cosmos companion is back from like 2004/2005, there have been a lot of changes since then
your parts should basically be resting on each other for the spot weld to work
maybe you aren't selecting the appropriate faces?
please post your model
In real model (before meshed) I ensure that everything is in contact and the spot weld location is on the face that resting on each other.
However, during meshing, since I use sheet metal object, they will be surface meshed on the mid-surface (not on the contact location of the spot weld), which I think may cause this problem.
Here attached is the model. All the red, blue and green spots are the location for the spot welds.
Thanks! I am using Solidworks 2013 SP3.0
build a simplified rep to check your methodology and post it here if you are still having trouble
Okay. Another thing I want to ask, is no penetration contact set necessary? Because I don't really need so much high accuracy in this kind of test.
Basically, I get rid of the problem by doing these:
1. Make mid-surface from the sheet metal
2. Exclude the sheet metal objects (so the spot weld can be specified on the mid-surface mesh) from analysis
3. Specify the spot weld on the facing mid-surface faces.
4. Remove the no-penetration contacts. (because when i set it on, STAR.exe immediately crashed)
what are you going to use instead of no penetration? if you aren't going to use that, don't bother with spot welds, it will be fully welded.
UPDATE: I managed to apply the No Penetration condition. But the degree of freedom is very high 3,785,413 DOF. The solution is also not converging. But, when I use draft-quality meshed, the DOF reduced to 857,351 and I am able to solve it. But I doubt it's accurate because it is draft quality mesh. Any other suggestion?
1) treat as sheet metal
2) welding face must be in no penetration
3)no gap allowed in mate
4) check weld dia like that properties
Can I ask you if you are able to make and analyse this simple model? Solidworks does not allow me to make spot weld because of the same error.
Two sheet metal that is spot welded among each other.
1. Both of them is treated as sheet metal (mid-surface meshed)
2. No penetration is applied.
If you are able to do it, may i ask if you can provide step to step about it?
UPDATE: Somehow, I manage to correct the error by adding split lines.
post your simple model and the one you fixed so that people that have this problem in the future can take a look
it sounds like maybe there were too many contact elements? i'm not really sure i'm clear on what a split line would do to fix the issue
Ok I'll post the model soon. But, tbh, I really dont know why the problem is gone.
Now my concern is:
The solver stuck on "Solving Contact Constraints" in 20% progress. Meanwhile the overall study progress stuck at 27.3%.
As you have said, my model has too many No Penetration contact sets among each panel parts which cause this problem. The number of D.O.F is quite large (about 3 Million D.O.F). I have searched on the forum, and they stated to check if there is anything that cause the problem using draft-quality mesh. The run using the draft-quality mesh can be finished and the results is out. (So, I assume that it is because too many DOFs) I also know that the draft mesh results wont be accurate.
Hence, do you have any suggestion to handle this problem (maybe the meshing etc)? I dont know any method to reduce the D.O.F anymore because I have used shell-meshed, half-model, etc. and the D.O.F is still high. I also tried adding split lines and use Control Mesh for crucial area only (like the contact points) in order to reduce number of elements . But the problem persists. I really need your help and I cannot afford switching to other softwares.
Also, I am not allowed to alter No Penetration contact because it won't be a proper modelling. Basically, this is for the university's final year project.
if it gets completely hung up, you probably have a setup issue
if it is just slow, that is just the way it is with a lot of contact
simplify your model and set it up step by step until you find the issue you're running into
I'm having a similar problem on using the on-line tutorial "Spot Weld Connectors".
1) If I run the simulation as the tutorial states. I get this gap alert.
It allows me to continue and get the this result which closely matches the tutorial results. See screen shot for notes.
2) I reset up the simulation per the following, see screen shot for notes. Here I did not get the "Gap alert", but the welds are not stressed at the end like I would expect.
1) Which one is to correct set-up?
2) Is this gap alert normally ignored?
3) Is there a different setup to avoid this gap alert.
Software is SW2014
car_model.zip 3.2 MB