By running a Motion study with the mathematical model, data from the physical study was replicated which not only showed that HD’s mathematical models and Motion study were accurate but, gave a benchmark to work from. When optimising the design of a critical clip interface, the study could be re-run and overlaid with the physical data for comparison. From here, the focus was to improve the product’s performance by decreasing the force required to operate it.
From this, HD were able to iterate, develop, and retest a new and more effective design. By using Motion testing, the original design’s performance could be compared against the new design.
After this theoretical work, an injection moulded component of the new design was manufactured and physically tested creating a further set of results which could be compared against the theoretical force profile generated in Motion – they were remarkably similar. Using Motion eliminated numerous iterations of prototype designs to get to this point – saving time and reducing costs.
Simulation is often overlooked as a software add-on to SolidWorks. It’s highly versatile so can be used to validate early concepts, reduce prototype iterations and quickly optimise designs to suit key performance parameters.