – section view Heat fluxes – vector plot

Confidential
Information
Lesson 6 Results
VAR logo

Stress analysis results

Von Mises stresses Energy norm error plot

Confidential
Information
 Lesson 6 Discussion
VAR logo

Thermal and Static analysis

had different contact
conditions and therefore
different meshes
What is the contact
condition between the
gasket and the housing?
Is this contact valid during
the static analysis?

Confidential
Information
 Exercise 6: Gas Tank
VAR logo

Thermal analysis and stress analysis of a gas tank

Objective:- Run a thermal analysis on a propane tank with an applied solar radiation,
a convection due to a breeze, and a fixed temperature due to the grill.
Create a thermal Study
Material Properties:- Brass for the Tank valve body and Alloy steel for the Cylinder,
and Tank body
Apply a heat flux of 200 (W/m2) on 3 faces exposed to the sun
Apply a convection coefficient of 5 W/m2K and a bulk temperature of 294.6 °K (21.45
°C or 70.6 °F) on all the faces of the shell, exposed portion of the valve and cylinder
except the rectangular portion
Apply a prescribed temperature of 27 °C (80.6 °F) on the rectangular face
Mesh and Run the analysis

Create a static study

Apply fixed restraints on the grill and top edge
Import thermal results at a temperature of 16 oC
Mesh and Run the analysis

Confidential
Information
Exercise 6: Gas Tank
VAR logo

Thermal analysis and stress analysis of a gas tank

Confidential
Information
 VAR logo here
Position: Horizontal VAR logo
5.86” & Vertical .46”,
both from top left corner

Lesson 9
Drop Test Analysis

Confidential
Information
Drop test analysis
VAR logo

Evaluate the effect of the impact of a part or an

assembly with a rigid or flexible planar surface
Calculates impact and gravity loads automatically.
No other loads or restraints are allowed
Equlibrium of forces:
Inertial_forces + Elastic_forces = Gravitational_force +
Impact_force
(Damping is ignored)
Dynamic problem – forces and displacements are
changing with time
Explicit time integration to solve the problem

Confidential
Information
Drop test analysis
VAR logo

Drop Test Icons

The drop test analysis is defined by editing three automatically created icons:
Setup
Result Options
Contact/Gaps

Drop Test Parameters

The orientation of the impact plane may be normal to gravity or parallel to a
reference plane. The free falling body moves in the direction of gravity as a rigid
body until impact with the rigid plane. The program determines the region of
impact based on the direction of velocity at impact and the orientation of the
impact plane.
The velocity at impact v is calculated as v = sqrt (2gh)
As an alternative to the drop height, we can define the velocity at impact.
No rotations are considered until initial impact occurs.

Confidential
Information
Input and results in drop test
VAR logo

Input:
Drop height or Velocity at impact
Gravity
Orientation
Observation time - For how long after impact should one
observe or capture the solution?
Stiffness of the impacted surface (wall)
Results:
Observe displacements and stresses at various times
Contact force at surface of impact

Confidential
Information
Lesson 9 Topics
VAR logo

Goals

 Drop test analysis

• Analysis Basics
• Analysis Setup

 Post-processing options for

drop test analysis

Confidential
Information
Key Results
VAR logo

Rigid target – Von Mises stresses

Confidential
Information
Key Results
VAR logo

Rigid target – stress time history graph

Confidential
Information
Key Results
VAR logo

Soft target – Von Mises stresses

Confidential
Information
Key Results
VAR logo

Vertex 1 – resultant acceleration history

Soft target reduces the acceleration peaks.

Confidential
Information
Key Results
VAR logo

Elastic Material Elasto-Plastic

Material

Confidential
Information
Exercise 10: Clip
VAR logo

Drop test of a clip

Confidential
Information