SolidWorks FEA Simulation

At Hamilton By Design, we use SolidWorks Simulation FEA to help mining, manufacturing, power generation and industrial clients make better decisions before anything is cut, welded or installed.

Whether you’re upgrading a chute, checking a pressure vessel, or validating a complex brownfield retrofit, our team can simulate real-world loads, temperatures and constraints so you know how your design will behave in service.

Why use SolidWorks FEA with Hamilton By Design?

Mechanical engineers with real site experience – CHPPs, conveyors, reclaimers, pressure vessels, structures and plant equipment.
Seamless link to 3D CAD – we model in SolidWorks, analyse in SolidWorks Simulation, then deliver fabrication-ready drawings.
Engineering-grade results – correct boundary conditions, meshing control and code-aligned assessment where required.
Clear reports for decision-makers – not just stress plots, but explanations, factors of safety and practical recommendations.

Our SolidWorks FEA Capabilities

We offer a broad range of analysis types, from straightforward linear static checks through to advanced contact, thermal and fatigue studies.

1. Linear Static & Structural Integrity

For components and assemblies under static loading:

Linear Static (parts and assemblies)
Linear Static – multi-body assemblies
Beam and Shell element models for frames, platforms, platework and tanks
Static Stress (parts)
Static Stress (assemblies)
Contacts and contact sets (bonded, no-penetration, friction etc.)
Large displacement behaviour for flexible or slender structures

Typical use cases:

Platforms, walkways, supports, frames
Brackets, bases, machine frames and guarding
Brownfield modifications and tie-ins

2. Modal, Frequency & Buckling Analysis

Understanding how structures respond to vibration and instability:

Frequency / Modal analysis
Modal / Frequency analysis (eigenfrequencies and mode shapes)
Buckling Analysis (eigenvalue / linear buckling)
Modal / Buckling studies for slender structures

Typical use cases:

Avoiding resonance in platforms, ducts, chutes and pipework
Screening structures against equipment running speeds
Checking risk of buckling under compressive loads

3. Thermal Analysis (Steady & Transient)

Thermal loading can be just as critical as mechanical loading. We perform:

Steady State Thermal analysis
Transient Thermal analysis
Coupled thermal–stress workflows (temperature → stress)

Typical use cases:

Hot chutes, ducts, kilns and enclosures
Equipment in high-temperature environments
Evaluating thermal gradients prior to stress assessment

4. Fatigue & Life Estimation

Assessing how long components are likely to last under cyclic loading:

Fatigue analysis using Stress-Life (SN curves)
Fatigue Analysis / Fatigue (SN Curves)
Fatigue – Stress-Life (SN curves) for variable loading conditions

Typical use cases:

High-cycle fatigue in vibrating plant and supports
Welded details on chutes, frames and platforms
Repeated loading on mechanical components

5. Drop Test & Impact-Type Events

Where equipment may be dropped, impacted or experience short-duration loads:

Drop Test simulations (rigid and flexible bodies)
Drop Test (explicit-like method within SolidWorks Simulation)

Typical use cases:

Handling frames, lifting devices, skids
Enclosures, housings and protective covers
Equipment subject to accidental drop or impact

6. Pressure Vessel & Stress Linearisation

We support pressure vessels and pressurised equipment with:

Pressure Vessel evaluation
Pressure Vessel / Stress Linearization for membrane and bending stress extraction
Assessment against design criteria (in conjunction with relevant codes/standards as required)

Typical use cases:

Tanks, vessels, pipework branches and nozzles
Pressure retaining components in process plants

7. Topology Optimisation & Design Refinement

For weight reduction and concept development:

Topology Optimisation for parts and sub-assemblies
Using optimisation results to drive manufacturable designs in SolidWorks

Typical use cases:

Lightweight brackets and frames
Concept development where weight, stiffness or cost must be balanced

8. Motion & Load Extraction

Understanding motion and using it to drive realistic FEA loads:

Time-based Motion studies
Load extraction from motion into FEA (reaction forces, accelerations, etc.)

Typical use cases:

Mechanisms with moving arms, linkages or tooling
Equipment where dynamic loads dominate over static loads

9. Advanced Contacts, Meshing & Convergence

Robust results rely on correct discretisation and contact definition. We provide:

Advanced Contacts (nonlinear contact behaviour, friction, separation)
Advanced meshing strategies for complex geometry
Local mesh refinement around welds, holes, notches and stress raisers
Mesh convergence checks for confidence in results

Reporting & Engineering Documentation

Every simulation is backed by clear, traceable documentation, including:

Description of the model, loads, boundary conditions and assumptions
Material properties and factors of safety used
Key plots: stress, displacement, factor of safety, temperature, modes, buckling shapes etc.
Fatigue life estimates where applicable
Mesh screenshots and convergence discussion
Practical engineering recommendations (e.g. increase plate thickness, add stiffeners, adjust weld details).

These reports can be issued in PDF format for internal review, client submissions or integration into your broader design dossier.

How We Work With You

Define the problem – loads, constraints, operating conditions and success criteria.
Build or import the CAD model – we model in SolidWorks or clean up your existing geometry.
Set up the study – select the appropriate FEA type, materials, contacts and mesh.
Run and refine – iterate as needed to achieve stable, converged results.
Recommend improvements – we help you interpret the results and adjust the design.
Deliver documentation – final models, plots and reports ready for approval or fabrication.

Discuss Your Next SolidWorks FEA Project

If you need confidence that your design will perform as intended – whether it’s a small bracket or a critical plant upgrade – our team can help.

Hamilton By Design combines SolidWorks FEA simulation with practical engineering and fabrication understanding to de-risk projects across mining, heavy industry, power generation and manufacturing.

Get in touch to discuss your next project, share a model, or explore whether FEA can help you solve a specific problem before it becomes a shutdown headache.

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What Is FEA — and Why It Matters

FEA divides complex geometry into a network of small, interconnected elements.
By solving the physical equations that govern stress, strain, and displacement across those elements, engineers can predict how a structure behaves under load, vibration, or temperature.

Instead of relying solely on hand calculations or over-built safety factors, FEA provides quantitative insight into performance — letting us see where structures flex, where stress concentrates, and how design choices affect real-world outcomes.

In mechanical engineering, that means fewer prototypes, lower material costs, and far greater design confidence.

1. Static Analysis — The Foundation of Structural Validation

Static linear analysis is the foundation of most FEA work.
It evaluates how a structure responds to steady, time-independent loads such as gravity, pressure, or fixed equipment weight.

Through static analysis, engineers can:

Visualise stress and displacement distribution across a part or assembly.
Evaluate safety factors under different loading conditions.
Check stiffness and material utilisation before fabrication.
Identify weak points or stress concentrations early in design.

This baseline validation is the difference between a design that “should” work and one that will.

2. Assembly-Level Simulation — Seeing the Whole System

Few machines fail because a single part breaks.
Most failures happen when components interact under load — bolts shear, brackets twist, or welds experience unplanned tension.

FEA allows engineers to simulate entire assemblies, including:

Contact between parts (bonded, sliding, or frictional).
Realistic boundary conditions such as bearings, springs, or pinned joints.
The influence of welds, fasteners, or gaskets on overall performance.

This system-level view helps mechanical engineers design not only for strength, but also for compatibility and reliability across the full structure.

3. Mesh Control — Accuracy Where It Counts

A simulation is only as good as its mesh.
By controlling element size and density, engineers can capture critical detail in stress-sensitive regions like fillets, bolt holes, and weld toes.

Modern FEA tools use adaptive meshing — refining the model automatically in areas of high stress until the solution converges.
That means precise, efficient results without excessive computation time.

4. Thermal-Structural Interaction — When Heat Becomes a Load

Many mechanical systems face thermal as well as mechanical challenges.
Whether it’s ducting in a process plant or hoppers near heat sources, temperature gradients can cause expansion, distortion, or thermal stress.

FEA allows engineers to:

Model steady-state or transient heat transfer through solids.
Apply convection, radiation, or temperature boundary conditions.
Combine thermal and structural analyses to study thermal expansion and thermal fatigue.

Understanding how heat and load combine helps ensure equipment remains stable, safe, and accurate throughout its lifecycle.

5. Modal and Buckling Analysis — Designing Against Instability

Some risks are invisible until they’re simulated.
Vibration and buckling are two of the most overlooked — yet most common — causes of structural failure.

Modal Analysis

Determines a structure’s natural frequencies and mode shapes, helping designers avoid resonance with operating machinery, fans, or conveyors.

Buckling Analysis

Predicts the critical load at which slender members or thin-walled panels lose stability — allowing engineers to reinforce and optimise designs early.

By identifying these limits before fabrication, engineers can prevent problems that are expensive and dangerous to discover on site.

Design Optimisation — Smarter, Lighter, Stronger

Good design is rarely about adding material; it’s about using it wisely.
FEA supports parametric and goal-based optimisation, enabling engineers to vary geometry, thickness, or material and automatically test multiple configurations.

You can set objectives such as:

Minimising weight while maintaining strength.
Reducing deflection under fixed loads.
Optimising gusset or flange size for stiffness.

This process of “digital lightweighting” drives better performance and cost efficiency — especially valuable in industries where both material and downtime are expensive.

7. Communication and Confidence

FEA isn’t only a calculation tool — it’s a communication tool.
Colour-coded plots, animations, and automated reports make it easier to explain complex mechanical behaviour to project managers, clients, or certifying bodies.

Clear visuals turn stress distributions and displacement fields into a shared language — helping stakeholders understand why certain design choices are made.

Real-World Applications Across Mechanical Engineering

Application	Type of Analysis	Key Benefit
Chutes & Hoppers	Static + Buckling	Confirm wall thickness and frame design for structural load and vibration
Conveyor Frames	Modal + Static	Avoid resonance and ensure adequate stiffness
Pressure Equipment	Thermal + Static	Evaluate thermal stress and hoop stress under load
Machine Brackets	Static + Optimisation	Reduce weight while maintaining rigidity
Platforms & Guarding	Buckling	Validate stability under safety loading
Welded Frames & Supports	Static	Check deformation, stress, and weld performance

These examples show how FEA becomes an everyday design partner — embedded in the workflow of mechanical engineers across manufacturing, resources, and infrastructure.

The Engineer’s Advantage: Data Over Assumption

In traditional design, engineers often relied on prototypes and conservative safety factors.
Today, simulation delivers the same assurance — without the waste.

By applying FEA early in the design cycle, mechanical engineers can:

Predict failure modes before they occur.
Shorten development time.
Reduce material usage.
Justify design decisions with quantitative proof.

FEA enables engineers to focus less on guesswork and more on innovation — designing structures that are both efficient and dependable.

Engineering Integrity in Practice

At Hamilton By Design, we integrate FEA into every stage of mechanical design and development.
It’s how we ensure that every frame, chute, and mechanical system we deliver performs as intended — safely, efficiently, and reliably.

We use FEA not just to find the limits of materials, but to push the boundaries of design quality — delivering engineering solutions that last in the toughest industrial environments.

Design backed by data isn’t a slogan — it’s how we engineer confidence.

Building a Culture of Verified Design

When FEA becomes part of everyday engineering culture, it changes how teams think.
Designers begin to see structures not just as drawings, but as living systems under real forces.

That shift builds trust — between engineer and client, between concept and reality.
It’s what defines the future of mechanical design: informed, optimised, and proven before the first bolt is tightened.