Reduce Field Failures with COSMOS

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Reduce Field Failures with COSMOS Analysis
Tools
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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

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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
• QA

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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

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Torsion Failures(ductile material behavior)
Turbine Helical shaft failure
Engine Shaft Torsional Buckling
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Gross Plastic Deformation(GPD)
Engine shaft/bearings
Turbine
Material is misshapen, stretched, or
deflected beyond its elastic limit
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Ductile Brittle Failures in Tension
Brittle
Ductile
(Necking)
Note Shear Lip Formation
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Fatigue Failures
Fatigue (Stress Riser)
Chunk Failure
Fatigue Zone
Origin
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Bending Deformation and Failures
Wing Carry Through Beams (Inflight
failure)
Pitch Control Rod (Crash impact forces)
Rotor Mast
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Buckling
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Why Do Designs Fail?

• Errors in Design or manufacture
• Excessive loads during catastrophic events
• Insufficient Technical Knowledge
• Material deficiencies
• Operational errors

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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
• QA

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What is Design Analysis?

• Design analysis is ability to simulate
  prototype-test iterations and optimize designs on
  computer without building physical prototypes

Design
Final testing
Analysis
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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

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Why Invest in Design Analysis?
Improve Product Quality 67
Avoid Field Failures 59
Reduce Number of Prototypes 56
Send an email to sjain_at_solidworks.com to obtain a
free copy of this report
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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

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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
• QA

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Design Analysis Process

• 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.

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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
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Products

• COSMOS/Works
• Stress
• Thermal
• Frequency Buckling
• Optimization

• COSMOSFloWorks
• Computational fluid dynamics

• COSMOS/Motion
• Motion simulation

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COSMOS - Complete Analysis Portfolio
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Poll

• This webcast was informative.
• Agree
• Somewhat agree
• Disagree
• How was your viewing experience?
• Good
• Average
• Poor

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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
• QA

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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 lt gt