Mesh generation in Solidworks - Dashboard Guide

Dashboard Mode - Mesh generation

Goal

Understand how mesh generation affects simulation accuracy and performance in SolidWorks.

Sample Data: Mesh Settings and Results

Mesh Size (mm)	Element Count	Simulation Time (s)	Max Stress (MPa)
5	1200	30	250
3	3200	75	260
1	15000	350	265
0.5	45000	1200	267
0.2	120000	3500	268

Dashboard Components

• KPI Card: Average Simulation Time
  Formula: Average of Simulation Time (s) column
  Result: (30 + 75 + 350 + 1200 + 3500) / 5 = 1031 s
• KPI Card: Max Stress at Finest Mesh
  Formula: Max Stress value where Mesh Size = 0.2 mm
  Result: 268 MPa
• Line Chart: Mesh Size vs Simulation Time
  X-axis: Mesh Size (mm)
  Y-axis: Simulation Time (s)
  Shows how simulation time increases as mesh size decreases
• Line Chart: Mesh Size vs Max Stress
  X-axis: Mesh Size (mm)
  Y-axis: Max Stress (MPa)
  Shows stress convergence as mesh refines
• Table: Detailed Mesh Data
  Shows all columns from sample data for reference

Dashboard Layout

+----------------------+----------------------+
| Average Simulation   | Max Stress at Finest |
| Time (KPI)          | Mesh (KPI)           |
+----------------------+----------------------+
|                      Line Chart: Mesh Size vs Simulation Time             |
+--------------------------------------------------------------------------+
|                      Line Chart: Mesh Size vs Max Stress                  |
+--------------------------------------------------------------------------+
|                      Table: Detailed Mesh Data                           |
+--------------------------------------------------------------------------+

Interactivity

A slicer allows filtering by Mesh Size ranges (e.g., coarse, medium, fine). Selecting a range updates all charts and KPIs to show data only for that range. For example, filtering to fine mesh sizes (0.5 mm and below) updates the KPIs and charts to reflect only those rows.

Self Check

If you add a filter to show only mesh sizes 1 mm and finer, which components update and what changes occur?

• Average Simulation Time KPI updates to average simulation time for mesh sizes 1, 0.5, and 0.2 mm.
• Max Stress KPI updates to max stress at 0.2 mm mesh size.
• Both line charts update to show only data points for mesh sizes 1, 0.5, and 0.2 mm.
• Table filters to show only rows with mesh sizes 1, 0.5, and 0.2 mm.

Key Result

Dashboard shows how mesh size affects simulation time and max stress in SolidWorks simulations.

Practice

1. What is the main purpose of mesh generation in SolidWorks simulations?

easy

A. To color the model for better visualization

B. To divide the model into small elements for analysis

C. To create 3D animations of the model

D. To export the model to other software

Solution

1. Step 1: Understand mesh generation concept

   Mesh generation breaks the model into small pieces called elements for detailed analysis.

2. Step 2: Identify the purpose in simulation

   This division allows simulation software to calculate physical behaviors accurately.

3. Final Answer:

   To divide the model into small elements for analysis -> Option B

4. Quick Check:

   Mesh generation = dividing model for analysis [OK]

Hint: Mesh means breaking model into small parts for study [OK]

Common Mistakes:

• Confusing mesh with coloring or animation
• Thinking mesh exports the model
• Assuming mesh is for visual effects only

2. Which of the following is the correct way to describe mesh refinement in SolidWorks?

easy

A. Decreasing element size in important areas for accuracy

B. Increasing element size to speed up simulation

C. Removing mesh elements to simplify the model

D. Changing mesh color to highlight stress zones

Solution

1. Step 1: Understand mesh refinement meaning

   Refinement means making mesh elements smaller in key areas to improve detail.

2. Step 2: Identify correct description

   Decreasing element size in important areas increases accuracy without slowing entire simulation too much.

3. Final Answer:

   Decreasing element size in important areas for accuracy -> Option A

4. Quick Check:

   Refine mesh = smaller elements where needed [OK]

Hint: Refine means smaller elements in key spots [OK]

Common Mistakes:

• Thinking refinement means bigger elements
• Confusing refinement with removing elements
• Mixing mesh color with mesh size

3. Given a mesh with element size set to 5 mm in the whole model and refined to 1 mm in a small area, what is the expected effect on simulation time and accuracy?

medium

A. Simulation time increases and accuracy increases

B. Simulation time increases and accuracy decreases

C. Simulation time stays the same and accuracy decreases

D. Simulation time decreases and accuracy decreases

Solution

1. Step 1: Analyze element size effect on simulation

   Smaller elements increase calculation steps, so simulation time goes up.

2. Step 2: Analyze element size effect on accuracy

   Smaller elements in important areas improve detail and accuracy of results.

3. Final Answer:

   Simulation time increases and accuracy increases -> Option A

4. Quick Check:

   Smaller mesh = longer time + better accuracy [OK]

Hint: Smaller mesh means slower but more accurate [OK]

Common Mistakes:

• Assuming smaller mesh speeds simulation
• Thinking accuracy drops with refinement
• Ignoring local refinement effects

4. You set a mesh element size to 0 mm in SolidWorks. What is the likely outcome?

medium

A. The software will generate the finest possible mesh automatically

B. The mesh will be very coarse with large elements

C. The mesh will ignore the size and use default values

D. An error or warning will occur because 0 mm is invalid

Solution

1. Step 1: Understand valid mesh element sizes

   Mesh element size must be a positive number greater than zero.

2. Step 2: Predict software behavior with invalid input

   Setting 0 mm is invalid and will cause an error or warning to prevent simulation issues.

3. Final Answer:

   An error or warning will occur because 0 mm is invalid -> Option D

4. Quick Check:

   Zero mesh size = error [OK]

Hint: Mesh size cannot be zero, causes error [OK]

Common Mistakes:

• Assuming zero means finest mesh
• Thinking zero defaults to coarse mesh
• Ignoring input validation rules

5. You want to simulate stress on a complex bracket with thin walls and thick base. How should you set up the mesh to get accurate results efficiently?

hard

A. Refine mesh on thick base and keep coarse mesh on thin walls

B. Use a uniform coarse mesh everywhere to save time

C. Refine mesh only on thin walls and keep coarse mesh on thick base

D. Use the finest mesh everywhere regardless of geometry

Solution

1. Step 1: Identify critical areas for stress accuracy

   Thin walls are more likely to have stress concentration and need finer mesh.

2. Step 2: Apply mesh refinement strategy

   Refine mesh on thin walls for accuracy, keep coarse mesh on thick base to save time.

3. Step 3: Avoid unnecessary refinement

   Using finest mesh everywhere increases time without much benefit on thick base.

4. Final Answer:

   Refine mesh only on thin walls and keep coarse mesh on thick base -> Option C

5. Quick Check:

   Refine critical areas, coarse elsewhere = efficient accuracy [OK]

Hint: Refine mesh on thin parts, coarse on thick parts [OK]

Common Mistakes:

• Refining mesh uniformly wastes time
• Refining thick base wastes resources
• Ignoring geometry differences in mesh setup