A Beginner’s Guide to FEA Simulations using SolidWorks

Welcome back to our blog series on FEA Simulations using SolidWorks! 

In our previous blog posts, we explored the variety of analyses you can perform in SolidWorks, including static, dynamic, linear, nonlinear, and more. Today, we dive into the world of simulation by introducing you to the simulation environment, specifically focusing on SolidWorks 2019. Before we proceed, it's assumed that you're already familiar with SolidWorks’ 3D modeling suite. If not, you may want to revisit our previous posts before jumping into simulations. 

Ready? Let's get started! 

Getting started: Accessing the simulation environment 

Once SolidWorks is installed on your system, simply open it by double-clicking the SolidWorks icon or typing “SolidWorks” in your search bar. After the software launches, you may be greeted with either a welcome tab or a plain screen. If it's the latter, press ‘Ctrl+N’ to create a new document. You will then see a dialog box allowing you to choose between a Part, Assembly, or Drawing file. Since we’re working with a part model, select Part. 

For this guide, we’ve already created a model, so we'll go ahead and open it. Use CTRL+O to navigate to the desired file and load your part. In this case, we will be working with a door handle model. 

A quick recap of the basics 

Before diving into simulations, let’s quickly revisit a few core commands in SolidWorks: 

1. Units System: Consistency in units is vital. Select your unit system from the bottom-right corner of the screen. Options include MKS (meters-kilogram-seconds), CGS, MMGS (millimeter-gram-seconds), and IPS (inch-pound-seconds). For more control, you can customize the units via "Edit Document Units." 

2. Planes and Origin: SolidWorks operates on three planes—XY (front), YZ (top), and ZX (right)—which can be shown or hidden as needed. Activate them by right-clicking on the plane and selecting “Show” or “Hide.” 

3. Materials: In the Feature Manager, you can assign materials to your model by right-clicking the Material option and selecting from common materials like steel, brass, or custom-defined ones.  

Introduction to the simulation environment 

Now, onto the fun part—simulations! Before accessing the simulation module, ensure that the SolidWorks Simulation add-in is enabled. Navigate to the SolidWorks Add-ins tab and click SolidWorks Simulation. This will activate the necessary tools for FEA (Finite Element Analysis). 

Creating your first study 

1. Click on the Simulation tab and select New Study. This will prompt you to choose the type of simulation—since we're starting simple, we’ll select Static and name our study “Handle Static.” 

2. After creating your study, assign material properties if not already done. Right-click the models name in the Feature Manager and select Apply Material. For our example, we’ll be using Brass.  

Setting up the simulation 

Connections: Since this model doesn’t have any specific connection points (like hinges or sliders), we won’t need to add connections for this part. 

Fixtures: Handles are typically secured by screws, so we’ll replicate this by applying fixed geometry to the holes where the screws would be. Right-click Fixtures in the Simulation tree, choose Fixed Geometry, and select the cylindrical surfaces of the holes. 

Loads: Now, let's apply a force to simulate someone pulling the handle. Right-click External Loads and select Force. For this simulation, we’ll apply a 500N force, pulling outward on the cylindrical part of the handle. 

Fine-tuning the force direction 

By default, the force direction may point inwards, but we need it to act outwards. Adjust the direction by selecting Select Direction in the property manager. Choose the Front Plane to ensure the force is perpendicular to the handle's surface. Once everything is set, input the force value of 500N and click OK. 

Meshing the Model

Meshing is essential for simulations. Right-click Mesh in the design tree and choose Create Mesh. SolidWorks allows you to control the mesh density—move the slider to the right for a finer mesh or left for a coarser one. For this simple simulation, we’ll use a 5 mm mesh size.  

Once you're satisfied with the mesh, click OK to generate it. If you're working on a more complex model with intricate geometries, you can opt for a Curvature-based Mesh.

Running the simulation 

With the mesh in place, it’s time to run the simulation. Click on Run to start the analysis. Once complete, you’ll see a deformed model, showcasing the stress and strain caused by the applied force. 

Understanding the results 

At first glance, the model may appear highly deformed. Don't panic! This is due to an exaggerated deformation scale (around 626 times in this case) designed to make subtle changes visible. To see the true scale, double-click the deformation scale box and select True Scale in the options.  

With the deformation corrected, you'll see that the handle barely deforms under 500N, which makes sense given that it’s made of brass—a strong material. 

Conclusion 

Congratulations! You've just completed your first static simulation in SolidWorks. In this session, we introduced the simulation environment, explored the basics of applying forces and constraints, and learned how to interpret results. This is just the beginning—future blog posts will dive deeper into more advanced FEA simulations, covering topics like dynamic analysis, thermal effects, and nonlinear materials. 

This blog is part of our ongoing series on FEA Simulations using SolidWorks. If you missed the previous posts, check them out here

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