Comparing Ansys and SolidWorks Structural Analysis of Bus Superstructure in Rollover Tests

Lim, Arthur (2025) Comparing Ansys and SolidWorks Structural Analysis of Bus Superstructure in Rollover Tests. Final Year Project (Bachelor), Tunku Abdul Rahman University of Management and Technology.

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Abstract

This project presents a comparative study of bus rollover crash−worthiness simulations using SolidWorks and Ansys to evaluate structural performance according to UNECERegulationNo. 66. The regulation stipulates safety requirements for bus superstructures to protect passengers during rollover accidents. The primary objective is to assess the reliability of SolidWorks’ simulation capabilities by comparing its results to those obtained with Ansys, a more established finite element analysis (FEA) tool widely used in the industry. In the literature reviewsection, it basically involves the discussions on safety regulations and the evolution of rollover testing, thereby stressing the need for accurate simulation techniques in compliance with UNECE standards. As in previous studies with LS-DYNE and Ansys, the importance of structural components, such as roof and floor joints, in mitigating the intrusion of residual space, is illustrated. However, as of the current study, there is limited research on the use of SolidWorks for bus rollover simulation, which the project aims to address. A methodology for bus safety structure modeling is presented by using numerical methods to simulate virtually a rollover test for assessing bus rollover crash-worthiness according to the United Nations Economic Commission for Europe (UNECE) Regulation No. 66, as well as to assess and ensure the structure’s reliability and safety under operating conditions which focuses on key metrics such as deformation, stress distribution, and energy absorption during the rollover event. The simulation is carried out using the finite elements analysis method on the model, and the results are compared in both Ansys and SolidWorks. Materials’ physical and geometrical nonlinearity is considered during the calculations. In addition, this work includes an experimental rollover test in accordance with UNECE Regulation No. 66, with the goal of verifying the supplied modeling methodology through the use of numerical methods. In the simulation, a safety structure and rollover stand (similar to those used in models) are used which a finer mesh applied to regions with expected high deformation to ensure accuracy. The project’s results are presented using explicit dynamics in Ansys whereas SolidWorks utilizes implicit solvers optimized for non-linear dynamic analysis. When the findings from SolidWorks and Ansys are compared, it is determined whether the created safety structure model in SolidWorks is as dependable and appropriate for use. Preliminary findings suggest that while SolidWorks provides consistent motion analysis results compared to Ansys using preliminary model, some differences in parameter settings and solver capabilities impact the detail and accuracy of stress distribution predictions. Further refinement of meshing and solver configurations is needed to optimize SolidWorks for highprecision structural simulations. This research contributes valuable insights into the capabilities and limitations of SolidWorks as a cost-effective alternative to Ansys for performing complex structural simulations. The developed workflow for bus rollover simulations could serve as a practical guide for future studies and engineering applications, potentially improving safety analysis practices in the transportation industry.