Reduce Field Failures with COSMOS™ Analysis Tools

Reduce Field Failures with COSMOS™ Analysis Reduce Field Failures with COSMOS™ Analysis ToolsTools

PollPollPollPoll

• I have used COSMOSXpress– Yes– No

• I am a COSMOSWorks user– Yes– No, I do not use any analysis tools– No, I use other analysis tools

AgendaAgendaAgendaAgenda

• What is field failure?• What is Design Analysis and how it can help fix

product design flaws and reduce failures? • Design analysis in five simple steps • Q&A

What is Field Failure?What is Field Failure?What is Field Failure?What is Field Failure?

• When a product does not meet the intended performance requirement it is considered to have failed

• Failures can be local – part level or catastrophic – system level

• Product failures can sometimes lead to loss of life

Turbine: Helical shaft failure

Engine ShaftTorsional Buckling

Torsion FailuresTorsion Failures(ductile material behavior) (ductile material behavior) Torsion FailuresTorsion Failures(ductile material behavior) (ductile material behavior)

Material is misshapen, stretched, or deflected beyond its elastic limit

Engine shaft/bearings Turbine

Gross Plastic DeformationGross Plastic Deformation(GPD)(GPD)Gross Plastic DeformationGross Plastic Deformation(GPD)(GPD)

Ductile (Necking)

Brittle

Note Shear Lip FormationDuctile & Brittle Failures Ductile & Brittle Failures

in Tensionin TensionDuctile & Brittle Failures Ductile & Brittle Failures in Tensionin Tension

Fatigue Zone

Chunk Failure

Fatigue (Stress Riser)

Origin

Fatigue FailuresFatigue FailuresFatigue FailuresFatigue Failures

Rotor Mast

Wing Carry Through Beams (Inflight failure)

Pitch Control Rod (Crash impact forces)

Bending Deformation and Bending Deformation and FailuresFailuresBending Deformation and Bending Deformation and FailuresFailures

BucklingBucklingBucklingBuckling

Why Do Designs Fail?Why Do Designs Fail?Why Do Designs Fail?Why Do Designs Fail?

• Errors in Design or manufacture• Excessive loads during catastrophic events • Insufficient Technical Knowledge • Material deficiencies • Operational errors




What is Design Analysis?What is Design Analysis?What is Design Analysis?What is Design Analysis?

• Design analysis is ability to simulate prototype-test iterations and optimize designs on computer without building physical prototypes

Design Final testing ProductionAnalysis

Scope of Design AnalysisScope of Design AnalysisScope of Design AnalysisScope of Design Analysis

• Reduce Prototypes– Does this design work?– Does this design behave the way I think it does?

• Improve product quality, innovative designs• Relative Merit

– Which of these candidate designs appears to be the best?

– Weed out the lesser designs• Failure Analysis

Why Invest in Design Analysis?Why Invest in Design Analysis?Why Invest in Design Analysis?Why Invest in Design Analysis?

Improve Product Quality 67%

Avoid Field Failures 59%

Reduce Number of Prototypes 56%

Send an email to [email protected] to obtain a free copy of this report

Comments From Companies Using Comments From Companies Using Design AnalysisDesign AnalysisComments From Companies Using Comments From Companies Using Design AnalysisDesign Analysis

• Don Bartlett, Senior Staff Engineer, Fanuc Robotics, NA “The biggest advantage was timesaving 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"

• Greg Dato, Kinemetrics Inc. Pasadena, California "With COSMOS we saved at least 2 months and thousands of

dollars in wasted hardware. By using COSMOS integrated with our CAD system, we can electronically test multiple designs, then typically build just one prototype."

• Karsten Hoffman, Project Leader, Dräger, Germany “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. Otherwise, we would have to either send the calculation work outside or build real prototypes so that we can carry out precise measurements




Design Analysis ProcessDesign Analysis ProcessDesign Analysis ProcessDesign Analysis Process

1. Geometry definition.2. Define component materials.3. Define physical situation with

boundary conditions.4. Mesh & run the analysis (solve the

system of equations).5. View and evaluate the results.M

odify

, U

pdat

e, R

efin

e

Example – Analyzing a Connecting Example – Analyzing a Connecting ArmArmExample – Analyzing a Connecting Example – Analyzing a Connecting ArmArm

You will learn:• Starting COSMOSWorks• Learning the basic steps of design analysis• Assessing the safety of the design• Change the geometry and recompute the stresses

Fixed

50 lb Force

Material: Alloy Steel

ProductsProductsProductsProducts

COSMOSFloWorks• Computational fluid dynamics

COSMOS/Works• Stress• Thermal• Frequency & Buckling• Optimization

COSMOS/Motion• Motion simulation

COSMOS - Complete Analysis Portfolio COSMOS - Complete Analysis Portfolio COSMOS - Complete Analysis Portfolio COSMOS - Complete Analysis Portfolio

StaticStatic VibrationVibration ThermalThermal NonlinearNonlinear

FlowFlowMotionMotion

OptimizationOptimization

ElectromagneticElectromagnetic

Post-dynamicsPost-dynamics

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Thank You!Thank You!Thank You!Thank You!

• Visit the SolidWorks website at http://www.solidworks.com to learn more about SolidWorks and its product offerings.

• Contact your local SolidWorks reseller for information on pricing and training. To find a reseller in your area call:– 1-800-693-9000 (US and Canada)– +1-978-371-5011 (Outside the US and Canada)

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Reduce Field Failures with COSMOS™ Analysis Tools