Mesh generation in Solidworks - Real Business Scenario

Scenario Mode

👤 Your Role: You are a design engineer at a manufacturing company.

📋 Request: Your manager wants you to analyze the stress distribution on a new product design by generating a mesh model for simulation.

📊 Data: You have the 3D CAD model of the product in SolidWorks. The model includes all parts and assemblies with material properties assigned.

🎯 Deliverable: Create a mesh of the product model suitable for finite element analysis (FEA) and prepare a report showing mesh quality and element count.

Sample Data

Part Name	Material	Dimensions (mm)	Mesh Type	Element Size (mm)
Base Plate	Aluminum	200x150x10	Tetrahedral	5
Support Arm	Steel	100x50x20	Tetrahedral	3
Cover	Plastic	150x100x5	Hexahedral	4
Screws	Steel	10x10x30	Tetrahedral	1
Bracket	Aluminum	80x40x15	Tetrahedral	3

1

Step 1: Open the product 3D CAD model in SolidWorks.

File > Open > Select product assembly file (.sldasm)

Expected Result

Product assembly model is loaded and visible in SolidWorks workspace.

2

Step 2: Assign material properties to each part if not already assigned.

Right-click part > Material > Edit Material > Select appropriate material (Aluminum, Steel, Plastic)

Expected Result

All parts have correct material properties assigned.

3

Step 3: Access the Simulation add-in and create a new study for mesh generation.

Simulation tab > New Study > Static > OK

Expected Result

New static study is created and ready for mesh setup.

4

Step 4: Set mesh parameters for each part based on the recommended element size and mesh type.

Right-click Mesh > Create Mesh > Set element size (e.g., 5mm for Base Plate) > Select mesh type (Tetrahedral or Hexahedral)

Expected Result

Mesh parameters are set for each part according to the table.

5

Step 5: Generate the mesh for the entire assembly.

Right-click Mesh > Create Mesh > Click Generate

Expected Result

Mesh is generated with elements distributed as per settings.

6

Step 6: Review mesh quality metrics such as element shape, size, and aspect ratio.

Simulation > Mesh > Mesh Quality > Review reports

Expected Result

Mesh quality report shows acceptable element quality with no distorted elements.

7

Step 7: Export mesh statistics including total element count and quality summary.

Simulation > Mesh > Export Mesh Info > Save report

Expected Result

Mesh report file is saved with element counts and quality metrics.

8

Step 8: Prepare a summary report with screenshots of the mesh and key statistics.

Use SolidWorks screenshot tool and document editor to compile report

Expected Result

Report includes mesh images, element counts, and quality summary ready for manager review.

Final Result

Mesh Generation Report
======================

Parts Mesh Summary:
- Base Plate: 1600 elements (Tetrahedral, 5mm)
- Support Arm: 4500 elements (Tetrahedral, 3mm)
- Cover: 3000 elements (Hexahedral, 4mm)
- Screws: 1200 elements (Tetrahedral, 1mm)
- Bracket: 2000 elements (Tetrahedral, 3mm)

Mesh Quality:
- Average element quality: 0.85 (Good)
- No distorted elements detected

Visual:
[Mesh screenshot here]

End of Report

✓Mesh element sizes are set appropriately for each part balancing accuracy and computation time.

✓Mesh quality metrics indicate a reliable mesh suitable for stress simulation.

✓Total element count is approximately 12,300, manageable for the simulation software.

Bonus Challenge

Optimize the mesh by refining element size only in high-stress areas to reduce total element count without losing accuracy.

Show Hint

Use simulation results from a coarse mesh to identify high-stress zones, then apply local mesh refinement in those areas.

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