Using SimulationXpress for Free FEA Analysis

SOLIDWORKS SimulationXpress is a powerful yet accessible tool for structural simulation and validation. Whether you are new to finite element analysis (FEA) or just curious about how loading might affect your model, SimulationXpress offers a great starting point to run first-pass FEA analysis on SOLIDWORKS parts.

What is SimulationXpress?

SOLIDWORKS SimulationXpress is a free, user-friendly stress analysis tool that provides an initial analysis of parts for engineers, designers, and other CAD users. Doing an initial stress analysis on a part saves time and money associated with multiple rounds of real-world destructive testing.

Using SimulationXpress as an initial evaluation, you will have more confidence in your part passing real-world testing when the time comes, since it uses the same technology as the full simulation products from SOLIDWORKS. If you find this tool valuable, then consider upgrading to the full SOLIDWORKS Simulation package for more in-depth analysis.

How to Activate SimulationXpress

First, to use SimulationXpress, you need to activate your license. To activate SimulationXpress or other Xpress products, do the following:

1. Open the Xpress Products menu found under the Tools drop-down on the main SOLIDWORKS header bar.
2. Select SimulationXpress.
3. Click on the my.solidworks.com/xpress link to go to the product code portal.
4. Log in with a 3DEXPERIENCE ID tied to a license on subscription and request your code.
5. Paste the code in the SOLIDWORKS prompt to enable the Xpress tool.
6. Hit OK.

SOLIDWORKS SimulationXpress activation window

How to Use SimulationXpress

In our example, we will be looking at a force applied to a bracket. SimulationXpress will provide stress and strain results for us to evaluate and make decisions on how we want to improve our design. In addition, we can look for a factor of safety in the part that we can specify. Once we do our analysis, we can then move on to refining our part.

Using the SimulationXpress Wizard

After launching SimulationXpress, the SOLIDWORKS tree will update to show a new simulation study with sections for loads, fixtures, and materials. The Task Pane will update to show the SimulationXpress wizard, which will walk you through each stage of the analysis.

The SOLIDWORKS SimulationXpress interface

Before beginning, you can change the simulation options to set the units for the study. Hitting Next will begin the setup process for the simulation.

Adding Fixtures

The first step to running a study is adding fixtures. With SimulationXpress, you are limited to fixed geometry, meaning that whatever faces are selected are controlled in all degrees of freedom.

Assigned fixed faces to the model

The wizard includes different examples of fixed geometry with animated GIFs. If you need more fixture types, consider upgrading to SOLIDWORKS Simulation.

Adding Loads

Next, you will add one or multiple loads to the model. Loads are forces or pressures acting on the object and applying some sort of load to the part to cause deflection.

Applying a force to the vertical faces of the model

Select the geometry you wish to apply the load to and specify the intensity of it. By default, the load will be applied in the normal direction to the faces; however, you can also specify direction vectors for the force.

Defining Materials

With loads and fixtures out of the way, you need to define a material for the model. If one is already applied to the SOLIDWORKS part, it will be carried over and shown in the simulation wizard.

The SOLIDWORKS Simulation material library

However, if one was not defined previously, you can do so now. SOLIDWORKS provides a robust material library that contains many common materials and allows you to create custom ones.

Running the Simulation

Once all the steps in the simulation wizard are completed, you can run the FEA analysis.

The final FEA analysis setup

The first thing shown will be an exaggerated animation of the study’s deformation. This will provide insight into whether the study setup needs to be changed or if the model behaves as expected and you can move on to results.

Interpreting the Structural Analysis Results

After the study is solved, you will be presented with a variety of results. The Factor of Safety plot will outline where the maximum stress is lower than the yield point of the material and where it is above it. Other plots include Von Mises Stress, Displacement, and Deformation. The plots are typically scaled up so you can visibly see changes in the model.

The Factor of Safety plot from the study

Once the review is completed, results can be exported with an automated report in a Microsoft Word format. This will include study setup information along with screenshots of the different stages in the study. An eDrawings file can also be created that includes the simulation results.

Moving Beyond First-Pass Structural Analysis

SOLIDWORKS SimulationXpress is a great first-pass simulation tool to see how basic loads affect the SOLIDWORKS models. While limited to a single SOLIDWORKS part file and not assemblies, it can still provide invaluable insights to your projects.

There are times, however, when you need to set up more complex simulation studies on assembly files to solve drop test studies or topology optimization. SOLIDWORKS Simulation provides a comprehensive FEA analysis toolset that can enable your team to optimize the structural robustness of your parts and assemblies.

To learn more about SOLIDWORKS Simulation, click here.