Cosmos Works Tutorials

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Power • Accuracy • Functionality
V E R S I O N
6.0
T u t o r i a l s

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1
Introduction
This manual provides you with step-by-step tutorials to use COSMOS/Works.

These tutorials assume that you are familiar with SolidWorks. The tutorials are
grouped as follows
q Static Analysis Tutorial
q Contact Stress Analysis Tutorial
q Importing Motion Loads
q Frequency Analysis Tutorial
q Buckling Analysis Tutorial
q Thermal Analysis Tutorial
q Optimization Analysis Tutorial
Although you can begin with the tutorials, we recommend that you read the
COSMOS/Works Fundamentals, COSMOS/Works Interface, and Analysis
Background chapters of the COSMOS/Works User’s Guide to familiarize yourself
with some of the fundamentals, including:
q Design Study Concepts
q The COSMOS/Works Manager, and
q COSMOS/Works Analysis Capabilities
Learning to Use COSMOS/Works 1-1

✍ Structural Research and Analysis Corporation continuously updates the
COSMOS/Works program to improve accuracy and performance. Please note
that when you try the tutorials in this manual, you may obtain slightly
different results depending on the version of SolidWorks and COSMOS/
Works installed on your computer.
1-2 COSMOS/Works Tutorial

2
Static Analysis Tutorial
This chapter presents step-by-step lessons for performing linear static analysis.
q Lesson 1: Analysis of a Bracket Part
q Lesson 2: Analysis of a Crank Assembly
q Lesson 3: Analysis of a Thin Bracket (Shell Model)
q Lesson 4: Analysis of an I-beam (Shell Model)
q Lesson 5: Analysis of a Funnel (Shell Model)
q Lesson 6: Analysis of a Fuel Storage Tank (Shell Model)
q Lesson 7: Analysis of a Pulley Under a Bearing Force
q Lesson 8: Stress Concentration Around a Hole in a Plate

Chapter 2 Static Analysis Tutorial n Lesson 1: Analysis of a Bracket Part
Lesson 1: Analysis of a Bracket Part
In this lesson, you will learn how to:

q Retrieve a part and create a static analysis study,
q Assign material to the part,
q Insert restraints and pressure loading,
q Mesh the part,
q Run static analysis,
q Use COSMOS/Works menu system and new
toolbars to perform analysis steps, and
q Visualize the static analysis results.
Retrieve the Part

To retrieve the part:
1 Start COSMOS/Works.
2 Click File, Open. The Open dialog box
opens.
3 Change the Look in folder to ...\Examples
where “...” refers to the COSMOS/Works
installation directory.
4 From the Files of type drop-down list,
select Part Files (*.prt; *.sldprt).
2-2
5 Double-click the Tutor1.prt file. The part opens.
✍ If you do not see the COSMOS/Works menu in the SolidWorks menu bar,
click Tools, Add-ins, then click the COSMOS/Works checkbox and click OK.
To set the unit options:

1 Click Tools, Options. The System Options-General dialog box opens.
2 On the Document Properties tab, click Units.
3 From the Linear units menu select Millimeters.
4 Click OK.
✍ We recommend that you use File, Save As to save the part to a different name
before defining a study so that you can use the original file again.
Create a Static Analysis Study

The first step in performing analysis with COSMOS/Works is to create a design
study. You can use the COSMOS/Works Manager or the menu system to create
and manage studies. We will use the COSMOS/Works Manager to manage all
aspects related to design analysis studies.

To start the COSMOS/Works Manager:

COSMOS/Works Manager
Click the COSMOS/Works Manager icon
located at the lower left corner of the window.
✍ To return to the normal FeatureManager design
tree, click the FeatureManager icon .
To create a static analysis study:

1 In the COSMOS/Works Manager, right-click
the Tutor1 part icon and select Study,
- or -
From COSMOS/Works menu, select Study,
- or -
Click the Study button on COSMOS/
Works Main toolbar.
The Study dialog box opens.
2 Click the Add button. The Study Name dialog box opens.
3 In the New Study field, type in the name of the study, for example, Static-1.
4 From the Analysis Type drop-down list, choose Static (default).
5 In the Mesh Type box, click the Solid button.
6 Click OK. The study name appears in the Studies
list box.
7 Click OK.
To set the properties of the static study:

1 In the COSMOS/Works Manager, right-click the
Static-1 study icon and select Properties. The
Static dialog box opens.
2 In the Solver box, make sure that FFE is selected.
2-4
3 Click OK.
Preprocessing
Assign Material
To assign a material from the COSMOS/M Library:

1 In the COSMOS/Works Manager tree, right-click the Tutor1 icon under Solids
folder and select Apply/Edit Material,
- or -
From COSMOS/Works menu, click Apply Material to All,
- or -
Click the Apply Material to All button on the COSMOS/Works Main
toolbar.
The Material dialog box opens with the COSMOS/M Library tab selected.
2 From the Material Type drop-down menu, verify that Steel is selected.
3 In the Material Name list box, verify that Alloy Steel is selected.

4 Optional: From the Unit System

drop-down menu, click the
desired system of units to use in
displaying the material
properties.
✍ In general, you can use any
system of units regardless of
the units you used to create
the model.
5 Optional: From the Property
Type drop-down menu, choose
All, Structural, or Thermal.
Only structural or thermal
properties will be listed if you
select Structural or Thermal,
respectively.
✍ The Unit System option is
used for display convenience only when you select a material from the
library. It does not change the actual values or affect the results. The proper
unit system must be selected if you choose to input values for material
properties manually.
6 Click OK. COSMOS/Works assigns Alloy Steel to the part. A checkmark

appears on the part icon.
7 To list the properties of the applied material, right-click the Tutor1 icon under
the Solids icon and click Details. The material information is listed in the
Details window.
2-6
Insert Loads and Boundary Conditions
For static analysis, you must apply sufficient restraints to stabilize the part and
apply at least one type of loading. In this example, we will fix the two holes in the
part’s base and apply pressure normal to the front face of the cylinder.
Apply
pressure
normal to
this face
Fix these holes
To fix the two holes:

1 Select the face of one hole. Press and hold down the Ctrl key and select the face
of the other hole. The two faces highlight as shown in the figure.
2 In the COSMOS/Works Manager tree, right-click the Load/Restraint icon and
select Restraints,
- or -
From COSMOS/Works menu, select Insert, Restraints,
- or -
Click the Restraint button on COSMOS/Works Loads toolbar.
The Restraints dialog box opens.

3 From the Type box, select Immovable.
4 Optional: To change the color of the restraint symbol, click the Color button.
The Color palette opens. Select the desired color and click OK.
5 Click OK. Restraints are applied to the
selected spotted faces and displayed in the
selected color.
To apply uniform pressure:

1 Select the front face of the cylinder. The
face highlights.
2 In the COSMOS/Works Manager tree,
right-click the Load/Restraint icon and
select Pressure,
- or -
From COSMOS/Works menu, click Insert, Pressure,
- or -
Click the Pressure button on COSMOS/Work Loads toolbar.
The Pressure dialog box opens.
3 In the Type box, click the Normal to selected face button.
4 In the Distribution box, make sure that Uniform is selected.
2-8
5 From the Units menu, select English (IPS).
6 In the Value field, enter 1000 to apply 1000 psi.
✍ Although the unit of length for the model is millimeters, you can choose to
specify pressure in any other system of units.
✍ You can view the value of the applied pressure in other units by changing the
unit field.
7 Click OK. The pressure is applied.
✍ You can edit the definition of any load or boundary condition by right-
clicking the corresponding icon in the COSMOS/Works Manager tree.
Mesh the Part

The meshing process prepares the model for the numerical solution. The quality
of the mesh controls the quality of the results. We will use high quality mesh for
this part.

To set mesh preferences:

1 In the COSMOS/Works Manager
tree, right-click the Mesh icon
and select Preferences. The
Preferences dialog box opens
with the Mesh tab selected.
2 In the Mesh Quality box, select
High.
3 In the Mesh Control box, select
Smooth Surface.
4 In the Mesher Type box, select
Standard.
5 From the Jacobian Check menu,
make sure that 4 Points is
selected.
6 Click OK.
To mesh the part:

1 In the COSMOS/Works Manager tree, right-click the Mesh icon and select
Create.
- or -
From COSMOS/Works menu, click Mesh, Create,
- or -
Click the Mesh button on COSMOS/Works Main toolbar.
The Mesh dialog box opens and an average element size is suggested. You can
change the element size by typing in its field or using the slider. A finer mesh
gives more accurate results but requires more computer resources and takes
more time to solve. In this example, however, we will use the default element
size.
2-10
2 Click OK. The Mesh Progress window opens and the program starts meshing.
After the mesh is completed, the Solid Mesh completed message appears.
3 Click OK. Notice the checkmark that appears on the Mesh icon.
To view the mesh:

right-click the Mesh icon and select Show
Mesh. The mesh is displayed in the
SolidWorks window.
2 Right-click the Mesh icon again and select
Hide Mesh to hide the mesh.
3 Right-click the Mesh icon and select
Details to display information about the
mesh: global element size, tolerance,
quality option, and the number of nodes
and elements
You are now ready to run the analysis.

Run Static Analysis
To run static analysis:

1 In the COSMOS/Works Manager tree, right-click the
Static-1 study icon and select Run,
- or -
From COSMOS/Works menu, select Run,
- or -
Click the Run button on COSMOS/Works Main toolbar.
Analysis starts. When the analysis is completed, you will get the Static
Analysis Completed message.
2 Click OK.
Postprocessing Static Results

COSMOS/Works provides advanced high quality rendering and visualization tools
as an option during result visualization. You can switch to the Standard result
visualization scheme which is useful in the case of very large models.
To calculate the reaction forces on the faces of
the two holes:
1 Hide the restraint and pressure symbols by
right-clicking the Load/Restraint folder
and selecting Hide All.
2 Select the faces of the two holes as shown
in figure.
3 In the COSMOS/Works Manager, right-
click the Displacement folder and select
Select these faces
Reaction Force. The Reaction Force dialog
box opens.
4 From the Units menu, select lb. The sum of
the reaction forces on the selected faces and
on the entire model will be listed in the
selected unit.
2-12
To verify the results of the reaction force, multiply the area of the
circular face (2.8389 in 2 ) by the applied pressure (1000 psi) to get the
reaction force on the entire model.
To calculate the reaction forces on the vertical face:
Select this face
1 Select the vertical face of the bracket.

2 Right-click the Displacement folder and select Reaction Force .
3 In the Reaction Force dialog box, change the Units field to lb. The sum of the
reaction forces on the selected face will be listed. Note that the listed values
are all zeros as expected.
To calculate the reaction forces on the bottom face of the bracket:

1 Select the bottom face of the bracket.
2 Right-click the Displacement folder and select Reaction Force.
3 In the Reaction Force dialog box, change the Units field to lb. The reaction
force components will be listed. Note that the reaction force components in the
X, Y, and Z directions are not zeros. This is due to the fact that the edges of the
two holes are contributing to the reaction force on that face.

✍ If you select the edges of the two holes and calculate the reaction forces, you
should obtain the same values as those obtained when you select the bottom
face.
Select this face
To set result visualization (Graphics) option:

1 Click COSMOS/Works,
Preferences. The Preferences
setting box opens.
2 Click the Graphics tab.
3 In the Display box, click the
Advanced button.
4 Click OK.
Built-in Standard Plots
von Mises Stress Plot

Von Mises stresses are calculated
from stress components in various
directions. They give an overall
picture of the stress. Refer to the
Analysis Background chapter for more details.
To plot von Mises stresses:

1 In the COSMOS/Works Manager tree, click the (+) sign to the left of the Stress
folder. The Plot1 icon appears in the Stress folder.
2-14
2 Double-click the Plot1 icon.
✍ By default, the stresses are plotted
on the deformed shape.
To set the color map of the plot:

tree, right-click the Plot1 icon and
select Color Map. The Color Map
dialog box opens. The Color Map
dialog box gives you 4 options,
Default, Rainbow, Gray Scale, and
User-defined.
2 Make your selection and click OK.
✍ If you select the User-defined option, you will need to specify the number
of colors you want to use. You can use up to 9 base colors. To change or
define a color, click its box, and choose a color from the color palette.
To change the stress units:

1 In the COSMOS/Works Manager tree, right-click the Plot1 icon in the Stress
folder and select Edit Definition. The Stress Plot dialog box opens with the
Properties tab selected.
2 From the Stress Units menu, select the desired units and click OK.
To animate the stress plot:

Plot1 icon in the Stress folder and select Animate.
The Animation dialog box opens.
2 Click the right arrow button to start the
animation.
3 Click the square button to stop the animation.
4 Close the Animation dialog box.
✍ You can save your animation as an AVI movie

file by checking the Save As AVI checkbox.

To view an AVI file with Media Player:

1 In the Animation dialog box, check Save As
AVI file.
2 Check View with Media Player and click
Browse to specify the path and name of the
file.
3 Click . The Video Compression dialog
box opens.
4 Accept the defaults and click OK.
Equivalent Element Strain Plot

The equivalent element strains are calculated
from strain components in various directions.
Refer to the Analysis Background chapter for
the definition of the equivalent element strain.
To generate the equivalent element strain plot:

1 In the COSMOS/Works Manager tree, click the (+) sign to the
left of the Strain folder. The Plot1 icon appears.
Resultant Displacement Plot

Resultant displacements are calculated from displacement components in various
directions.
2-16
To generate the resultant displacement
plot:
tree, click the (+) sign to the left of
the Displacement icon. The Plot1
icon appears.
Deformation Plot
To generate the deformed shape plot:

tree, click the (+) sign to the left of
the Deformation icon. The Plot1
icon appears.

Section Plot
To generate a section plot of the first

principal stress:
tree, right-click the Stress folder
and select Define. The Stress Plot
dialog box opens.
2 Click the Display tab.
3 From the Result Type box, click
Node Values.
4 In the Plot Type box, click
Section.
5 From the Fringe Type drop-down
list, click Filled, Discrete.
6 In the No. of Sections field, type
in 1.
7 From the Component drop-down
list, click P1: Normal Stress (1st principal).
8 Click OK. The section plot is generated and a new icon (Plot2) appears in the
Stress folder of the study.
2-18
To control the section plot:
1 In the COSMOS/Works Manager, right-click the Plot2 and select Clipping. The
Section Clipping dialog box opens.
2 In the Uncut field, select Fringe.

3 In the Cut Direction field, select Outside.
4 Click the Sensitive checkbox.
5 Drag the sliders to modify the distance and orientation of the section.
6 Click OK.
To change the cutting tool (primitive) for the section plot:

1 Right-click the Plot2 icon in the Stress folder and click Edit Definition.
3 Double-click the 0 Plane: in the cutting tool list box. The primitive selection
menu opens.

4 Click the desired primitive (Plane, Cylinder, or Sphere).

5 Click OK.
To generate a default design check plot:

1 Click the (+) sign next to the Design
Check folder. The Plot1 icon appears.
2 Double-click the Plot1 icon, the Design
Check Wizard Step 1 of 3 window
opens.
3 Click the Maximum von Mises stress
button.
4 Click Next. The Design Check Wizard
Step 2 of 3 window opens.
5 In the Set stress limit box, click the to
Yield strength button.
2-20
6 Click Next. The Design Check Wizard Step 3 of 3 window opens.
7 Click the Areas below factor of safety button and enter a value of 1 in the field
next to it.
8 Click Finish. Regions with a factor of safety less than 1 (unsafe regions) will
be shown in red.
Unsafe regions

Printing Plots
To print a plot:
icon of the plot you want to print and select Print.
The Print dialog box opens.
2 Set your printing options and click OK.
Saving Result plots:
To save a plot as a BMP or VRML file:

1 In the COSMOS/Works Manager, double-click the icon of the plot.
2 Right-click the plot icon and select Save As. The Save As dialog box opens.
3 In the Save in field, specify the folder where the plot is to be saved.
4 In the File name field, enter a name for the plot.
5 In the Save as type field, select VRML files (*.wrl), Bitmap files (*.bmp), XGL
files (*.xgl), or ZGL (*.zgl) files.
6 Click Save.
Generating a Report for the Study

The Report utility
provides an excellent
way for reviews by
colleagues and
supervisors as well as
placement on web
sites.
1 Click COSMOS/
Works, Report. The
Report setting box
opens.
2-22
2 Click the desired section in the
Settings for list box for a preview
of its contents.
3 Click Set to enter or modify its
contents. The corresponding Set
dialog box opens.
4 Specify the desired information
or make the desired change.
5 Click OK.
6 Repeat steps 2 through 5 for other
sections. You can insert bitmap
images, AVI movies, and VRML
files in the appropriate sections.
7 Click OK.
This lesson is completed.

Chapter 2 Static Analysis Tutorial n Lesson 2: Analysis of a Crank Assembly
Lesson 2: Analysis of a Crank Assembly
In this lesson, we will analyze the crank subassembly shown below. This sub-
assembly contains 4 components (parts) as follows:
q Crank Pulley,
q Crank Arm Axle, and
q Two Crank Arms.

q Retrieve the assembly,
q Create a static analysis study,
q Assign materials to the various components of the assembly,
q Insert restraints and loads,
q Mesh the assembly,
2-24
q Run static analysis,
q Visualize the static analysis results,
q Create a frequency analysis study,
q Copy materials, restraints, and loads from the static analysis study,
q Run frequency analysis, and
q Visualize frequency analysis results.
✍ A special authorization (intermediate configuration) is required to work with
assemblies.
Retrieve the Assembly
To retrieve the assembly:

1 Start SolidWorks.
2 Click File, Open. The Open dialog box opens.
3 Change the Look in folder to ...\Examples where “...” refers to the COSMOS/
Works installation folder.
4 From the Files of type field, select Assembly Files (*.asm; *.sldasm).
5 Check the Preview checkbox.
6 Double-click the Crank.ASM assembly file. The Crank assembly opens.

✍ If you do not see the COSMOS/Works menu, click Tools, Add-ins, then
check the control box for COSMOS/Works and click OK.
To set the unit of length:

1 Click Tools, Options. The System Options-General dialog box opens.
2 On the Document Properties tab click Units.
3 From the Linear units menu select Inches.
4 Click OK.
✍ We recommend that you click File, Save As to save the part to a different
name before defining a study so that you can use the original file again.
Analysis of assemblies in COSMOS/Works is simple and straightforward. The
steps required to analyze an assembly are identical to those required to analyze a
part except for the option to apply different materials to different components.
2-26
Click the COSMOS/Works Manager toggle icon
located at the lower left corner of the SolidWorks
window.

1 Right-click the Crank icon and select Study. The Study dialog box opens.
2 Click Add. The Study Name dialog box opens.
3 In the New Study field, type in the name of the study, for example, Initial.
4 From the Analysis Type drop-down list, select Static (default).
5 In the Mesh Type box, click Solid.
6 Click OK. The study name appears in the Studies list box.
7 Click OK to close the Study dialog box.
Define Material for Each Component

In the assembly environment, the Solids folder contains an
icon for each component (part) of the assembly. The name
of the part appears next to the corresponding material icon.
You can assign a different material to each part, or one
material to all parts at once.

To assign a material to the CrankArm Axle part:

1 In the COSMOS/Works Manager tree, right-click CrankArm Axle-1 in the
Solids folder and select Apply/Edit Material. The Material dialog box opens
with the COSMOS/M Library tab selected.
2 From the Material Type drop-down list make sure that Steel is selected.
3 From the Material Name list box, select Stainless Steel (ferritic).
4 Click OK. The selected material will be assigned to the CrankArm Axle part.
To assign materials to the other parts:

Repeat the steps above to assign Gray Cast Iron to CrankPulley-
1, and Alloy Steel to CrankArm-1 and CrankArm-2.
✍ If you have an assembly with the majority of the parts made
of the same material, you can apply the following procedure:
1 Assign this material to all parts by right-clicking the Solids folder and
selecting Apply Material to All.
2 Edit the material definition for each part with a different material by right-
clicking its icon and selecting Apply/Edit Material.
2-28
Apply Loads and Restraints
We will fix the outer face of the pulley, and apply a force in the negative X-
direction to the face of one of the pedals.
Apply a force to this face in

the negative X-direction
Fix this face
To fix the outer face of the pulley:

1 Select the outer cylindrical face of the pulley. The face highlights.
2 Right-click Load/Restraint folder and select Restraints. The Restraints dialog
box opens.
select this face

3 In the Type box, select Immovable (No Translation).

4 Click OK.
To apply uniform force to one of the pedals:

1 Select the face of the pedal of CrankArm-2. The face highlights as shown.
2 Right-click the Load/Restraint folder and select Force. The Force dialog box
opens.
select this face
2-30
3 In the Type box, click Apply Force/Moment.
4 From the Distribution box, make sure that Uniform
is selected.
5 From the Units drop-down list, select English (IPS).
6 Click the Along Plane Dir1 checkbox.
7 In the Value field, enter -200 (pounds).
8 Click OK. The total force is applied.
Mesh the Assembly

The whole assembly is meshed at once.

1 Right-click the Mesh icon and
select Preferences. The
Preferences dialog box opens
with the Mesh tab selected.
2 In the Mesh Quality box, click
High.
3 In the Mesh Control box, select
Smooth Surface.
4 In the Mesher Type box, select
Standard.
5 In the Jacobian Check field,
make sure that 4 Points is
selected.
6 Click OK.
To mesh the assembly:

1 Right-click the Mesh icon and select Create.
2 In the Global Size field, enter 0.6 (inches).
3 Click OK. The Mesh Progress window opens and
the program starts meshing the parts one by one.

To Show/Hide the mesh:

1 Right-click the Mesh icon, and select Show Mesh .
The mesh is displayed as shown.
2 Right-click the Mesh icon again and click Hide Mesh
to hide the mesh,
- or -
Click the Show/Hide Mesh button on COSMOS/
Works Main toolbar.
3 Right-click the Mesh icon and select Details to
display information about the mesh: global element size, tolerance, quality
option, and the number of nodes and elements.
Run Static Analysis

1 Right-click the Initial study icon and click Run. The analysis starts. When the
analysis is completed, you will get the Static Analysis Completed message.
2 Click OK.
Visualize the Results of Static Analysis

COSMOS/Works gives you the option to use the Standard or the Advanced
graphics for result visualization.
To set the graphics option:

1 Click COSMOS/Works, Preferences. The Preferences dialog box opens.
2 Click the Graphics tab.
3 In the Display box, click Advanced.
4 Click OK.
✍ Use the Standard option for very large models.
von Mises Plot
To visualize von Mises Stresses:

folder. The plot1 icon appears.
2-32
2 Double-click the Plot1 icon. The von Mises stress plot is generated.
3 To change the display units of the stress, right click the Plot1 icon and select
Edit Definition. The Stress Plot dialog box opens.
4 On the Properties tab, select psi from the Stress Units menu.
1 Right-click the Plot1 icon and select Animate.

2 To save the animation as an AVI file, check the Save
as AVI File box.
3 To start the animation, click the play button .
4 To stop the animation, click the stop button .
To change the color map for the stress plot:

1 Right-click the Plot1 icon and click Color Map. The Color Map dialog box
opens.
2 From the drop-down list select a color map. The available color maps are:
Default, Rainbow, Gray Scale.
3 Enter the desired number of chart colors you want to use in the plot.
4 After making your choice, click Apply to see the effect dynamically.

5 Click OK.
To create your own color map:

1 Right-click the Plot1 icon and
select Color Map. The Color Map
dialog box opens.
2 From the drop-down list select
User Define .
3 Enter the number of colors you
want to use in the plot.
4 Choose the colors you want to use.
To change a color, click its box
and select the desired one from the
color palette.
5 Click OK.
Section Plots
To generate a section plot:

and select Define.
2 On the Properties tab, select psi
from the Stress Units menu.
Section.
5 From the Fringe Type drop-down
list, select Filled, Tone.
6 From the No. of Sections menu,
click the spin box to specify a
number of sections, for example,
3.
7 Double-click 0 Plane: in the list
box to select a cutting tool, for
example, Cylinder.
8 Repeat step 6 for 1 Plane and 2 Plane.
2-34
9 Click OK. The section plot is generated.
To control the Section plot:

1 Double-click the Plot2 icon under the Stress folder.
2 Right-click the Plot2 icon in the COSMOS/Works Manager and select
Clipping. The Section Clipping dialog box opens.
3 From the Uncut Part drop-down list, select Fringe.

4 From the Cut Direction drop-down list, select Both.
5 Check the Sensitive checkbox.
6 Modify the sections as desired using the sliders. To modify a section, click its
tab and drag the Radius and Center sliders.
7 Click OK.

Vector Plot
To generate a vector plot:

1 In the COSMOS/Works Manager tree, right-click the Stress folder and select
Define. The Stress Plot dialog box opens.
2 Click Display tab.

3 In the Plot Type box, click Vector.
4 From the Fringe Type drop-down list, select Filled, Discrete.
5 In the Component list box, select P1: Normal stress (1st principal).
6 Click OK.
2-36
Generating a Report for the Study
To generate a report:
1 In the COSMOS/Works Manager, right-click the Initial study icon and select
Report. The Report dialog box opens.
2 Click a section in the Settings for list box to preview its contents.
3 Click Set. The corresponding Set dialog box opens.

4 Edit the contents as desired and click OK.
5 Repeat steps 2-3 for other sections of the report.
6 For the result sections of the report, you may add AVI files, and image files as
desired.

Chapter 2 Static Analysis Tutorial n Lesson 3: Analysis of a Thin Bracket (Shell Model)
Lesson 3: Analysis of a Thin Bracket (Shell Model)

q Open a part and create a static analysis
study (shell elements),
q Mesh the part with shell elements,
q Run static analysis, and
q Visualize the static analysis results.
Open the Part
To open the part:

1 Click File,
Open. The
Open dialog
box opens.
2 Change the
Look in folder
to ...\Examples
where “...”
refers to the
COSMOS/
Works
installation
folder.
3 From the Files
of type drop-
down list,
select Part
Files (*.prt; *.
sldprt).
4 Double-click the sheet.prt file.
5 Verify that COSMOS/Works appears in the top menu bar of SolidWorks.
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✍ If you do not see the COSMOS/Works menu, click Tools, Add-Ins. Check the
COSMOS/Works checkbox and click OK.
To verify the units:

1 On the SolidWorks menu bar, click Tools, Options.
3 Make sure that Inches appears from the Linear units drop-down menu.
4 Click OK.
✍ At this point, we recommend that you click File, Save As to save the part
with a different name before defining a study so that you can use the
original file again.
Before performing the analysis with COSMOS/Works, we will scale the part
down by a factor of 0.1.
To scale the part:

1 Click Insert, Features, Scale. The Scale
dialog box opens.
2 In the Type box, make sure that Centroid
appears in the About menu.
3 Make sure also that the Uniform box is
checked.
4 In the Scaling factor field, type 0.1.
5 Click OK. The model will be scaled down by
the specified factor.
To restore the normal view of the model, click the Zoom to Fit tool on the
View toolbar.

study. We will use the COSMOS/Works Manager to manage all aspects related to
design analysis studies. Equivalent commands are available in the pull-down
menus.

Click the COSMOS/Works Manager button located at the lower left corner of
the window.


1 Right-click the Sheet part icon and select Study.
3 In the New Study field, type in Shell as the name
of the new study.
4 From the Analysis Type drop-down list, select
Static (default).
5 In the Mesh Type box, click the Shell using
midsurfaces button. The program displays a message about the limitations of
shell modeling in this version.
6 Read the message and click OK.
7 Click OK. The study name
appears in the Studies list box.
8 Click OK.
Set the Properties of the Study
To set the properties of the study:

1 Right-click the study icon
and select Properties. The
Static dialog box opens.
2 In the Solver box, make sure
that FFEPlus is selected.
3 Click OK.
✍ FFE does not support
high-order shells. If you
choose FFE, the program
will automatically switch
to FFEPlus.
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Assign Material

1 Right-click the Sheet icon in the Solids folder and select Apply/Edit Material.
The Material dialog box opens with the COSMOS/M Library tab selected
.
2 From the Material Type drop-down list, verify that Steel is selected.
3 From the Material Name list box, verify that Alloy Steel is selected.
4 From the Unit System drop-down list, click the desired system of units to use it
in displaying the properties.
5 From the Property Type drop-down list, choose All.
6 Click OK. The material is assigned to the part and a checkmark appears on the
Sheet icon in the Materials folder.
7 To verify the material assignment, right-click the Sheet icon and select Details.

Insert Loads and Restraints

We will fix the three holes and apply pressure to the bottom plate.
To insert restraints:
1 Select the face of any hole. You can
use the Zoom In tool to make sure you
select the proper face.
2 Hold down the Ctrl key and select the
faces of the other holes. The selected
faces should highlight as shown in the
figure.
right-click the Load/Restraint folder
and select Restraints. The Restraints
dialog box opens.
✍ Notice that the Selected Entities box lists the number of selected faces,
edges and vertices. In this case, 3 faces are selected.
4 From the Type box, verify that Fixed is selected to set all translations and
rotations to zero.
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✍ The Immovable option sets the translations to zero while the Fixed option
sets both translations and rotations to zero.
✍ The Units option is irrelevant when selecting Immovable or Fixed.
6 Click OK.
To insert uniform pressure:

1 Select the face of the model shown in the figure.
2 In the COSMOS/Works Manager tree, right-click the Load/Restraint and select
Pressure. The Pressure dialogue box opens.
Select this face
✍ Notice that the Selected Entities box lists one selected face.
3 In the Type box, click Normal to selected face to apply pressure normal to the
selected face.
4 From the Distribution box, make sure that Uniform is selected.


6 In the Value field, enter 1.00 to apply 1.00 psi.
✍ You can list the value of the applied

pressure in other units by changing the
unit field.
Mesh the Part

The meshing process prepares the part for the
numerical solution. The quality of the mesh
controls the quality of the results.

1 Right-click the Mesh icon and select Preferences. The Preferences dialog box
opens with the Mesh tab selected.
2 From the Mesh Quality box, click High.
3 In the Mesh Control, check Smooth Surface and uncheck Automatic
Transition.
4 In the Mesher Type box, select Standard.
5 From the Jacobian Check drop-down menu, select 4 Points (default).
6 Click OK.
To mesh the part:

1 In the COSMOS/Works Manager tree, right-click
the Mesh icon and select Create. The Mesh dialog
box opens and an average element size is
suggested. We will use the default element size.
✍ The Global Size and Tolerance are given in the
preferred units used to create the part.
the program starts meshing. After the mesh is completed, you will get the Shell
Mesh completed message.
3 Click OK. Notice that a check mark appears on the Mesh icon.
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1 Right-click the Mesh icon and select Show Mesh. The mesh is displayed as
shown.
2 Right-click the Mesh icon again and select Hide Mesh to hide the mesh.
3 Right-click the Mesh icon and select Details to display the information about
the generated mesh.
Flip misaligned shells

Stresses on the top face of a shell element are, in general, different from those on
its bottom face. Therefore, it is essential to align faces of adjacent shells properly
before running the analysis. After meshing is completed, COSMOS/Works allows
you to easily identify top and bottom faces of shell elements. After showing the
mesh, top faces will be shown in the shaded color of the model and bottom faces
will be shown in the selected Fill Color in the Mesh Preferences dialog box.
By visual inspection of the model, you will find that there are two faces that have
to be flipped. These faces are shown in the following figure.

✍ You may get different misaligned shells based on the version or service pack
of SolidWorks that you are using. ,
Flip these shell elements
To flip misaligned shells:

1 In the graphics area, select one of the faces shown in figure.
2 In COSMOS/Works Manager, right-click the Mesh icon and select Flip shell
elements. The shell elements will be flipped.
3 Repeat steps 1-2 for the other face.
Run Static Analysis

1 In the COSMOS/Works Manager tree, right-click the Shell study icon and
select Run. Static analysis starts. When the analysis is completed, you will get
the Static Analysis completed message.
2 Click OK. COSMOS/Works automatically creates postprocessing folders in the
COSMOS/Works Manager tree. For static analysis, the program creates folders
for stress, displacement, strain, deformed shape and design check results.
Postprocessing Results of the Static Study

First, let us generate the standard plots for static analysis.
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Von Mises stresses are calculated based on the stress components. They give an
overall picture of the stress field.
To plot von Mises stresses on the top faces of the model:

icon. The Plot1 icon appears in the Stress folder.
2 Double-click the Plot1 icon. The von Mises stress fringe plot is generated.
✍ The default plots are always generated on the top faces of the shell model.
To change the units of the plot:

1 Right-click the Plot1 icon and select Edit Definition. The Stress Plot dialog
box opens.
2 On the Properties tab, select psi from the Stress Units menu.
3 Click OK.
✍ By default, the stresses are plotted on the deformed shape.
To plot von Mises stresses on the bottom faces of the model:

1 In the COSMOS/Works Manager, right-click the Plot1 icon and select Edit
Definition. The Stress Plot dialog box opens.
3 In the Plot Type box, select Bottom from the Shell Face drop-down menu.

4 Accept the rest of the defaults and click OK.

folder and select Animate. The Animation dialog box opens.
2 Click the right arrow button to start the animation.
✍ You can save your animation as an AVI movie file by checking the Save
As AVI checkbox.
To plot equivalent element strain:

1 In the COSMOS/Works
Manager tree, click the (+)
sign to the left of the
Strain icon. The Plot1 icon
appears in the Strain
folder.
2 Double-click the Plot1
icon. The equivalent
element strain fringe plot
is generated.
3 Click the Animate in the COSMOS/Works Manager to animate the plot as was
described for the stress plot.
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To plot the resultant displacement:

Manager tree, click the (+) sign
to the left of the Displacement
icon. The Plot1 icon appears in
the Displacement folder.
2 Double-click the Plot1 icon. The
resultant displacement fringe
plot is generated.
Deformation Plot
To generate the deformed shape plot:

1 In the COSMOS/Works Manager tree, click the (+) sign to the left of the
Deformation icon. The Plot1 icon appears in the Deformation folder.
Printing and Saving Plots
To print a plot:
1 In the COSMOS/Works Manager tree, double-click
the desired plot icon.
2 Right-click the desired plot and select Print. The Print
dialog box opens.
3 Click OK to print.
To save a plot as VRML or BMP file:

1 In the COSMOS/Works Manager tree, double-click
the desired plot.
2 Right-click the desired plot and select Save As. The Save As dialog box opens.
3 From the Save As Type drop-down list, select VRML files (*.wrl), or Bitmap
files (*.bmp).
4 Set the location and the name of the file.
5 Click Save.

Chapter 2 Static Analysis Tutorial n Lesson 4: Analysis of an I-Beam (Shell Modeling)
Lesson 4: Analysis of an I-Beam (Shell Modeling)
In this lesson, we will create two studies for the I-beam shown below. We will use
shell meshing in the first study and solid meshing in the second study.
Open the Part
To open the part:

2 Change the Look in folder to
...\Examples where “...” refers to the
folder of the COSMOS/Works
installation.
3 From the Files of type drop-down
list, select Part Files (*.prt; *.sldprt).
4 Double-click the Ibeam.SLDPRT file.
✍ At this point, we recommend that you click File, Save As to save the part
✍ If you do not see the COSMOS/Works menu, click Tools, Add-ins, check
the COSMOS/Works checkbox and click OK.

Click the COSMOS/Works Manager icon located at
the bottom of the FeatureManager window.

1 On SolidWorks menu, click COSMOS/Works, Study. The Study dialog box
opens.
2-50
3 In the New Study field, type Shell Study as the
name of the new study.
4 From the Analysis Type drop-down list, choose
Static (default).
5 In the Mesh Type box, click the Shell using
midsurfaces button. The program displays a
message that the shell modeling can be applied to
thin parts only. Click OK.
6 Click OK. You will return to the Study dialog box.
7 Click OK.
Assign Material
To Assign a Material from the COSMOS/M Library:

1 Right-click the Ibeam icon in the Solids folder and select Apply/Edit Material.
2 From the Material Type drop-down list, select Steel.
3 From the Material Name list box, select Alloy Steel.
4 Click OK. The material is assigned to the part.
Insert Restraints and Loads

We will fix one end of the beam and apply normal pressure to the top flange.
To fix one end of the beam:

1 Select the face at one end of the
beam. The face highlights as shown.
2 Right-click the Load/Restraint
folder and select Restraints. The
Restraints dialog box opens.
Select this face
✍ In the Selected Entities box,

notice that one face is selected.
3 From the Type box, click Fixed.
4 Click OK

To apply uniform pressure to the flange:

1 Select the top face of the top Select this face
flange. The face highlights as
shown.
2 Right-click Load/Restraint folder
and select Pressure. The Pressure
dialog box opens.
✍ In the Selected Entities list box,
notice that one face is selected.
3 In the Type box, click Along plane

Dir 2 (direction 2 of Plane 1).
4 From the Distribution box, make
sure that Uniform is selected.
5 From the Units drop-down list,
verify that SI is selected.
6 In the Value field, enter -1000.
8 Right-click the Load/Restraint folder again and choose Hide All to hide load
and restraint symbols.
Mesh the Part

2 In the Mesh Quality box, select High.
3 In the Mesh Control box, select Smooth Surface.
5 From the Jacobian Check drop-down menu, select 4 Points.
6 Click OK.
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To mesh the part:
1 Right-click the Mesh icon and select Create. The Mesh dialog box.
2 Drag the slider to the most right position on the
scale as shown.
✍ The type of mesh (shell or solid) was
specified when the study was created. The
Global Size and Tolerance are given in the
preferred units used to create the part.
3 Click OK. Meshing starts.
4 After the meshing is completed, you will get the
Shell Mesh completed message. Click OK. Notice the checkmark that appears
on the Mesh icon in the COSMOS/Works Manager tree.
To view the mesh:

1 Right-click the Mesh icon and select Show Mesh.
2 Right-click the Mesh icon again and click Hide Mesh to hide the mesh.
3 Right-click on Mesh icon and choose Details to display meshing information.

Running Static Analysis

1 Right-click the Shell Study icon and select Run. Analysis starts. When the
analysis is completed, you will get the Static Analysis completed message.
2 Click OK. COSMOS/Works automatically creates result folders in the
COSMOS/Works Manager tree under the Shell study icon.
Postprocessing Results of the Shell Study

icon. The Plot1 icon appears in the Stress folder.
✍ The default plots are always generated on the top faces of shell models.
To plot von Mises stresses on the bottom faces of the model:

1 In the COSMOS/Works Manager, right-click the Plot1 icon in the Stress folder
and select Edit Definition. The Stress Plot dialog box opens.
3 In the Plot Type box, select
Bottom from the Shell Face drop-down menu.
4 Click OK.
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1 Right-click the Plot1 icon
in the Stress folder and
select Animate. The
Animate dialog box opens.
2 Click the right arrow button
to start the animation.
3 Click the square button
to stop the animation.
4 Close the Animation dialog
box.
To plot the equivalent element

strain:
Manager tree, click the (+) sign
to the left of the Strain icon.
The plot1 icon appears in the
Strain folder.

Manager tree, click the (+)
sign to the left of the
Displacement icon. The
Plot1 icon appears in the
Displacement folder.
2 Double-click the Plot1
icon.

Verify the Results with Solid Mesh
Create a Solid Mesh Study
To create a solid mesh static analysis study:

1 From the COSMOS/Works menu, click Study. The Study dialog box opens.
2 Click the Add button. The Study Name dialog box opens.
3 In the New Study field, type Solid Study (or any
other name) as the name of the new study.
Static (default).
5 From the Mesh Type box, click the Solid button.
7 Click OK.
Assign Material and Apply Loads/Restraints

You can apply material and restraints exactly as described for the Shell study.
Instead, we will use drag and drop to define the new study.
To assign material:
1 Right-click the Solids icon in Shell Study folder and select Copy.
2 Right-click the Solids Study folder and select Paste. The material will be
copied.
- or -
Drag the Solids icon from the Shell Study and drop it on the Solid Study folder.
The material is copied.
To apply loads/restraints:
1 Right-click the Load/Restraint folder in the Shell Study folder and select Copy.
2 Right-click the Solid Study folder and select Paste. The loads and restraints
will be copied.
- or -
Drag the Load/Restraint folder from the Shell Study and drop it on the Solid
Study. The restraints are copied.
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Mesh the Part
We will the use same mesh preferences as those we used in the shell example.
To mesh the part:

2 Click OK to accept the default element size.
To show/hide the mesh:

Show Mesh. The mesh is displayed.
2 Right-click the Mesh icon again and
click Hide Mesh to hide the mesh.
Details to display the information
about the mesh.
Run Static Analysis

1 Right-click the Solid Study icon and select Run. Analysis starts. When the
2 Click OK.

Postprocessing Results of the Solid Study
Von Mises Stress Plot

1 Click the (+) sign to the left of the Stress icon in the Solid study. The Plot1 icon
appears in the stress folder.
2 Double-click Plot1. The von Mises stress fringe plot is generated.
To plot the equivalent element strains:

1 In the COSMOS/Works Manager tree, click the (+) sign to the left of the Strain
folder in the Solid study.
2 Double-click Plot1.
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To plot the resultant displacements:

Displacement icon.

Chapter 2 Static Analysis Tutorial n Lesson 5: Analysis of a Funnel (Shell Model)
Lesson 5: Analysis of a Funnel (Shell Model)
In this lesson, you will learn:

q Applying local boundary conditions
q Applying non-zero prescribed
displacements
q Shell meshing
Open the Part
To open the part:

1 Start SolidWorks. The initial window of SolidWorks opens.
2 From the File menu, click Open. The Open dialog box opens.
3 Browse to the folder in which you installed COSMOS/Works.
4 Click the Examples folder.
5 Choose the funnel.prt file.
6 Click Open. The part file opens.
✍ If you do not see the COSMOS/Works menu, choose Tools, Add-ins, click
the control box for COSMOS/Works and click OK.
To check the units:

1 Click Tools, Options.
3 Make sure that Millimeters appears in the Linear units field.
4 Click OK.
✍ At this point, it is recommended that you click File, Save As to save the part
2-60
To start the COSMOS/Works Manager: COSMOS/Works Manager
Click the COSMOS/Works Manager button located at
the lower left corner of the SolidWorks window.

1 From the COSMOS/Works menu, click Study. The
Study dialog box opens.
2 Click the Add button. The Study Name dialog box
opens.
3 In the New Study field, type Shell Study (or any other
name) as the name of the new study.
Static (default).
5 From the Mesh Type box, click Shell using midsurfaces. A message window
opens.
6 Read the message and click OK.
appears in the Studies list box.
8 Click OK. You will return to the
Study dialog box.
9 Click OK.
Assign Material
1 Right-click the funnel icon in the Solids folder and select Apply/Edit. The
Material dialog box opens with the COSMOS/M Library tab selected.
2 From the Material Type drop-down list, select Plastics.
3 From the Material Name list box, select Nylon 6/10.
4 From the Unit System drop-down list, click the desired system of units to use it
in displaying the properties.
5 From the Property Type drop-down list, choose All.
6 Click OK.

Insert Loads and Restraints

A rigid cylindrical boss of a 121 mm radius is to fit in the cylindrical base of the
funnel. As the inner radius of the base is 120 mm, this condition may be simulated
by prescribing a 1 mm displacement in the radial direction.
To prescribe radial translation:

1 Select the inner face of the cylindrical base. The face highlights as shown.
2 Right-click the Load/Restraint folder and select Restraints. The Restraints
dialog box opens.
Select this face
3 In the Selected Entities list box, notice that one face is selected.
4 From the Type box, click On Cylindrical Face.
5 From the Displacement Units drop-down list
select mm.
6 Click the checkbox associated with Radial
Displacement. A checkmark appears.
7 Type in 1.0 in the Radial Displacement field.
8 Click OK.
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To fix the bottom face in the axial direction:
Select Axis1 from SolidWorks
1 Change the view as shown and select the FeatureManager
bottom face of the funnel.
2 Click the FeatureManager button at the
lower left corner of the SolidWorks window
to switch to the FeatureManager tree.
3 Press and hold down Ctrl and click Axis1 in
the FeatureManager tree.
4 Click the COSMOS/Works Manager button to
switch back to the COSMOS/Works Manager
Select this face
tree.
dialog box opens.
6 In the Selected Entities list box, notice that one face is selected.
7 In the Type box, verify that Use Reference plane or Axis is selected.
8 In the Selected References list box, verify that Axis1 is selected.
9 Click the checkbox of Axial Displacement and verify that 0 is entered in its
field.
10 Click OK. The restraint is applied so that this face may not move in the axial
direction.

To make the top face immovable: Select this face
1 Change the view as shown and select the top

face of the funnel.
2 Right-click the Load/Restraint folder and
select Restraints. The Restraints dialog box
opens.
3 From the Selected Entities list box, notice
that one face is selected.
4 In the Type box, click Immovable (No
Translation).
5 Click OK. The restraint is applied so that this face cannot move in any
direction.
✍ Immovable and Fixed are different for shells. Fixed sets all translations and
Rotations to zero while Immovable sets only the translations to zero.
6 Right-click the Load/Restraint folder in the COSMOS/Works Manager tree
and choose Hide All to hide the restraint symbols.
2-64 COSMOS/Works User’s Guide

Mesh the Part

3 In the Mesh Control, select Smooth Surface.
6 Click OK.
To mesh the part:

the Mesh icon and select Create.
2 Accept the default element size and click OK. The
Mesh Progress window opens and the program
starts meshing.
3 When the mesh is completed, you will get the
Shell Mesh completed message. Click OK to close
the dialog box.
To show/hide the mesh:

1 In the COSMOS/Works Manager tree, right-click the Mesh icon and select
2 Right-click the Mesh icon again and select Hide Mesh to hide the mesh.

3 Right-click the Mesh icon and select Details to display information about the
generated mesh.
Flip this face
Before flipping After flipping

By visual inspection of the model, you will find that there is one face that has to
be flipped. This face is shown in the above figure.
of SolidWorks that you are using.
To flip misaligned shells:

1 In the graphics area, select the face shown in figure.
2 In COSMOS/Works Manager, right-click the Mesh icon and select Flip shell
elements. The shell elements will be flipped.

Run Static Analysis

1 Right-click the Shell Study icon and select Run. Analysis starts. When the
2 Click OK.
Visualizing the Results

folder. The Plot1 icon appears in the Stress folder.
2 Double-click Plot1. The stresses on the top face are plotted.
Global Coordinate
System
✍ The default plots are displayed on the top faces of the model.
To plot von Mises stress on the bottom faces of the model:

1 Right-click the Plot1 icon in the Stress folder and select Edit Definition. The
Stress Plot dialog box opens.

4 Click OK.
✍ To visualize extreme stresses, we recommend that you plot the stresses on top
and bottom faces for all shell models.
To change the display settings of the result axes:
1 Activate Plot1 by double-clicking its icon.
2 Right-click Plot1 and select Axes. The Axes dialog box opens.
3 In the Axis box, move the size sliders to the positions shown in figure.
4 In the Ticks fields, enter 6.
5 In the Grid box, check XY, YZ, and ZX checkboxes.
6 Click OK.
Global coordinate system displayed with the settings shown in the

Axes dialog box shown to the left
2-68
To change the stress units:
folder and select Edit Definition. The Stress Plot dialog box opens with the
Properties tab selected.
2 From the Stress Units menu, select the desired unit and click OK. The plot with
new units will be displayed.

1 Right-click the Plot1 icon in the Stress folder and select Animate. The
Animation dialog box opens.
✍ You can save your animation as an AVI movie file by checking the Save As
AVI checkbox.
To plot the equivalent element strains:

1 In the COSMOS/Works Manager tree, click the (+) sign to the left of the Strain
icon. The Plot1 icon appears in the Strain folder.


tree, click the (+) sign to the left
of the Displacement icon. The
Plot1 icon appears in the
Displacement icon.
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Lesson 6: Analysis of a Fuel Storage Tank (Shell Model)

q Create a coordinate system,
q Apply variable pressure,
q Visualize stress and displacement results.
Fuel Density of Fuel is

0.029 lb/in3.
p(y) =γy
Description
An aluminum storage tank is partially filled with a fuel of density γ = 0.029 lb/in3.
The fuel exerts a hydrostatic pressure that can be simulated by applying a varying
pressure. A linearly varying pressure (p(y) =γy) will be applied to all inner faces
of the tank below the fuel surface, where y refers to the vertical distance measured
from the surface of the fuel.
In order to apply the pressure p(y) =γy, the faces of the tank were split at the
surface of the fluid so that we can apply the pressure to the walls of the tank below
the surface of the fluid. We will also create a coordinate system at the fluid
surface with its y axis pointing downwards in order to be able to describe the
pressure variation in the y direction according to the above equation.

Chapter 2 Static Analysis Tutorial n Lesson 6: Analysis of a Fuel Storage Tank (Shell Model)
Open the Model and Create a Static Study

Open the Fuel_Storage_Tank part located in the Examples folder of the
COSMOS/Works installation.
To create static analysis study:

1 Right-click the Fuel_Storage_Tank part icon and select Study.
2 In the Study dialog box, click the Add button. The Study Name dialog box
opens.
3 In the New Study field, enter variable pressure as the name of the study.
4 From the Analysis Type menu, make sure that Static is selected.
5 In the Mesh Type box, select Shell using midsurfaces. You will be prompted
with a message that the shell meshing works only for simple thin parts and is
being improved by both SRAC and SolidWorks. Close this information
window by clicking OK.
7 Click OK to close the Study dialog box.
✍ In the variable pressure study we will use the first shell meshing technique,
namely, Shell using midsurfaces. In order for this technique to work,
SolidWorks 2000 with SP3 service pack or higher should be installed on
your computer.
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Assign Material to the Model
Assign Aluminum Alloy (1060 Alloy) from the COSMOS/M Material Library to
the tank.
Apply Restraints and Pressure to the Model
Apply displacement restraints to the bottom faces of the tank
To restrain the bottom face of the tank:

1 Select the bottom faces of the tank (3 faces).
Load/Restraint icon and select Restraints .
3 In the Type box, select Immovable.
4 Click OK.
Apply the hydrostatic pressure

First, we will create a coordinate system at the
Fix these faces
surface of the fuel with its y- axis pointing
downward.
To create a coordinate system at the surface of the fuel:

1 In SolidWorks menu bar, click Insert, Reference Geometry, Coordinate
System. The Coordinate System dialog box opens.
2 Click inside the Origin box and select the vertex shown in the figure.
3 Click inside the Y Axis box, and select the edge shown in the figure.
4 Click OK. The coordinate system will be created and highlighted.

Select this edge as the Y-axis
Select this vertex

as the origin
To apply hydrostatic pressure to the inner faces of the tank:

1 Select the coordinate system you
just created, hold the Ctrl key down
and select all inner faces that are
below the fluid surface in the tank
(total of 7 faces).
2 In the COSMOS/Works Manager,
right-click the Load/Restraint icon
and select Pressure. The Pressure
dialog box opens.
3 In the Type box, select Normal to
selected face.
4 In the Distribution box, make sure
that Variable is selected.
5 From the Units menu, select English
(IPS).
6 In the Value field, enter 1.0.
7 In the Selected Coord. System box, make sure that Coordinate System1 is
selected.
8 In the Equation for Variable Pressure fields, enter 0.029 in the field
corresponding to the y coefficient and 0 in all other fields.
9 Click OK.
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Mesh the Model
To mesh the part:

1 Right-click the Mesh icon and select Preferences. Use the options shown in
figure below.
2 Right-click the Mesh icon again and select Create.
3 Click OK to accept the default element size and tolerance.
To show the mesh:

Right-click the Mesh icon and click Show Mesh. The mesh will be displayed.

By visual inspection of the model, you will find that there are two faces that have
to be flipped. These faces are shown in the figure below.
of SolidWorks that you are using.

To flip misaligned shell elements:

1 Select one of the misaligned faces.
2 Right-click the Mesh icon and select Flip shell elements.
3 Select the other face and repeat steps 1-2.
Before Flipping Select these faces and After Flipping

flip the associated elements
Run the Analysis

Right-click the study icon and select Run.
Visualize Stress and Displacement Results
To plot von Mises stress on the top

faces of the model:
click the (+) sign to the left of the
Stress folder.
✍ The default plots are always
displayed on the top faces of
the model.
2-76
To plot von Mises stress on the bottom faces of the model:
1 Right-click the Plot1 icon in the Stress folder and select Edit Definition. The
Stress Plot dialog box opens.
4 Click OK.
To plot displacement results:

Manager, click the (+) sign to
the left of the Displacement
folder.
2 Right-click the Plot1 icon in
the Displacement folder and
select Edit Definition. The
Displacement Plot dialog box
opens.
3 On the Properties tab, select in
(inch) from the Displacement
Units drop-down menu.
4 Click OK.

Lesson 7: Analysis of a Pulley Under a Bearing Force
q Create a coordinate system, and
q Apply forces with prescribed intensity.
f(θ) = F0Sin(θ) = (F0)(y/a)
X
a θ
f(θ) = F0Sin(θ) = (F0)(y/a) where f(θ) is

the intensity of the force, a is the radius of
the hole, and F0 is a scale factor calculat-
ed by the program such that the sum of all
forces is set equal to the specified force
value.
Description
COSMOS/Works lets you handle bearing problems in two ways:
• You can model the assembly of the axle and the pulley. The forces are
transferred through the gap elements generated automatically by setting the
Contact/Gaps option on the faces of contact between the axle and the pulley.
• You can model the pulley only and approximate the force intensity exerted by
the axle. The validity of the approximation depends on the validity of the
assumed force intensity for the problem at hand.
The second approach is used in this lessons force exerted by the axle on the pulley
is approximated by a 700 pound force acting normal to the lower face of the hole.
The intensity is assumed to be f(θ) = Sin(θ), where θ is defined as shown in the
figure.

The surface of central hole of the pulley was split into two faces. We will create a
coordinate system at the center of the hole as shown in the figure and use it to
specify a total normal force with given intensity.
Open the Model and Assign Material

1 Open the Pulley-Bearing part located in the Examples folder of the COSMOS/
2 Start the COSMOS/Works Manager.
3 Create a Static analysis study. Make sure to select the Solid option while
defining the study.
4 Assign Steel Alloy from the COSMOS/M Material Library to the pulley.
Apply Restraints and Force to the Model
Apply displacement restraints
To restrain a portion of the lower face of the rim:

1 Select the face shown in the figure.
2 In the COSMOS/Works Manager, right-
click the Load/Restraint icon and select
Restraints.
4 Click OK.
Select this face to apply restraints

Chapter 2 Static Analysis Tutorial n Lesson 7: Analysis of a Pulley Under a Bearing Force
Apply the bearing force

First, we will create a coordinate system at
the center of the pulley.
To create a coordinate system at the center of
the pulley:
1 In SolidWorks menu bar, click Insert,
Reference Geometry, Coordinate
System . The Coordinate System dialog
box opens and a default coordinate system
is created.
2 Flip the y-axis by clicking the Flip
checkbox under Y Axis. Create a local coordinate system to
define variable force
3 Click OK.
To apply the bearing force:

1 With the newly created
coordinate system selected
from the previous
procedure, hold the Ctrl key
down and select the lower
half of the surface of the
central hole.
Manager, right-click the
Load/Restraint icon and
select Force. The Force
dialog box opens.
3 In the Type box, select
Apply Normal Force .
4 In the Distribution box,
make sure that Variable is
selected.
5 From the Units menu, select
English (IPS).
6 In the Force field, enter 700.
2-80
7In the Selected Coord. System box, make sure
that Coordinate System1 is selected.
8In the Equation for Variable Force fields, enter
1.3333 in the field corresponding to the y
coefficient and 0 in all other fields. 1.333. is the
coefficient of y in the force intensity equation:
f(y) = (1/a)y = (1/0.75)y= 1.333 y.
where a is the radius of the cylindrical hole.
9 Click OK.
✍ The summation of the magnitudes of the forces applied normal to the face will
be 700 pound force. The horizontal components over the face will cancel each
other.
Mesh the Model
To mesh the part:

select Preferences. Use the
options shown in figure.
2 Right-click the Mesh icon again
and select Create.
3 Click OK to accept the default
element size and tolerance.
Run the Analysis


Visualize Stress and Displacement Results
To plot von Mises stress:
1 In the COSMOS/Works Manager, click the (+) sign to the left of the Stress
folder.
2 Right-click the Plot1 icon and select Edit Definition.
3 Click the Setting tab.
4 Change the Scale Factor to 2000.
5 Click OK.

Manager, click the (+) sign
to the left of the
Displacement folder.
2 Right-click the Plot1 icon
and select Edit Definition.
3 Click the Setting tab.
4 Change the Scale Factor to
2000.
5 Click OK.
2-82
To list the reaction forces:
1 Select the restrained portion of the lower face of the rim.
2 Right-click the Displacement folder and select Reaction Force . The Reaction
Force dialog box opens to list the reaction forces on the selected face as well as
on the entire model.
3 From the Units menu select lb.
Global coordinate system of the problem

Explanation of reaction forces

The following graph shows the forces that developed on the contact area between
the pulley and the axle,
Fn(θ)=Fosin(θ) is the normal force applied at an angle (θ)
Fo
θ
Y Fn Fosin(θ)cos(θ)
Fosin(θ)
2
Fosin (θ)
The program calculates Fo such that the summation
of the magnitudes of all applied forces is set equal
to the specified force value (700 lb)
According to the above graph,

The summation of the magnitudes of the normal forces =700 lb
The summation of the magnitudes of the horizontal forces=700- 541.17= 158.83lb
The summation of the magnitudes of the vertical forces= Reaction forces on the
entire model= 541.17 lbs
✍ The applied net horizontal force is zero.
2-84
Lesson 8: Stress Concentration Around a Hole in a Plate

q use the p-adaptive method to improve the solution, and
q visualize convergence graphs related to the p-adaptive method.
Description
In this problem, we will study the stress concentration around a hole at the center of a plate
subjected to in-plane pressure loading.
20”
20”
1” radius
10”
The plate is 20” x 20” x 1” and the radius of
the hole is 1”. Due to the symmetry of the
model, we will analyze a quarter of the plate
as shown in the figure.
The face of the plate is subjected to a normal

10”
uniform tensile pressure of 1000 psi. The
hole will cause a stress concentration.
1 in

Chapter 2 Static Analysis Tutorial n Lesson 8: Stress Concentration Around a Hole in a Plate
Open the Model and Create a Study

1 Open the Plate-with-hole part located in the Examples folder of the COSMOS/
2 In the COSMOS/Works Manager, right-click the top icon and select Study.
3 Click the Add tab, enter a name for the study, select Static from the Analysis
Type menu (default), make sure to select Solid (default) in the Mesh Type box,
and click OK.
✍ The p-adaptive method is not supported for shells.
4 Click the Properties button and then click the Adaptive tab.
5 Click the Use p-Additive for solution checkbox.
6 From the Stop when drop-down menu, select Total Strain Energy (default) and
enter 0.02 in the change is % or less field.
✍ In general, strain energy has a rapid convergence. This is why we entered a
small value for the allowable change in the strain energy.
2-86
7 In the Update elements with strain energy error of % or more, enter 1.0.
8 In the Starting p-order field, enter 2 (default).
9 Click OK to accept all other defaults.
10 Click OK.
Assign Material
To assign Material to the part:

1 Right-click the Solids folder and select Apply Material to All.
2 Click the COSMOS/M Library tab.
3 Click OK to apply Alloy Steel to the part.
Apply Loads and Boundary Conditions
To apply the symmetry restraints: Restrain this

edge normal
1 Select face A (as shown in the
to Plane1
figure).
2 Right-click the Load/Restraint Face B:
folder, select Restraints. Restrain
this face in
3 In the Type box, choose the Use direction 1
of Plane1
Reference Plane or Axis option.
Plane1 appears in the selected
Reference field. Face A: Restrain this
face in direction 2 of
4 Click the Along Plane Dir 1 Plane1
checkbox and enter 0 in its field.
5 Click OK.
6 Repeat the above steps for face B (as shown in the figure) to restrain it in
direction 2 of Plane1.
To stabilize the plate in the direction normal to Plane1:

1 Select the upper edge (as shown in the figure) of the plate.
2 Right-click the Load/Restraint folder and select Restraints.
3 In the Type box, select the Use Reference Plane or Axis , Plane1 appears in the
selected Reference field.
4 Click the Normal to plane checkbox and enter 0 in its field.

5 Click OK.
To apply the tensile pressure:

1 Select the face shown in the figure.
2 Right-click the Load/Restraint folder and
select Pressure.
3 In the Type box, select the Along Plane
Dir 1 option.
4 In the Distribution box, choose Uniform,
1000 psi
English (IPS) units. Pressure
5 In the Value field, enter 1000 (psi).
6 Click OK.
Mesh the Plate
To set mesh preference:

1 Right-click the Mesh icon and select Preferences.
2 Select the options shown in the figure.

3 Click OK.
✍ It is recommended to choose the At Nodes option from the Jacobian Check
drop-down menu when using the p-method.
2-88
To mesh the plate:
2 In the Global Size field, enter 2.0. This is an
intentionally large value to show the power of
the p-method.
3 Click OK. Click OK when meshing is
completed.
To show the mesh, right-click the Mesh icon
and select Show Mesh.
Run Static Analysis

Right-click the icon of the study and select Run to start static analysis. The p-
method will run static analysis 3 loops before reaching convergence. Click OK
when the analysis is completed.
Visualize the Results
To plot the normal stress in the X-direction:

1 In the COSMOS/Works Manager, right-click the Stress folder and select
Define.
2 Click the Display tab and select the SX: Normal stress (X-dir.) component.
3 Click OK.

To graph the % Change in Global Criterion:

1 In the COSMOS/Works Manager, right-click the study folder icon and select
Convergence Graph.
2 Click OK.
To graph Total Strain Energy:

1 Right-click the study folder
icon again and select
Convergence Graph.
2 Click the checkbox for %
Change in Global Criterion to
uncheck it.
3 Click the checkbox for Total
Strain Energy.
4 Click OK.
2-90
To graph all convergence
components:
Manager, right-click the study
folder icon and select
Convergence Graph.
2 Check all the available
checkboxes.
✍ When you plot more than one
graph, the y-axis will be
normalized to unity.
3 Click OK.
Verify the Results
Maximum Normal Stress Results (SX):

Analytical Using the Without using the p-method
Solution p-method (same mesh)
Maximum
2539.5 psi
3059 psi (16% error)
Normal 3024 psi
(1.16% error) (obtained by deactivating the p-
Stress Sx
method and re-running the analysis)
Reference
Roark and Young, “Formulas for Stress and Strains,” Fifth Edition, McGraw-Hill Book
Company, Chapter 15, pp-594.

3
Contact Stress Analysis Tutorial
This chapter presents step-by-step lessons to show you how to use the Contact/
Gaps Options.
q Lesson 9: Analysis of a Rotating Shaft Assembly
q Lesson 10: Analysis of an Eyebar Assembly
q Lesson 11: Analysis of Two Contacting Cantilevers with Rough Surfaces

Chapter 3 Contact Stress Analysis Tutorial n Lesson 9: Analysis of a Rotating Shaft Assembly
Lesson 9: Analysis of a Rotating Shaft Assembly

q Set a global Contact/Gaps option,
q Mesh an assembly,
q Visualize the stress results.
Description
The imbalance in the motor causes a dynamic force of 5 pounds on the rotating shaft. The
worst scenario occurs when the shaft rotates at a frequency that is equal to one of the natural
frequencies of the assembly (resonance). Assuming a damping ratio (ξ) of 5%, the dynamic
force effect may be approximated by applying a static force of magnitude 1/(2ξ) times the
magnitude of the dynamic force. We will, however, use a static force of 150 pounds (50
pounds times a factor of safety of 3) to evaluate the stresses caused by the imbalance at the
interface between the shaft and bearings. Note that the direction of the imbalance changes as
the shaft rotates. In this example, we will consider a force in the upward direction.
Retrieve the Part

1 Start SolidWorks.
2 From the File menu, select Open. The Open dialog box opens.
4 Click the Examples\Contact folder.
5 From the Files of type menu, select Assembly Files (*.asm;*.sldasm).
3-2
6 Choose the Contact-Ex-1 assembly file in the Contact folder.
7 Click Open. The assembly opens.
✍ If you do not see the COSMOS/Works menu, click Tools, Add-Ins, select
COSMOS/Works and click OK.
✍ Lightweight components do not function properly with COSMOS/Works. To

turn off the automatic loading of components as lightweight, turn off the
option with Tools, Options, Performance.
✍ It is recommended that you click File, Save As to save the assembly with a
different name before defining a study so that you or can use the original file
again.


✍ The Contact/Gaps capability works with static analysis only, it does not work
with frequency, buckling, or thermal analysis.

Click the COSMOS/Works Manager tab located at the lower left corner of
SolidWorks window.
✍ To return to the FeatureManager design tree, click the FeatureManager
tab. .
1 Right-click the Contact-Ex-1
assembly icon and click
Study. The Study dialog box
opens.
2 Click the Add button. The
Study Name dialog box
opens.
3 In the New Study field, type
in Imbalance.
4 From the Analysis Type drop-
down menu, choose Static
(default).
5 From the Mesh Type box,
choose Solid.
appears in the Studies list
box.
7 Click the Properties button.
The Static analysis setting
box opens.
✍ You can use either the Direct Sparse or the FFEPlus solver for static
problems involving contact.
8 In the Solver box, check FFEPlus.
9 Click the OK button. You will return to the Study dialog box.
10 Click the OK button. The study is created.
3-4
Preprocessing
Assign Material
To assign material from the COSMOS/M Library:

Solids folder icon and click Apply Material to All. The
Material dialog box opens with the COSMOS/M
Library tab selected.
2 Click the OK button to assign the default Alloy Steel to

all parts in the assembly.
✍ Notice the checkmarks that appear on the icons in the Solids folder indicating
that a material has been assigned to each of them.

The imbalance in the motor-shaft assembly is estimated to cause a static force of
50 pounds. Since we want to perform static analysis, we will use a factor of safety
of 3 and apply 150 pounds. The force can be in any direction, however, in this
study, we apply the force in the vertical direction pointing upward.
To insert restraints:
1 Select the bottom faces of the bearing
supports as shown (select one face,
press and hold down the Ctrl key and
select the other one). The two faces
should highlight as shown in the
figure.
click Restraints. The Restraints dialog box opens.
✍ Notice that the Selected Entities box lists the number of selected faces, edges
or vertices. In this case, two faces are selected.
3 From the Type box, choose
Immovable.
4 Click the OK button. Restraints
are applied to the selected faces
and displayed in the selected
color.

To apply a uniform upward force:

1 Click the FeatureManager tab and select Plane2 located at the bottom of
the FeatureManager design tree. Plane2 highlights in the graphics area.
2 With Plane2 selected from step 1, click the COSMOS/Works Manager tab .
3 Press and hold the Ctrl key and select the lower face of the shaft connected to
the motor. The face highlights.
select Force. The Force dialog box opens.
select Plane2
select the lower face

of the shaft
5 In the Type box, click Apply Force/Moment.

6 From the Distribution box, make sure that
Uniform is selected.
8 In the Force box, check Normal to plane
checkbox and enter -150 in its field.
✍ Note that when you check the Normal to
plane checkbox, Plane2 will appear in the force symbols on the lower
Selected Reference field. face of the shaft
9 Click OK. The force is applied.
3-6
Mesh the Assembly
To consider contact in the analysis, you have to set its options before meshing the
model. You can specify global contact conditions that apply to all contacting
faces, and in addition, you can specify contact conditions to selected pairs of
faces. For more information about available contact options in COSMOS/Works,
please refer to Meshing Your Model chapter in the User’s Guide.
In this lesson we will set the default global contact option.
To set a contact condition:

the Contact\Gaps icon. A right-mouse menu
opens.
2 Make sure that Touching Faces: Node to
Node option is checked.
✍ If you want to change the contact condition later on, you have to remesh the
model in order for this change to take effect in the analysis.
To set the meshing preferences:

1 In the COSMOS/Works Manager tree, right-click the Mesh icon and click
Preferences. The Preferences dialog box opens with the Mesh tab selected.
4 In the Mesher Type, select Standard.
6 Click OK.
To mesh the part:

the Mesh icon and click Create. The Mesh dialog
box opens.
2 In the Global Size field, type in 0.5 (inches). The
Tolerance will automatically change to 5% of the
Global Size (0.025).
the program starts meshing the model.

To view the mesh:

right-click the Mesh icon and select
Hide Mesh .
Details to display information about
the mesh.
Run Static Analysis

As noted earlier when defining the properties of the study, contact analysis works
with either the Direct Sparse or the FFEPlus solver. Right-click the Imbalance
icon in the COSMOS/Works Manager tree and select Details to verify this
requirement.

1 In the COSMOS/Works Manager tree, right-click the Imbalance study icon and
click Run. Analysis starts. When the analysis is completed, you will get the
Static Analysis Completed message.
2 Click OK.
Visualizing Static Results

Von Mises stress is calculated from stress components in
various directions. It gives an overall picture for the stress
field on the model.
To plot von Mises stress field:

1 In the COSMOS/Works Manager tree, click the (+)
sign to the left of the Stress icon. The Plot1 icon
appears under the Stress icon.
3-8
2 Double-click the Plot1 icon. Von Mises stresses are plotted as shown.

1 In the COSMOS/Works Manager tree, right-click the Plot1 icon under the
Stress tree and click Animate. The Animation dialog box opens.
3 Click the square button to stop.
✍ You can save your animation as an AVI movie file by checking the Save As
AVI control box.

To plot von Mises stresses on the true deformed shape:

1 Right-click the Plot1 icon and choose Edit Definition.
2 Click the Settings tab.
3 Change the scale to 1.0.
4 Click OK.
5 Click View, Orientation, and double-click *Front.
6 Click the Pin to have the Orientation box available at
all times.
✍ Notice that due to the applied upward force, stresses have developed at the
upper contact of the shaft with the bearing due to compression.
✍ No stress concentration appears at the lower connection since a gap will
develop at the front end as will be illustrated by a section plot.
3-10
Section Plot
To generate a section plot of von Mises stress:

and click Define. The Stress Plot
dialog box opens.
2 On the Properties tab, select psi
from the Stress Units drop-down
menu.
Section.
5 From the Fringe Type menu select Filled, Discrete.
6 Click the Settings tab.
7 In the Boundary Options list box select None.
8 In the Scale Factor field, enter 2000.
9 Click OK.
10 To change the orientation of the model, double-click Isometric in the
Orientation box.
Using the Clipping tool with the

section plot:
2 Right-click the Plot2 icon in
the COSMOS/Works Manager
and click Clipping. The Section
Clipping setting box opens.
3 In the Cut Direction menu,
choose Both.
4 Click OK to close the Section Clipping dialog box.
5 Double-click *Right in the Orientation box. The following plot is generated.

6 Zoom-in to the stress concentration area, the

circles show the contact areas where
compressive stresses develop. The rectangles
show the areas where they separate from each
other and gaps develop between them.
✍ You can create other studies by applying
forces in other directions.
3-12
Lesson 10: Analysis of an Eyebar Assembly

q Define global and local contact conditions.
q Use the symmetrical restraint condition.
q Visualize the stress results.
Fixed
Tensile Pressure
Description
The Eyebar assembly is loaded and supported as shown. We will use a global Node to Node
contact condition on contacting faces to evaluate stress concentrations.
Due to symmetry, we will analyze one quarter of the model with the appropriate boundary
conditions. Since most of the steps are identical to the first example in this chapter, we will
describe them briefly.
Plane of symmetry
Plane of symmetry
No motion normal to the two planes of symmetry.

Chapter 3 Contact Stress Analysis Tutorial n Lesson 10: Analysis of an Eyebar Assembly
Open the Model, Assign Material, and Apply Loads/Restraints

1 Open the QuarterEyeBar assembly located in the Examples\Contact folder of
the COSMOS/Works installation directory.
✍ We recommend that you click File, Save As to save the assembly with a
different name before defining a study so that you can use the original file
again.
2 Start COSMOS/Works Manager.
3 Create a Static analysis study.
Make sure to modify the No normal motion
properties of the study to use the
FFEPlus solver.
4 Assign the default Alloy Steel
from the COSMOS/M Material
Library to both parts.
5 Constrain the 5 flat faces
coinciding with the two planes
of symmetry in the normal
direction.
6 Apply the Immovable restraint to the end of the bolt.
3-14
7 Apply a tensile pressure of -300 psi to the end face of the eyebar part as shown
in the figure.
Immovable Face
300 psi
Mesh the Model

Before we proceed with the meshing of the
model, we need first to specify a contact
condition at the contacting surfaces. We will
define a global contact condition between
the common surfaces of the bolt and the
eyebar as Node to Node contact type.
To define a global contact condition:

In the COSMOS/Works
Contact/Gaps icon and check
Touching Faces: Node to Node.
✍ In order for the specified

contact condition to be
considered when running the
analysis, you should specify
the contact condition before
meshing the model.
1 Right-click the Mesh icon and select Preferences. Use the options shown in
the figure.

Chapter 3 Contact Stress Analysis Tutorial n Lesson 10: Analysis of an Eyebar Assembly
3 Accept the default element size and click OK.
To run the analysis:

To Visualize Stress results:

1 Click the (+) sign to the left of the Stress folder.
2 Right-click the Plot1 icon and select Edit Definition.
3 On the Properties tab, select psi from the Stress Units drop-down menu.
4 Click the Display tab and select P1: Normal stress (1 st principal).
5 Click OK.
6 To change the view of the model, click the Front tool .
Defining Alternative Contact Condition

Instead of choosing a global Touching Faces: Node
to Node contact condition on the contacting faces of
the model, we could have defined, in addition to the
global option, a local Free contact condition
between the two faces shown in the figure. By
making such choice, we implicitly assume that the
selected faces will separate upon applying the
pressure. The advantage of making such choice is
that less computing time is needed to solve such Since these faces will separate when the
problem due to the reduction of the contact pressure is applied, you can define a Free
contact condition between them.
constraint equations.
3-16
Lesson 11: Analysis of Two Contacting Cantilevers
with Rough Surfaces

q Define a Contact/Gaps condition,
q Specify a friction coefficient for use with contact,
q List reaction forces and find out forces developed due to friction,
q Visualize the results.
Fixed 200 psi normal pressure
Fixed
Description
The two cantilevers initially contact each other as shown in the figure. A pressure
is applied to the upper face of the upper cantilever. We will mesh this model with
a global Node to Node contact condition. The lower cantilever will deform under
the action of loads transferred through the contact. The program calculates friction
forces at the faces of contacting elements by multiplying the coefficient of friction
by the corresponding normal forces.
✍ The lower face of the upper cantilever and the upper face of the lower
cantilever are contacting each other partially. COSMOS/Works automatically
takes care of this situation by generating compatible meshes on the contacting
portions of the two faces.

Chapter 3 Contact Stress Analysis Tutorial n Lesson 11: Analysis of Two Contacting Cantilevers with Rough
Open the Model, Assign Material, and Apply Loads/Restraints

1 Open the Friction assembly located in the Examples\Contact folder of the
COSMOS/Works installation directory.
✍ We recommend that you click File, Save As to save the assembly with a
different name before defining a study so that you can use the original file
again.
2 Create a Static analysis
study.
3 Make sure to modify the
properties of the study to
activate the Include Friction
flag and enter 0.05 in the
Friction Coefficient field.
Also make sure to use the
Direct Sparse solver.
✍ You can use the FFEPlus

solver in cases where each
part is adequately restrained
(stable) without considering
the contact condition. The
FFE solver cannot be used
with contact problems.
4 Assign the default Alloy Steel
from the COSMOS/M
Material Library to both
parts.
5 Fix the two far faces of the cantilevers.
6 Apply a normal pressure of 200 psi to the upper face of the upper cantilever.
3-18
Mesh the Assembly
To define a contact option on the

contacting faces:
In the COSMOS/Works
Contact/Gaps icon and select
Touching Faces: Node to Node.
✍ Only portions of the two

faces are in contact. For
proper representation of the
contact condition, the
mesher treats the contacting
portions as if they were
separate faces.

1 Right-click the Mesh icon
and select Preferences. Use the
options shown in the figure.
select Create.
3 In the Global Size field, enter
1.0 inches.
✍ If your preferred unit of length is not inches, make sure to enter an global
size equivalent to 1.0 inch.
4 Click OK.


To visualize stress results:

1 Click the (+) sign to the left of the Stress folder.
2 Double-click the Plot1 icon in the Stress folder.
Gap
Contact
To visualize displacement results:

1 Click the (+) sign to the left of the Displacement folder.
2 Double-click the Plot1 icon in the Displacement folder.
3-20
Reaction Forces
Friction forces should develop reaction forces in the Z-direction at the supports.
To view the X, Y, and Z directions: Y
1 Click the FeatureManager tab. X
2 Click Plane1. The global X, Y, and
Z directions are illustrated in the
figure.
To list reaction forces: Z

1 Select the left support.
2 Right-click the Displacement folder and
select Reaction Forces.
3 From the Units drop-down menu, select lb.
4 Click the Update button.
5 Select the right support.
Reaction forces at the left support
7 Select both supports.
The total applied force is 200 psi times 80 in2 = 16,000

Pounds (lbs) in the negative Y-direction. Notice that the
upward reactions at the left and right supports are
11,057 and 4,943.3 lbs, respectively. A Z-force of about
247.3 lbs develops at both supports due to friction.
Reaction forces at the right support

✍ Small unbalanced forces develop in the
model due to approximations and
numerical round-off errors. For example,
you can see that, for the entire model,
there is an unbalanced Z-force of -
0.00021958 lbs, and an unbalanced X-
force of 5.4894e-5 lbs.
Reaction forces with both supports

Results of a Similar Study Without Friction
To remove friction:
1 Right-click the study icon and select Properties.
2 Uncheck the Include Friction checkbox.
3 Right-click the study icon and select Run. The stress and displacement results
without friction are shown below.
3-22
4
Importing Motion Loads
Introduction
Many products contain moving assemblies of components (mechanisms).
Mechanisms play a crucial role in the performance of such products. Dynamic
Designer/Motion is a design software produced by Mechanical Dynamics, Inc. for
the simulation of mechanical systems. Embedded in SolidWorks, it enables
designers to model 3D mechanisms as virtual prototypes.
After making sure that the mechanism is working properly in Dynamic Designer/
Motion, you naturally want to make sure that the parts of the assembly are safe
under the action of the loads generated by the specified motion. COSMOS/Works
can automatically import motion loads from the Dynamic Designer/Motion for
SolidWorks. This chapter presents a step-by-step lesson on how to define a
motion in Dynamic Designer/Motion and run static analysis based on importing
motion loads from Dynamic Designer /Motion.
This example is intended to provide you with a self-contained document for using
Dynamic Designer/Motion for the purpose of calculating motion loads to be used
by COSMOS/Works. For formal description of the capabilities of Dynamic
Designer /Motion, please refer to the Dynamic Designer/Motion for
SolidWorks User ’s Guide and the corresponding on-line help.
✍ To be able to import motion loads to COSMOS/Works, you must install
Dynamic Designer/Motion on your system. For more information about
Dynamic Designer/Motion, please contact your sales representative at
Structural Research and Analysis Corporation.

Chapter 4 Importing Motion Loads n Lesson 12: Importing Motion Loads from Dynamic Designer/Motion
Lesson 12: Importing Motion Loads from Dynamic

Designer/Motion
In this lesson you will learn how to:

q Open the landing gear assembly,
q Switch to the Dynamic Designer/Motion environment,
q Define moving and grounded parts,
q Define motion,
q Run the simulation,
q Export motion results to a spreadsheet, and
q Transfer the motion loads to COSMOS/Works to perform static analysis and
visualize the results.
Description
In this tutorial, we will show you how to use Dynamic
Designer/Motion and COSMOS/Works to analyze a
landing gear assembly mechanism. The landing gear
mechanism is part of a retractable nose wheel of a
conceptual light aircraft. The main purpose of the
mechanism is to bring the gear down to a locked position.
The locked position is controlled by a diagonal bracing
which, when fully extended, has an electro-mechanical
latch to lock it in position. In real-life, the pilot activates a
switch to release this latch and a pre-loaded spring ensures Link Arm
that the diagonal brace retracts to the initial position. The
actuator can retract the under carriage only when the
diagonal brace is free to move. Dynamic loads induced by
this motion will be automatically transferred to COSMOS/
Works to perform design analysis.
We will calculate the stresses that develop in the link arm due to motion loads. To
demonstrate the tight integration between Solid/Works, Dynamic Designer/
Motion, and COSMOS/Works, we will modify the part and repeat the motion and
design simulations after modifying the geometry.
4-2
✍ The magnitudes of the loads generated by the moving mechanism may not be
significant compared to loads caused by the impact of landing. You can create
another study to simulate the impact of landing.
Load the Landing Gear Model
To load the landing gear assembly file:

1 Start SolidWorks.
3 Navigate to the folder ...\Examples\Motion, where “...” refers the COSMOS/
4 Change the Files of type field to Assembly Files (*.asm; *.sldasm).
5 Select the landing_gear.SLDASM file, and click Open.

✍ Make sure that the Motion menu appears on

SolidWorks menu bar. if you do not see it,
click Tools, Add-Ins. In the Add-Ins dialog
box, check Dynamic Designer Motion
checkbox and click OK. When Dynamic
Designer Motion is loaded successfully, a tab
will be added at the lower left corner of
the SolidWorks window.
Define Moving and Grounded Parts

Now we will build the joints and other motion entities for the mechanism in
Dynamic Designer.
To start the IntelliMotion browser:

Click the Dynamic Designer/Motion tab located at the lower left corner of the
SolidWorks window.
To define grounded and moving parts:

1 In the IntelliMotion browser, select mount1-1,
mount2-1, and mount3-1 parts.
2 Right-click the selected parts and click Ground Part.
3 Select the remaining parts, click the right button of
the mouse, and select Moving Part.
Define Actuator Motion

We will specify a motion to the Actuator part.
To define motion to the Actuator:

1 Click the (+) sign to the left of the Actuator-1
part to show its contents.
2 Double-click the Concentric7 cylindrical joint.
This will take you to the Joints folder in the
IntelliMotion browser.
4-4
3 In the Joints folder, right-click the
Concentric7 folder and select
Properties. The Edit Mate-Defined
Joint dialog box opens with the
Motion tab selected.
4 In the Motion On field, select
Translate Z.
5 In the Motion Type field, select
Displacement.
6 Select Harmonic as a function type for
the motion from the Function menu.
7 Enter the following numerical values
in the corresponding fields.:
• -90 (mm) in the Amplitude field,
• 9 (deg/sec) in the Frequency field,
• 0 (sec) in the Time Offset field,
• 90 (sec) in the Phase Shift field, and
• -90 (mm) in the Average field.
8 Click to accept the entries.
9 Click to apply the motion.

Run the Motion Simulation
To set the simulation options:

1 On SolidWorks menu bar, click
Motion, Toolbar. The
Simulation toolbar opens.
2 Click . The Dynamic
Designer Options dialog box
opens with the Simulation tab
selected.
3 In the Simulation Parameters
box, select Duration from the
menu, and enter 40 (sec) in its
field.
4 In the Number of Frames field,
enter 60.
5 Click OK to accept other default
settings.
To run the motion simulation:

Click the simulation button to start the simulation. To close the Simulation
toolbar, click .
4-6
Export the Results to Spreadsheet
To export the motion results

to a spreadsheet:
1 On the SolidWorks menu
bar, click Motion,
Export Results, To
Spreadsheet. The
Export Results to Excel
dialog box opens.
2 In the Elements with
Results list box, click the
(+) sign to the left of the
Concentric7 folder (at
the bottom of the list)
and select TranslateZ
Motion.
3 In the Results
Characteristics list box select Force.
4 From the Components list box, select Magnitude.
5 Optional: Enter a name for the plot in the Title field, for example, Force.
6 Click the Add 1 Curves button.

7 Click OK. The selected results will be plotted in Excel.
✍ Microsoft Excel is required for plotting the curve. However, you still can
transfer loads even if you don’t have EXCEL.
Export Motion Loads to COSMOS/Works

Next, we will export the motion loads developed in the model to COSMOS/
Works for analysis. However, we need to select a particular time instant at which
the loads are to be transferred to COSMOS/Works.
To export the motion loads to COSMOS/Works:

1 Click Motion, Toolbar. The
Simulation toolbar opens.
2 Drag the slider to frame
number 16 (corresponds to
10 sec).
3 On SolidWorks menu bar, click Motion, Export Results, To COSMOS/Works.
The Unassigned Load Entities dialog box opens. Click the Derive Joint Load
Entities from Mates button, and then click OK.
4 In the Save As dialog box, select the COSMOS/Works working directory to
save the load information file landing_gear_16.txt.
4-8
5 Click the simulation button to delete the results and return to the initial
position.
6 Close the simulation toolbar and save the assembly.
Read the Load File into COSMOS/Works
To import the motion loads to COSMOS/Works:

1 On the SolidWorks menu bar, click COSMOS/Works, Import Motion Loads.
The Open dialog box opens.
2 Select the load information file generated in the previous step (i.e., the
landing_gear_16.txt file) and click Open.
3 In the Available Loads list, actu_pist-1:Body Forces will be selected. Click it

to deselect it, and then click link_arm-1:Body Forces.
4 Click to move the link_arm-1:Body Forces to the Selected Loads list
box.
5 Click OK to close the Import Motion Loads dialog box.
Open the Part in COSMOS/Works

1 Click the FeatureManager tab.
2 Right-click the link_arm<1> icon and select Open link_arm.sldprt. The part
will be opened in the graphics area.

3 Click the COSMOS/Works Manager tab. You will see study Frame-16 with
gravity and centrifugal load already applied to the part. This study was created
automatically when you imported the motion load file to COSMOS/Works.
Define Materials
We will apply Plain Carbon Steel to the link arm part. Right-click the link_arm
material icon and select Apply/Edit Material. In the Material dialog box, select
Plain Carbon Steel from the Material Name list box and click OK.
Apply Restraints
We will fix the two cylindrical faces of
the link arm.
To fix the inner cylindrical faces:
1 Select the two faces as shown in the
Fix these two faces
figure.
3 In the Restraints dialog box, select Fixed.
4 Click OK.
4-10
Create the Mesh
To set the mesh preferences:

4 In the Mesh Control box, check Smooth Surface.
5 From the Jacobian Check menu, make sure that 4 Points in selected.
6 Click OK.
To mesh the part:

Right-click the Mesh icon and select Create. In the Mesh dialog box, click OK to
accept the element size suggested by the program.
Run the Analysis

Right-click the Frame-16 study icon and select Run. When the analysis is
completed, click OK to close the message window.
To plot stress results:

1 Click the (+) sign next to the Stress folder.
2 Double-click the Plot1 icon to generate the stress plot.

To animate stress results:

1 Right-click the Plot1 icon under Stress folder and select Animate.
2 In the Animation dialog box click the Play button to start the animation.

1 In the COSMOS/Works Manager, click the (+) sign next to the Displacement
folder.
2 Double-click the Plot1 icon to generate a displacement plot.
Modify the Link Arm Part

We will modify the link arm part by creating a cut through the part’s thickness.
To modify the part:

1 Switch to the SolidWorks environment
by clicking the FeatureManager tab.
2 Right-click the Mirror1 icon and select
Suppress.
3 Right-click the Cut Extrude 1 icon and
select Edit Definition. The Cut
Extrude Feature dialog box opens.
4 From the Type menu, select Through
All.
5 Click OK.
The assembly rebuilds
6 Switch to the landing_gear assembly with the new changes
document. Click Yes to rebuild the
assembly with the new changes.
4-12
Run the Motion Analysis with the Modified Geometry
To rerun the analysis with the modified assembly:

1 On the SolidWorks menu bar click Motion, Toolbar. The Simulation toolbar
opens.
2 Click the simulation button to run the simulation.
3 In the simulation toolbar, drag the slider to frame number 16 and click Motion,
Export Results to COSMOS/Works.
4 In the Save As dialog box, browse to the COSMOS/Works working directory
and click Save.
5 Click the simulation button to delete the results and return to the initial
position.
Export Motion Loads to COSMOS/Works

To transfer the motion loads to COSMOS/Works:
1 Click COSMOS/Works, Import Motion Loads. The Open dialog box opens.
2 Select the load file saved in the previous step and click Open.
3 In the Import Motion Loads dialog box, change the study name to Frame-16
Modified.
4 In the Available Loads list box, click the link_arm-1: Body Forces and move it
to the Selected Loads list box.
5 In the Selected Loads list box, click actu_pist-1:Body Forces and move it to
the Available Loads list box.
6 Click OK.

Analyze the Part in COSMOS/Works

1 Click the FeatureManager tab.
2 Right-click the link_arm<1> icon and select Open link_arm.sldprt. The part
will be opened in SolidWorks graphics area.
3 Click the COSMOS/Works Manager toggle icon. You will see the study
Frame-16-Modified with gravity and centrifugal loads already applied to the
part.
To assign material properties to the part:

1 Open the Frame-16 study folder and select the Solids folder.
2 Drag and drop it onto the Frame-16-Modified study folder.
Apply Restraints
To fix the faces of the holes:
1 Select the faces of the holes.
3 In the Restraints dialog box, select Fixed.
4 Click OK.
4-14
To mesh the model:
Right-click the Mesh icon and select Create. Click OK to accept the default
element size and tolerance suggested by the program.

Right-click the Frame-16-Modified study icon and select Run. After the analysis is
To visualize the stress results:

1 Click the (+) sign to the left of the Stress folder under the Frame-16-modified
study.
2 Double-click the Plot1 icon. Compare the results with respect to Frame-16
study.

5
Frequency Analysis Tutorial
This chapter presents step-by-step lessons for performing frequency analysis.

q Lesson 13: Frequency Analysis of a Bracket Part
q Lesson 14: Frequency Analysis of a Crank Assembly

Chapter 5 Frequency Analysis Tutorial n Lesson 13: Frequency Analysis of a Bracket Part
Lesson 13: Frequency Analysis of a Bracket Part
Frequency analysis, also known as modal or dynamic analysis, calculates the

resonant (natural) frequencies and the corresponding mode shapes.
q Visualize the frequency analysis results.
Retrieve the Part

1 Start SolidWorks.
2 Click File, Open. The Open dialog box
opens.
3 Change the Look in folder to ...\Examples
where “...” refers to the COSMOS/Works
installation folder.
4 From the Files of type drop-down list,
select Part Files (*.prt; *.sldprt).
5 Double-click the Tutor1.prt
part file. The part file opens.
6 Verify that COSMOS/Works
appears in the top menu bar of
SolidWorks.
✍ If you do not see the
COSMOS/Works menu,
click Tools, Add-ins, then
click the checkbox for
COSMOS/Works and click
OK.
5-2
✍ We recommend that you use File, Save As to save the part with a different
Create a Frequency Analysis Study

study. We will use the COSMOS/Works Manager to define and manage all
aspects of the study.

Click the COSMOS/Works Manager icon located at COSMOS/Works Manager
the lower left corner of the window.
✍ To return to the FeatureManager design tree,
click the FeatureManager icon .
To create a frequency analysis study:

1 Right-click the Tutor1 part icon and select Study.
3 In the New Study field, type in a name for the
study, for example, Freq-1.
4 From the Analysis Type drop-down list, select
Frequency.
5 In the Mesh Type box, click Solid.
6 Click the OK button to return to the Study dialog box.
7 Click OK.

Assign Material Properties
Assign Material

1 In the COSMOS/Works Manager tree, right-click the Tutor1 icon under Solids
folder and select Apply/Edit Material. The Material dialog box opens with the
COSMOS/M Library tab selected.
2 From the Material Type drop-down menu, verify that Steel is selected.
3 In the Material Name list box, verify that Alloy Steel is selected.
4 Click OK.
Apply Restraints
To fix the two holes:

1 Select the face of one hole. Press and hold down the Ctrl key and select the face
of the other hole.
select Restraints. The Restraints dialog box opens.
3 From the Type box, select Immovable.
4 Click OK.
Mesh the Part

1 In the COSMOS/Works Manager tree, right-click the Mesh icon and click
Preferences. The Preferences dialog box opens with the Mesh tab selected.
2 In the Mesh Quality box, click High.
5 Make sure that 4 Points is selected from the Jacobian Check menu.
6 Click OK.
5-4
To mesh the part:
1 Right-click the Mesh icon and select Create. The Mesh dialog box opens and
an average element size is suggested.
2 Click OK to accept the default element size. After meshing is completed, you
will get the Solid mesh completed message.
3 Click OK. A checkmark appears on the Mesh icon.

right-click the Mesh icon and select
Show Mesh. The mesh is displayed in
the SolidWorks window.
2 Right-click the Mesh icon again and
click Hide Mesh to hide the mesh.
Details to display information about
the mesh.
Run Frequency Analysis
To run frequency analysis:

1 Right-click the Freq-1 study icon and click Run. The analysis starts. When the
analysis is completed, you will get the Frequency Analysis Completed
message.
2 Click OK.

List and Visualize the Frequency Analysis Results
To list frequency results:

Click COSMOS/Works, List Results, Mode Shape. The following list will be
displayed.
To plot the fundamental mode shape:

1 Click the (+) sign to the left of the
Deformation folder. The Plot1 icon
appears.
To plot other mode shapes:

right-click the Deformation folder
under the Freq-1 study and select
Define. The Deformed Shape Plot
dialog box opens.
2 In the Mode Shape No. field, enter 2,
3, etc., to plot other mode shapes.
3 Click OK.
5-6

Chapter 5 Frequency Analysis Tutorial n Lesson 13: Frequency Analysis of a Crank Assembly
Lesson 13: Frequency Analysis of a Crank Assembly

q Visualize the frequency analysis results.
Retrieve the Part

1 Start Solid Works.
Works installation directory.
4 In the Files of type field, select Assembly Files (*.asm; *.sldasm).
5 Double-click the Crank.ASM assembly file.
✍ If you do not see the COSMOS/Works menu, click Tools, Add-ins, then check
the control box for COSMOS/Works and click OK.
Create a Frequency Analysis Study
To create a frequency analysis study:

2 Right-click the Crank icon, and click Study. The Study dialog box opens.
4 In the New Study field, type in a name for the study, for example, Freq-2.
5 From the Analysis Type menu, select Frequency.
6 Click OK to return to the Study dialog box.
7 Click OK.
5-8
To assign material to the CrankPulley-1 part:

1 Right-click the CrankPulley-1 icon and select Apply/Edit Material. The
2 From the Material Type menu, select Iron.
3 From the Material Name list box, select Gray Cast Iron.
4 Click OK.
To assign materials to the other parts:

Repeat the steps above to assign the following materials:
• Stainless Steel (ferretic) to CrankArmAxle-1, and
• Alloy Steel to CrankArm-1 and CrankArm-2.
Apply Restraints
To apply loads and restraints to the assembly:

1 Select the outer cylindrical face of the pulley.
2 Right-click the Load/Restraint folder and select
Restraints. The Restraints dialog box opens.
3 In the Type box, select Immovable (No
Translation).
4 Click OK.
Mesh the Assembly
To set the meshing properties:

6 Click OK.

Chapter 5 Frequency Analysis Tutorial n Lesson 13: Frequency Analysis of a Crank Assembly

1 Right-click the Mesh icon and select Create. The
Mesh dialog box opens.
3 Click Ok. When the meshing is completed, you
will get the Solid Mesh completed message.
4 Click OK.
Run the Frequency Analysis
To run frequency analysis:

Right-click the Freq-2 study, and select Run. The analysis starts. After completing
the analysis, the program creates two folders for the Displacement and the
Deformation in the Freq-2 study.
List and Visualize the Frequency Analysis Results
To list the frequencies:

1 Click COSMOS/Works, List Results, Mode Shape. The Mode Shape window
opens and lists the frequencies.
2 Click Close to close the window.
5-10
To plot the first mode:
Deformation folder of Freq-2 study.

6
Buckling Analysis Tutorial
This chapter presents step-by-step lessons for performing buckling analysis.

q Lesson 15: Buckling of Thin Plates Using Shell Elements
q Lesson 16: Buckling Analysis of a Bar
q Lesson 17: Buckling Analysis of a Bracket

Chapter 6 Buckling Analysis Tutorial n Lesson 15: Buckling of Thin Plates (Shell Models)
Lesson 15: Buckling of Thin Plates (Shell Models)
Buckling analysis calculates the buckling (critical) load factors and the
corresponding buckling modes.
q Use different ways of shell modeling,
q Create the shells,
q Assign material and thickness to the shells,
q Apply restraints and loads to shells,
q Mesh the shells,
q Run buckling analysis,
q Visualize the buckling analysis results by listing critical load factors and
plotting buckling modes.
Description of the Problem

Three rectangular plates 10” x 2” are connected as shown in the figure. The
central plate has a thickness of 0.4”. Each of the other two plates has a thickness
of 0.2”.
0.4” thickness
0.2” thickness
6-2
Shell Modeling Options
COSMOS/Works offers 3 different procedures to create shell models.
First Option: Shell Using Midsurfaces

This option requires the creation of a solid model and creating a study selecting
the Shell Using Midsurfaces option. The program extracts midsurfaces and
assigns thicknesses of different shells automatically. Only one material can be
assigned to the part. This option is not available for assemblies. The midsurface of
a generated shell element coincides with the associated extracted midsurface. We
recommend this option for sheet metals and simple thin parts.
Second Option: Shell Using Faces of a Solid

This option also requires the creation of a solid part or assembly and creating a
study selecting the Shell Using Surfaces option. You can select the faces to be
meshed and assign the desired thicknesses and materials. Adjacent shells are
bonded automatically. The midsurface of a generated shell element coincides with
the associated face.
Third Option: Shell Using a Surface Model

This option requires the creation of a surface model and creating a study selecting
the Shell Using Surfaces option. You can select the faces to be meshed and assign
the desired thicknesses and materials. Adjacent shells are bonded automatically.
The midsurface of a generated shell element coincides with the associated
surface.

Chapter 6 Buckling Analysis Tutorial n First Option: Using Midsurfaces
First Option: Using Midsurfaces
Retrieve the Part

4 From the Files of type drop-down list, select Part Files (*.prt; *.sldprt).
5 Double-click the 3plates-midsurfaces part file.

Click the COSMOS/Works Manager icon located at the lower left corner of
Solid Works window.
Define a Buckling Analysis Study

To define a buckling analysis study:
1 Right-click the 3plates-midsurfaces icon and
select Study. The Study dialog box opens.
study, for example, Buckling-1.
4 From the Analysis Type menu, click Buckling.
5 In the Mesh Type box, select Shells using
midsurfaces.
6 Click OK. The new study name appears in the
Studies list box.
7 Click OK.
6-4

1 Right-click the 3plates-midsurfaces icon in the Solids folder and select Apply/
Edit Material. The Material dialog box opens with the COSMOS/M Library tab
selected.
2 From the Material Type menu, verify that Steel is selected.
4 Click OK.

In this tutorial, we will fix one end and apply a force of 100 Pounds to the other
end.
Apply 100 Pound

Force on this face
Fix this face
To fix the left end:

1 Select the left end face as shown in the figure.
2 Right-click the Load/Restraint icon and select Restraints. The Restraints
dialog box opens.
3 In the Type box, select Fixed.
4 Click OK.
To apply the force:

1 Select the right end face as shown above.
2 Right-click the Load/Restraint icon and select Force. The Force dialog box
opens.
3 In the Type box, check Apply Normal Force.
4 From the Distribution box, check Uniform.


6 In the Value field, enter 100 to apply 100 Pounds.
7 Click OK.
Mesh the Part

1 Right-click the Mesh icon and select Preferences. The Preference dialog box
6 Click OK.
To mesh the part:

an average element size of 0.37808 inches is suggested.
2 Click OK. After meshing is completed, you will get the Shell Mesh Completed
message.
3 Click OK. Meshing starts.
4 Click OK when meshing is completed.
To align the shells:

1 Right-click the Mesh icon and select Show Mesh. The mesh is displayed in the
SolidWorks window.
Flip this face
After flipping
2 Select the left shell.
6-6
3 Right-click the Mesh icon and select Flip Shell Elements.
of SolidWorks that you are using. You need to align all shells before running
the analysis.
4 Right-click the Mesh icon and select Hide Mesh to hide the mesh.
Run Buckling Analysis

To run buckling analysis:
1 In the COSMOS/Works Manager tree, right-click the Buckling-1 study icon
and select Run. Analysis starts. When the analysis is completed, you will get
the Buckling Analysis Completed message.
2 Click OK when analysis is completed.
List and Visualize Buckling Results
To list buckling results:

1 Click COSMOS/Works, List Results, Mode shape. The buckling load factor is
listed as 1.54
2 Click Close to close the Mode Shape list box.
To plot the buckling mode:

Deformation icon.
To animate the mode shape:

1 Right-click the Plot1 icon under the Deformation folder and select Animate.
The Animation dialog box opens.
✍ You can save the animation as an AVI file and view it with the Media Player
by checking the corresponding checkboxes.

Calculate the Buckling Load

The buckling load factor (BLF) is defined as the ratio of the critical buckling load
to the applied loading. You can think of the BLF as a factor of safety against
buckling. A BLF less than unity indicates that the model is not safe under the
specified loading. The following table illustrates the interpretation of possible
BLF values.
BLF Value Buckling Status Notes

1 < BLF COSMOS/Works does The applied loading is less than the
not predict buckling. estimated critical loading.
0 < BLF < 1 COSMOS/Works The applied loading exceeds the
predicts buckling to estimated critical loading.
occur.
BLF = 1 COSMOS/Works The applied loading is equal to the
predicts buckling to estimated critical loading.
occur.
BLF = -1 COSMOS/Works does COSMOS/Works will predict buckling
not predict buckling. if you reverse the direction of loading.
-1 < BLF < COSMOS/Works does COSMOS/Works would predict
0 not predict buckling. buckling if you were to reverse the
direction of loading.
BLF < -1 COSMOS/Works does COSMOS/Works will not predict
not predict buckling. buckling even if you reverse the
direction of loading.
To calculate the buckling load:

Critical load factor = 1.54
Critical buckling load = 100 (applied force) x 1.54
= 154 Pounds
6-8
Second Option: Using Faces of a Solid
Retrieve the Part

5 Double-click the 3plates-faces part file.

Solid Works window.

1 Right-click the 3plates-faces icon and select
Study. The Study dialog box opens.

4 From the Analysis Type menu, select Buckling.
5 In the Mesh Type box, select Shell using surfaces.
6 Click OK. The new study name appears in the Studies list box.
7 Click OK.

Chapter 6 Buckling Analysis Tutorial n Second Option: Using Faces of a Solid
Define the Shells
To define the 3 shells:

1 Select the 3 faces shown in the figure.
2 Right-click the Shells folder icon in the COSMOS/Works Manager tree and
select Define by Selected Surfaces. The Define Shell dialog box opens.
Select these 3 faces
This dimension is
irrelevant
3 From the Units drop-down menu, select in (Inches).

4 In the Value field, type in 0.2.
5 Click OK. The program creates an icon for each of the 3 faces in the Shells
folder.
To modify thickness of the middle shell:

1 In the Shells folder, click the Shell-2 icon. The middle shell highlights.
2 Right-click the Shell-2 icon and select Edit Definition.
5 Click OK. The program changes the thickness of the middle shell from 0.2” to
0.4”.

1 Right-click the Shells folder icon and select Apply Material to All. The
4 Click OK.
✍ You can assign a different material to each shell.
6-10
Applying loads and restraints on the end faces, as performed in the midsurface
study, will not work with this option. We will apply the restraint and force to the
edges of the shells instead as follows:
To fix the left edge:

1 Select the left edge of left shell as shown in the figure.
2 Right-click the Load/Restraint icon and select Restraints.
The Restraints dialog box opens.
✍ Notice that the Selected Entities box lists the number of
selected faces, edges and vertices. In this case, one edge is
selected.
4 Click OK.
To apply the force:

1 Select the right edge of the right shell face as shown in the
figure.
2 Right-click the Load/Restraint icon and select Force. The
Force dialog box opens.
3 From the Units drop-down menu, select English (IPS).
4 Click the Along plane Dir1 (of Plane 1) checkbox and enter -100 in its field.
5 Click OK.
Mesh the Part, Run the Analysis, and Visualize the Results
The rest of the steps are similar to the previous study:

1 To mesh the part, right-click the Mesh folder icon and select Create. Use the
default global element size of 0.74002”.
2 Right-click the Mesh icon and select Show Mesh. If needed, align the shell
elements by selecting the misaligned face, right-clicking the Mesh icon, and
selecting Flip Shell Elements.
3 Right-click the Mesh icon and select Hide Mesh.
4 To run buckling analysis, right-click the study folder and select Run.

Chapter 6 Buckling Analysis Tutorial n Third Option: Using Reference Surfaces
5 When analysis is completed, click OK.

6 To list buckling results, click COSMOS/Works, List Results, Mode Shape. The
buckling load factor is listed as 1.54.
✍ The small difference in the result is due to differences in geometry modeling
and the default global element size used in meshing. The default global
element size in the this case is almost twice the default global element size in
the first case. The results indicate that the solution has converged to the
correct answer.
Third Option: Using Reference Surfaces
Retrieve the Part

2 Click File, Open. The Open dialog
box opens.
3 Change the Look in folder to
...\Examples where “...” refers to the
COSMOS/Works installation folder.
4 From the Files of type drop-down
The model consists
list, select Part Files (*.prt; *.sldprt). of 3 surfaces
5 Double-click the 3plates-surfaces
part file. The part is made up of 3
reference surfaces.
6 Click the surfaces to identify the 3 surfaces.

Solid Works window.
6-12

1 Right-click the 3plates-Surfaces icon and select

4 From the Analysis Type menu, select Buckling.
5 In the Mesh Type box, select Shell using surfaces.
7 Click OK.
Define the Shells
To define the 3 shells:

1 Right-click the Shells folder icon in the COSMOS/Works Manager tree and
select Define by All Ref Surfaces . The Define Shell dialog box opens.

4 Click OK. The program creates an icon for each of the 3 surfaces in the Shells
folder.
To modify thickness of the middle shell:

1 In the Shells folder, click the Shell-3 icon. The middle shell highlights.
2 Right-click the Shell-3 icon and select Edit Definition.

Chapter 6 Buckling Analysis Tutorial n Third Option: Using Reference Surfaces

5 Click OK. The program changes the thickness of the middle shell from 0.2” to
0.4”.

1 Right-click the Shells folder icon and select Apply Material to All. The
4 Click OK.
✍ You can assign a different material to each shell.

We will apply the restraint and force to the edges as follows:
To fix the left edge:

1 Select the left edge of left shell
as shown in the figure. Apply 100 Pounds
on This Edge
icon and select Restraints. The
Restraints dialog box opens.
✍ Notice that the Selected
Entities box lists the number
of selected faces, edges and
vertices. In this case, one edge
is selected.
4 Click OK. Fix This Edge
To apply the force:

1 Select the right edge of the right shell face as shown in the figure above.
2 Right-click the Load/Restraint icon and select Force. The Force dialog box
opens.
6-14
4 Click the Normal to plane (Plane 1) checkbox and enter -100 in its field.
5 Click OK.
Mesh the Part, Run the Analysis, and Visualize the Results
The rest of the steps are similar to the previous study:

1 To mesh the part, right-click the Mesh folder icon and select Create. Use the
default global element size of 0.23238”.
2 Right-click the Mesh icon and select Show Mesh. If needed, align the shell
elements by selecting the misaligned surface, right-clicking the Mesh icon, and
selecting Flip Shell Elements.
✍ You can specify a global element size larger than the default. We have seen
in the previous studies that element sizes of about 0.38 and 0.74 inches
gave similar results.
3 Right-click the Mesh icon and select Hide Mesh.
4 To run buckling analysis, right-click the study folder and select Run. When
analysis is completed, click OK.
5 To list buckling results, click COSMOS/Works, List Results, Mode shape. The
buckling load factor is listed as 1.5332.
✍ The small difference in the result is due to differences in geometry modeling
and the default global element size used in meshing. The default global
element size in the this case is smaller than the default global element sizes in
the first and second studies. The results indicate that the solution has
converged to the correct answer.

Lesson 16: Buckling Analysis of a Bar

q Verify the dimensions of your model,
q Create a buckling analysis study,
q Apply loads and boundary conditions,
q Mesh the part, and
q Visualize the buckling analysis results, and calculate the buckling load.
Fixed end
Bar dimensions are 1”X1”X20”
1,000
pound
force
Opening the Bar Part
To open the part:

1 Start SolidWorks.
2 From the File menu, click Open.
4 Click the Examples folder.
5 Choose the Bar.SLDPRT file.
6 Click Open.

Verifying the Dimensions of the Model
We recommend that you verify the dimensions of your model before creating
analysis studies.
To verify the length of the bar:

1 Select one of the long edges of the bar.
2 Click Tools, Measure. The length should be 20 inches.
3 Close the Measure dialog box.
4 Verify that the cross section is 1 inch by 1 inch.
Creating a Buckling Analysis Study

study.
To create a buckling analysis study:

1 In the menu bar, click COSMOS/Works, Study.
- or -
In the COSMOS/Works Manager, right-click the Bar icon in the Solids folder
and select Study. The Study dialog box opens.
3 In the New Study field, type in the name of the study, for example, Buckling
Study.
4 From the Analysis Type drop-down menu, choose Buckling.
5 In the Mesh Type box, select Solid.
6 Click OK. The new study name appears in the studies list box.
7 Click OK.

Chapter 6 Buckling Analysis Tutorial n Lesson 16: Buckling Analysis of a Bar
Assigning Material

1 In the COSMOS/Works Manager, right-click the Bar icon and select Apply/Edit
Material.
2 Click the COSMOS/M Library tab.
3 From the Material Type drop-down menu, select Steel.
4 From the Material Name list box select Alloy Steel.
5 Click OK.
✍ Notice the checkmark that appears on the part icon indicating that you have
assigned a material to the part successfully.
Defining Loads and Boundary Conditions

We will fix one end of the bar and apply a 1,000 pound force to the other end.
To apply a uniform force to the right end of the bar:

1 Select the face at the right end of the bar.
2 Right-click the Loads/Restraint folder and select Force.
3 In the Type box, check the Apply Normal Force option.
4 From the Distribution box, make sure that Uniform is selected.
6 In the Value field, enter 1000 to apply a compressive 1,000 pound force.
7 Click OK.
To fix the left end of the bar:

1 Rotate the bar to make the left end visible.
2 Select the face at the left end of the bar.
dialog box opens.
5 Click OK.
6-18
Meshing the Model

5 Make sure that 16 Points is selected in the Jacobian Check drop-down menu.
6 Click OK.
To mesh the part:

2 Drag the slider to the extreme left to use an element size that is twice as the
suggested size.
3 Click OK. When meshing is completed, click OK.

select Show Mesh.
select Hide Mesh to hide the
mesh.
You are now ready to run buckling
analysis.

Chapter 6 Buckling Analysis Tutorial n Lesson 16: Buckling Analysis of a Bar
Running Buckling Analysis

1 Right-click the Buckling Study icon. A right-mouse menu opens.
2 Click Run. Analysis starts. When analysis is completed, click OK.
Visualizing the Results of Buckling Analysis

Double-click the Plot1 icon in the
Deformation folder.
To list the buckling load factor:

Click COSMOS/Works, List Results, Mode
Shape .
Buckling Load Factor

buckling. A positive BLF less than unity indicates that the model is not safe under
the specified loading.

BLF = 15.678
Estimated buckling load = (BLF) (Applied Loading)
= 15.678 x 1000 = 15,678 pound force
Theoretical buckling load
(Euler’s buckling load) = (π)2 (EI)/(4L2) = 15,421 Pound force
Where
L = 20 inches
E = Modulus of Elasticity = 30e7 psi
I = moment of inertia of the cross section = 14/12 in4
Error = 1.67%
6-20
Lesson 17: Buckling Analysis of a Bracket Part
Buckling analysis calculates the buckling (critical) load factors and the
corresponding buckling modes.
q Retrieve a part and create a buckling analysis study,
q Mesh the part,
q Visualize the buckling analysis results by listing critical load factors and
plotting buckling modes, and
q Remesh the part with mesh controls, rerun the analysis, and compare the
results.
Retrieve the Part

5 Double-click the Tutor2 part file.

Solid Works window.

Chapter 6 Buckling Analysis Tutorial n Lesson 17: Buckling Analysis of a Bracket Part
Create a Buckling Analysis Study
To create a buckling analysis study:

1 Right-click the Tutor2 icon and select Study. The Study dialog box opens.
3 In the New Study field, type in a name for the study, for example, Buckling-1.
4 From the Analysis Type menu, click Buckling.
7 Click OK.
Preprocessing

1 Right-click the Tutor2 icon in the Solids folder and select Apply/Edit Material.
4 Click OK. Apply
pressure
normal to
this face
In this tutorial, we will fix the hole and the
face shown in figure, and apply pressure
normal to the top planar face.
Fix this face
To fix the hole: Fix this hole
1 Select the hole face.

2 Right-click the Load/Restraint icon and
select Restraints. The Restraints dialog
box opens.
✍ Notice that the Selected Entities box lists the number of selected faces,
edges and vertices. In this case, one face is selected.
6-22
5 Click OK.
To fix the end face:

1 Select the end face of the angle as shown in the figure.
2 Right-click the Load/Restraint icon and select Restraints. The Restraints
dialog box opens.
4 Click OK.
To apply uniform pressure:

1 Select the top planar face as shown in figure.
2 In the COSMOS/Works Manager tree, right-click the Load/Restraint folder and
select Pressure. The Pressure dialog box opens.
3 In the Type box, select Normal to selected face.
4 From the Distribution box, select Uniform.
6 In the Value field, enter 100 to apply 100 psi.
7 Click OK.

Mesh the Part

6 Click OK.
To mesh the part:


3 Click OK. After meshing is completed, you will get the Solid Mesh Completed
message.
4 Click OK.

1 Right-click the Mesh icon and select Show Mesh.
The mesh is displayed in the SolidWorks
window.
2 Right-click the Mesh icon and select Hide Mesh
to hide the mesh.
Running Buckling Analysis

1 In the COSMOS/Works Manager tree, right-click the Buckling-1 study icon
and select Run. Analysis starts. When the analysis is completed, you will get
the Buckling Analysis completed message.
2 Click OK.
6-24
List and Visualize the Buckling Results
To list buckling results:

1 Click COSMOS/Works, List Results, Mode Shape. The buckling load factor is
listed as 692.69.
2 Click Close to close the Mode Shape list box.

1 In the COSMOS/Works Manager tree, click the
(+) sign to the left of the Deformation icon.
To animate the mode shapes:

1 Right-click the Plot1 icon under the
Deformation folder and select Animate. The
Animation dialog box opens.
2 Click the right arrow button to start the
animation.
3 Click the square button to stop the
animation.
✍ You can save the animation as an AVI file and
view it with the Media Player by checking the
corresponding checkboxes.
Calculate the Buckling Load

buckling. A BLF less than unity indicates that the model is not safe under the
specified loading. The following table illustrates the interpretation of possible
BLF values.
Critical buckling load = 100 (applied pressure) x 692.69
= 69,269 psi

✍ You can reduce the error by rebuilding the mesh using a smaller global
element size and rerunning the study again.
Remesh the Model With Mesh Control

Now we will remesh the model using the Automatic Transition option.

1 Right-click the Mesh icon, and select Preferences. The Preferences dialog box
2 In the Mesh Control box check the Automatic Transition checkbox.
3 Click OK.
To mesh the model:

1 Right-click the Mesh icon and select Create. A message window opens that
warns you of the deletion of the previous results when remeshing the model.
Click OK.
2 In the Mesh dialog box, enter 0.25 in the Global Size field.
3 Click OK.
The Transition Mesh Option
6-26
Rerun the Analysis
Run the buckling analysis with the active mesh
options by right-clicking the Buckling-1 icon and
selecting Run.
Visualize the Buckling Results

1 In the COSMOS/Works Manager tree, click the (+)
sign to the left of the Deformation icon.
Critical buckling load= 100 (applied pressure) x 686.87
= 68,687 psi

7
Thermal Analysis Tutorial
This chapter presents step-by-step lessons for performing thermal analysis.

q Lesson 18: Steady State Analysis of a Computer Chip
q Lesson 19: Transient Analysis of the Computer Chip
q Lesson 20: Thermal Stress Analysis of the Computer Chip
q Lesson 21: Steady State Thermal Analysis of a Pipe with Fins

Chapter 7 Thermal Analysis Tutorial n Lesson 18: Steady State Thermal Analysis of a Computer Chip
Lesson 18: Steady State Thermal Analysis of a

Computer Chip

q Retrieve an assembly and create a thermal analysis study,
q Assign a material to each part of the assembly,
q Define thermal loads and boundary conditions,
q Mesh the Assembly,
q Run thermal analysis, and
q Visualize the results.
Introduction
Electronic components very often become the hottest spots in many electronic
systems. The heat generated by electronic components transfers throughout the
electronic system and can cause potential problems. Thermal analysis, therefore,
provides you with valuable information for your electronic system designs.
Heat transfers by conduction, convection, and radiation. Most electronic systems
experience all these modes of heat transfer, though only one of them may
dominate a particular design condition. For example, radiation becomes
significant at high temperatures but may be negligible at low temperatures.
In this lesson, we will analyze the heat transfer in an electronic chip. Any such
chip has many electronic components-such as diodes, transistors, resistors, and
capacitors-all integrated in a single chip. A chip carrier or substrate, made of
ceramic, plastics, or glass, protects it from diverse environmental effects. The
carrier receives heat transferred from the chip and then transfers it to the chip
case. This process takes place, primarily, through a combination of conduction
and convection.
7-2
Description of the Model
The assembly has the following parts:
q Substrate: rectangular block with dimensions 40x40x1 mm.
q 16 chips: each is a rectangular bock with dimensions 6x6x0.5 mm.
q The material of the Substrate is Ceramic Porcelain.
q The coefficient of thermal conductivity of the chip (k) = 130 W/m oC.
q The specific heat of the material of the chip = 670 J/kgm/oK
q The elasticity modulus of the material of the chip =4.1e+11 N/m2.

q Power dissipated in each chip = 0.2 W.
q Convection heat transfer coefficient (Film coefficient) = 25 W/m2 oC.
q Bulk temperature = 300 oK.

Due to the symmetry of the model, we will analyze one quarter of it and apply
symmetric boundary conditions at the physical boundaries of the model.
Retrieve the Model

3 Change the Look in folder to ...\Examples\Thermal where “...” refers to the
4 From the Files of type menu, select Assembly Files (*.asm, *.sldasm).

5 Double-click COMPUTER_CHIP assembly file.
Create a Thermal Analysis Study

Start the COSMOS/Works Manager, click the COSMOS/Works Manager toggle
button .
To create a thermal analysis study:

1 Right-click the COMPUTER_CHIP icon and select Study. The Study dialog box
opens.
2 Click Add. The Study name dialog box opens.
3 In the New Study field, enter a name for the study, for example, Thermal-1.
4 From the Analysis Type menu, select Thermal.
7 Click OK.
7-4
Assign Material Properties to the Parts of the Assembly
As we mentioned before, we will assign Ceramic Porcelain from COSMOS/M
library to the Substrate, but we will enter the numerical value of the coefficient of
thermal conductivity, specific heat, and the elasticity modulus of the chip material
manually.
To assign material properties to the Substrate:

1 Right-click the Substrate-1 icon under the Solids folder and select Apply/Edit
Material. The Materials dialog box opens with the COSMOS/M Library tab
selected.
2 From the Material Type menu, select Other Non-metals.
3 From the Material Name list box, select Ceramic Porcelain.
4 Click OK.
To enter material properties for the chips manually:

1 Right-click the Chip-1 icon under the Materials folder and select Apply/Edit
Material.
2 Click The Input Properties tab.
3 From the Material Property Name list box, select KX Thermal conductivity.
4 From the Unit System menu, select SI.
5 In the Input Property Value field, enter 130 and click Set.
6 Repeat steps 3-5 to enter the numerical values for the elastic modulus
(EX=4.1e11) and specific heat (C=670).
7 Click OK.
8 Repeat steps 1-7 to input material properties for the other chips in the
assembly.
✍ We will use the specific heat C when running transient analysis on the
assembly (lesson 19), and the elasticity modulus EX when running thermal
stress analysis (lesson 20) later in this tutorial.
Apply Thermal Loads and Boundary Conditions

We will apply the following thermal loads and boundary conditions to the
assembly:

q A symmetric thermal boundary conditions (zero heat flux) at the planes of

symmetry of the assembly (the highlighted faces in figure).
q Convection boundary conditions at the opposite faces and the bottom face of
the assembly.
q Heat power (volume heat) to the four chips on the substrate face.
Apply heat power to these four components
Apply zero heat flux to

these faces (planes of
symmetry of the model).
To apply symmetric thermal boundary conditions on the planes of symmetry of

the model:
1 Select the two faces shown in figure.
2 Right-click the Load/Restraint folder, and select Heat Flux. The Heat Flux
dialog box opens.
3 In the Heat Flux field, type in 0.
4 Click OK.
To apply convection boundary conditions to the other faces of the assembly:

1 Select the opposite faces and the bottom face of the assembly.
2 Right-click the Load/Restraint folder, and select Convection. The Convection
dialog box opens.
3 From the Units menu, make sure that SI is selected.
4 In the Film Coefficient field, enter 25.
5 In the Bulk Temperature field, enter 300.
6 Click OK.
7-6
To apply heat power boundary condition to the top faces of the chips:
1 Under the Solids folder, select Chip-1, Chip-2, Chip-3, and Chip-4. Press and
hold the Ctrl key while selecting these components.
2 Right-click the Load/Restraint folder
and select Heat Power. The Heat
Power dialog box opens.
3 In the Units menu, make sure that SI is
selected.
4 In the Heat Power field, enter 0.2.
5 Click OK.
Mesh the Model

1 Right-click the Mesh icon, and select Properties. The Preferences dialog box
6 Click OK.
To mesh the model:

1 Right-click the Mesh icon and select Create. The Mesh dialog box opens.
2 Click OK to accept the defaults. The meshing starts, when completed, a Solid
Mesh Completed message appears.

3 Click OK to close the message window.
Run the Analysis
To run the thermal analysis on the assembly:

1 Right-click the Thermal-1 study icon and select Run. The analysis starts.
When completed, a Thermal Analysis Completed message appears.
Visualize the Results of Thermal Analysis
To plot temperature distribution on the assembly:

1 Click the plus sign to the left of the Thermal folder.
7-8
This lesson is completed. The next lesson will use the same assembly.

Chapter 7 Thermal Analysis Tutorial n Lesson 19: Transient Thermal Analysis of the Computer Chip
Lesson 19: Transient Thermal Analysis of the

Computer Chip

q Create a transient thermal analysis study,
q Define thermal loads and boundary conditions by drag and drop,
q Run transient thermal analysis, and
q Visualize results of thermal analysis at different time steps.
Introduction
Steady state analysis gives you thermal results when the model reaches thermal
equilibrium and the temperature of each particle remains constant afterwards.
Steady state analysis does not tell you how long it takes to reach this condition.
Transient analysis, on the other hand, answers questions such as: what will be the
temperature profile after a given period of time?.
In this lesson, you will learn how to perform transient thermal analysis on the
computer chip assembly. In this kind of analysis, the temperature changes with
time and we will be interested in calculating the temperature distribution in the
chip at different instances of time. Since the model and boundary conditions are
the same as those used during the steady state lesson (lesson 18), we will use drag
and drop procedure to ease the process of assigning the materials and applying the
loads and boundary conditions.
Create a Transient Thermal Analysis Study
To create a transient analysis study:

1 Right-click the COMPUTER_CHIP icon at the top of the COSMOS/Works
Manager and select Study. The Study dialog box opens.
3 In the New Study field, enter a name for the study, for example, Thermal-2.
7 Click OK.
7-10
To set the properties of the thermal study to the transient option:
1 Right-click the Thermal-2
study icon and select
Properties. The Thermal
dialog box opens.
2 In the Solution Type box,
select Transient.
3 In the Total Time field, enter
300 (seconds).
4 In the Time Increment field,
enter 25.
5 In the Initial Temperature
field, enter 300 OK.
6 Click OK.
Assign Materials to the Assembly by Drag and Drop
To assign materials to the assembly parts:

1 Click the (+) sign to the left of the Thermal-1 study icon to expand the study
items.
2 Drag the Solids folder from Thermal-1 study and drop it onto Thermal-2 study
icon. The materials will be copied from Thermal-1 to Thermal-2.
Apply Thermal Loads and Boundary Conditions by Drag and Drop
To apply thermal loads and boundary conditions:

1 Click the plus sign to the left of the Thermal-1 study icon to expand the study
items.
2 Drag the Load/Restraint folder from Thermal-1 study and drop it onto
Thermal-2 study icon. The thermal loads and boundary conditions will be
copied from Thermal-1 to Thermal-2.

Chapter 7 Thermal Analysis Tutorial n Lesson 19: Transient Thermal Analysis of the Computer Chip
Run Transient Analysis
To run the transient thermal analysis:

1 Right-click the Thermal-2 study icon and select Run. The analysis starts.
When completed, a Thermal Analysis Completed message appears.
Visualize the Transient Thermal Analysis Results

Here we are interested in plotting the temperature profiles at different time
instants. We will plot the temperature profiles at the first, third, ninth, and the last
time steps.
To plot the temperature profile after the first time step (after 25 seconds):
1 Click the plus sign to the left of the Thermal folder. Plot1 icon appears.
2 Right-click the Plot1 icon, and select Edit Definition. The Thermal Plot dialog
box opens.
3 In the Time Step No.field, enter 1.
4 Click OK.
7-12
To plot the temperature profile after the third, ninth, and the last time step:
1 Right-click the Thermal folder under Thermal-2 study icon, and select Define.
The Thermal Plot dialog box opens.
2 In the Time Step No. field, enter 3.
3 Click OK.
4 Repeat steps 1-3 to plot temperature profiles at other times steps (by entering 9
and 12 respectively in the Time Step No. field in the corresponding dialog box).
This lesson is completed. The next lesson uses the same document.

Chapter 7 Thermal Analysis Tutorial n Lesson 20: Thermal Stress Analysis of the Computer Chip
Lesson 20: Thermal Stress Analysis of the Computer Chip

q Create a static analysis study to find out the stresses generated by thermal
loading from thermal studies,
q Define restraints,
q Run the analysis, and
q Visualize stress results due to thermal loading.
Create a Thermal Stress Analysis Study
To create a thermal stress analysis study:

1 Create a static analysis study
with any name, for example,
Thermal Stress.
2 Right-click the Thermal
Stress study icon and select
Properties. The Static
dialog box opens.
3 Check the Include Thermal
Effects checkbox.
4 In the Thermal Options box,
Select Temperatures from
thermal study.
5 From the Thermal Study
menu, select Thermal-1
(here we will use the thermal
results from the Thermal-1
study).
6 In the Reference
temperature at zero strain
field, enter
300 oK.
7 Accept the rest of the defaults and click OK.
7-14
Assign Materials to the Assembly Parts by Drag and Drop
Use the drag and drop technique to copy material properties from Thermal-1 (or
equivalently, Thermal-2) study to Thermal Stress study.
Apply Restraints to the Assembly

We will fix the free faces of the assembly and apply symmetry boundary
conditions to the faces coincident with the planes of symmetry of the model.
Fix these faces
Face 2
Face1
Apply structural symmetry

boundary condition
on these faces.
To restrain the free faces of the chip assembly:

1 Select the free faces of the chip assembly (shown as dotted lines in the figure).
dialog box opens.
3 Select Immovable (No Translation).
4 Click OK.
To apply structural symmetry boundary condition to faces on the planes of

symmetry of the model (faces 1 and 2 in the figure):
1 Switch to the FeatureManager and select Plane1.
2 Switch back to the COSMOS/Works Manager, and select Face 1 while pressing
the Ctrl key down.

Chapter 7 Thermal Analysis Tutorial n Lesson 20: Thermal Stress Analysis of the Computer Chip
4 Select Use Reference Plane or Axis . make sure that Plane 1 appears in the
Selected Reference box.
5 Under Displacement, check Along plane Dir 1 and enter 0 in its field.
6 Click OK.
7 Select Face 2 of the chip and repeat steps (1-5) mentioned above except that in
step 4 check Along plane Dir 2.
Run the Thermal Stress Analysis
To run thermal stress analysis:

1 Right-click Thermal Stress study icon and select Run.
2 When the analysis is completed, click OK to close the message window.
Visualize Stresses Due to Structural and Thermal Loadings

1 Click the plus sign to the left of the Stress folder. Plot1 icon appears.
2 Right-click Plot1 icon and select Edit Definition. The Stress Plot dialog box
opens.
3 Select psi from the Stress Units menu under the Properties tab.
7-16
4 Click the Settings tab, and enter 1 in the Scale Factor field.
5 Click OK.
This lesson is completed. You can close this document. The next lesson
uses different document.

Chapter 7 Thermal Analysis Tutorial n Lesson 21: Steady State Thermal Analysis of a Pipe with Fins
Lesson 21: Steady State Thermal Analysis of a Pipe

with Fins

q Use the Split Line function for the proper application of boundary conditions,
and
q Specify thermal boundary conditions and run thermal analysis.
Introduction
Convection is the mode of energy transfer between a solid surface and an
adjacent moving fluid or gas. It involves the combined effects of conduction and
fluid motion. The rate of heat transfer from a surface at a temperature Ts to a
surrounding medium at T m is given by the simple law:
·
Q convection = hA ( Ts – Tm )
When the temperatures Ts and Tm are fixed by design considerations, as is often

the case, there are two ways to increase the rate of heat transfer: to increase the
convection heat transfer h or increase the surface area A. Increasing h may
require the installation of a pump or a fan. This approach may or may not be
practical. The alternative is to increase the surface area by attaching extended
surfaces called fins made of highly conductive materials such as aluminum.
Finned surfaces are commonly used in practice to enhance heat transfer, and they
often increase the rate of heat transfer considerably.
In the analysis of fins, we consider steady operation with no heat generation in the
fin, and we assume the thermal conductivity k of the material to be constant. We
also assume the heat transfer coefficient h to be constant and uniform over the
entire surface of the fin.
In this lesson we will analyze the
Pipe
effect of adding a fin on the steady
Fins
state temperature distribution in a
heating pipe, where a heating fluid
carries heat from a heat source to a
destination. A portion of the pipe is
shown in the figure along with its
dimensions.
7-18
For the convenience of the analysis,
we will assume that there is no
significant change in the fluid
temperature as it moves along the pipe.
Moreover, we will assume that the heat
transfer coefficient h is the same for all Heating_Pipe Assembly
surfaces. In performing the analysis,
we will use the portion shown in the
figure as a representative of the whole assembly due to repetitive symmetry.
Description
The assembly consists of the following components:
q An 8-mm long stainless steel pipe with an outer radius of 15 mm and an inner
radius of 13 mm.
q A 2-mm thick aluminum fin (alloy # 2024) with an outer radius of 30 mm
attached to the surface of the pipe.
We will apply the following thermal loads and boundary conditions to the
assembly:
q The inner face of the pipe is maintained at a fixed temperature of Ts=180 oC.
q The ambient temperature far enough from the assembly is Tm= 25 oC.
q The heat transfer coefficient (h) of the outer face of the pipe (without fin) is 60
W/m2 oC.
q The heat transfer coefficient (h) for the whole assembly (pipe + fin) is 50 W/m2
o
C
Retrieve the Assembly

1 Start SolidWorks.
3 Change the Look in folder to ...\Examples\Thermal where “...” refers to the
4 From the Files of type menu, select Assembly Files (*.asm; *.sldasm).

5 Double-click Heating_Pipe assembly file.
Splitting the Outer Face of the Pipe

For the proper application of the
convection boundary condition to the Face 1
outer face of the pipe, we need to
split it into three faces as shown in
Face 2
the figure. We will use the Split Line
function of SolidWorks to do so.
Face 3
To split the outer face of the pipe:
Splitting the outer face of the pipe into
1 Right-click the Pipe<1> part in three faces using Split Line function
the FeatureManager and select
Edit Part.
2 Click the plus sign to the left of the Pipe<1> icon to expand its items.
3 Click Plane1 under the Pipe<1> icon.
7-20
4 Click the Sketch tool to open a
sketch on Plane1.
5 While pressing the Ctrl key, select
the outer circular edge of the upper
face of the fin.
6 Click the Convert Entities tool
to project the selected edge onto
Select this edge
Plane1. of the fin (step 5)
7 From the menu bar click Insert,
Curve, Split Line or click the Split
Line tool on the Curves toolbar.
The Split Lines dialog box opens.
8 Make sure that Projection is
selected in the Types of split box.
Click Next.
9 In the Project Split Line dialog box,
click inside the Faces to split box
and select the outer face of the pipe. Projection of the selected
edge on Plane1 (step 6)
Click Finish. The face is split into
two faces.
10 Repeat steps (3-9) this time using
the lower circular edge of the fin
and the lower portion of the outer
face of the pipe. When you are
done, the outer face of the pipe will
be split into three faces.
11 Close the editing mode of the Pipe Select the outer face of
part by clicking . the pipe to split (step 9)
12 Click the Rebuild tool .
Performing the Analysis on the Pipe Part

We will first perform thermal analysis on the Heating_Pipe assembly without fin.
To do so, we will open the Pipe part in SolidWorks.
To open the Pipe part:

While in the FeatureManager, right click the Pipe<1> icon and select Open
pipe.sldprt. The part will open in SolidWorks.

Create a Thermal Study
To create a thermal analysis study:

1 Start the COSMOS/Works Manager by clicking the icon .
2 Right-click the Pipe icon at the top of the COSMOS/Works Manager and select
4 In the New Study field, enter a name for the study, for example, No Fin.
7 Click OK to return to the Study dialog box.
8 Click OK.
Assign Material to the Pipe Part

Right-click the Solids folder and select Apply Material to All. Select Alloy Steel
from the COSMOS/M Material Library.
To apply a temperature boundary condition to the pipe’s inner face:

1 Select the pipe’s inner face. Apply fixed
temperature
2 Right-click the Load/Restraint icon and to this face
select Temperature. The Temperature dialog
box opens.
3 From the Units menu, select Celsius.
4 In the Temperature field, enter 180.
5 Click OK.
To apply convection boundary conditions to the outer faces of the pipe:

1 Select the three faces on the outer boundary of the pipe.
2 Right-click the Load/Restraint icon and select Convection. The Convection
dialog box opens.
3 Make sure that SI is selected from the Units menu.
7-22
6 Click OK.
Mesh the Model
To set the Mesh preferences: Apply convection

boundary conditions
1 Right-click the Mesh icon and select Preferences. to these faces

6 Click OK.
To mesh the model:

2 Click OK to accept the default mesh size.
Run Thermal Analysis

Right-click the icon of the study and select Run.
Visualize the Resultant Heat Flux Plots
To plot a section view of the resultant heat flux distribution:

1 Click the (+) sign to the left of the Thermal folder.
2 Right-click Plot1 icon and select Edit Definition. The Thermal Plot dialog box
opens.
3 From the Units menu under the Properties tab, select SI.
4 Click the Display tab and select Section in the Plot Type box.
5 From the Component menu, select HFLUXN: Resultant heat flux .
6 Click the Settings tab and select None from the Boundary Options list.
7 Click OK.

8 To view the section plot properly, click *Right from the Orientation box.
Create Another Thermal Study on the Whole Assembly

Now that we performed thermal analysis on the pipe without fin, the next step is
to investigate the effect of the fin on the steady state temperature distribution.
To save the pipe part and rebuild the assembly:

1 Save the Pipe part by clicking File, Save.
2 Close the Pipe part by clicking File, Close. You will get the following
message,
3 Click Yes.
To create a thermal study on the assembly:

2 Create a thermal study with the name With Fin.
To assign material to the fin component:

Assign Alloy Steel to the Pipe part and Aluminum Alloys (2024 Alloy) to the
Fin part.
7-24
We will apply the following thermal loads and boundary conditions:
q A temperature boundary condition on the inner face of the pipe in exact the
same way we did in the No Fin study (i.e., with Ts=180 oC).
q Convection boundary conditions to the outer faces of the assembly (5 faces)

with an overall heat transfer coefficient of 50 W/m2 oC.
To apply convection boundary conditions to the outer faces of the assembly:

1 Select the outer faces of the assembly. This time the faces of the fin should be
included in the selection.
2 Right-click the Load/Restraint icon
and select Convection.
3 In the Convection dialog box, select
SI from the Units menu.
4 Enter 50 as the value of the Film
Coefficient and 298 for the Bulk
Temperature.
5 Click OK. Selection for the convection boundary
conditions in the Fin study
Mesh the Model

Mesh the assembly with an element size of 0.11212 cm. This is the same element
size we used to mesh the pipe component in the previous study. Also we will use
the same meshing preferences. With this choice we can establish a basis for
comparison of the results from the two studies.
Run Thermal Analysis on the Study

Right-click the icon of the study and select Run.
Visualize the Resultant Heat Flux Plots
To plot a section view of the resultant heat flux distribution:

1 Click the plus sign to the left of the Thermal folder under the Fin study.
2 Right-click Plot1 icon and select Edit Definition. The Thermal Plot dialog box
opens.

3 From the Units menu under the Properties tab, select SI.
4 Click the Display tab and select Section in the Plot Type box.
5 In the Component list box, select HFLUXN: Resultant heat flux.
6 Click the Settings tab and select None from the Boundary Options list.
7 Click OK.
8 To view the section plot properly,
click *Right from the Orientation
box.
Conclusion
By looking at the resultant heat flux
values on the outer faces of the model
for both cases (with and without fin),
one can realize the effectiveness of the
fin in dissipating heat out of the model. By closer investigation of the values of
the resultant heat flux at the common face of the fin and the pipe, one can easily
realized that the fin has enhanced the heat transfer rate by over an order of
magnitude.

8
Optimization Analysis Tutorial
This chapter presents step-by-step lessons for performing optimization analysis.

q Lesson 22: Shape Optimization of a Cantilever Bracket
q Lesson 23: Shape Optimization of a Cylinder Assembly

Chapter 8 Optimization Analysis Tutorial n Lesson 22: Shape Optimization of a Cantilever Bracket
Lesson 22: Shape Optimization of a Cantilever Bracket

q Create an optimization analysis study,
q Define the objective function, design variables, and behavior constraints, and
q Visualize the results of the optimization process.
Introduction
The purpose of this lesson is to show you how to perform optimization analysis on
a given part. The fundamental ingredients of an optimization analysis study are:
an objective function, design variables, and behavior constraints. The objective
function usually defines the goal of the optimization process. In this release, you
can set the objective function to minimize/maximize the mass, volume, natural
frequency, and buckling load factor of a given design. The design variables, on
the other hand, are the changeable dimensions of the model that we are seeking to
optimize. The constraints define the conditions that the optimized design must
satisfy (please refer to Chapter 9 in the User’s Guide book for more details).
In this lesson we will be seeking an optimum design of a cantilever bracket,
subjected to structural loading and boundary conditions, that will minimize its
volume. We will start the lesson by performing static analysis on the initial
design, then we will create an optimization study, and perform the optimization
analysis to find the optimum design of the part.
Description Normal
pressure DV1
Fixed
The initial design of the cantilever face
bracket has the following dimensions;
The part is subjected to the following
loading and restraints:
DV3
• A normal pressure with the value
of 5x106 N/m2 on the top
horizontal face, and
• The part is fixed on the vertical DV2
back face.
8-2
We are seeking an optimum design of this part that minimizes its volume. The von
Mises stress resulting from the specified loading is not to exceed a certain value
(3x108 N/m2). The design variables (DV1, DV2, and DV3 in the graph) are to be
within some upper and lower bounds. The optimization problem that we are trying
to solve in this lesson has the following elements:
Objective Function
Minimize the volume of the cantilever part subject to the specified loading and
restraints.
Design Variables
The upper and lower bounds imposed on the design variables are:
• Design Variable DV1 (in mm): 10 < DV1 < 25,
• Design Variable DV2 (in mm): 10 < DV2 < 25, and
• Design Variable DV3 (in mm): 20 < DV3 < 50.
Constraints
The von Mises stress on
the optimum design is
not to exceed 3x108 N/
m2, within 5%
tolerance.
Load the Part

To load the part:
1 Start SolidWorks.
2 Click File, Open.
The Open dialog
box opens.
3 Navigate to the
folder
...\Examples\Optimi
zation, where “...”
refers to the
installation folder of
COSMOS/Works.
4 Make sure that the Files of type field is set to Part Files (*.prt, *.sldprt).

5 Select the Cantilever_Bracket.SLDPRT file, and click Open.
Create an Initial Static Analysis Study

We will perform static analysis on the initial design. To do so we start the
COSMOS/Works Manager by clicking the COSMOS/Works Manager toggle icon
.
To define a static analysis study on the initial design:

1 In the COSMOS/Works Manager, right-click the Cantilever_Bracket icon and
select Study.
2 In the Study dialog box, click Add. The Study Name dialog box opens.
3 In the New Study field, type in Initial Stress.
4 From the Analysis Type menu, select Static.
5 From the Mesh Type box, select Solid.
7 Click OK.
Define Material Properties
To define material properties to the part:

1 Right-click the Canilever_Bracket icon in the Solids folder and select Apply/
Edit Material.
2 In the Material dialog box, select Alloy Steel from the Material Name list box.
3 Click OK.
Apply Loads and Restraints Apply normal

pressure to
this face
To fix the vertical face of the bracket:
1 Select the vertical face of the bracket.
2 Right-click the Load/Restraint folder,
and select Restraints. Fix this
face
3 In the Restraints dialog box, select
Fixed.
4 Click OK.
8-4
To apply normal uniform pressure to the upper horizontal face of the bracket:
1 Select the horizontal face of the bracket.
2 Right-click the Load/Restraint folder and select Pressure.
3 In the Pressure dialog box, select SI from the Units menu.
4 Enter a value of 5x106 in the Value field.
5 Make sure that Normal to selected face is selected.
6 Click OK.
Mesh the Model

1 Right-click the Mesh icon and select Preferences.
5 Make sure the 4 Points is selected from the Jacobian Check menu.
6 Click OK.
To mesh the model:

2 Click OK to accept the default element size.
Run the Initial Analysis
To run static analysis on the initial design:

Right-click the Initial Stress study icon and select Run. When the analysis is

Visualize Stress Results
To plot von Mises stress:

1 Click the plus sign next to the Stress folder.
Create an Optimization Study
To create an optimization study:

the Cantilever_Bracket icon and select Study.
2 In the Study dialog box, click Add. The Study
Name dialog box opens.
3 In the New Study field, type Min Volume.
4 From the Analysis Type menu, select
Optimization.
6 Click OK.
8-6
To view the properties of the optimization study:
1 Right-click the Min Volume study icon
and select Properties. The
Optimization dialog box opens.
2 The Maximum no. of design cycles is
set to 20.
3 Click OK.
Define the Objective Function
To define the objective function:

1 Right-click the Objective icon and
select Edit/Define. The Objective
dialog box opens.
2 Click Add. The Objective dialog box opens.

3 In the Design Goal box, make sure that Minimize is
selected.
4 In the Response Quantity list box, select Volume.
5 In the Available Studies list box, make sure that
Initial Stress is selected.
6 In the Convergence Tolerance field, enter 5.
7 Click OK. You will return to the first dialog box.
8 Click OK.
✍ Note the red checkmark that appears on the
Objective icon indicating that this item has been defined.

Define the Design Variables

Next, we will define the design variables that the program will adjust so that the
final goal (minimizing the volume) is achieved. To make the selection of the
design variables easy, right-click the Mesh icon and select Hide Mesh.
To define the design variables of the study:

1 Right-click the Design Variables icon and select Edit/Define. The Design
Variables dialog box opens.
2 In SolidWorks graphics area, select any dimen-

sion by clicking it once, for example, DV1 (=25
mm), and click Add. The corresponding Design
Variable dialog box opens. This dialog box
will help you assign upper and lower bounds of
the selected design variable.
3 In the Lower bound field, enter 10 (mm).
4 In the Upper bound field, enter 25 (mm).
5 In the Convergence tolerance field, accept the
default value.
6 Click OK. The dimension will listed in the Design Variables dialog box.
7 To assign upper and lower bounds to the other dimensions (represented by
DV2 and DV3), repeat steps (2-6).
8 Click OK to close the Design Variables dialog box.
8-8
Define Behavior Constraints
As we mentioned earlier, we will require that the maximum von Mises stress on
the optimized design to be less than 3x108 N/m2 within 5% tolerance.
To define a study constraint:

1 Right-click the Constraints icon and select Edit/Define. The Constraints dialog
box opens.
2 Click Add. The Constraint dialog

box opens.
3 In the Response Type box, make the
following selections; Static, Initial
Stress, Nodal Stress, and VON: von
Mises stress.
4 From the Units menu, select N/m2.
5 In the Bounds box, enter the
following numerical values in the
specified fields
• Lower bound: 0,
• Upper bound: 3e8, and
• Tolerance: 5.
6 Click OK. The specified constraint will be listed in the Constraints dialog box.
7 Click OK.

Run the Optimization Analysis

Right-click the Min Volume study icon and select Run. The analysis starts. As the
analysis runs, you will see the design variables changing in each design cycle until
they reach their optimum values calculated by the program. When the analysis is
completed successfully, a Convergence Achieved message window appears. Click
OK to close the message window.

Upon a successful completion of the optimization analysis on your model,
postprocessing folders are generated.
Final Design
Design after iteration No. 5 Final Design
View the Initial and Final Designs

To view the initial or final design:
1 Click the plus sign next to the Design Cycle Result folder.
2 Double-click the Initial Design icon. The initial design will display.
3 Double-click the Final Design icon. The final design will display.
To view the design at a certain cycle:

1 Right-click the Design Cycle Result folder and
select Define. The Design Cycle Result dialog box
opens. This dialog box tells you the number of
design cycles the program took to achieve
convergence.
2 In the Iteration No. field, enter the desired
number of iterations after which you want to see
the status of your design variables, for example, 5.
3 Click OK.
8-10
Convergence of Graphs
To plot the convergence of the design

variables:
1 Right-click the Design History Graph
folder and click Define. The Design
History Graph dialog box opens.
2 From the Graph Parameters menu,
select Design variables.
3 Move all design variables from the
Available Data box to the Plot Data
box by clicking the double-arrow
button.
4 Check Normalized to initial value checkbox.
5 Click OK. The following convergence plot will be generated in a separate
window.
To plot the convergence of other optimization parameters:

1 Right-click the Design History Graph folder and click Define. The Design
2 From the Graph Parameters menu, select the parameter you want to plot.
3 Move that data you want to plot from the Available Data box to the Plot Data
box.
4 Click OK.

Local Trend Graphs
To plot the objective function versus a design variable:

1 Right-click the Design Local Trend
Graph icon and select Define. The Local
Trend Graph dialog box opens.
2 In the X-Axis box, select a design
variable, for example,
D11@Sketch@Cantilever_Bracket.
3 In the Y-Axis box, select Objective.
4 Check Normalized to initial value
checkbox.
5 Click OK.
8-12
To plot a constraint versus a design variable:
1 Right-click the Design Local Trend
Graph icon and select Define. The Local
Trend Graph dialog box opens.
2 In the X-Axis box, select a design
variable, for example,
D13@Sketch@Cantilever_Bracket.
3 In the Y-Axis box, select Constraint. The
drop-down menu field changes to VON:
von Mises stress.
4 Check Normalized to initial value
checkbox.
5 Click OK.

Round Off the Final Design Dimensions and Rerun Your Analysis
The final dimensions of your design may or may not have decimal figures.
Typically, for fabrication purposes, these figures should be rounded off to the
closest number that can be measured within the precision of the fabrication
process. The changes in dimensions of the final design may lead to higher
stresses than those calculated by the program. In order to make sure that your
stress constraint is still satisfied on your final model, you need to rerun static
analysis on the finalized design and check the values of stresses throughout your
model.
8-14
Lesson 23: Shape Optimization of a Cylinder Assembly

q Create an optimization analysis study,
q Define the objective function, design variables, and behavior constraints, and
q Visualize the results of the optimization process.
Introduction
The purpose of this lesson is to show you how to perform optimization analysis on
a given assembly subjected to constraints from multiple studies.
In this lesson we will be seeking an optimum design of a cylinder, subjected to
thermal and structural loading that minimizes its volume. We will start the lesson
by performing thermal and static analyses on the initial design, then we will create
an optimization study, and perform the optimization analysis to find the optimum
design that satisfies the constraints set by the user.
Description
The initial design of the cylinder has the following dimensions.
Heat Source
at the bottom

Chapter 8 Optimization Analysis Tutorial n Lesson 23: Shape Optimization of a Cylinder Assembly
The cylinder assembly consists of two parts; a heat source which is a circular disk
located at the bottom of the assembly, and a heat sink which constitutes the rest of
the cylinder. The heat source is made of Aluminum Alloy, and the heat sink is
made of a Alloy Steel. Due to the symmetry of the model, we will analyze only a
quarter of it. The model is subjected to the thermal loads shown in figure.
Convection and
radiation boundary
conditions on this face
Convection
boundary
condition
on these
faces.
Convection boundary
condition on the bottom
Heat power to face of the heat sink
the heat source
Symmetry boundary conditions on the
component
faces of symmetry of the model.
Objective Function
Minimize the volume of the cylinder assembly subjected to the specified loading
and restraints.
Design Variables
The upper and lower bounds imposed on the design variables are:
• The outer radius of the cylinder: 6 < R < 10 inches,
• The thickness of the cylinder wall: 1.5 < T < 2 inches, and
• The height of the cylinder: 8 < H < 10 inches.
Constraints
The following constraints are to be applied:
• The temperature throughout the model is not to exceed 430 oK.
• The von Mises stress on the model is not to exceed 8x108 Nm-2.
8-16
Open the Assembly
To open the assembly:

1 Start SolidWorks.
3 Navigate to the folder ...\Examples\Optimization, where “...” refers to the
installation folder of COSMOS/Works.
4 Make sure that the Files of type field is set to Assembly Files (*.asm,
*.sldasm).
5 Select the Quarter_Cylinder.SLDASM file, and click Open.
Create a Steady State Thermal Study

We will perform steady state thermal analysis on the initial design. To do so we
start the COSMOS/Works Manager by clicking the COSMOS/Works Manager
toggle icon .
To define a steady state thermal study on the initial design:

1 In the COSMOS/Works Manager, right-click the Quarter_Cylinder icon and
select Study.

3 In the New Study field, type in Thermal Study.
5 In the Mesh Type box select Solid.
7 Click OK.

We will assign an Aluminum Alloy to the heat source and Alloy Steel to the heat
sink.
To assign material properties to the heat source:

1 Right-click the Quarter_Heat_Source-1 icon in the Solids folder and select
Apply/Edit Material. The Material dialog box opens.
2 From the Material Type menu, select Aluminum Alloys.
3 From the Material Name menu, select Aluminum Alloy (1060 alloy).
4 Click OK.
To assign material properties to the heat sink:

1 Right-click the Quarter_Heat_Sink-1 icon in the Solids folder and select Apply/
Edit Material. The Material dialog box opens.
2 From the Material Type menu, select Steel.
3 From the Material Name menu, select Alloy Steel.
4 Click OK.
8-18
Apply Thermal Loads
To apply convection to the faces of the heat

sink:
1 Select the inner, outer, top, and bottom
faces of the heat sink (5 faces).
and select Convection.
3 In the Convection dialog box, select SI
from the Units menu.
6 Click OK.
To apply thermal symmetry boundary conditions on the faces of symmetry of

the model:
1 Select the faces of symmetry of the
model (4 faces).
2 Right-click the Load/Restraint folder,
and select Heat Flux.
3 In the Heat Flux dialog box, enter 0 in
the Heat Flux field.
4 Click OK.
To apply radiation boundary condition to

the outer face of the heat sink:
1 Rotate the model to the appropriate
view and select the outer face of the
model.
and select Radiation.
3 In the Radiation dialog box, select
Kelvin from the Units menu.
4 In the Emissivity field, enter 0.9.
5 In the View Factor field, enter 1.

6 In the Ambient Temperature field, enter 310.

7 Click OK.
To apply heat power to the heat source part:

1 Select the heat source part by clicking the Quarter_Heat_Source-1 icon in the
Solids folder. Make sure that the selected part is highlighted in the graphics
area.
2 Right-click the Load/Restraint folder and select Heat Power. The Heat Power
dialog box opens.
3 From the Units drop-down menu, make
sure that SI is selected.
4 In the Heat Power field enter 300
(Watts).
5 Click OK.
✍ The program uses the heat power
loading when applied to components
as a uniformly distributed
volumetric heat source.
Mesh the Model

1 In the COSMOS/Works Manager, right-click the Mesh icon and select
Preferences. The Preferences dialog box opens.
3 In the Mesh Control box, check Smooth Surface checkbox.
5 From the Jacobian Check menu, make sure that 4 Points is selected.
6 Click OK.
To mesh the model:

2 In the Global Size field, enter 1 (in inches).
3 Click OK.
8-20
Run the Analysis
To run thermal analysis on the initial design:

Right-click the Thermal Study study icon and select Run. When the analysis is
Visualize Thermal Results
To plot temperatures:
1 Click the plus sign next to the Thermal folder.
Create a Thermal Stress Study

Next, we will create a static study
and compute the stresses
developed in the model due to both
thermal and structural loadings.
To create a thermal stress study:

Quarter_Cylinder icon and
select Study.
3 In the New Study field, enter an name for your study, for example, Thermal
Stress.
4 From the Analysis Type menu, select Static.
5 In the Mesh Type box select Solid.
7 Click OK.

To set the properties of the static study:

1 Right-click the Thermal
Stress icon, and select
Properties. The Static dialog
box opens.
2 Check Include Thermal
Effects checkbox.
3 In the Thermal Options box,
select Temperatures from
thermal study.
4 Make sure that Thermal
Study is selected in the
Thermal Study field.
5 In the Reference temperature
at zero strain field, enter 300
(in Kelvins)
6 In the Solver box, select FFE.
7 Click OK.
Assign Material to the Model

Drag the Solids folder from the Thermal Study and drop it onto the Thermal Stress
study icon.
- or -
1 Right-click the Solids folder in the Thermal Study and select Copy.
2 Right-click the Thermal Stress study icon and select Paste.
Apply Structural Restraints

We will apply symmetry boundary condition to the faces of symmetry (4 faces) of
the model, and fix the bottom faces of model (2 faces). To go back to the shaded
view of the model, right-click the Mesh icon and select Hide Mesh.
8-22
To restrain the left faces:
1 Switch to the FeatureManager and
click Plane1 in its tree.
2 Switch back to the COSMOS/Works
Manager.
3 Select the two faces on Plane1 as
shown in the figure.
folder and select Restraints.
5 In the Type dialog box, check Use
Reference Plane or Axis.
Restrain these
6 In the Displacement box, check two faces along
Normal to plane and enter 0 in its Dir 1 of Plane1
field.
7 Click OK.
To restrain the right faces:

1 Select the other two faces of symmetry as shown in the figure.
3 In the Type dialog box, check Use Reference Plane or Axis .
4 In the Displacement box, check Along Plane Dir 1 and enter 0 in its field.
5 Click OK.
To fix the bottom faces of the model:

1 Select the two faces at the bottom of the model.
2 Right-click the Load/Restraint folder, and click Restraints.
3 In the Restraints dialog box, check Fixed.
4 Click OK.
Run Static Analysis

Right-click the Thermal Stress study icon and select Run. The analysis starts.
When completed, click OK to close the message dialog box.

Visualize Thermal Stresses

click the plus sign to the left of the
Stress folder under the Thermal
Stress study.
2 Right-click Plot1 icon and select
Edit Definition. The Stress Plot
dialog box opens.
3 Click the Settings tab and enter 1 in the Scale Factor field.
4 Click OK.
Now, we will perform optimization analysis on the model, to find the optimum
design (dimensions) that will minimize its volume. We will apply constraints
from both Thermal Study and Thermal Stress studies.
Create an Optimization Study
To create an optimization study:

Quarter_Cylinder icon and select Study.
2 In the Study dialog box, click Add. The Study
Name dialog box opens.
3 In the New Study field, type Optimization Study.
4 From the Analysis Type menu, select
Optimization.
5 Click OK. You will return to the Study dialog
box.
6 Click OK.
To set the properties of the optimization study:

1 Right-click the Optimization Study icon and select Properties. The
Optimization dialog box opens.
2 Set the Maximum no. of design cycles to 20.
3 Click OK.
8-24
Define the Objective Function
To define the objective function for the optimization study:

1 Right-click the Objective icon and select Edit/Define. The Objective dialog box
opens.
2 Click Add. The Objective dialog box opens.

3 In the Design Goal box, make sure that Minimize is
selected.
4 In the Response Quantity list box, select Volume.
5 In the Available Studies list box, select Thermal
Stress study.
6 In the Convergence Tolerance field, enter 1.
7 Click OK. You will return to the Objectives dialog
box.
8 Click OK.

Define Design Variables

To define the design variables of the study:
1 Right-click the Mesh icon and select Hide Mesh. The model displays in the
shaded view mode and its dimensions are visible and ready for user selection.
✍ Hiding the mesh (or the results) is necessary for the next step of defining
the design variables of the study.
2 Right-click the Design Variables icon and select Edit/Define. The Design
Variables dialog box opens.
3 To add a design variable to the study select, for example, the radius dimension
(D2@Sketch1@Quarter_Heat_Sink.Part) and click the Add button in the
Design Variables dialog box. The Design Variable dialog box opens.
4 In the Lower bound field, enter 6 (in).
5 In the Upper bound field, enter 10 (in).
6 In the Convergence tolerance field, enter 2.
7 Click OK. The dimension will listed in the Design Variables dialog box.
8 To assign upper and lower bounds to the other dimensions (the wall thickness
and height), repeat steps (2-6) with the appropriate lower and upper bounds and
tolerance (as shown in the figure).
9 Click OK to close the Design Variables dialog box.
Defining the lower and upper

List of all design variables defined in
bounds of a design variable
in the current study
8-26
Define Behavior Constraints
To define a stress constraint:
1 Right-click the Constraints icon and
select Edit/Define. The Constraints
dialog box opens.
box opens.
following selections; Static,
Thermal Stress, Nodal Stress , and
VON: von Mises stress.
4 From the Units menu, select N/m^2.
following numerical values in the specified fields
• Lower bound: 0,
• Upper bound: 2e9, and
• Tolerance: 2.
To define a temperature constraint:

box opens.
following selections; Thermal,
Thermal Study, Thermal, and
TEMP: Nodal temperature.
3 From the Units menu, select Kelvin.
following numerical values in the
specified fields
• Lower bound: 0,
• Upper bound: 430, and
• Tolerance: 2.
5 Click OK. The specified constraint will be listed in the Constraints dialog box.
6 Click OK to close the Constraints dialog box.

Run the Optimization Analysis

Right-click the Optimization Study icon and select Run. The analysis starts. As
the analysis runs, you will see the dimensions specified as design variables
changing in each design cycle until they reach their optimum values calculated by
the program. When the analysis is completed successfully, a Convergence
Achieved message window appears. Click OK to close the message window.
View the Initial and Final Designs
To view the initial or final design:

1 Click the plus sign next to the Design
Cycle Result folder.
2 Double-click the Initial Design icon.
The initial design will be displayed. Initial Design
3 Double-click the Final Design icon.

The final design will be displayed.
To view the design at a certain cycle:

1 Right-click the Design Cycle Result
folder and select Define. The Design
Cycle Result dialog box opens. It
displays the number of iterations
needed to achieve the optimum design.
Final Design
2 In the Iteration No. field, enter the
desired one, for example, 4.
3 Click OK.
Design variables after 4 iterations
8-28
Convergence Graphs
To plot the default design variable convergence graph:
1 Click the plus sign to the left of the Design History Graph folder.
To plot the convergence of all design variables:

1 Right-click the Design History Graph folder and click Define. The Design
2 From the Graph
Parameters menu, select
Design variables.
3 Move all design variables
from the Available Data
box to the Plot Data box
by clicking the double
arrow button.
4 Click OK. The following
convergence plot will be
generated in a separate
window.

Local Trend Graphs
To plot the objective function versus the first design variable:

1 Click the plus sign to the left of the Design local Trend Graph folder.
✍ You can generate other graphs by right-clicking the Design Local Trend
Graph folder and selecting Define.
8-30

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Cosmos Works Tutorials

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Power • Accuracy • Functionality

Information is subject to change without notice. NASTRAN is a registered trademark of the

This manual provides you with step-by-step tutorials to use COSMOS/Works.

Learning to Use COSMOS/Works 1-1

1-2 COSMOS/Works Tutorial

Learning to Use COSMOS/Works 2-1

Lesson 1: Analysis of a Bracket Part

In this lesson, you will learn how to:

Retrieve the Part

To set the unit options:

Create a Static Analysis Study

Learning to Use COSMOS/Works 2-3

To start the COSMOS/Works Manager:

To create a static analysis study:

To set the properties of the static study:

To assign a material from the COSMOS/M Library:

Learning to Use COSMOS/Works 2-5

4 Optional: From the Unit System

6 Click OK. COSMOS/Works assigns Alloy Steel to the part. A checkmark

Fix these holes

To fix the two holes:

Learning to Use COSMOS/Works 2-7

3 From the Type box, select Immovable.

To apply uniform pressure:

Mesh the Part

Learning to Use COSMOS/Works 2-9

To set mesh preferences:

To mesh the part:

To view the mesh:

Learning to Use COSMOS/Works 2-11

Run Static Analysis

To run static analysis:

Postprocessing Static Results

To calculate the reaction forces on the vertical face:

Select this face

1 Select the vertical face of the bracket.

To calculate the reaction forces on the bottom face of the bracket:

Learning to Use COSMOS/Works 2-13

Select this face

To set result visualization (Graphics) option:

Built-in Standard Plots

von Mises Stress Plot

To plot von Mises stresses:

To set the color map of the plot:

To change the stress units:

To animate the stress plot:

✍ You can save your animation as an AVI movie

Learning to Use COSMOS/Works 2-15

To view an AVI file with Media Player:

Equivalent Element Strain Plot

To generate the equivalent element strain plot:

Resultant Displacement Plot

To generate the deformed shape plot:

Learning to Use COSMOS/Works 2-17

To generate a section plot of the first

2 In the Uncut field, select Fringe.

To change the cutting tool (primitive) for the section plot:

Learning to Use COSMOS/Works 2-19

4 Click the desired primitive (Plane, Cylinder, or Sphere).

To generate a default design check plot:

Learning to Use COSMOS/Works 2-21