1. Reduce Field Failures with COSMOS™ Analysis Tools
Webcast Only
10:25 AM – Thank you for joining us for the this. We will begin in about 5 minutes.
10:30 AM – Thank you for joining us for the this webcast. We will begin in just a few minutes.
10:35 AM – Good day to all of you, and thank you for being here to see how COSMOS analysis tools can help you reduce field failures. My name is Suchit Jain and joining me is Ram Ramalingam who will be typing in answers to your questions during the presentation. Please note that this webcast is not intended to be a training session. For SolidWorks training please contact your reseller.

2. Poll I have used COSMOSXpress I am a COSMOSWorks user Yes No
No, I do not use any analysis tools
No, I use other analysis tools
Before I start - to better understand your analysis background please go ahead and mark you answers to the following questions

3. 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
Today we will cover a basic overview of field failures and look at some specific types of structural failures. Then we will discuss how engineers can reduce field failures of their products using design analysis or FEA technology. After that we will demonstrate SolidWorks & COSMOSWorks to show to show you analysis demonstration in real time. Finally, we will have a few minutes of Q & A to answer questions you type in during the presentation. Let us begin with a basic overview and background.

4. 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
When a product does not perform as intended during its operation it is considered to have failed. Failures can be local at a part level or total failure of the whole system or assembly. Consider a connecting rod of an engine. The cost of the part may be low but if engine is damaged by the failure then the repair cost can be 100 times more. If the engine is in a taxi then the vehicle may be out of service for several days costing may be 10 times more in lost revenue. And if the taxi driver loses control because of the engine failure (due to the connecting rod failure) there may be loss of a life.
It is widely recognized that 80 to 90% of mechanical failures arise from stress or fatigue problems.
In next few slides let look at some specific types of mechanical failures

5. Torsion Failures (ductile material behavior)
Turbine: Helical shaft failure
Here is an example of torsion failure in an helical shaft. Torsion failures can occur in ductile material such as aluminum
Torsion Failures (ductile material behavior)
Engine Shaft
Torsional Buckling

6. Gross Plastic Deformation (GPD)
Engine shaft/bearings
Turbine
Here is another example of failure due to permanent Plastic Deformation in engine shaft and bearings. Once a material is stretched beyond its elastic limit it will have permanent deformation even if the operational load is removed
Gross Plastic Deformation (GPD)
Material is misshapen, stretched,
or deflected beyond its elastic limit

7. Ductile & Brittle Failures in Tension
(Necking)
Here is another example of Ductile & Brittle material Failures in Tension. Ductile material tend to stretch under tension resulting in smaller cross section or necking. Brittle material break off without necking – e.g glass
Note
Shear Lip
Formation
Ductile & Brittle Failures in Tension

8. Fatigue Failures Fatigue (Stress Riser) Chunk Failure Fatigue Zone
Origin
Fatigue failures occur when components are subjected to repeated loading.
Fatigue Failures

9. Bending Deformation and Failures
Wing Carry Through Beams
(Inflight failure)
Pitch Control Rod
(Crash impact forces)
Rotor Mast
Here are some examples of failure due to bending deformation
Bending Deformation and Failures

10. Buckling failures occur when a component have excessive deformation and tend to occur in thin and slender components. Buckling failure do not occur due to material failure.
Buckling

11. Why Do Designs Fail? Errors in Design or manufacture
Excessive loads during catastrophic events
Insufficient Technical Knowledge
Material deficiencies
Operational errors
So why do designs fail?.
There are several reasons for design failures and except in cases catastrophic events most of them can be avoided. At one time it was thought that nothing could be done to prevent the catastrophic effects of large earthquakes, hurricanes, tornadoes or floods, and they were generally regarded as acts of God. It is now recognized that deaths or injuries resulting from catastrophic events can be reduced drastically by proper design and manufacturing.
Failure due to design and manufacture include errors in concept; failure to consider a load or combination of loads; deficient connection details; calculation errors; misuse of computer software; failure to consider maintenance requirements and durability; inadequate or inconsistent specifications for materials and unclear communication of design intent.
With advancements in modern technology failures due to lack of technical know how have started to decline. In history however, there are several cases of failures due to insufficient technical knowledge. For e.g. nsufficient technical knowledge knowledge of aerodynamic instability led to the collapse of the Tacoma Narrows suspension bridge. Other examples occur in the areas of fatigue and brittle fracture, for example the failure of Liberty ships during World War II.
manufacturing or fabrication defects may exist in the most reliable structural materials, such as standard structural steel sections or centrally-mixed concrete

12. 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
Now lets discuss the use of Design Analysis in reducing these field failure and also help in identifying design flaws early in the design cycle.

13. 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
Leveraging the combined powers of 3D solid modeling and design analysis software, engineers can now test a design on the computer instead of using prototype-test iterations for design. CAD models have become virtual prototypes, and design analysis has supplanted physical testing, enabling faster, less costly, and more optimized product development

14. 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
Design analysis makes it possible to perform design iterations quickly and inexpensively on computer models instead of on costly physical prototypes. You can use design analysis to verify whether or not your design will work, and if it behaves as you expect and intend it to. You can see if you have put too much load on for the component to handle, possibly causing breakage.
Design analysis also provides significant product quality benefits, enabling engineers to detect design problems far sooner than a prototype could be built. Design analysis can be used in the conceptual design phase to test out radical new designs without cutting metal. These might be designs you previously would not test because they would be too tedious or time consuming to build and test.
Thirdly, Design analysis facilitates studies of more than one design option and aids in developing optimized designs. Quick and inexpensive analysis often reveals non-intuitive solutions and benefits engineers by providing them with a better understanding of product characteristics ,
Finally, design analysis provides a set of tools that can be used for failure analysis

15. Why Invest in Design Analysis?
Improve Product Quality
67%
Avoid Field Failures
59%
Reduce Number of Prototypes
56%
Here is another report which summarizes the results of a third-party survey of the productivity gains experienced by hundreds of users of COSMOS analysis software. This data is useful to companies considering the purchase of new analysis software that operates with their current CAD solution. The findings of the survey show that using COSMOS analysis software for product development produces the following results:
100% of the companies reported an increase in productivity;
67% of the respondents reported an improvement in product quality;
59% of the respondents reported fewer product field failures;
56% reported a reduction in the number or prototypes;
If you would like a free copy of this report, please send me an at
Send an to to obtain a free copy of this report

16. 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
We have over 15 thousand customers using COSMOS analysis products in their product development process. Here are comments from few customers:…

17. 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
Before we start the live demonstration of SolidWorks and COSMOSWorks lets review the steps involved in performing analysis on your designs .

18. Design Analysis Process
Modify, Update, Refine
Geometry definition.
Define component materials.
Define physical situation with boundary conditions.
Mesh & run the analysis (solve the system of equations).
View and evaluate the results.
The basic 5-step process we will go through to get the stress information is as follows:… The nice thing is that COSMOSWorks walks us through each of these steps, making it simple to pick up and immediately use.

19. 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
As an example of all we have talked about up to now, let us analyze a connecting arm from an infrared spectrograph.
Webcast Only:
We will now switch to a live demonstration of SolidWorks and COSMOSWorks.
Again a reminder - you will need to click on the “Expand View” button at the bottom of the window to see the full expanded view
Fixed
Material: Alloy Steel

20. Products COSMOS/Works COSMOSFloWorks COSMOS/Motion Stress Thermal
Frequency & Buckling
Optimization
COSMOSFloWorks
Computational fluid dynamics
COSMOS/Motion
Motion simulation
Here is the COSMOS flagship analysis products

21. COSMOS - Complete Analysis Portfolio
Static
Vibration
Thermal
Nonlinear
Optimization
Post-dynamics
Here is a complete list of COSMOS analysis portfolio. We provide …… We do conduct frequent web seminars on analysis topics shown here. Watch out for future invitations!
Motion
Flow
Electromagnetic

22. Poll This webcast was informative. How was your viewing experience?
Agree
Somewhat agree
Disagree
How was your viewing experience?
Good
Average
Poor
Well Now is the time for another quick poll. I will open the poll now, please go ahead and mark your choices!.

23. 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
Webcast Only
We had several good questions during the session which you had typed for us. Hopefully we have been able to type all the answers. I will now answer a few of these questions…

24. Thank You!
Visit the SolidWorks website at 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:
(US and Canada)
(Outside the US and Canada)
My address: < >
Well we are done for the day. Thank you for attending this presentation. ……