Performing a Drop Test Simulation Using SolidWorks

Welcome to another installment of our CAE Simulation using SolidWorks series! In this blog, we’ll explore how to set up and perform a drop test simulation using the SolidWorks simulation module. Drop tests are essential in ensuring the durability and reliability of components subjected to impact. For this demonstration, we’ll analyze a PCB (Printed Circuit Board) assembly to predict the stresses that occur during a drop.

This guide is perfect for professionals and students alike, especially those enrolled in the Skill-Lync SolidWorks course or looking to enhance their knowledge of CAE in SolidWorks.

Why Perform a Drop Test Simulation?

PCB boards are integral to electronic devices, supporting various components soldered onto them. When these devices are dropped, the solder joints are prone to failure due to the impact. A drop test simulation helps predict the stresses experienced by the PCB and its components, allowing engineers to implement design changes that ensure durability.

Setting Up the Drop Test in SolidWorks

1. Importing the Model

• Open SolidWorks and load the PCB assembly model.
• Familiarize yourself with the components, ensuring that all necessary parts are correctly modeled.

2. Creating a New Study

• Click on New Study and select Drop Test from the list of analysis types.
• Name the study appropriately and click OK.

3. Assigning Materials

• PCB Board: Apply PBT General Purpose from the Plastics material library.
• Electronic Components: Assign Alloy Steel as the material.
• Note: For realistic simulations, ensure each component’s material matches its real-life counterpart.

4. Defining Drop Parameters

Set the drop height to 1 meter. This represents the distance from the lowest point of the model to the point of impact.

Define the gravity direction:

• Expand the feature tree.
• Select the Front Plane and then the Top Plane.
• Reverse the direction of gravity, ensuring it aligns with the intended drop orientation.

5. Configuring Solution Time

SolidWorks automatically calculates the solution time after impact, representing the time required for elastic waves to propagate throughout the body. While this value can be manually adjusted, we’ll proceed with the default setting for this demonstration.

Running the Simulation

• Right-click the study and select Run.
• Since drop test simulations can take significant time to compute, prepare for a longer runtime.

For this blog, we have precomputed the results to expedite the demonstration.

Interpreting the Results

1. Stress Distribution

• The stress plot highlights areas of maximum stress propagation upon impact.
• Animate the results to visualize the stress waves traveling through the PCB.
• Observation: High-stress concentrations are typically found at the edges and solder joints.

2. Recommendations

• Reinforce high-stress areas by using more robust materials or additional support structures.
• Implement design modifications to reduce the likelihood of solder joint failure.

3. Displacement Analysis

• Evaluate displacement plots to understand how the PCB and its components move during impact.
• Ensure displacements are within acceptable limits to prevent permanent deformation.

Why Choose SolidWorks for Drop Test Simulations?

SolidWorks offers an intuitive platform for performing CAE simulations, including drop tests. Its comprehensive suite of tools allows engineers to predict stresses, displacements, and potential failures with high accuracy. Enrolling in a program like the Skill-Lync CAE Training ensures you gain hands-on experience with industry-relevant projects, preparing you for real-world challenges.

Conclusion

Drop test simulations are crucial in the design and validation of electronic components. By following the steps outlined above, you can confidently set up and analyze drop tests using SolidWorks CAE simulation tools.

If you’re eager to dive deeper into topics like SolidWorks simulation step-by-step, CAE fundamentals in SolidWorks, or SolidWorks advanced tutorials, consider enrolling in the Skill-Lync SolidWorks course. With expert guidance and practical projects, you’ll master simulations like a pro.

Ready to enhance your engineering skills? Join the Skill-Lync Training Program and become an expert in CAE simulations with SolidWorks!

This blog is part of our ongoing CAE Simulation using SolidWorks. If you missed the previous posts, check them out here.

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