SOLIDWORKS Simulation Mesh Refinement

SOLIDWORKS Simulation is a powerful FEA tool that can solve studies from linear static to non-linear dynamic analysis. These studies help to get a better understanding of how designs will behave in real-world conditions by using a set of boundary conditions and meshing criteria to analyze a problem. To really master simulations, it’s important to know how and when to use SOLIDWORKS Simulation mesh refinement.

At a very high level, meshes can be defined as the small computational elements that break a model into simpler parts for calculations. These calculations are necessary to obtain accurate results for physical behaviors such as stress, heat, frequency, and contacts. There are times during a simulation study when the mesh may need to be refined for one reason or another. This could be to improve the accuracy of results, confirm that results are converging, resolve poor mesh element errors, or for many other reasons.

How To Refine a SOLIDWORKS Simulation Mesh

When users create a mesh in a simulation study, they may slide the Mesh Density slider between Coarse and Fine. A finer mesh is more refined, while a coarser mesh is less refined. A design with proper mesh refinement will have more than just global mesh settings applied; a properly refined mesh will often include mesh controls as well.

Applying a mesh properly ensures that users are getting the most accurate results in the areas of concern while taking only as much time as necessary to run the study. Overrefining the mesh may seem like a good idea, but this will cause simulations to run longer for minimal accuracy differences. Good places to start when focusing on stress refinement may include locations where high levels of stress or contacts are expected, or where there may be complex geometry. These sections may need mesh control in addition to modified Mesh Parameters.

Mesh Parameters within the global mesh settings

To apply mesh controls, right-click on Mesh from the Simulation Tree and select Apply Mesh Control. SOLIDWORKS allows for faces, edges, vertices, points, and components to be used for mesh controls. The mesh element size is further refined beyond the global mesh settings for the areas selected. SOLIDWORKS Simulation prioritizes mesh controls over the mesh specified in the global mesh settings.

Applying mesh control in SOLIDWORKS Simulation

SOLIDWORKS Simulation Mesh Refinement for Result Convergence

The goal of mesh refinement is to drive more accurate results, but another benefit of mesh refinement is confirming that results are converging. How can users be confident that results are accurate and believable if a study has only been run once? Reliable studies have been run multiple times to confirm that there are no stress singularities.

Unrefined mesh near a fillet

Stress singularities may occur in point loads, point fixtures, sharp corners, and in corners of bodies making contact. These are areas where stress is theoretically infinite and therefore never converges to a value. It is important to understand the difference between stress singularities and stress concentrations. As the mesh is refined, stress concentrations will converge to a finite value. Most of the time, stress singularities will be seen in a corner where two faces meet. Adding a fillet to that corner will usually resolve the stress singularity.

Fillet with high mesh refinement

When is Enough, Enough?

The key aspect of mesh refinement is understanding the balance between accuracy and computational efficiency. While a finer mesh provides more precise results, excessive refinement can lead to significantly increased solve times and higher memory usage, which may not always be necessary. A well-optimized mesh should focus on areas of interest while maintaining a reasonable element count.

Ultimately, mastering mesh refinement in SOLIDWORKS Simulation allows engineers to make informed design decisions, optimize performance, and ensure product reliability without unnecessary computational overhead. By applying these best practices, users can achieve more accurate simulations while maintaining efficiency in their analysis workflow.

Looking to further improve your SOLIDWORKS Simulation skills? Register for an upcoming training course here.