SolidWorks COSMOS FEA | A Beginner’s Guide to Power Applications | No.1 Step to Find the Perfect Electronics Application | Process Application

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COSMOSWorks is a SolidWorks-integrated design analysis optimization programme. The Finite Element Method ( FEM) is the programme for simulating and forecasting the operating conditions of your ideas. The solution of vast systems of equations is needed for FEM. COSMOSWorks, which is powered by fast solvers, allows designers to easily verify the integrity of their projects and find the best solution.

COSMOSWorks is available in many kits to suit the analytical needs. It shortens market time by computer testing of the prototypes rather than costly and time intensive field experiments.

Solidworks COSMOS Analysis Benefits

Upon designing your concept in SolidWorks, you must ensure that this really operates well in the field. In the lack of analytical techniques, the only way to complete this objective is to go through costly and time-consuming product production processes. The following phases are usually included in a product design and development cycle:

  1. Use the SolidWorks CAD framework to build the model.
  2. Make a prototype of the concept.
  3. Put the prototype to the test in the real world.
  4. Assess the effects of the field experiments.
  5. Make changes to the specification depending on the outcome of the field tests.

This procedure is repeated until a suitable solution is found. The following tasks will be made easier with the help of analysis:

  1. Cost reduction, rather than costly ground experiments, by simulating model testing on a computer.
  2. Reduce marketing time by reducing product development cycles.
  3. Enhance the service by rapidly evaluating several hypotheses and ideas before making the final call.

SolidWorks COSMOS Static FEA Studies

Static experiments measure the displacements, reaction forces, stresses and safety factor. In some situations where pressures reach a certain degree, material fails. The evaluation of factor of safety is based on a criterion of failure.

Static experiments can help prevent failure because of high stresses. A safety factor below ‘one’ is evidence of material failure. Significant safety factors in a contiguous region mean low stresses and the possibility of removing any material from the area.

SolidWorks COSMOS Frequency FEA studies

A body interrupted from its place of rest is prone to vibrate at certain frequencies known as natural or resonant frequencies. Standard frequency is the lowest natural frequency. The body takes a certain form with each natural frequency, called the ‘mode shape’.

The study of frequency measures both the natural frequencies and the mode shapes involved. In theory, there are infinite modes within a body. In principle, there are as many modes as degrees of freedoms (DOFs) in the FEA. In certain cases, few modes are taken into account.

Frequency analysis can help prevent failure due to excessive resonance stresses. It also contains data that can be used to solve problems involving dynamic reaction.

SolidWorks COSMOS Buckling FEA Studies 

Buckling applies to axial loads causing unexpected, large displacements. Due to buckling at load levels that are lower than those needed to cause material failures, slender (Slim) structures subject to axial loads may fail. The result of various load levels can be buckling in various modes. Just the least load of buckling is of concern in certain situations.

Buckling experiments can help prevent buckling failure.

SolidWorks COSMOS Thermal FEA Studies

Thermal experiments use heat generation, conduction, convection, and radiation to measure temperatures, temperature gradients, and heat transfer. Thermal experiments can prevent unwanted thermal conditions such as excessive heat and freezing.

SolidWorks COSMOS Optimization FEA Studies

Optimization experiments use a geometric framework to automate the quest for the best design. COSMOSWorks has technology that can easily detect patterns and find the best solution for the fewest number of runs. The following terms must be described for optimization studies:

The objective of the Project:

The study’s goal should be specified. Take, for example, the bare minimum of materials.

Geometry Constraints or Design Variables:

Choose the variables that will shift and set their ranges. For eg, a hole’s diameter can range from 1.0” to 2.0”, while a sketch’s extrusion can range from 2.0” to 3.0”.

Constraints on Performance:

Define the requirements to be met by the optimal specification. For eg, a stress factor can not surpass with a certain value and the natural frequency is within a certain range.

Solidworks COSMOS Power Application:


Solidworks COSMOS cfd_heat_exchanger-flow-simulation-heat-transfer-rates-mass-flow-rates-pressure-drops

Solidworks COSMOS has been widely used in the power industry to study efficiency of sub systems involved in power generation. Combination of what if scenarios can be studied with ease to understand system response and enhance reliability.

Following Functionalities have been benefited the Power sector immensely:

  • Remaining Life Analysis of Static and Rotating components such as turbine parts
  • Heat transfer analysis of heat exchangers, boilers, pre-heaters, headers among others.
  • Fluid flow analysis in cyclones, waste heat recovery systems, chimneys, cooling towers and environmental and pollution control sub systems
  • Efficiency estimation of pumps
  • Energy flow studies in wind power applications
  • Solutions to Vibration induced failure problems
  • Strength and stiffness calculations for pressure vessels, structural members and tanks
  • Earth quake response (Seismic) Analysis of sub-systems
  • Creep analysis and aging calculations for high temperature applications

Solidworks COSMOS Process Application:


cfd_thermal_analysis_wind_loads-calculation-wind-analysis-in-high-rise-structure-architectural analysis

COSMOS has found numerous applications in Petrochemical, textile and allied Industries. Renowned process industries world wide have adopted COSMOS to enhance life expectancy, reduce cost and improve reliability and efficiency of sub-systems and component’s.

Some of the capabilities of COSMOS include:

  • Stress and deflection calculations for pressure vessels, agitators, environment tanks, process equipment’s and comparison to ASME Code
  • Nozzle stress calculations
  • Wind loading, Hydro static pressure testing of process equipment’s and qualification of equipment’s to seismic excitation based on zonal classification.
  • Heat transfer simulation of heat exchangers (Plate type, Shell and Tube Type, Air-Cooled), Super heaters, Evaporators, Condenser’s, Cooling Tanks, Boilers, Distillation Columns and Chillers
  • Fluid induced vibration simulation of columns, tube bundles, pipe supports among others
  • Life expectancy calculation’s for dryers (Static and Rotary), Centrifuges, Rotating equipment’s and load bearing members
  • High Temperature applications involving seals and gaskets
  • Stiffness, Stress and Life calculations for expansion joints

Solidworks COSMOS Electronics Applications:



Electronics industry worldwide has adopted COSMOS for quick and accurate simulations to obtain reliable answers for challenging situations arising out of thermal and vibratory input.

Some of the popular uses include:

  • Shock calculations of enclosures, support structures, electronic systems as per MIL, NAVSEA, BS and Indian Standards for equipment’s used in aircrafts, ships and off road vehicles
  • Thermal management of electronic device enclosures
  • Forced cooling in electronic sub systems and optimization of heat sinks
  • Thermal management of Printed Circuit Boards
  • Vibration analysis for impact printers & Electro-Mechanical actuation systems
  • Natural and Forced convection cooling of controllers ( Internal and External)
  • Heat Transfer efficiency of cold plates.

Solidworks COSMOSWorks feels great and offers a complete set of tools that enables you to describe the product not only in 3D, but also to assess performance and operating properties within the same environment, leveraging links between the CAD, FEA and CFD. In a conclusion, it’s pretty cool.

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