A Manufacturer’s Guide to

Maximizing the Productivity Gains of

Finite Element Analysis (FEA)

CTURER’S GUIDE TO MAXIMIZING THE PRODUCTIVITY GAINS OF FINITE ELEMENT ANALYSIS A MANUFACTURER

AnalysisMainstream

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Before a new product goes into production, prototypetesting takes place to ensure that the product's per-formance meets customer expectations. Some testsrequire only simple physical mockups, while othertests, such as structural integrity tests, may requirethe production of fully functional physical prototypes.

Fully functional prototypes are expensive, take timeto manufacture, and extend product developmentcycles, especially when numerous prototypes arerequired. Prototype testing often reveals problemsthat require design modifications, resulting in theneed for additional prototyping and testing to exam-ine the modified design. Typically, several costlydesign-prototype iterations are necessary beforearriving at the final product design.

In the real manufacturing world, the delay andexpense related to prototyping and testing oftenreduce the number of design-prototype-test iterations, which has an adverse impact on productquality. Companies simply cannot afford to build andtest the number of prototypes needed to arrive at anoptimized design and are willing to accept a designthat is "good enough" rather than continuing to

optimize the design. Physical prototyping and testinghave become major obstacles to successful productdevelopment, creating bottlenecks that add costs andextend design cycles, frequently without producingthe best possible product design.

Faced with competitive pressures for more innova-tive, streamlined designs and safer, more reliableproducts, many manufacturers leverage computer-aided engineering (CAE) technology to simulate prototype-test iterations and optimize designs basedon a thorough understanding of the physical behaviorof a design. By using mainstream design analysistechnology to predict design behavior, engineers canoptimize product designs on the computer withoutbuilding a single prototype.

This guide is designed to help engineers and productdevelopers understand the value of 3D design analy-sis and to describe how to evaluate and select adesign analysis system that provides maximum benefits to the product development process.

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“Using some of the optimization features, we

can typically take 15-20% additional mass out.

COSMOS™ is the tool that makes it possible.”

Jim Staats, Vice President,

Alliance Spacesystems Inc.

2

"The biggest advantage was time saving

over our previous methods. COSMOS is so

fast and easy to use that we were able to

make the 20 analysis runs that were

required to understand the problem and

solve it."

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During the early 1990s, the product developmentprocess began evolving from the prototype-testapproach to a new product development paradigmthat is driven by computer-aided design (CAD) technology. Rather than incurring the costs and timedelays related to building and testing prototypes,engineers began to analyze computer models of theintended design using the finite element method,better known as finite element analysis (FEA).

Design analysis with FEA is a software technologythat engineers use to simulate the physical behaviorof a design under specific operating conditions. FEAbreaks a solid model down into geometric "ele-ments," which are mathematically represented onthe computer as a 3D mesh overlaying and permeating the solid model, to solve differentialequations that govern physical phenomena as theyapply to simulated geometries. Using FEA, engineerssimulate responses of designs to operating forcesand use these results to improve design perform-ance, minimizing the need for physical prototypes.

Early design analysis software packages were separate, highly specialized applications that were

used for unique and specific simulations that couldnot be tested effectively with prototypes. Nuclearreactor containment buildings are an example of theearly use of design analysis, simulating a testingscenario that was extremely hazardous to duplicatewith an actual prototype.

While the benefits of design analysis for all types ofproduct development are obvious, the mainstream,industry-wide shift away from physical prototypesand towards 3D design analysis which began in themid-1990s continues because of the following important developments:

» 3D solid modeling software became powerful, affordable, and easy to use;

» Design analysis software became powerful,affordable, and accessible to nonspecialists;

» The Microsoft® Windows® operatingsystem enabled the use of CAD and analysis applications on PCs;

» Computer hardware became powerful, affordable, and reliable.

Notice the common themes here: more powerful,easier to use, and less expensive. The computingpower of the mainframe computers of the 1980s

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Don Bartlett, Senior Staff Engineer,

Fanuc Robotics NA

Bucyrus International, Inc.

is a global leader in the manufacture of

shovels, drills, and draglines for the surface

mining industry. By using COSMOS software,

Bucyrus® reduced their analysis time by 20%

and shortened the design cycle by 25%.

3

is now available on the desktop at a fraction of theoriginal price. The development of advanced designanalysis tools enables manufacturers to take advan-tage of the availability of affordable computing powerand reap the benefits of mainstream design analysis.

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Leveraging the combined powers of 3D solid modeling and design analysis software, engineerscan now test a design on the computer instead ofusing prototype-test iterations for design. CAD mod-els have become virtual prototypes, and designanalysis has supplanted physical testing, enablingfaster, less costly, and more optimized productdevelopment. In addition, computer-based designanalysis allows for more in-depth examination ofproduct performance than would ever be possibleusing even the most detailed prototypes, resulting inmore innovative, reliable, and marketable products.

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Studies have shown that 80% of a product's manufacturing costs are locked into the approveddesign, which is why the ability to perform quick andinexpensive design iterations prior to releasing thedesign has become a critical competitive advantage.

Design analysis makes it possible to perform designiterations quickly and inexpensively on computermodels instead of on costly physical prototypes. Evenif prototyping costs were not important considera-tions, design analysis provides significant productquality benefits, enabling engineers to detect designproblems far sooner than a prototype could be built.Design analysis also facilitates studies of more thanone design option and aids in developing optimizeddesigns. Quick and inexpensive analysis often revealsnonintuitive solutions and benefits engineers by pro-viding them with a better understanding of product characteristics.

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Numerous misconceptions surround the use ofdesign analysis software. Many engineers believethat FEA-based design analysis is esoteric, expen-sive, and hard to use. Some engineers believe designanalysis software requires a Ph.D. to operate, is onlyused by really big companies, and is unnecessary forthe type of work they do. Studies have shown thatseven out of ten design engineers using 3D CAD havethese impressions.

As a result, many engineers take untested designsstraight to prototype or even directly into production,thereby jeopardizing product quality and valuablecustomer relationships. In other cases, designerssimply stay the course by reproducing outdated prod-ucts, preferring to continue with concepts that haveworked in the past instead of striving for innovationand breaking new ground. Their premise is: "If itisn't broken, don't try to fix it." Staying with the status quo can cost a company a lot of money in lostopportunities for introducing higher-quality, moreaesthetically pleasing, modern products that moreconsumers want to buy. Not optimizing productdesign can increase expenses, for example, the useof excessive amounts of materials, that could be

trimmed by implementing design analysis and opti-mizing designs. Saving just one-tenth of a penny perunit can add up to a sizable sum when a manufactur-er produces thousands of units. In other words, even"if it isn't broken, it still might need fixing."

Now that design analysis is fully automated and veryaffordable - some analysis capabilities are includedfree as part of some 3D CAD packages - the misconceptions regarding design analysis are fadingaway as more and more engineers evaluate designanalysis tools.

“To develop a new artificial jaw joint, different

model variations were created using different

plate/screw materials, and static analysis was

performed in COSMOSWorks™ to see how

using different materials would affect

the stress. ”

A connecting arm before and after optimization

Tomoaki Kawamoto and Toshio Sugahara, Researchers,

Okayama University, Faculty of Dentistry

5

In its simplest terms, design analysis is a powerfulsoftware technology for simulating physical behavioron the computer. Will it break? Will it deform? Willit get too hot? These are the types of questions forwhich design analysis provides accurate answers.Instead of building a prototype and developing elabo-rate testing regimens to analyze the physical behav-ior of a product, engineers can elicit this informationquickly and accurately on the computer. Becausedesign analysis can minimize or even eliminate theneed for physical prototyping and testing, the tech-nology has gone mainstream in the manufacturingworld over the past decade as a valuable productdevelopment tool and has become omnipresent inalmost all fields of engineering.

Design Analysis employs the finite element analysis(FEA) method to simulate physical behavior of aproduct design. The FEA process consists of subdi-viding all systems into individual components or"elements" whose behavior is easily understood andthen reconstructing the original system from thesecomponents. This is a natural way of performinganalysis in engineering and even in other analyticalfields, such as economics. For example, a controlarm on a car suspension is one continuous shape.

An analysis application will test the control arm bydividing the geometry into 'elements,' analyzingthem, then simulating what happens between theelements. The application displays the results ascolor-coded 3D images, red usually denoting an areaof failure, and blue denoting areas that maintaintheir integrity under the load applied.

Engineers use design analysis for just about everytype of product development and research effortimaginable. Analyzing machine designs, injection-molded plastics, cooling systems, products that emitelectromagnetic fields, and systems that are influ-enced by fluid dynamics are just some examples ofhow companies leverage design analysis.

KryoTech, Inc.,

a manufacturer of innovative cooling systems

for personal computers, shortened its design

cycle from one year to three months, in part

by using COSMOS integrated design analysis

inside SolidWorks software.

What is Design Analysis?

In this picture red zones indicate potential failure

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In the field of mechanical engineering, design analy-sis can solve a wide range of product developmentproblems. Engineers can use design analysis to predict the physical behavior of just about any partor assembly under any loading conditions: from asimple beam under a bending load to car crash simulations and vibration analysi’s of aircraft. Thetrue power of design analysis is the ability to perform any of these types of studies accuratelywithout building a single thing. All that is needed isa CAD model.

The most common design analysis application in thefield of mechanical engineering is stress analysis.Engineers study the stresses (both structural andthermal) on a part to determine whether it will fail ornot and whether design modifications are necessaryto overcome potential problems. Design analysis isalso used to determine the potential for deformationof parts, resonant frequencies and modes of vibra-tion of parts and assemblies, dynamic and seismicresponses, contact stresses, and temperature distri-bution, to list a few. Design analysis is also used toanalyze fluid flow, whether it be a gas or liquid in apipeline, the mixture of air and fuel in an engineintake manifold, or molten plastic filling up a mold.

Besides working very closly with CAD packages,commercial design analysis applications also interface with increasingly popular programs formotion analysis to create complete virtual analysisand test systems. In other engineering disciplines,design analysis is used successfully to study electromagnetic fields, soil mechanics, groundwaterflow, bone growth, etc.

“With some software programs, you just

know that you are benefiting. I would say

that COSMOS has definitely paid for itself

ten times over.”

COSMOSFloWorks™ was used to model air flow through this

circuit board environment

Steve Massey, Mechanical Engineer,

Sturman Industries

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Steve Prentice Design Limited

is an automotive consulting firm using

COSMOS software for first pass analysis.

In 18 months, we have completed more con-

cept projects than ever before, taking them to

a greater level of definition in less time than

customers believed possible.

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Design analysis provides the greatest benefits whenimplemented very early in the design cycle becausethat's when it is easiest and most cost-effective tomake design changes. When analysis is performedin conjunction with solid modeling, design engineerscan leverage analysis results to fix, improve, or optimize designs.

For many years, design analysis was the exclusivedomain of highly specialized analysts, who wouldanalyze models after a design engineer had finishedhis or her work. This approach resulted in a lot ofwasted time related to the back-and-forth interactionbetween designers and analysts, especially whensolid models had to be recreated in a separate analysis package.

But in recent years, the benefits of using design analysisas part of conceptual design have become apparent.When properly trained to use today's modern, integratedanalysis systems, design engineers are better positionedthan analysts to leverage analysis results to modify solidmodels as design iterations progress. The direct involve-ment of design engineers in analyzing their own designsallows for quick turnaround times and ensures thatdesign modifications indicated by analysis results arepromptly implemented in the design progress.

In many ways, design analysis technology is helpingto blur the lines of demarcation among traditionalengineering organizations. While drafting, designing,and analyzing product designs were traditionally separate tasks executed by different people, theavailability of powerful, easy-to-use, and affordableCAD and design analysis software has fostered agreater sense of collaboration among all engineeringfunctions.

Analysts continue to play an important role by con-ducting the more advanced and time-consumingtypes of analysis.

Users can communicate analysis results with

other members of the design teams with

tools such as SolidWorks eDrawings

“With COSMOS the time-savings are so dra-

matic they are, in a sense, unquantifiable. We

can change geometry and complete the analy-

sis within a half hour. If we had to do these

three-dimensional calculations by hand, it

would take days.”

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This bracket provides a simple example of howdesign analysis is used. The design of this brackethas just been completed, and we are ready to makeproduction drawings based on the CAD model.

However, we are not sure if the bracket is going to bestrong enough to withstand service loads withoutexcessive deformations and stresses. Productiondeadlines are approaching and we are almost overbudget, so we need answers quickly and inexpensive-ly. Design analysis can give us these answers usingnothing more than our original CAD model and ananalysis package.

With an integrated design analysis system, we canconduct the analysis directly on our solid modelwithout ever leaving our CAD package. Once we haveour geometry, we can set up the model, run theanalysis, and analyze the results in a few easy steps.

SStteepp 11

First, we define and assign material properties to themodel.

SStteepp 22

Next, we apply the proper loads and supports thatrepresent real-life loading conditions.

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Chris Andre, Mechanical Engineer,

Genetronics

True Technologies

is an audio engineering consulting firm.

Faced with a part that was failing after only

20 minutes of use, they turned to analysis for

help. Once the part was optimized in COS-

MOS, it operated for more than 1,000 hours

without failure, even when the power was

increased 50%.

9

SStteepp 33

Now, we mesh the geometry. Meshing is basicallysplitting the geometry into small, simply shapedpieces called finite elements. Design analysis usesfinite elements to calculate our model's response toour indicated loading conditions. Meshing is doneautomatically with little, if any, need for user intervention.

SStteepp 44

After the model is meshed, the analysis solution pro-ceeds. This step is entirely automated with no userintervention necessary.

SStteepp 55

Once our solution is complete, we can analyze theresults. Of course, the results depend on the type ofanalysis performed. In our case, we were interested instructural properties like deflections and stresses.We can also use design analysis to evaluate resonantfrequencies, temperature distribution, or structuralresponse to dynamic loads.

Our analysis results will either verify the function ofour design or show us where we have problems thatrequire design modifications to achieve the requiredquality, stress level, natural frequency, etc. With inte-grated analysis packages, design modifications caneasily be performed on the same CAD model that weused for the initial analysis.

“Using COSMOSWorks means that we can run

calculations on the various design approaches

during the design stage easily and quickly. We

can then compare them against one another.”

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Using analysis as a design tool produces higher qual-ity products faster and at lower cost. Obtaining thesebenefits, of course, requires an investment in purchasing design analysis software and in trainingusers. New hardware is typically unnecessarybecause existing CAD workstations are generallyadequate for running analysis software.

The actual return on investment (ROI) that a companyrealizes from implementing design analysis softwaredepends on the company's analysis needs, the specific analysis package selected, how the analysissoftware is implemented, and the amount of trainingconducted.

In many cases, the cost of the analysis software andtraining is recovered during the first year of implementation.

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Although a comprehensive ROI assessment prior toimplementing 3D design analysis is useful for plan-ning purposes, simple calculations based on easilyquantified metrics also provide useful insights.Here's one example from the field of automotiveengineering.

The cost of prototyping and testing simple parts suchas an engine bracket, pulley, or door hardware caneasily run from $10,000 to $20,000 and these steps

take several weeks to complete. Compare thatexpense to the cost of a single license of integrateddesign analysis software and user training, and it'splain to see how design analysis software can benefita company.

Analysis results can be produced in a matter of hoursin most instances, an important competitive advan-tage for all manufacturing companies. Cost reductionbenefits from using design analysis instead of tradi-tional prototyping/testing are even greater whencomplex parts and products are involved.

For complex parts, prototyping/testing costs can easily run into hundreds of thousands of dollars andcan take several months to complete. While an ROIcalculation can capture easily quantifiable cost-savings, there are additional benefits that are moredifficult to quantify, such as the ability to analyzemultiple design configurations, the potential forreducing warranty costs, and the impact of improvedproduct quality overall.

ROI will differ in each individual case, and companiesshould also consider the penalty costs associatedwith not using design analysis for productdevelopment. Clearly, the cost and product qualitybenefits associated with using design analysis as partof product development can result in substantialreturns on a company's investment in design analysissoftware.

Design Analysis and the Bottom Line

Karsten Hoffman, Project Leader,

Dräger Medical

SANDIA National Laboratories

spent five months of effort and only achieved

90% completion with a competitive analysis

product. After switching to COSMOS,

SANDIA National Laboratories was able to

analyze a very detailed solid model

consisting of 306 parts in just one week.

11

“There is no doubt that COSMOS helped us to

reduce our project design time. When we

began the project, we had estimated that it

would take a total of eight months. By using

COSMOS, we saved two full months of

development work.”

There are many different design analysis programson the market. How should manufacturing companiesgo about evaluating and selecting the analysis pack-age that is best suited for use as a design tool?Which design analysis package will produce the highest return on investment when implemented inthe design process?

There are several important issues to consider whenevaluating and choosing design analysis software:

Design analysis packages should be integrated withCAD systems. While it is possible to exchange infor-mation between CAD and analysis packages throughneutral files like GES or STEP, this method is timeconsuming, unpredictable, prone to error, and offersno bidirectional associativity between CAD and analy-sis models. A direct interface between the two is thebest option.

An integrated design analysis package functions wellonly if the CAD software is a feature-based, parametric, fully associative solid modeler. Thesetypes of CAD systems enable design engineers totemporarily suppress unimportant geometric featureswithout permanently deleting them and to easilyexamine different design configurations by takingadvantage of the parametric nature of the CADmodel.

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In a truly integrated system, the CAD softwarebecomes the host for the analysis application. Thisnot only allows for quick design analysis iterations,but substantially reduces training time because allgeometry functions (generally, the most time-consuming part of design analysis) are performed inthe already familiar CAD package.

Design analysis software should be easy to use, butshould also include capabilities for user intervention. Integrated design analysis software should provideuser control over meshing, type and order of ele-ments, idealization scheme and the desired solutionmethod. While the default choices offered byadvanced design analysis software are acceptable inmost cases, the user should be able to controlspecific analysis tasks if intervention becomes necessary or desired.

Design analysis software should have a goodautomesher and a fast solver. The quality of the finiteelement mesh is essential for producing accurateanalysis results and a fast solver is important forproducing analysis results in a timely fashion. Havingboth a good mesher and a fast solver reduces oreliminates the need for geometry preparation prior tomeshing. Even large CAD models mesh and solvequickly with fast automeshers and fast solvers.

Evaluating Design Analysis Software

David Rachels, Engineer,

Purolator-Facet

SpaceShipOne,

the first private manned spacecraft was

designed and built by Scaled Composites,

Inc. The company used COSMOS

software for composite analysis for about

15 years, which helped contribute to the

unique look of the spacecraft.

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Design analysis software should handle most of thecommon types of analysis. How powerful should theanalysis system be in terms of capabilities?Engineers are sometimes tempted to select an analysis package that can handle all possible types of analysis, just in case the need arises one day.

High-end analysis packages perform well in thehands of a highly trained analyst, but perform poorlywhen used concurrently with CAD during the productdevelopment process. Rather than selecting the mostpowerful analysis software available, manufacturersshould look for the package that addresses themajority of their needs in the best possible manner.

The analysis types performed in most concurrentdesign analysis processes include:» Linear stress analysis» Contact stress analysis» Frequency model analysis» Steady-state thermal analysis» Buckling analysis

Integrated design analysis systems should supportthese types of analysis with the option to add moreadvanced analysis capabilities later. Chances are thateven if an occasional project may require moreadvanced types of analysis, such as nonlinear ordynamic analysis, the analysis will be too complex fora design engineer to implement the design process.

It is wise to place complex analysis into the hands ofa trained analyst. When more advanced analysisbecomes necessary, integrated design analysis packages facilitate data exchange between designengineers and analysts without the need for modelreconstruction or translation. Thus, an integrateddesign analysis package should ideally be a subset ofa larger analysis program.

Design analysis software should also incorporatetools for communicating design intent to the rest ofthe product development organization. Analysis packages should have effective tools for presentingresults in a clear and concise manner.

Mesh of front suspension of snowmobile.

“COSMOS helped me see that there were two

viable solutions: doubling the thickness or

designing a ring dent. It was less costly to

double the thickness of the material, so that

was the solution I chose.”

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Automatic generation of reports and results shouldmake analysis findings accessible to anybody withstandard office environment software without havingto use the analysis software itself. Result files shouldbe created in standard graphic formats, such as .htmlfor Internet graphics and .avi for animated plots.

Analysis expertise and resources should be availableand accessible to users. Does the design analysispackage provide access to online help systems, tele-phone technical support, and users groups and con-sultants independent from the software vendor?

The final consideration when evaluating and selectinga design analysis system is the cost. Design analysissoftware should not be overly expensive, either interms of licensing costs, the cost of implementation,or training costs. However, the price tag alone shouldnot be the only consideration. Many times, the cost ofbuying inappropriate software far outweighs the sav-ings realized on the purchase price.

There's also projected ROI to consider. A packagethat's a little more expensive just might producehigher cost-savings that make up for the higher costmany times over.

In summary, when evaluating and selecting a designanalysis system, consider the following:

TThhee CCAADD ssyysstteemm sshhoouulldd bbee::» A feature-based, parametric, fully associative

solid modeler» Able to create all geometry for CAD and

analysis functions» Able to move between design and analysis

models while keeping geometries linked

TThhee ddeessiiggnn aannaallyyssiiss ppaacckkaaggee sshhoouulldd bbee::» Integrated with a feature-based, parametric,

fully associative solid modeler » Designed to minimize the need for user

involvement with specific analysis tasks butoffer tools to control analysis tasks when necessary

» Packaged with an advanced mesher and a choice of fast solvers

» Able to handle all common types of analysis,such as static, frequency, buckling contact,and thermal

» Scalable to high-end analysis packages for analysts

» Packaged with tools for communicating withthe rest of the product developmentorganization

» Capable of providing good user support» Reasonably priced

Tao You, Engineer,

Fleetguard, Inc.

15

Cambridgeport Air Systems

replaced three physical prototypes by using

analysis, saving an estimated $5,000-$6,000.

“COSMOS not only proves that designs will

work, but it also helps our engineers reveal

errors in designs and fix them before they

would ever show up during manufacturing or

testing.”

15TTrraaiinniinngg CCoonnssiiddeerraattiioonnssPreparing and training design engineers to reapthe benefits of design analysis is just as importantas selecting the right package for a manufacturer'sneeds. Design engineers generally need to conductonly simple types of analysis and today's integrateddesign analysis packages make FEA theory com-pletely transparent to the user. Most design engi-neers possess the requisite knowledge to usedesign analysis from their engineering background.

The amount of analysis training required for adesign engineer to begin productive work should bea matter of days, not weeks or months. The keyelement in effective analysis training is providingusers with a solid conceptual understanding ofanalysis fundamentals, such as major assumptions,limitations, and inherent errors as well as commonmistakes, traps, and misconceptions.

The analysis training course should employ ahands-on computer approach so participants canbenefit from the synergy produced by acquiringsoftware skills while becoming familiar with analy-sis theory. Too much of an emphasis on "how to runthe software" may overshadow more importantissues related to analysis fundamentals and givethe impression that familiarity with the software

equals analysis expertise. Industry experience indi-cates that users who know the fundamentals ofanalysis can easily figure out how to operate soft-ware, but acquiring software operational skillsdoes not necessarily lead to a full understanding ofanalysis.

In summary, design analysis training should:» Focus on a conceptual understanding of

analysis» Avoid too much software-specific content at

the expense of analysis basics» Use hands-on analysis examples with a

progressing level of complexity» Employ examples that utilize CAD models» Combine theory with hands-on examples» Use integrated design analysis software

while stressing the differences between thetwo technologies

» Follow up later with software-specific training

While focused training on the proper use of analy-sis can make a good design engineer even better,the opposite can actually make them dangerous.Effective training makes all the difference.

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“By looking at the parts using COSMOS, we

were able to hit our target weight, strength,

and safety factors. We've improved our

engine reliability substantially using FEA

software on our components.”

MMaaiinnssttrreeaamm AAnnaallyyssiiss

Integrating mainstream analysis into the design cycleis an important step for manufacturers. Many com-panies, including the COSMOS customers referencedthroughout this guide, have already made this transi-tion, reaping business, engineering, and productivitybenefits in the process.

Today’s rapid advances in computer hardware andsoftware technology create an ideal opportunity formanufacturer’s to incorporate analysis into theirdesign process. As discussed throughout this guide,the basic steps for adding analysis involve:

» Understanding how analysis provides thesolution for many product design challenges

» Recognizing that analysis tools have evolved,becoming more streamlined and easy for non specialists to use

» Evaluating analysis tools thoroughly based oncapability and need

By following these steps, manufacturing organiza-tions can maximize the benefits of using mainstreamanalysis in mechanical design. In the process, mostmanufacturers realize increased sales and revenueand improved product quality and reliability.

To find out more about how COSMOS customers havebenefited from “Going Mainstream Analysis,” see thecustomer case studies published on the COSMOS web site (www.cosmosm.com).

Mainstream Analysis - The Time is Now!

John Calhoun, Engineer,

Robert Yates Racing

Firms that Benefit from COSMOS Analysis Products

Acme Electric Aerospace Division l Adams Rite Aerospace l Aerocontrolex Group l Aerojet GE Corp. l Aerospace Corporation lAerospace Industrial Development Corporation l ArmorWorks, Inc. l Avionics Specialties l Axsys Technology l BAE Systems l BFGoodrich Aerospace l Ceradyne Inc. l Dreesecode Software l Eagle Picher Technologies l Eaton Aeroquip l Electroimpact l FairchildFasteners l Fluid Components International l Fluid Regulators Corporation l Foster-Miler l Frontier Systems l Hartwel Corp. l HoneywelInternational Inc. l Huck International l Inbis Technology Ltd. l Industria l Innovative Engineering l Kaiser Electronics l LawrenceLivermore National Lab l Leigh Aerosystems Corp. l Lifeport Inc. l Litton Guidance & Control Systems l Lockheed Martin l MaestranzaAerea De Madrid l Mason Electric Co. l MHD Instruments l Michigan Aerospace l Mide Technology Corp l NASA Ames ResearchCenter l NASA Dryden Flight Research Center l NASA Glen Research Center l National Aerospace Laboratories l Pacific DesignTechnologies, Inc. l Parker Hannifin Corp. l Pratt & Whitney l Reynolds, Smith & Hils Inc. l Sandia National Laboratories l ScaledComposites l Smiths Aerospace l Stage III Technologies l Technology Research Institute l Tecstar, Inc. l TRW Space & ElectronicsGroup l Unison Industries l Universal Aerospace l Woodward FST l Wyle Laboratories l Advanced Integrated Manufacturing l AmericanExpedition Vehicles l AP Racing l Autoliv North America l Automation Tooling Systems l Automotive Systems Laboratory Inc l BalcrankProducts l Branick Industries, Inc. l Breed Technologies, Inc. l Casco Products Corp. l Castrol North America l Champion Laboratories,Inc. l Composite Group l D&R Technology Dechelis Machine l Delphi Packard Electric Systems l DSM Engineering l Epilog l Fey lAutomotive l Ford Rvt Visteon l General Motors l Gentex Corp l GM Powertrain l Grove Design l GRP Connecting Rods l Hartwel Corp.l Honda R&D l Honeywel Co., Ltd. l Immersion Corp. l Impco Technologies, CA l International Rectifier, Ca l Johnson Controls Laser-tronics l Lear Corporation l Litens Automotive Group l Lund Industries l Maxon Lift l MSX International l Nordson Corporation l NorgrenAutomotive, Inc. l Olin Brass l Performance Accessories l Power Trax l Raetech Corp. l Roush Technologies l Solakian Plastics lSpectra Premium Industries l Teleflex l Turbodyne Systems Inc. l Tuthil Transport Technologies l Ultra Dyne l Visteon AutomotiveSteering l Volkswagen de Mexico l Wetheril Assoc., Inc. l Wynn Oil Co. l Yakima Products, Inc. l Yazaki Europe Ltd. l Adaptive MicroSystems l Amerock l B. Braun Medical l Bainbridge Networks l Berliner Wasserbetriebe l Bril Manitoba l Bristol Babcock l Columbus-McKinnon Corporation l Cybex International, Inc. l Datastrip Products, Inc. l Delta Hudson Engineering, Ltd. l Diamondback Fitness lDorma Door Controls, Inc. l Easton Sports Composites l Eldon Design Associates, Inc. l Electronic Sensor Technology l Enersys Inc.l Eveready Battery l First Alert l Flex Products, Inc. l GE Lighting l Glad Manufacturing Company l GT Bicycles l Hewlett Packard lHitachi Corp. l Icon Health and Fitness Inc. l Interlink Technologies l JBL Professional l Johnson Outdoor l Kimberly Clark Corporationl Klein Bicycle l Klipsch Inc l Konica Corporation l Life Fitness Products l Lockheed Martin l Lucent Technologies l Masonite Internationall Matsushita Air Conditioning l McKee Foods Corp. l Medeco Security Locks l Milwaukee Electric Tool Corp. l Motorola Incorporated lNautilus Schwinn Fitness l NEC Machinery l Philips Medical Systems l Polaris l Polaroid Corporation l Procter & Gamble l RaytechCorporation l Rockford Corp l Smith & Wesson l Sony Wega GmbH l Spectra Logic l Stairmaster l Tality Inc. l Waterpik Technologiesl Waupaca Elevator l Western Digital l ABB Switchgear l Aerovironment Inc. l Alden Products l American Power Conversion l AmericanWater Heater Co. l Andis Company l Andrew Corp. l Anvik Corp l AVO International l Basler Electric l Battele Memorial Institute lChattanooga Group l Chromalox l Crouse-Hinds Div. Of Cooper l Daka Development Ltd. l Dynetics l Everbrite l Excelon Automationl Frazer-Nash Research LTD. l Greene, Tweed & Company, Inc. l Hansen Corporation l Heatrex Wescon Ind. l Hendry TelephoneProducts l IAP Research, Inc. l Interconnect Devices Inc. l Intermatic Inc. l Inventas AS l Jakel Inc. l Johnson Electric IndustrialManufactory Ltd. l JST Corporation l Kaman Aerospace Corp. l Kubota Corporation l LG Industrial Systems l MacLean Power Systemsl MAEC Cahors l Marathon Electric l Marlow Industries l MBM Technology l Microvision l Milwaukee Electric Tool l Motile l Nxtphase lPacific Scientific Co. l Petron Industries l Philips Oral Heathcare (Optiva) l Samtec, Inc. l Senco Products l Silicon Bandwidth, Inc. l SLMontevideo Technology l Southwire Co. (Wire And Cable Div.) l Star Trac By Unisen l Stratagene Cloning Systems l Subsea MudliftDriling Company, LC l Toshiba Intl Corp. l Trinton PLC l Universal Power Track l XiDEM Corporation l Alum-A-Lift l American Meter Co.l Amtech l Applied Materials l Ashbrook Corporation l Australian Submarine Corp. l Automatic Systems, Inc. l Baker Oil Tools lBarksdale, Inc. l Bimba Manufacturing l Bock Gmbh & Co., l Bouwdienst Rijkewaterstaat l Cannon Industries, Inc. l Carl ClossSchweisstechnik Gmbh CG Technologies l Datacard Corporation l Delta Design l Eastman Chemical Co. l Fanuc Robotics l FerrazShawmut l FleetMaster, Inc. l Flow Matrix Corp. l Foley Driling l Fuji Impulse Corp l Galbreath Incorporated l Haliburton Produtos Ltdal Hyundai Heavy Industry l Ingersol Miling Machine l Johnson Corporation l Matsushita Electronic Components l Milipore Corporationl Monterey Bay Aquarium Research Institue l Nakamura-Tome Precision Industry l Nanjing Aeronautics Ltd. l National Aerospace Labl National Nuclear Regulator l Neumag GMBH l Nortel Optoelectronics l Northrop-Grummen l Oil States Subsea Ventures Inc. l Prolec- GE l Quizix l Rytec Corporation l Sagian- Beckman Inst. l Seaway Industrial Products l Skyjack l Speedgrip Chuck Ltd. l TigercatIndustries l Volvo Parts AB l W.L. Gore & Associates l Westfalia Technologies l Worldwide Oilfield Machine l Yang Iron Works Co lYasunaga Corp. l Yehuda Tzabari l Zinser Textilmaschinen Gmbh l Zolner Gmbh l 3F Therapeutics, Inc. l 454 Corporation l AbbottLaboratories l Adac Labs l Advanced Instruments l ALZA Corporation l Applied Materials l Avail Medical l Bard Access Systems l BardEndoscopic Technology l Bard Interventional Products l Baxa Corporation l Baxter Healthcare Corp. l Bayer, Incorporated l BectonDickinson Medical Systems l Beere Precision Medical Instruments l Boston Scientific Corporation l Bryan D. Knodel, Inc. l Carr MetalProducts, Inc. l Catheter Innovations l Chattanooga Group l Chroma Vision l DJ Orthopedics l Draeger Medizintechnik GmbH l Dunleel EARTH-LITE l Elcam l Elscint l Endius Incorporated l Ethicon Endo SpA l Genetronics l GenoSpectra, Inc. l Glaxosmithkline l JohnsHopkins Applied Physics l Johnson & Johnson, Inc. l Lawrence Berkely Labs l Maquet AG l MedSource Technologies l Medventuresl Murray Inc. l Nova Biomedical l Okayama University l Pacifix l Packard Instrument Company l Pulmonetic Systems l Ranfac Corp. lRoesch AG l Spinal Concepts l Spinevision l Stratagene Cloning Systems l Stryker Patient Handling l Sulzer Dental l Tensys Medicall Thermo Labsystems Tomotherapy, Inc. l Vertis Neuroscience l Xiros Plc

SolidWorks Corporation

COSMOS Analysis Products

3000 Ocean Park Blvd, Ste 2001

Santa Monica, CA, 90405 USA

Phone: +1-800-469-7287

Outside the U.S.: +1-310-309-2800

Fax: +1-310-309-2801

Email: cosmosinfo@solidworks.com

www.cosmosm.com

Image courtesy of the National Optical AstronomyObservatory, operated by the Association ofUniversities for Research in Astronomy, under cooperative agreement with the NationalScience Foundation.

SolidWorks is a registered trademark of SolidWorksCorporation and COSMOS is a trademark ofSolidWorks Corporation. All other company andproduct names are trademarks or registered trade-marks of their respective owners. SolidWorks is aDassault Systemes company ©2006 SolidWorksCorporation. All rights reserved.

ANUFACTURER’S GUIDE TO MAXIMIZING THE PRODUCTIVITY GAINS OF FINITE ELEMENT ANALYSIS A MANUFAC

SolidWorks Europe

Phone: +33 4 42 15 03 85

Fax: +33 4 42 75 31 94

Email: info@solidworks-europe.com

SolidWorks Asia/Pacific

Phone: +65 6866 3885

Fax: +65 6866 3838

Email: info@solidworks-ap.com

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