Optimizing the Design of a Cyclone Separator Stand: Buckling Analysis with a Stiffener in SolidWorks

As part of the CAE Simulation using SolidWorks series, this blog delves into a critical aspect of structural analysis—buckling. Specifically, we’ll walk through the process of adding and positioning a stiffener between the legs of a cyclone separator stand, performing a design study to optimize its placement for maximum buckling resistance. If you’ve been working through the Skill-Lync SolidWorks course, this practical challenge will enhance your understanding of CAE simulation with SolidWorks. 

Getting Started: Preparing the Model 

To begin, open SolidWorks and load the step file provided for the assignment. 

Suppress the Cyclone Separator: 

• Expand the model list and suppress the cyclone separator part. This focuses the analysis solely on the stand. 
• Save the updated model as a SolidWorks part file. 

Choose the Sketch Plane: 

• Open the part file and select the Top Plane for sketching the stiffener. 
• Right-click the plane, choose Sketch, and set it to Normal To for a perpendicular view. 

Modeling the Stiffener 

• Adding a stiffener correctly is critical to improving the stand’s buckling resistance. 

Create the Sketch: 

• Use the rectangle tool to draw the stiffener’s profile. 
• Ensure it contacts the stand’s legs to avoid discontinuities. 

Extrude the Stiffener: 

• Go to Features > Extrude. 
• Offset the stiffener by 1.5 m initially, reversing the direction as needed. 
• Define the width as 75 mm (remember to specify units). 

Finalize the Stiffener: 

• Confirm the extrusion settings and click OK. Your stiffener is now ready for analysis. 

Setting Up the Buckling Analysis 

Create a New Study: 

• Click on Simulation > New Study and choose Buckling Analysis. 
• Name the study for clarity. 
• Apply Material and Constraints: 
• Assign Alloy Steel as the default material. 
• Fix the base of the stand by selecting the relevant faces. 

Apply the Load: 

• Define a compressive load of 150 kN acting on the stand. 

Mesh and Run the Simulation: 

• Use the default mesh settings and run the analysis. 
• View the results, including the Buckling Factor of Safety, which indicates the load multiplier required to cause buckling. 

Understanding the Initial Results 

• The initial buckling factor of safety is 27, indicating the structure can withstand 27 times the applied load before failure. 
• While this value is satisfactory, the placement of the stiffener may influence the buckling resistance. To identify the optimal position, we’ll perform a design study. 

Performing a Design Study 

Define the Parameters: 

• Add a parameter for the stiffener’s position (offset distance). 
• Set the range to vary between 0.25 m and 1.75 m with increments of 0.25 m. 

Set Constraints: 

• Add a sensor to ensure the buckling factor of safety remains above 25. 
• Define the goal to maximize the buckling factor of safety. 

Run the Optimization: 

• SolidWorks will iterate through nine scenarios based on the defined parameters. 
• View the table of results to identify the optimal configuration. 

Interpreting the Results

• The study revealed that placing the stiffener at an offset distance of 1 m produced the maximum buckling factor of safety, 27. 
• Adjustments to other parameters, such as width or material, could further enhance performance. 

Conclusion 

This exercise demonstrates how SolidWorks CAE simulation tools can optimize structural designs by balancing parameters like stiffener position. By leveraging features like Design Studies, engineers can automate complex analyses and identify the best configurations for structural safety and efficiency. 

If you’re keen to explore more advanced simulations, the Skill-Lync CAE Training program offers in-depth tutorials and projects tailored to industry needs. Whether you’re working on buckling analysis, dynamic simulations, or thermal analysis, Skill-Lync’s CAE course equips you with the expertise to excel. 

Start optimizing your designs today with Skill-Lync’s Full Course in SolidWorks and take your simulation skills to the next level! 

This blog is part of our ongoing CAE Simulation using SolidWorks. If you missed the previous posts, check them out here.  

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