Reduce Field Failures with COSMOS

Analysis Tools
Poll

• I have used COSMOSXpress

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

• What is field failure?

• What is Design Analysis and how it can help fix
product design flaws and reduce failures?
• Design analysis in five simple steps
• Q&A
What is Field Failure?

• When a product does not meet the intended

performance requirement it is considered to have
failed
• Failures can be local – part level or catastrophic –
system level
• Product failures can sometimes lead to loss of life
 Torsion Failures
(ductile material behavior)

Turbine: Helical shaft failure

Engine Shaft
Torsional Buckling
Gross Plastic Deformation
(GPD)
Material is misshapen, stretched,
or deflected beyond its elastic limit

Engine shaft/bearings Turbine

Ductile & Brittle Failures in Tension

Ductile Brittle
(Necking)

Note
Shear Lip
Formation
 Fatigue Failures

Fatigue (Stress Riser)

Chunk Failure

Origin Fatigue Zone

Bending Deformation and Failures

Rotor Mast

Wing Carry Through Beams

(Inflight failure)

Pitch Control
Rod
(Crash impact
forces)
Buckling
Why Do Designs Fail?

• Errors in Design or manufacture

• Excessive loads during catastrophic events
• Insufficient Technical Knowledge
• Material deficiencies
• Operational errors
Agenda

• What is field failure?

• What is Design Analysis and how it can help fix
product design flaws and reduce failures?
• Design analysis in five simple steps
• Q&A
What is Design Analysis?

• Design analysis is ability to simulate

prototype-test iterations and optimize
designs on computer without building
physical prototypes

Design Analysis Final testing

Production
Scope of Design Analysis

• Reduce Prototypes
– Does this design work?
– Does this design behave the way I think it does?
• Improve product quality, innovative designs
• Relative Merit
– Which of these candidate designs appears to be the
best?
– Weed out the lesser designs
• Failure Analysis
Why Invest in Design Analysis?

Improve Product Quality 67%

Avoid Field Failures 59%

Reduce Number of Prototypes 56%

Send an email to sjain@solidworks.com to

obtain a free copy of this report
Comments From Companies Using
Design Analysis

• Don Bartlett, Senior Staff Engineer, Fanuc Robotics, NA

“The biggest advantage was timesaving over our previous methods.
COSMOS is so fast and easy to use that we were able to make the 20
analysis runs that were required to understand the problem and solve
it"

• Greg Dato, Kinemetrics Inc. Pasadena, California

"With COSMOS we saved at least 2 months and thousands of dollars in
wasted hardware. By using COSMOS integrated with our CAD system,
we can electronically test multiple designs, then typically build just one
prototype."

• Karsten Hoffman, Project Leader, Dräger, Germany

“Using COSMOSWorks means that we can run calculations on the
various design approaches during the design stage easily and quickly.
We can then compare them against one another. Otherwise, we would
have to either send the calculation work outside or build real prototypes
so that we can carry out precise measurements
Agenda

• What is field failure?

• What is Design Analysis and how it can help fix
product design flaws and reduce failures?
• Design analysis in five simple steps
• Q&A
Design Analysis Process
Modify, Update, Refine

1. Geometry definition.
2. Define component materials.
3. Define physical situation with
boundary conditions.
4. Mesh & run the analysis (solve the
system of equations).
5. View and evaluate the results.
Example – Analyzing a Connecting
Arm

You will learn:

• Starting COSMOSWorks
• Learning the basic steps of design analysis
• Assessing the safety of the design
• Change the geometry and recompute the stresses
50 lb Force

Fixed

Material: Alloy Steel

Products

COSMOSWorks
• Stress
• Thermal
• Frequency & Buckling
• Optimization

COSMOSMotion COSMOSFloWorks
• Motion simulation • Computational fluid dynamics
Design Validation Products

COSMOSWorks
Adv. Professional

Designer Professional

Static Vibration Thermal Drop Test Fatigue Nonlinear Post-dynamics

COSMOSMotion COSMOSFloWorks COSMOSEMS COSMOSWorks Add-In

Motion Flow Simulation Electromagnetic
Optimization
Poll

• This webcast was informative.

– Agree
– Somewhat agree
– Disagree
• How was your viewing experience?
– Good
– Average
– Poor
Agenda

• What is field failure?

• What is Design Analysis and how it can help fix
product design flaws and reduce failures?
• Design analysis in five simple steps
• Q&A
Thank You!

• Visit the SolidWorks website at

http://www.solidworks.com to learn more about
SolidWorks and its product offerings.
• Contact your local SolidWorks reseller for
information on pricing and training. To find a
reseller in your area call:
– 1-800-693-9000 (US and Canada)
– +1-978-371-5011 (Outside the US and Canada)
• My email address: < >