BY CHRISTOPHER F.

SIKORA

Copyright 2013 Christopher Sikora

This manual is for educational purposes only. It may be printed, but not resold for profit for its content. SolidWorks is a registered trademark of Dassault Systmes SolidWorks Corp. SolidWorks is a product name of Dassault Systmes SolidWorks Corp. ACIS is a registered trademark of Dassault Systmes SolidWorks Corp. IGES Access Library is a trademark of IGES Data Analysis, Inc.

Other brand or product names are trademarks or registered trademarks of their respective holders.

The information discussed in this document is subject to change without notice and should not be considered commitments by Christopher F. Sikora. The software discussed in this document is furnished under a license and may be used or copied only in accordance with the terms of this license.

CAD 121 COURSE SYLLABUS

SolidWorks Advanced
Course Description: SolidWorks Advanced 3 credit hours Exploration of the theory and application of solid modeling techniques for product design and manufacturing. Prerequisite: SolidWorks Basics CAD 120 or consent of instructor. Course Objectives: Provide the student with the knowledge and practical experience in the areas of 3D CAD modeling of parts, assemblies, and the creation of mechanical drawings from the models. Textbook
SolidWorks Advanced (Free/pdf. provided) Instructional videos of lecture provided at www.vertanux1.com

Evaluation Scale: A B C D F Points: Exercises Mid Term Final 300 pts 300 pts 300 pts 90% to 100% 80% to 89% 70% to 79% 60% to 69% Below 60%

Attendance & Participation 100 pts Total 1000 pts

General Course Outline Date Week Topic 1. 2. 3. Import and Export 2D and 3D Translation, Advanced lofting exercise Mold Tools, Cast part, complex draft, setback fillets, and draft analysis. Design Tables SolidWorks Administration Equations Modeling complex parts using sweeps Advanced Sheet Metal Fabrication. Review for Mid Term Mid Term Exam (No Class) Spring Break Cylindrical and Conical Sheet Metal Parts, Palette forming tools. Assembly Automation methods for the workplace. Freeform Surfacing Weldments & Structural Steel IGES Translation Repair. Review for Final Final Exam

4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.

Required Hardware
16+ Gigabyte USB Flash / Thumb Drive

Software
SolidWorks Educational Edition

STUDENTS WITH DISABILITIES We welcome students with disabilities and are committed to supporting them as they attend college. If a student has a disability (visual, aural, speech, emotional/psychiatric, orthopedic, health, or learning), s/he may be entitled to some accommodation, service, or support. While the College will not compromise or waive essential skill requirements in any course or degree, students with disabilities may be supported with accommodations to help meet these requirements. The laws in effect at college level state that a person does not have to reveal a disability, but if support is needed, documentation of the disability must be provided. If none is provided, the college does not have to make any exceptions to standard procedures. All students are expected to comply with the Student Code of Conduct and all other college procedures as stated in the current College Catalog. PROCEDURE FOR REQUESTING ACCOMMODATIONS: 1. Go to SRC108 and sign release to have documentation sent to the college, or bring in documentation. 2. Attend an appointment that will be arranged for you with the ADA coordinator or designee. CLASSROOM PROCEDURES: 1. Attendance of each scheduled class meeting is required unless otherwise specified by the instructor. 2. Daily work problems and hand-outs will be maintained in a notebook and turned in upon the instructors request. 3. Reading assignments will be made prior to discussing the material. 4. Keep your drafting workstation clean and free of miscellaneous materials. 5. Please report any malfunctioning equipment to the instructor. LABORATORY UTILIZATION: 1. Regular daytime hours. The room is open for your use starting at 8:00AM daily. Even though classes are being held, you are encouraged to find an open area and work in the laboratory. 2. There are evening classes, but you may use the lab up to 10:00PM. 3. On weekends, the lab will be available on Saturdays from 9:00AM to 4:00PM. The lab will be closed on Sundays.

INSTRUCTORS RESPONSIBILITY: 1. Present material in a manner that can be understood by each student. 2. Respect each student as an individual, to be of assistance in any way possible, and to help solve problems, but not to solve problems for the student. 3. Keep records of your progress and to summarize your learning experiences with a final Attendance and Cheating Policies Introduction: Drafting is a technical profession in our society; consequently, presentations in this course are factual and technical, and final grades represent the students accomplishment of the learning activities. Attendance: Attendance at each class meeting is required. Attendance may be a factor when determining the final grade. Your instructor will specify his/her policy concerning the relationship of attendance and the final grade. Each instructor has the option of taking attendance for his/her personal use. If a student misses class because of illness, a field trip, or any other AUTHORIZED reason, the student is obligated to determine what was missed, and will be held responsible for that work. If a student is absent without an excused absence, he/she will also be held responsible, and must obtain all information from some source other than the class instructor. Instructors DO NOT have to accept any make-up work, do individual tutoring, or make special test arrangements for any UNEXCUSED ABSENCE. Cheating: Cheating in this department is interpreted to mean the copying, tracing, or use of another persons work for the purpose of completing an assignment. Individual initiative and personal performance in completing all ass ignments is required of all students. This course may seem to offer situations that are conducive to cheating. However, evidence of cheating on the part of any student will be sufficient cause for an assignment of an F for the course. Instructors reserve the right to change a grade after the end of the semester if there is evidence to warrants.

General Course Outline Date Week Topic 1. 2. 3. Import and Export 2D and 3D Translation, Advanced lofting exercise Mold Tools, Cast part, complex draft, setback fillets, and draft analysis. Design Tables SolidWorks Administration Equations Modeling complex parts using sweeps Advanced Sheet Metal Fabrication. Review for Mid Term Mid Term Exam Lab Cylindrical and Conical Sheet Metal Parts, Palette forming tools. Assembly Automation methods for the workplace. Freeform Surfacing Weldments & Structural Steel IGES Translation Repair. Review for Final Final Exam

4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.

EXAMS
Midterm and Final exams are to be taken on-site with the teacher or proctor present. All exams are closed book, note, and video. Absolutely no cell/smart phones or tables are permitted while taking the exams. Headphones and music are not permitted during the exams.

LABS
Labs are there to help challenge and sharpen your skills, and are a great resource for additional training. It is recommended you try to complete the labs on your own. Self -discovery is the best method of educational retention. ~ unknown

EXERCISES
All exercises must be completed before the end of the semester as a portfolio. 1. To create a portfolio at the end of each exercise, take a screen capture using ctrlprint screen keys on the keyboard. 2. Then open a word document and paste the image using ctrl-v. Type in the Exercise number next to the image. 3. Send the completed portfolio with your name on the front cover to me via email or hard copy. No more than two exercise images per page. COMPLETE THE FOLLOWING EXERCISES

1.

13:07

E12 SolidWorks 2012 Exercise 12 - DWG and DXF conversion to 3D model

2.

26:11

E13 SolidWorks 2012 Exercise 13 - Lofting with guide curves, Threads, Curvature Continuos Face Blend Fillets

3.

18:05

E14 SolidWorks 2012 Exercise 14 - Part editing, Molding prep, Draft

4.

11:33

E15 SolidWorks 2012 Exercise 15 - Mold Design, Cavity and Core creation, using cavity feature, creating drawings with layers.

5.

11:02

E16 SolidWorks 2012 Exercise 16 - Design Tables

6.

8:59

E17 SolidWorks 2012 Exercise 17 - Introduction to Equations inside SolidWorks

7.

15:18

E18 SolidWorks 2012 Exercise 18 - Sweeps with guide curves, embossed text, multi - thickness shelling

8.

14:50

E19 SolidWorks 2012 Exercise 19 - Sheet Metal in Top-Down assembly approach

9.

24:21

E20 SolidWorks 2012 Exercise 20 - Assembly Library Component Automation, Rendering

10.

23:21

E21 SolidWorks 2012 Exercise 21 - Introduction to Surfacing, importing a jpeg image file and tracing around it

11.

16:28

E22 SolidWorks 2012 Exercise 22 - IGES - IGS - STEP import repair. FeatureWorks

12.

4:10

E23 SolidWorks 2012 Exercise 23 - Cylindrical Sheet Metal parts, Linear sketch patterns

13.

2:57

E24 SolidWorks 2012 Exercise 24 - Conical Sheet Metal parts using the old 90's method, before the loft option became available. It still works.

14.

3:43

E25 SolidWorks 2012 Exercise 25 - Lofted Sheet Metal parts

15.

13:53

E26 SolidWorks 2012 Exercise 26 - Weldments, Structural Steel

10

CAD 121 TOTALS

E12 20pts L12 - 10 E13 20pts L13 - 10 E14 20pts L14 - 10 E15 20pts L15 - 10 E16 20pts L16 - 10 E17 20pts L17 - 10 E18 20pts L18 - 10 E19 20pts L19 - 10 E20 20pts E21 20pts L21 - 10 E22 20pts E23 20pts E24 20pts E25 20pts E26 20pts L26 - 10 EXERCISES TOTAL 300 LAB TOTAL 100pts MIDTERM 300pts FINAL 300pts TOTAL 1000pts

11

EXERCISE 12 Importing 2D DXF/DWG files DWG and DXF files can be very useful if imported into SolidWorks.
Objective: Create a 3D wheel from an imported 2D DWG file.

1.

Go to file/open and select DWG from the options. Locate the Wheel Hub file.

12

1.

Import to a new drawing.

2.

The next screen should look like this Select the show preview box.

13

3.

Once open the drawing should look like this

4.

Go to the layer icon located on the Line Format toolbar, to disable all but the geometry layer.

14

5.

Once the other layers are disabled your drawing should look like this Drag a fence around the bottom section view and be sure to include the centerline. Hit CTRL-C to copy the geometry.

6.

Go to File/New part. Click on the Right plane and hit CTRL -V to paste the geometry into the new part file.

15

7.

Go to the right view orientation and you should have this section view

8.

Click on the centerline and select the revolve feature. Hit okay.

16

9.

Right mouse button click on any portion of one of the slots and select chain. Hit the CTRL -C buttons to copy.

10.

Open the part file and select the Front plane. Hit CTR L-V to paste the slot. It may appear to the right of the wheel. Just edit the sketch and window around the slot sketch. Hold down the CTRL key and drag the main center point to the center of the wheel.

17

12. Extrude cut through all.

13. Add .125 fillets around the edges of the cutout. Then create a circular pattern from the one cutout.

14. The wheel is now completed.

18

L12 HOSE BASKET PROJECT KUPEC METALS INC.

Import the KUPEC DXF File and create a sheet metal garden hose enclosure. .125 Thick. Aluminum, Water-jet cut through glyphs.

19

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EXERCISE 13 Lofting with Guide Curves 1. Sketch the geometry as show below on the Front plane. Rebuild. (5 spline points) Use ordinate dimensions for simplicity.

2.

Offset a plane 8 from the front plane.

21

3.

Sketch the following on Plane 1. (5 spline points)

4.

Start a sketch on the top plane, and draw the following. (3 spline points)

22

5.

Start a new sketch on the top plane and draw the following. (5 spline points)

6.

Loft

23

7.

Loft completed.

8.

Creating Curvature Continuous Face Blend Fillets. Select the bottom

face and side face of the bottle. Select the fillets icon. Input .250 radius and check curvature continuous.

24

What are Curvature Continuous fillets?

Click Curvature continuous to resolve discontinuity problems and create a smoother curvature between adjacent surfaces. To verify the effect of the curvature continuity, you can display Zebra Stripes. You can also analyze the curvature using the curvature tool. Curvature continuous fillets differ from standard fillets in the following ways. They have a spline cross-section as opposed to a circular crosssection. Curvature continuous fillets are smoother than standard fillets because there is no jump in curvature at the boundary. Standard fillets include a jump at the boundary because they are tangent continuous at the boundary.

9.

Select the back flat face and go to Insert/Mirror all.

25

10.

Insert the neck of the bottle as shown below.

11.

Creating a Thread - Select the top face of the neck and go to the plane
wizard. Offset a plane .125 from the top.

26

12.

Start a sketch on the new offset plane. Select the top face of the neck and convert entities.

13.

Go to Insert, Curve, Helix/Spiral. Apply the following parameters.

27

14.

Now select the sketch tool and click on the portion of the helix closest to the top end point. This automatically creates a new plane perpendicular to the helix and starts a sketch on it.

15.

Now just draw the geometry of the thread.

28

16.

Rebuild, and go to the Sweep feature. Select Path and Profile. Finish.

17.

Select the end face of the thread, start a sketch and Convert Entities. Draw a vertical centerline .110 offset from the edge.

29

18.

Revolve 56 .

19.

Complete the other side the same way. Add additional features to finish bottle. Shell at .050.

30

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EXERCISE 14 Draft and Filleting Cast parts can be some of the most difficult to modify if draft and complex fillets have not been inserted early on with design intent.

Objective: Modify the casting to enable mold creation.

11.

Using the Mold Tools toolbar.

32

12.

Draft Angle Analysis.

Face Classification (source: SolidWorks help)

In the graphics area, each face displays a color based on the Draft angle you selected. Draft analysis results listed under Color Settings are grouped into four categories, when you specify Face classification :
Positive draft. Displays any faces with a positive draft, based on the reference draft angle you specified.

A positive draft means the angle of the face, with respect to the direction of pull, is more than the reference angle.

Negative draft. Displays any faces with a negative draft, based on the reference draft angle you specified. A negative draft means the angle of the face, with respect to the direction of the pull, is less than the negative reference angle.

Draft required. Displays any faces that require correction. These are faces with an angle greater than the negative reference angle, and less than the positive reference angle.

Straddle faces. Displays any faces that contain both positive and negative types of draft. Typically, these are faces that requires you to create a split line.

NOTE: Display colors may vary. The first time you use draft analysis, the system uses default colors. If you modify the colors, the system will use the new colors you specified.

33

13.

Here we can see that no draft is present on the current part.

14.

Applying Draft. Select the Draft icon, and then select the top planar face of the object.

34

15.

Applying setback fillets. Select the three intersecting edges, and then select the intersection vertex.

6.

Apply the following parameters.

35

16.

Add draft and fillets where required. Run a draft check to ensure all faces have draft. Typical Radii - .125, .060. Typical Draft 1 .

17.

This is how the finished model should appear after rendering.

36

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EXERCISE 15 Cavity & Core Creation Cavities and Cores can be created using SolidWorks.

Objective: Create a Cavity and Core from the Cast part used in E14.

18.

Start a new assembly and name it E15. Insert the E14 Finished part file into the new assembly at the origin. Insert a new part, name it Cavity, and drop it onto the Top plane of the E15 assembly. Draw the following. Note the origin location.

38

19.

Extrude-boss 6.

20.

Select the Cavity Icon. The next screen should look like this Select the E14 part file either from the screen or feature tree.

39

21.

Once the cavity has been initiated you will get the Resolve Result Ambiguity box. Just hit okay. This allows you to select the cavity or core separations available.

22.

Hide the E14 component and you should now see the cavity.

40

41

EXERCISE 16 Configurations with Design Tables Design Tables can be very useful for designing multiple variations of the same part.
Objective: Create a small, medium, and large configuration using an Excel Table.

1.

Sketch the following on the Front plane. Extrude 2.

2.

Sketch the circle and extrude cut through all.

42

3. 4.

RMB click on the Annotations folder in the tree. Select Show feature dimensions . Also, go to, View/Dimension Names

5.

You should now zoom out and see all the dimensions. Arrange them so they are clear to see.

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6.

Go to Insert/Design Table and select New.

7.

Type in the Small thru Large text in the left column. Then select cell 2-B and then double click on the dimension you wish to enter into the table.

44

8.

Once the four cells are filled in, type the following specification into the cells below.

9.

It should look like this when complete. Click in the view area and you will receive the following message if it was successful.

45

10.

Click on the configurations manager tab and you will see the new configurations. Double click on any of the configurations to see it.

11.

You are finished with the model. Make the Drawing.

46

47

48

EXERCISE 17 Advanced Equations 1. Here is an example of how to use equations. The images below represent the same model, but can easily be changed by double clicking on a dimension, and typing in a new value. This normally would create rebuild errors because the rib stack would need to be adjusted as well. Equations can be set up to automatically perform this task.
Objective: Using equations create a living hinge package, which can adapt to change

easily.

20.

Sketch the following on the Front plane. Dimension in the order as show.

49

21.

Extrude 1.5. Add 1 of draft when ready. (Note: Do not extrude with draft)

22.

Start a sketch on the bottom surface, and draw the following. Extrude with 1 of draft when ready.

50

23.

Create a linear pattern.

24.

Create a new sketch; Draw the following with coincident relations on both sides of the cylinder. Let it become a driven dimension. Rebuild. Rename sketch to Target gap distance.

51

25. 26.

Activate the View Feature Dimensions and Show Dimension Names. Rename the dimensions as seen below. This can be done by simply RMB click on any dimension you would like to change. Go to Properties and entering different names in the box on the top right.

27.

Creating Equations . Go to Tools/Equations. Then select double click in the

cell below Equations . Click once on the desired dimensions to have the names automatically insert into the equations editor.

52

53

What are Equations inside SolidWorks?

They crea te mathematical relations between model di mensions, using dimension names as va riables. When using equations in an a ssembly, one can set equations between parts, between a part a nd a suba s sembly, with mating dimensions, and so forth.

When deleting a feature or dimension that is used in a n equation, you have the option of deleting the equation or not.
NOTE: Di mensions driven by equations cannot be cha nged by editing the dimension va lue in the model.

28.

Here is an index of functions.

54

29.

Add the same equations on the left side of the model.

30.

Mirror all, both sides.

55

56

EXERCISE 18 Using Sweeps with Guide Curves Sweeps can be beneficial when creating symmetric freeform geometry.

1. 2. 3.

Start a sketch on the Front plane and draw a vertical line at 8 from the origin. Rebuild. Using a spline draw the following on the Front plane. Rebuild. Using a spline draw the following on the Right plane. Use the same vertical dims as in step 3.Rebuild.

57

4.

Sketch an Ellipse on the Top plane. This will be the profile.

5.

Hold CTRL and select the spline curve and the point on the Ellipse. Add a Pierce relationship. Rebuild

A Pi erce relation is when the s ketch point is coi ncident to where the a xi s, edge, or curve pierces the s ketch plane. The pi erce relation is used i n Sweeps with Guide Curves .

58

6.

Repeat step 5. Using the right side spline.

7.

Sweep

59

8.

Sweep completed.

9.

Creating Curvature Continuous Face Blend Fillets. Select the top

face and side face of the bottle. Select the fillets icon. Input .250 radius and check curvature continuous.

60

What are Curvature Continuous fillets?

Click Curvature continuous to resolve discontinuity problems and create a smoother curvature between adjacent surfaces. To verify the effect of the curvature continuity, you can display Zebra Stripes. You can also analyze the curvature using the curvature tool. Curvature continuous fillets differ from standard fillets in the following ways. They have a spline cross-section as opposed to a circular cross-section. Curvature continuous fillets are smoother than standard fillets because there is no jump in curvature at the boundary. Standard fillets include a jump at the boundary because they are tangent continuous at the boundary.

10.

Variable Radius Filleting . Select Fillet tool, then select the Variable fillet. Select desired edge and it will break the edge into quadrants. Enter dims as shown.

61

11.

The fillet should appear as shown.

12.

Create a Thread Shell at .1, and add embossed text. You are finished.

62

63

EXERCISE 19 Advanced Sheet Metal Design Sheet Metal part files can be very useful for extracting a flat pattern.

Objective: Model a sheet metal enclosure using T op-Down Assembly methods, and flatten it.

1.

Go to file/open and select E19. Hide the existing cover.

Sheet Metal Tool Bar: To activate the toolbar on the ribbon simply RMB click on any ribbon tab and check the Sheet Metal box.

64

2.

Insert a new part into the assembly; drop it on the Front plane of the assembly. Name it Cover (This will be the enclosure). Then select the inside shelled face. Convert Entities.

3.

Sketch the bottom ends as shown.

65

4.

Use the Base Flange icon to extrude as follows.

5.

Use the Hem icon to remove sharp edges from the bottom of the cover.

66

67

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EXERCISE 20 Assembly and Drawing Automation Assembly and Drawing creation can be virtually automated through the use of many techniques capable in the SolidWorks software.

Objective: Create the desk assembly and implement automation techniques.

Creating a Hardware Library using the Design Library 1. Install the Desk Parts sub folder (this contains all the hardware required for assembling the desk) into the E20 directory. 2. Then go to tools/options/system options/file locations and select Design Library from the pull down menu. Once selected click on the add button. This will enable you to browse to your Desk Parts folder.

69

3.

By doing this you have now enabled your parts to be accessed through the Design Library, Desk Parts folder. Enabling easy drag and drop access. Otherwise you can just use the Insert Component tool.

4.

Now start a new part file and begin to create the attached parts.
NOTE: The drawings are missing dimensions. You can use the desk components in the Design Library to attain the proper measurements.

70

5.

When all the parts are finished, start an assembly and begin to assemble the components as shown in the assembly drawing provided.

6.

Create a catalog image using Photoview 360. This is his how the finished model should appear after rendering.

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EXERCISE 21 Introduction to Surfacing 1. Here is an example of how to use surfaces. The spoon model will be used to introduce the user to the primary surfacing tools available in SolidWorks.

Objective: Create a spoon using the surfacing tools .

2.

Sketch the following on the Front plane.

75

3.

Sketch the following on the Right plane.

4.

Go to Insert/Curve/Projected and select the two sketches to create a 3D projected curve. Change the feature name to Guide.

76

5.

Draw the Path on the right plane.

6.

Create a new plane Normal to curve.

77

7.

Start a sketch on the new plane and draw the following using a spline. Use relations to constrain the sketch. Pierce Pierce Vertical Horizontal Midpoint

8.

Add a surface sweep.

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9.

Check for surface flaws by right mouse clicking on the surface and select display curvature. Trim off the bad end by sketching a line on the front plane.

9.

Select the trim surface icon.

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10.

Select the Base-Thicken tool. Add .050.

11.

You should now have a solid. Try and make the end on your own now.

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EXERCISE 22 Imported 3D Model Repair IGES files can be very useful for importing files from other systems.

Objective: Repair the imported IGES file, by knitting it into a solid.

1.

Go to File/Open, and select IGES.

Select IGES from Files of type. IGES Initial Graphics Exchange Standard. Once imported you will receive a message asking if you would like to run Import Diagnostics . Select Yes . Essentially in order to make use of this

2.

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(make a cavity/mold) it is imperative that it be knit into a solid. This is an indication that there may be gaps in the surfaces.

3.

Note: If you fail to select Import Diagnostics you can simply RMB click on the surface in the feature tree, and select Import Diagnostics.

4.

Select the Attempt to Heal in order to try and correct the gaps.

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5.

6. 7.

First try to have SWX automatically close the gaps by selecting the close All Gap Button. This works sometimes, but dont count on it. In this case it fails to close the gaps. Now we must manually address the problem by creating surfaces to close the gaps. Use your surfacing toolbar. Before canceling out of diagnosis be sure to locate and memorize the gaps. Changing the surface colors behind or around each gap easily does this.

8.

Activate the Surfaces tab and use the Surface loft tool. Select edges to use as Profiles and Guide Curves.

84

9. 10. 11.

Once all gaps are patched use the Knit tool to stitch them together. Be sure to select all surfaces and the main body. Then you can go to insert/base/thicken. Be sure to select Create solid from enclosed volume. You should now have a solid.

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EXERCISE 23 Sheet Metal Cylinders Sheet Metal part files can be very useful for extracting a flat pattern.

Objective: Model a sheet metal cylinder and add cut outs.

12.

Go to file/new and select new part and save as E23.

Sheet Metal Tool Bar: To activate the toolbar on the ribbon simply RMB click on any ribbon tab and check the Sheet Metal box.

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13.

Draw the following sketch on the Front plane, use the center point arc tool. Make both ends of the arc symmetric to a vertical centerline. Space @ .001

14.

Boss Extrude blind 2.5. Notice that it should be creating a thin feature and set the thickness to .060.

88

15.

Select the edge of the cylinder and select Insert Bends. Set radius to 0. Hit OK.

16.

Select the Flatten icon to verify. Then select the flatten icon to fold back up.

17.

To create a cut pattern on the sheet metal in the flattened state you must first flatten it using the Unfold tool. And select the break edge to be fixed.

89

Draw a rectangle as seen below. Use the Sketch pattern tool to pattern rectangle.

18.

Select the Fold icon, to refold it. Then you can use Flatten to verify.

90

EXERCISE 24 Sheet Metal Modeling Conical Parts Sheet Metal part files can be very useful for extracting a flat pattern.

Objective: Model a sheet metal cone and add cut outs.

1.

Go to file/new and select new part and save as E24.

2.

Draw the following sketch on the Front plane, use the circle tool.

91

3.

Boss Extrude blind 2.5 and add 13 Draft.

4.

Select the front and back planar faces, then select the Shell feature. Set thickness to .060. Hit OK.

92

5.

Select the Front plane and start a sketch on it. Draw the following angled cutout. Dimension the edges and set the thickness to .005.

6.

Cut Extrude Through All.

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7.

Select the cut edge of the part and then select the Insert bends icon.

8.

Select the Flatten icon to unfold.

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EXERCISE 25 Sheet Metal Lofts Lofted Sheet Metal creation can be very useful for complex sheet metal fabrication.

Objective: Model a lofted sheet metal part.

1. Begin by offsetting a plane 6 forward from the Front plane.

95

2. Sketch the following on the front plane. Leave a small open gap of .1 in the center top edge. Rebuild

3. Sketch the following on the offset plane. 1 Radius. Rebuild

96

4. Select the Sheet Metal Loft tool, and select the sections.

5. Flatten to verify.

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EXERCISE 26 Weldments Weldment creation can be very useful for automating layout designs and extracting cut lists.

Objective: Create the structural steel model using the weldment tools.

1.

Start a new part file (ANSI inch) and save it as E25.

2.

Activate the Weldments tool bar by RMB clicking on any ribbon tab, and select the Weldments checkbox .

98

3.

Start a sketch on the Top plane and draw the following.

4.

Select the Weldments Icon to convert the part to a weldment entity.

5.

Select the structural member icon. Also select one sketch line. Input values.

6.

Select the other three sketch lines. Notice the end but settings. 99

7.

Offsetting a plane parallel to a point . Select the front plane and a corner of the layout sketch you created in step 3. Go to the Plane Wizard.

100

8.

Sketch the layout of the leg. Start a sketch on the new plane and draw the following. Rebuild

9.

Select the Structural Members icon. Select the vertical and 45 degree angled line. Use the same settings as before. Hit the green check to apply.

101

10.

Select the Trim/Extend icon. Then select the Bodies and Boundaries.

11.

It should look like the image below.

102

12.

Select the bottom cut surface of the leg. Draw the following and extrude .75.

13.

Select the Fillet Weld icon and input the following information.

103

14.

Select the gusset icon and input the following information.

15. Use the mirror bodies tool to mirror the other legs into place. Finished.

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GOAL: FIND THE INTERNAL VOLUME OF THE BOTTLE.

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SUPPLIMENT SolidWorks - CAD Administration Finding adequate computer hardware to run Solidworks can be challenging, this lesson looks at the multiple aspects of selecting hardware as well as modifying settings inside SolidWorks to allow it to run efficiently and trouble free. Selecting an Operating System (OS). Windows Windows Windows Windows Windows XP Professional XP 64-Bit edition (SolidWorks 2013 is the last release for Windows XP) Vista 7 8

Virtual Memory Settings inside the OS. It may be a good idea to increase or adjust your virtual memory setting. The norm would be x2 x3 your current amount of ram. Example 512MB of Ram 1000 1500 MB Virtual Ram. And keep the initial size the same as the maximum size. It is said that this prevents write errors.

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Processors (CPU)
Intel Atom Celeron Pentium Core i3 Core i5 Core i7 Xeon AMD Sempron Athlon II Phenom X2,3,4,6 VISION A4,6,8,10 FX Series Opteron

BUDGET
MID-RANGE

HIGH END
PROFESSIONAL

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Multiprocessing
Most CPU manufacturers are beginning to deliver multiple core processors. This can be seen with the AMD FX which has up to eight processing cores.

Which one will run SolidWorks fastest? You can find benchmarks at www.spec.org specifically for SolidWorks or you can look for the generic OpenGL benchmark results that usually use an OpenGL video game.

The question is: C an SolidWorks benefit from multiple cores? Currently one might find an average of 10 15% performance increase with general modeling. This is because SolidWorks is not fully written to take advantage of multithreaded processes. However, using the SolidWorks Simulation, CFD, or Photoview rendering solutions one may discover 2x 12x faster performance versus a single core processor. This is because these SolidWorks applications do take full advantage of multithreaded processing. The biggest benefit one might find is the ability to multitask while working with an FEA analysis. This is a long process and you could actually open up another window of SolidWorks or Outlook and continue working while the analysis is running with little slow down in performance. To check out what your computer has inside without opening the case download the free version of CPUID CUP-Z http://www.cpuid.com/softwares/cpu-z.html Or ctrl-alt-del and start task manager to see how many threads your CPU has, as well as how much RAM.

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Graphics Cards
Here are a few brands that are in the Professional Category and actually have specific drivers that are written to run SolidWorks at its best. NVIDIA Quadro series (not NVS series) Quadro FX 600 erp.$159 (erp- estimated retail price) Quadro FX 2000 erp.$499 Quadro FX 4000 erp.$799

ATI FirePro series (not FireMV series) FirePro 3900 erp.$159 FirePro 5900 erp. $499 FirePro 7900

Intel Xeon P 4000 HD integrated graphics (P = Professional rated)

These cards are considerably more expensive that mainstream cards but the benefits of experiencing less crashes or visual problems with Pro/E outweigh the cost. If you are using SolidWorks at work, DONT SKIMP! Buy a professional grade video card. For home use the nVidia Geforce or AMD Radeon series are fair, but you will still experience some graphical glitches. GRAPHICS CARD SolidWorks BENCHMARK (source: www.tomshardware.com)

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With all SolidWorks documents closed go to Tools/Options/System and turn on software OpenGL.

If your graphics rotation of models is slow try adjusting the image quality. This is located in the document properties.

MEMORY (RAM) 4.0 16.0 GB From simple machined parts to complex assemblies. The more RAM the better. 3.0 GB+ Requires Windows XP/Vista/7 64 Bit Editions 110

File Translation for the CAD/CAE/CAM Industries

Outline 1. History of Translation in the industry (What is it, why was it needed?) a. 1979 Society of Manufacturing Engineers (SME) meeting. b. General Electric challenges the CAD industry.

2. Primary/Neutral translators a. STEP (Standard for the Exchange of Product Model Data) i. AP (Application Protocols) ii. Configurations iii. Parametric Data b. IGES (Initial Graphics Exchange Specification)

3. Types of data a. Raster b. Vector i. 2D Geometry ii. 3D Geometry 1. Curves 2. Surfaces 3. Solids (B-Rep) c. Configurations d. PD (Parametric Data)

4. Extracting information from translators. a. Variation b. Application

5. What the future holds.

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With the growing number of software applications available in the Computer Aided Design, Analysis, and Machining community (CAD/CAE/CAM), one might discover communication between applications to be difficult, because of incompatibilities between each application. Translators have been developed for this reason. In the beginning CAD/CAE/CAM applications where primarily used in the Scientific, and Aerospace communities. This CAD technology was developed in 1969 and within a decade had reached a point where various companies had developed multiple CAD applications. Users of these applications quickly discovered transferring data between systems was very difficult. Specialized programs had been written to address the task but no standards had been set. Frustration finally peaked at a Society of Manufacturing Engineers (SME) meeting in the fall of 1979. An attendee from General Electric (GE) challenged a panel of CAD vendors to create a universal translator to be used between the various CAD applications. Soon after the meeting, the panel had determined that such a task was possible, and set in motion the collaborative foundation to what would later be recognized as the Initial Graphics Exchange Specification (IGES). The IGES format is the most common translator used today, and it continues to evolve and improve with help of user feedback. For more information on IGES visit the web page. http://www.nist.gov/iges/ Since IGES there have been several other translator. One in particular named STEP (Standard for the Exchange of Product Model Data) was developed specifically by the Aerospace industry. Boeing and McDonald Douglas had been attempting to share data between their CAD systems. They discovered IGES was not adequate, and not well

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regulated. Variation was becoming an issue between CAD vendors due to poor regulation of the translator. They decided quality had to be better enforced to eliminate and reduce variation. They employed the International Organization for Standardization (ISO) to develop, regulate, and manage the initiative. A team consisting of Boeing, McDonald Douglas (Unigraphics), Catia, and Computer Vision was formed to assist with laying the foundation. They assembled scalable algorithms that could be transplanted into the base code known as Application Protocols (AP). These APs are used to identify the specific tasks available in the translator. For example AP 203 is the most common in that it has the ability to translate Solids data between systems. Another AP is the 214, which was later added to enhance the ability to transfer configuration information for manufacturing and inspection purposes. General Motors (GM) frequently uses the AP 214. Visual CAD data comes in many forms. A basic break down of this reveals two types. Raster and Vector. Raster data consists of multiple microscopic dots, which make up an image. Much like a photograph this method proves inadequate for CAD because of inaccuracy and it is limited to only two dimensional (2D) representation and manipulation capabilities.

Raster

Vector

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Vector geometry on the other hand proves robust in its ability to provide both 2D and three dimensional (3D) attributes, making it the criterion form for translating data. Vector geometry consists of continuous lines, arcs, splines, surfaces, or solid geometry representations. Dimensional attributes are applied to identify position and proportions. Enabling them to be easily modified, translated or scaled by simply changing values. The ultimate goal of the translator is to eventually enable all data created on one CAD system to be flawlessly translated into another. This capability is currently being worked on by ISO to be introduced into the STEP translation algorithm sometime in the future. No date or deadline has been set until the CAD industry can come up with a reasonable standard to do so. Several CAD vendors already have methods of either reading in native CAD files from other systems and rebuilding from scratch the Parametric Data (PD) or even directly translating the information. The following is a list of common translators and native CAD formats capable of being translated between SolidWorks. The list details if the file can be imported or exported, and what specific data can be obtained by it.

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TRANSLATOR
PARASOLID ACIS DWG DXF IGES STEP VDAFS CGR HCG CADKEY SOLIDEDGE UGII MDT INVENTOR PRO/ENGINEER HOOPS VRML VIEWPOINT REALITY WAVE EDRAWING JPEG TIFF STL ADD-INS

EXTENSION
X_T, X_B SAT DWG DWG IGES, IGS STEP, STP VDA WRL HCG PRT PAR PRT DWG IPT PRT,XPR,ASM,XAS HSF WRL MTS ZGL EPRT,EASM,EDRW JPEG,JPG TIFF STL DLL

IMPORT
X X X X X X X X X X X X X X X

EXPORT
X X X X X X X X X

VECTOR RASTER 2D 3D PD*

X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X

X X X X X X X X X X X X X

X X

X X X X X X X X X

X X X

Parasolid Is the core-modeling kernel utilized inside SolidWorks. Two types of parasolid translation are supported standard (.x_t) and binary (.x_b); both translate data flawlessly between native parasolid based systems. However, binary files are typically smaller in size.

ACIS Developed by Spatial Technologies a DASSAULT SYSTEMES company. Portions of this kernel are seamlessly integrated within SolidWorks. For example Spatials deformable surface husk technology is recognized as SolidWorks Shape feature. ACIS is the core-modeling kernel for many 3D CAD applications and is a good choice for translating clean and efficient models between systems using this kernel. A complete list of current ACIS kernel partners can be found at the internet address listed below.

DWG/DXF Drawing Exchange File. Support for versions AutoCAD R12 R2011.

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IGES Initial Graphics Exchange Specification. A common translator type, works with most systems. However, incomplete translations are frequent due to lack of strict regulations on software developers data creation.

STEP 203/214 St andard for the Exchange of P roduct model data. A well-regulated format software developers must follow strict regulations to offer STEP as a certified integrator. AP203 (Application Protocol) supports 3D geometry only. AP214 has additional support for configurations, commonly used by General Motors.

VDAFS Verband der Automobilindustrie (German Automotive Specification)

CGR Catia Graphics format

HCG Highly Compressed Graphics format

CADKEY Imports native Cadkey part file solids data only.

SolidEdge Imports native SolidEdge part file solids data only.

UGII Imports Unigraphics (Siemens NX) native part file solids data only.

MDT Mechanical Desk Top, (MDT 6.0 installed required to operate) has support for parametric entities. Will not import 2D drawing data.

Inventor - Imports native Inventor part file solids data only.

Pro/Engineer-Creo Imports Part and Assembly files. Capable of exporting v.20 part files. Has support for parametric entities from versions 16 Creo 1.0.

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In the past three years, data translation has made massive leaps in capabilities, which help end users communicate more efficiently with one another. Unfortunately there are still some CAD vendors holding back the progress made to have flawless data communication between all users. These vendors believe empowering any and all individuals to access data generated on proprietary CAD applications can be detrimental to the bottom line of their company. They actually have been known to encrypt their native files to prevent others who have not purchased the native CAD application from accessing the data, forcing them (usually tier 2 and 3 vendors) to purchase the application in order to better serve the customer. In summary, there have been vast improvements in translation between systems over the past decade. One can assume the final goal will eventually be attained, which will break down the communications barriers, enabling virtually all CAD systems to communicate flawlessly between one another.

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