Performing a Drop Test in SolidWorks: A Step-by-Step Guide

Welcome back to our blog series where we delve into SolidWorks FEA tutorial and explore the capabilities of SolidWorks for conducting Finite Element Analysis (FEA). In this session, we’ll walk you through the process of performing a drop test on a PCB board, from setting up the model to interpreting the results. This step-by-step guide will help you understand the workflow, and by the end of the blog, you'll be equipped with the knowledge to conduct a similar analysis on your own. 

If you're new to FEA, this tutorial serves as a practical introduction, and if you're considering a structured learning path, we also offer a comprehensive SolidWorks FEA course designed to help you master these concepts. 

What is a Drop Test? 

A drop test is a procedure used to evaluate how resistant an object is to physical impact when dropped from a certain height. The test simulates real-world conditions to predict damage and deformation. Whether it's for electronics like a PCB board, or everyday consumer products like phones, drop tests are critical in industries where product durability is a priority. 

In SolidWorks, the finite element method (FEM) is used to simulate such conditions, allowing engineers to make informed decisions based on accurate predictions. By creating a finite element mesh, we can break down complex models into simpler elements, allowing the software to analyze stress, displacement, and strain under load conditions. 

Setting Up the Drop Test in SolidWorks 

Step 1: Preparing the Model 

We begin by importing the PCB model into SolidWorks. Since this is an assembly of multiple components, SolidWorks reads the model and generates a solid part file. To start the drop test, you will need to access the SolidWorks Simulation license by navigating to the SolidWorks add-ins. 

Once the simulation license is activated, we can initiate a new study. Select the drop test from the simulation toolbar and rename the study, for example, “Drop Test PCB.” 

Step 2: Assigning Materials 

Next, we assign materials to the PCB. In this case, we will use custom plastic for the PCB board and low-carbon steel for the other components. Materials play a crucial role in FEA as they determine the mechanical properties of the components under analysis, such as elasticity, strength, and durability. 

Step 3: Creating the Finite Element Mesh 

Once materials are assigned, we proceed with meshing the model. SolidWorks uses the finite element mesh to discretize the model, allowing the software to solve complex calculations across individual elements. For this example, a curvature-based mesh is ideal, as the PCB has numerous small curves and details that require precision. Setting the mesh size to 9mm gives us a balance between accuracy and computational efficiency. 

Meshing is a critical part of any SolidWorks FEA analysis. By breaking the model into small, manageable elements, SolidWorks is able to calculate stress and deformation at a granular level, providing more accurate results. 

Step 4: Defining the Drop Test Parameters 

In a drop test, we need to define two key parameters: drop height and gravity. For this analysis, we define the drop height as 1,000 mm from the lowest point of the PCB model. The direction of gravity is set to 9.81 m/s², representing Earth’s gravity. If you were simulating a different environment, such as the surface of Jupiter, you could modify the gravity accordingly. 

SolidWorks also offers flexibility in defining the surface on which the object will land. For this test, we keep the target surface rigid, simulating a solid ground.  

Step 5: Running the Simulation 

Once the parameters are set, SolidWorks will simulate the drop test, showing us how the model behaves upon impact. While the drop test could take several hours to run due to the complexity of the calculations, SolidWorks allows you to pre-define result parameters like stress, displacement, and strain for easier analysis. 

Interpreting the Results 

After the simulation, we can view the key results such as the stress distribution across the PCB, the displacement it undergoes upon impact, and the strain developed during the test. These results give us insights into the durability of the PCB under real-world conditions. 

SolidWorks also allows us to animate the simulation, providing a dynamic view of how the PCB deforms during the drop. This visual representation is particularly useful for identifying critical stress points that may require design adjustments. 

Key Takeaways: Why SolidWorks FEA is Essential 

The SolidWorks FEA analysis capabilities provide a comprehensive toolkit for engineers to predict how products will perform under various physical conditions. Using the finite element method (FEM) and creating a detailed finite element mesh, you can simulate and analyze the behavior of any component, from a small electronic part like a PCB to large structural elements. 

If you're interested in diving deeper into FEA, our SolidWorks FEA course covers everything from the basics of meshing and simulation to more advanced topics like fatigue analysis and vibrational analysis. 

Conclusion 

In this blog, we’ve walked you through the process of performing a drop test in SolidWorks, covering everything from model setup to interpreting simulation results. By leveraging the finite element method and mastering the art of finite element mesh generation, you can significantly enhance your design process and improve product reliability. 

Ready to explore more? Check out our SolidWorks FEA tutorial series or sign up for our SolidWorks FEA course to take your simulation skills to the next level. 

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

Would you like to have a more interactive demonstration of the above concepts? 

Skill-Lync has released a FREE comprehensive course covering FEA with SolidWorks in detail! Check it out here. 

Right from the user interface's fundamentals, menus and options, this course covers most aspects of the tool from a practical perspective. It even includes a certificate to add to your resume after completion! 

Check out our hands-on course today and add SolidWorks to your list of skills!  

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