Cosmos- Solidworks Presentation Presentation Agenda Created by: Paul Terstappen Jon Vokey Andrew Northcott Mark Howell -Introduction to FEA and Cosmos - -shows the basic uses of the cosmos application in Solidworks - -shows the optimization feature that can be used in the Cosmos application in Solidworks -Advanced applications available in the various CosmosWorks packages -Sample Videos of the advanced applications -Key points recapped Introduction to FEA Introduction to Cosmos -First developed in 1943 and is based on an energy principle such as minimum total potential energy. -With the use of Equations of equilibrium, along with the application of the appropriate physical considerations being applied to each element, a system of equations is generated. -Is an approximate answer, but increasing the elements increases the accuracy. Cosmos -CosmosWorks is the software FEA package that is integrated with Solidworks. The CosmosWorks package is extremely user friendly and works very well. -This package allows the user to improve product quality by exposing the areas that are prone to weakness and failure. Trimming excess material is also a task that the Cosmos package can handle. -Advancing along with technology. Introduction to Cosmos con t (Basic Cosmos Operation) Key features in CosmosWorks -Extremely simple to compare alternative designs -Ability to optimize the design based on criteria and given circumstances -The ability to study the interaction between different assembly components -The ability to study real world situations and conditions -The ability to interpret the results with powerful visualization tools -The ability to find high stress areas, calculate safety factors and find max loads -Export results data into useable forms such as HTML, Excel ect -The ability to study the effects of temperature on the object -Study various simulations such as drops, repeated cycles, fatigue, loads ect.. -For this are using simple handle with a downward force on the object -We will run thru the basic Cosmos commands including setting up materials, restraints and loads -Graphics of the results will be shown to help with the analysis 1
1) Select the Cosmos icon from the toolbars 2) Once the Cosmos menu loads select the options tab 1) Select the system of units you want to use in this example choose SI 2) Once the units are selected select a location to save them in 3) Click next to go 1) The material menu comes up and allows you to select the material you want. 2) In this example we choose a steel and we selected AISI 1020 steel 3) Click next to go 1) Restraint tab appears 2) Click next to go enter restraints 1) Name the restraint in the text box 2) Click in the red box and go to the graphics area to select the location of the restraints 3) For this example the rack is to be mounted to a wall so face 1 and face 2 are restrained 4) Click next to go 1) The restraint that was just created now appears in the restraints menu 2) Now we are given the option to add, edit or delete restraints. 3) For this example we leave it alone as we only have the one restraint 4) Click next to go 2
1) Load tab appears 2) Click next to go enter loads 1) Now you are asked to select the type of loading force or pressure we chose a force 3) Click next to next menu 1) Name the load in the text box 2) Click in the red box and go to the graphics area to select the location of the loads 3) For this example the rack is to have a downward force applied on it, so a face 1 is selected 4) Click next to go 1) The first option given is the load direction for this chose to normal the force to the top plane 2) The second option given is to select the force value for the load, for this select 1000 N 3) Two more options are given, we select flip direction to have the force act down 4) Click next 1) The load that was just created now appears in the load menu 2) Now we are given the option to add, edit or delete loads. 3) For this leave it alone as we only have the one load to apply 4) Click next to go 1) The analysis menu now shows up 2) We are given the option analysis with the default settings or to change the settings. 3) For this will analyze with the default settings 4) Click next to prompt the next menu 3
Example 1) The analysis menu shows up 2) We are asked if we want to run the analysis 3) Hit the run button to begin the analysis, this process may take a few minuets. 4) Wait for the analysis to finish 1) The analysis is complete and the lowest factor of safety found in our design is shown our safety factor is 7.55. This number can be further used in analysis to help determine max loads ect. 3) Click next to optimize tab 1) The optimize tab gives us the option to optimize the design for this will select NO, the second example will deal with optimization 2) Select No and click next to next tab 1) The results tab comes up displaying numerous options for displaying the results obtained 2) We will show you the stress distribution model and the displacement model to show the areas of concern on this model 3) Once the option is select hit next to generate the results 1) This display shows the stress distribution in the part, there are options for animations as well which we will show at the end of the example 1) This display shows the displacement distribution in the part, there are options for animations as well 4
(Optimization) Stress Distribution in the Element Animation -For this are using the part the we designed that would help show the optimization function of CosmosWorks -We will run thru the basic Cosmos commands again however this time we will be optimizing the design based on our loads and restraints. -Un needed material will be removed where allowed. 1) Select the Cosmos icon from the toolbars 2) Once the Cosmos menu loads select the options tab 1) The material menu comes up and allows you to select the material you want. 2) In this example we choose a aluminum and we selected 6061 alloy 3) Click next to go 1) Name the restraint in the text box 2) Click in the red box and go to the graphics area to select the location of the restraints 3) For this example the part is to be mounted to a flat surface so the 4 holes along with the base are restrained 4) Click next to go 1) The first option given is the load direction for this chose to normal the force to the top plane 2) The second option given is to select the force value for the load, for this select 100 N 3) Two more options are given, we select flip direction to have the force act down 4) Click next 5
1) The analysis menu shows up 2) We are asked if we want to run the analysis 3) Hit the run button to begin the analysis, this process may take a few minuets. 4) Wait for the analysis to finish, the analysis needs to be completed for the optimization to work 1) The analysis is complete and the lowest factor of safety found in our design is shown our safety factor is 1.23. This number will be used to help with the optimization 3) Click next to optimize tab 1) The optimize tab gives us the option to optimize the design for this will select YES 2) Select YES and click next to next tab 1) The first menu that appears with the optimization tab allows us to select the criteria to use for optimizing we will use the safety factor set at a value of 1 as the criteria that the part can be optimized to 3) Click next to move on 1) The second menu that appears with the optimization tab allows us to select the dimension we want to alter for optimizing we will use the diameter of the extension shaft as the varying dimension 3) Set upper and lower limits for dimensions 4) Click next to move on 1) With all the criteria and restrictions in place we can click the optimize button to begin the optimization 2) This step may take some time depending on the computer speed ect 6
1) Once the optimization is completed the results are shown we can trim the weight from 0.7227 kg to 0.7211 a savings of 0.22% material This trimming in the shaft still maintains a safety factor of 1 3) The option of an animation is given 1) All the analysis results are now displayed for the newly adjusted arm diameter 2) This shows the stress distribution in the part, not letting the safety factor below 1 at any point. In this case the high stress point is shown in red. 3) An animation option is given again to help display the results Advanced Applications of Cosmos Stress Distribution in the Element Animation Cosmos is available in various packages -The basic package is named CosmosWorks Designer, this is the package that is included on most solidworks packages it includes the basic elements as we demonstrated in the 2 examples -The middle of the road package is named CosmosWorks Pro, this package begins to include the effects of temperature changes, natural frequencies, buckling, drop tests and cycle loading. These advanced options are a huge asset in the design process. -The most advanced package is named CosmosWorks Advanced Pro, this allows the user to analyze non linear materials, layers within composites, and allows analyze of more advance parts and assemblies Advanced Cosmos Applications - We have come across a few animations displaying the results of some of the more advanced Cosmos Applications that we are not able to perform our self as we do not have the Pro or advanced pro Cosmos Add in s - These animations include drop test, temperature effect, fatigue loading, frequency, optimization and advanced stress analysis Drop Test Video -The flooring surface that the phone is dropped on can be altered to act as various surfaces -All the parts in the assembly will deform together showing how the assembly will interact amongst it self -This simulates your part being dropped and helps test strength and durability of the part or assembly 7
Fatigue Test Video -Can obtain and display life expectances for parts in an assembly -Makes suggestions on what parts need to be altered to extend the overall life of the assembly -Simulates the movement of the parts in a complete assembly, changes to materials ect.. Can be made to alter the life of the part Thermal Test Video -Evaluates temperature of mechanical parts which are greatly effected by temperature variations -Can analyze convection, conduction and radiation Frequencies Test Video -Evaluates natural frequencies, buckling loads and mode shapes -This is a topic that is normally over looked in design -Can analyze isotropic and orthotropic behavior -Measure in-plane stiffness -Analyze take into consideration all contributing factors Optimization Test Video -Minimizes material use and overall weight -Users can automatically optimize the shape of their design based on various analysis -Users can set numerous constraints such as force, mass, dimension, pressure Key points/conclusion Stress Test Video -Analyze can be done in either part or assembly work spaces -User can select from numerous material properties, restraints, loads and many other constraints -Cosmos gives numerous graphical display options to help convey the results obtained -Finite Element Analysis software can be used to in many applications to simulate the reaction of an element to a number of applications. -Aids in producing stiffness and strength visualization while minimizing things like weight, materials, and costs -Allows a detailed image of where structures bend or twist, and indicates the distribution of stresses and displacements. -Allows entire designs to be constructed, refined, and optimized before the design is manufactured. 8
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