Running accurate simulations in SolidWorks Simulation is essential for engineers who want reliable results for structural, thermal, and motion analyses. However, many users experience common issues such as mesh distortion, unrealistic boundary conditions, and inaccurate material definitions. This article explains the recommended methods to reduce errors in SolidWorks simulations and provides practical steps to improve the accuracy of your engineering workflow.
1. Define Accurate Material Properties
One of the most common causes of simulation errors is using incorrect or incomplete material data. Always make sure that density, elastic modulus, thermal conductivity, and yield strength are defined properly. Using high-quality material libraries can significantly reduce errors and improve the performance of your SolidWorks Simulation setup.
2. Refine the Mesh Strategically
Mesh quality plays a major role in determining the accuracy of Finite Element Analysis (FEA). Apply mesh refinement to critical areas such as fillets, holes, and stress concentration zones. Avoid global refinement unless necessary, as this can increase computing time without improving simulation accuracy.
3. Apply Realistic Boundary Conditions
Incorrect boundary conditions often lead to inaccurate simulation results. Ensure that fixtures, loads, and constraints reflect real working conditions. When running a structural analysis, always confirm if the applied forces match actual physical interactions.
4. Use Appropriate Solver Settings
Selecting the right solver can have a significant impact on the stability of the simulation. For complex geometries, use the iterative solver to improve convergence and reduce error accumulation. Always verify solver messages and warnings to ensure your simulation is running correctly.
5. Validate Results with a Simplified Model
A good engineering practice is to run a simplified test model before analyzing the full assembly. This step helps identify potential issues early and ensures that your SolidWorks Simulation configuration is correct. Comparing numerical results with hand calculations is also recommended.
6. Check Contacts and Interactions
Incorrect contact definitions can cause unrealistic deformation or simulation failure. Review contact types such as bonded, no-penetration, or frictional contact to ensure they match real-world physics. Proper contact settings help reduce errors and improve the reliability of SolidWorks simulations.
Conclusion
By applying these recommended methods—accurate materials, refined mesh, realistic boundary conditions, correct solver selection, simplified models, and proper contact definitions—you can significantly reduce errors in SolidWorks simulations. These techniques help engineers achieve better performance, stability, and confidence in their simulation results.
SolidWorks, Simulation, Engineering Analysis, CAD Tips, FEA
