CHAPTER 1

INTRODUCTION TO SOLID WORKS

1. SolidWorks is a 3D mechanical CAD program that runs on Microsoft Windows which was developed by SolidWorks Corporation, headquartered in USA, a subsidiary of Dassault Systemes. SolidWorks provides engineers, designers and other creative professional with the need to design the worlds greatest products. SolidWorks mechanical design automation software is featured based, parametric modeling design tool that helps engineers provide competitive design solutions to the mainstream market. SolidWorks provides a full range of integrated modeling, simulation, visualization; communication and validation tools that product designers need to develop better products faster and at lower cost. In addition, its unique capabilities enable the mechanical designer to concentrate on the product design. SolidWorks enable the design engineer to: y y y y y y y Precisely turn creative concepts into 3D designs. Create the most ergonomic designs possible. Produce design iterations in less time. Reduce prototyping time and costs. Work with customer data. Manage product information more effectively. Render highly detailed 3D designs. 1.1. MODULES: SolidWorks extends design applications through full integration with bestin-class solutions. The following are modules used in SolidWorks: 1.1.1. Part Modeling: This module produces parts easily and rapidly by creating features such as extrudes, revolves, thin features, lofts, sweeps, advanced shelling, features pattern and holes. 1.1.2. Assembly modeling: It gives a user the ability to design with user controlled associability. SolidWorks builds these individuals parts and sub-assemblies into an assembly in a hierarchical manner. This is based on the relations defined by the constraints. 1.1.3. Surface Modeling: For designing dies, casting or injection molds, surface modeling capability is important. SolidWorks Surface module can create complex models from freeform shapes. Complex surfaces can be created by using lofts and sweeps with guide curves, drag-handlers for easy control and innovative surface features. 1.1.4. Sheet Metal Design: Sheet metal parts are generally used as enclosures for components or to provide support to other components. Sheet metal part can be

designed on its own without any references to the parts it will enclose, or designed in the context of an assembly that contains the enclosed the components. 1.1.5. Drawing: 2D drawing module develops complete production ready engineering drawings without drawing the sketches, makes revisions quickly and accurately, and generates bills of materials and balloons automatically, easily controlling and alignment of balloons. 1.2. FEATURES: SolidWorks is software developed for mechanical design engineers and contains many features that facilitate the engineers to easily create and manage designs. Some of the important features of SolidWorks are as follows: 1.2.1. Feature-based: Just as an assembly is composed of a number of individual piece parts, a SolidWorks model also consists of individual constituent elements. These elements are called as features. The idea behind feature based modeling is that the designer constructs an object composed of individual feature that describe the manner in which the geometry supports the object, if its dimension changes. The first feature is called the base feature. Features can be classified as either sketched or applied. 1. Sketched features: These are based upon a 2D sketch. Generally the sketch is transformed into a solid by extrusion, rotation, sweeping or lofting. 2. Applied features: These are created directly on the solid model. Fillets and chamfers are examples of this type of feature. 1.2.2. Parametric: The dimensions and relations used to create a feature are captured and stored in the module. This enables not only to capture your design intent, but also quick and easily make changes to the model. In the revolved body, hole size is reduced parametrically since all the circles are driven by relation and dimension. A change in one hole reflects the others. 1.2.3. Solid modeling: A solid model is the most complete type of geometry model used in CAD systems. It contains all the wireframe and surface geometry necessary, to fully describe the edges and the faces of the models. In addition it has the information called the topology that relates the geometry together. An example of topology would be which faces (surfaces) meet at which edge (curve). This intelligence makes operations such as filleting as easy as selecting an edge and specifying a radius. 1.2.4. Fully associative: a SolidWorks model is fully associative with the drawings and the assemblies that reference it. Changes to the model are automatically reflected in the associated drawings and assemblies. Similarly, changes in the drawing or assembly, and those changes will be reflected in the model. Constraints: Geometric relationships such as parallel, perpendicular, horizontal, vertical, concentric and coincident are some of the constraints supported in SolidWorks.

In addition, equations can be used to establish mathematical relationships among parameters. By using constraints and equations, guarantees the design concepts, such as through holes or equal radii that are captured and maintained. 1.3. DESIGN INTENT: Design intent is plan about how the model should behave when it is changed. For example, if modeling a boss with a blind hole in it, the hole should move when the boss is moved. To use the parametric modeler SolidWorks efficiently, it is necessary to consider the design intent before modeling. Several factors contribute to how to capture design intent and these are: 1.3.1. Automatic relations 1.3.2. Equations 1.3.3. Added relations 1.3.4. Dimensioning 1.4. GRAPHIC USER INTERFACE: The SolidWorks user interface is a native Windows interface and therefore behaves in the same manner as other Windows applications. SolidWorks supports multiple document interfaces, but only one window activates at a time. The important aspects of the interface are as follows: 1.4.1. MENUS 1.4.2. TOOLBARS 1.4.3. FEATURE MANAGER 1.4.4. PROPERTY MANAGER 1.4.5. COMMAND MANAGER 1.4.6. GRAPHICS AREA 1.4.7. TRIAD 1.4.8. CONFORMATION CORNER 1.4.9. CALLOUTS 1.4.10. SPLIT GRAPHICS AREA DISPLAY 1.4.11. SHADED PREVIEWS 1.4.12. TASKPANE 1.4.13. STATUS BAR

CHAPTER 2

SKETCHER
Any feature that is created SolidWorks needs a sketch to begin with. All base features are essentially sketched features and are created by using a sketch. A sketch is a combination of entities like lines and arcs. Sketch is drawn in sketcher environment by: y y Invoking the sketch command and using the same to build the feature. Invoking the feature based command and thereby, entering the sketcher environment by default.

The sketching environment of SolidWorks can be invoked any time in the Parts, Assembly and Drawing modes. 2.1. Working with sketch entities: In the sketch environment, in order to start with sketch tools selection of origin (in red color), triad and a conformation corner from the top right is done. The conformation corner is used for executing or terminating any command. Then a reference triad appears in parts and assembly documents to assist in orienting the viewing of models. Some sketch entities are: 2.1.1. Inferencing lines 2.1.2. Centerlines 2.1.3. Lines 2.1.4. Arcs: tangent arc, 3point arc and center point arc. 2.1.5. Circles: center based and perimeter based 2.1.6. Ellipse 2.1.7. Rectangle: corner, center, 3point corner, 3point center and parallelogram. 2.1.8. Slots: straight, centrerpoint straight and 3point arc 2.1.9. Polygon: 2.1.10. Parabola 2.1.11. Spline 2.1.12. Point 2.2. Editing sketches: The sketch or a profile may not be complete with sketch entities alone. The sketch needs to be edited to accommodate the design and to incorporate the design changes. The sketch tools menu provides a set of functionalities to edit 2D geometry, these tools are: 2.2.1. Fillet 2.2.2. Chamfer 2.2.3. Offsetting 2.2.4. Converting 2.2.5. Trim

2.2.6. Extending 2.2.7. Splitting 2.2.8. Jog 2.2.9. Mirror 2.2.10. Scaling 2.2.11. Stretching 2.2.12. Area hatch/fill 2.2.13. Sketch patterns: linear, circular and arc pattern. 2.2.14. 3D sketching

CHAPTER 3

PART MODELING
The 3D part is the basic building blocks of the SolidWorks mechanical design software. Parts are modeled following a feature based approach. Features are complex combinations of objects and operators considered together as a unit which can be modified or duplicated. Order of operations is kept in a FeatureManager design tree and parametric changes can propagate through the tree. Base feature is the first solid feature that is created when a model is created in the part mode. It is important to select the base feature carefully as the other features carefully as the other feature are built on the basis of these features. Base features are usually created using datum planes. SolidWorks Part module enables to design models as solids in a progressive 3D solid modeling environment. 3.1. Terminologies used: The SolidWorks software employs many terms that need to be familiar with, while using the software. 3.1.1. Feature: All operations performed to create the design are stored as feature in SolidWorks. Sketched features are based on sketches and applied features are based on edges or faces. 3.1.2. Plane: Planes are flat and infinite. They are presented on the screen with visible edges. They are used as the primary sketch surface for creating boss and cut features. 3.1.3. Sketch: In the SolidWorks system, the name used to describe a 2D profile is a sketch. Sketches are created on flat faces and planes within the model. They are generally used as the basis for bosses and cuts, although they can exit independently. 3.1.4. Boss: Bosses are used to add materials to the model. The critical initial feature is always a boss. After the first feature, as many bosses as required to complete the design can be added. As with the base, all bosses begin with a sketch. 3.1.5. Cut: A cut is used to remove materials from the model. It is the opposite of the boss. Like boss, cuts begin as 2D sketches and these remove material by extrusion, revolution or other methods. 3.1.6. Design intent: The design intent implies the plan and the method for creating and changing the model. Relationships between features and the sequence of their creation, all contribute to design intent. 3.2. Reference geometry: Reference geometry feature assist in creating the CAD models. Reference geometry includes planes, axes, points and coordinate systems. These reference geometries act as a reference for drawing the sketches in sketched features, defining the

sketch planes and assembling the components. They also serve as a reference for various placed and sketched features and so on. These features have neither mass nor volume. 3.2.1. Reference Planes: Generally, all engineering components or design are multi featured models. In addition, all the features of a model all not created on the plane on which the base feature is created. Therefore, a default plane has to be selected or create a new plane that is used as the second plane for the sketching feature. The three default planes that are available with the SolidWorks environment are Front Plane, Top Plane and the Right Plane. These planes are mutually perpendicular to each other. 3.2.1.1. Reference Axes: These are construction axes creating Reference Planes, coordinate systems, Circular patterns and so on. 3.2.1.2. Reference Coordinate System: It is used for creating features, analyzing the geometry analyzing the assemblies and so on. 3.2.1.3. Reference Curves: These are used to create paths to create complex shapes. 3.3. Placed Features: Placed features are construction features that operate on existing features. These tools help to improve the efficiency of modeling using SolidWorks. They do not require any sketched entity. The following tools are discussed below: 3.3.1. Hole: It is used to create a cylindrical hole on a planar face. Hole wizard is used to add standard holes such as counterbore, countersink, tapped and pipe tap holes. It also allows creating a user-defined hole and can control all the parameters of the hole including the termination options. 3.3.2. Fillet: It is used to round an internal or external edge of a model. Various types of fillets are: 3.3.2.1. Constant radius fillet: This is used to create a fillet of a constant radius along the selected entity. The entities which can be selected are faces, edges, features and loops. 3.3.2.1.1. Multiple radius fillets: It helps in creating a fillet of different radii, to all selected edges. 3.3.2.1.2. Fillet with or without tangent propagation: It applies the fillet feature to all entities that are tangential to selected edge, face, feature or loop. 3.3.2.1.3. Setback fillet: It is created where three or more edges are merged into a vertex. It is used to smoothly blend transition surface generated from edges to the fillet vertex. 3.3.2.2. Variable radius fillet: It creates a fillet of different radii along the length of selected edge at specified intervals. It can also create a smooth transition or a straight transition between the vertices where the radii are applied.

3.3.2.3. Face fillet: It is used to add a fillet between two sets of faces. It blends the first set of faces with the second set of faces. It adds or removes the material according to the geometric conditions. 3.3.2.3.1. Hold line: It specifies the radius and the fillet by determining a hold line. The hold line can be a set of a split line projected on a face. 3.3.2.3.2. Curvature continuous: It selected to apply the face fillet feature with continuous curvature throughout the fillet feature. 3.3.2.3.3. Constant width: it is extremely useful to apply a face fillet to the faces that are at an angle other than 90 degree. 3.3.3. Chamfer: It is used to create a bevel feature on selected edges, faces or vertex of a model to reduce stress concentration and remove the sharp edges. 3.3.3.1. Edge chamfer: These are created on the edges. 3.3.3.2. Vertex chamfer: It chops the selected vertex to the specified distance. 3.3.4. Shell: It is a process in which the material is scooped out from a model and the resulting model is hollowed from inside. 3.3.5. Rib: It is a special type of extruded feature created from open or closed sketched contours. It adds material of a specified thickness in a specified direction between the contour and an existing part. 3.3.6. Draft: It is used to add taper to the selected faces of the model which makes the molded part to remove easier from the mold. It can be inserted in an existing part or while extruding a feature. Types of draft: 3.3.6.1. Neutral plane 3.3.6.2. Parting line 3.3.6.3. Step draft 3.3.7. Patterns: Patterns are one or two dimensional incremental array of features created from a single feature called the parent feature or the leader. It is required to specify the total number of features to be created, including the one that is being patterned. Pattern offers the following benefits: i. Creating a pattern is an easier way to reproduce a feature. ii. The entire instance in the pattern is related parametrically. Therefore, any change in the original feature, automatically updates the pattern definition. iii. It may be easier or more effective to perform operations once on the multiple features contained in a pattern, rather than on the individual features. 3.3.7.1. Linear pattern: It reproduces selected feature linearly i.e. in rows and columns by defining the number of instances and spacing between the pattern in the number of instances and spacing callouts. 3.3.7.2. Circular pattern: It arranges the selected feature in a circular fashion by specifying the pattern angle and the number of instances in the angle and number of instances.

3.3.7.3. Curve driven pattern: It is used to pattern the features, faces or bodies along a selected reference curve. The reference curve can be a sketched entity, an edge, an open profile or a closed loop. 3.3.7.4. Table driven pattern: It is created by specifying the X and Y coordinates with reference to a coordinate system. 3.3.7.5. Fill pattern: It lets to select an area defined by coplanar faces or a sketch that lies on coplanar faces. The command fills the defined region with a pattern of features or a predefined cut shape. If sketch is used for the boundary, then pattern direction has to be selected. 3.3.8. Mirror: It is used to copy or mirror the selected feature, face or body about a specified mirror plane, which can be a reference plane or a reference face. 3.4. Advanced modeling tools: The part modeling tools assist to create a better and an accurate design by capturing the design intent in the model. 3.4.1. Dome creation: It is used to create dome on the selected part. One or more dome features simultaneously can be created on the same model. 3.4.2. Freeform: It meets the needs of consumer product designers, who create curvilinear designs. It modifies faces of surface or solid bodies. It can modify one face at a time and face can have any number of sides. Designers have direct, interactive control of deformations by creating control curves and control points; these control points can be push or pull to modify. Use the triad to constrain pull or push direction. 3.4.3. Shape feature creation: It creates a deformed surface on a model expanding, constraining and tightening the selected surface. A deformed surface is flexible, much like a membrane. It can be expanded, constrained and tightened using control sliders. 3.4.4. Deform: It used to alter shapes of complex surface or solid models, either in a local area of globally, without the concern for sketches or feature constraints used to create models. It is useful when creating design concepts or making geometric changes to complex models that would otherwise take long using traditional sketch, feature or history editing. 3.4.4.1. Curve to curve deformation: It is a precise method for deforming complex shapes that transit from initial curves to target curves. The initial and target curves can be edges of faces, surfaces and section curves or free sketch curves. Options for controlling deform shapes allows: i. Fix edges and faces so that they cannot move. ii. Add additional faces or bodies to deform. iii. Set stiffness and shape accuracy.

3.4.4.2. Surface push: Surface push deform modifies surfaces of target bodies by displacing (pushing) them with tool body surfaces. The target body surface approximate tool body surfaces while maintaining a one to one correspondence between every target surface before and after the deformation. Surface push deform provides more efficient control of deformed shape compared with point deform. It is also a predictable way to create specific features based on tool body shapes. Exact coordinates can be set to place the tool bodies or these can be dynamically moved with a triad in the graphics area. Push direction can be selected for the tool body, target bodies to deform, a tool body or bodies and a deform deviation value to define the deform shape where the target and the tool bodies intersect. It is used design free form surfaces, tooling, plastics, soft packaging, sheet metal and other applications where it is useful to incorporate the characteristics of tool bodies into existing designs. 3.4.5. Indent creation: It creates an offset pocket or protrusion feature on a target body that exactly matches the contour of a selected tool body, using thickness and clearance values to create the feature. Depending on the body type selected, clearance needs to be specified between the target body and the tool body and a thickness for the indent feature. The indent feature can deform or cut material from the target body. The indent feature updates itself whenever there is a change in the shape of the original tool body, used to create the pocket. Indent is useful in many applications where complex offsets with thickness and clearance values are required. Some examples include packaging, stamping, molds, press fits for machinery and so on. Requirements for indent creation are: i. Either the target body or the tool body must be a solid body. ii. The target body must be in contact with the tool body or the clearance value must enable a protrusion through the target body. iii. The target and tool bodies do not have to be in contact with each other, but the clearance value must be large enough to create an intersection with the target body. iv. To indent a solid with a surface tool body, the surface must completely intersect the solid. 3.4.6. Flex: It deforms complex models in an intuitive manner. Four types of flexes which can be created are: 3.4.6.1. Bending: It alters bodies around a bend line that corresponds to the X-axis of the triad, using the position of the two trim planes to determine the region of flex. This flex type can be used for many applications including industrial

10

design, mechanical design, solving spring-back conditions in metal stamping, removing undercuts from complex surface shapes and so on. 3.4.6.2. Twisting: It twists the geometry about the triads Z-axis. 3.4.6.3. Tapering: It tapers the model along the Z-axis of the triad. 3.4.6.4. Stretching: It stretches the model along the Z-axis of the triad. 3.4.7. Wrap bodies: It wraps a sketch onto a planar or non-planar face. It creates wrap feature on cylindrical, conical or extruded models. A planar profile can be selected to add multiple, closed spline sketches. The wrap feature supports contour selection and sketch reuse. 3.4.8. Creating fastening features: The fastening features streamline creation of common features for plastic and sheet metal parts. Following features can be created: 3.4.8.1. Mounting boss: It is a strengthening feature consisting of a cylinder boss with a hole or a boss on top. It also has rectangular fins at the base. 3.4.8.2. Snap hook: it is a boss feature used in conjunction with the snap hook groove or an existing groove to attach one part to another. 3.4.8.3. Snap groove: It is a cut feature used in conjunction with snap hook to create feature, based on the position and size of snap hook. Snap hook should be created before creating a snap hook groove. 3.4.8.4. Vents: It is a cut feature used to represent a vented opening in a sheet metal part or a plastic molded part. It is based on a sketch that is created priory.

11

CHAPTER 4

ASSEMBLY MODELING
Assembly is a combination of two or more components using parametric relationship. In SolidWorks, these relationships are called Mates. These mates enable to constrain degrees of freedom of the components at their respective work positions. Components can be part or sub assembly. Components are linked to the assembly file. The full associability of SolidWorks reflects any change made on a part, in all assemblies where the part is used. 4.1. Assembly design approaches: There are two approaches for making an assembly. 4.1.1. Bottom-up design: It is traditional method. In it parts can be created, insert them into an assembly, and constraint them as required by design. It is the preferred technique when using previously constructed, off-the-shelf parts. An advantage of bottom-up design is that, because components are designed independently, their relationships and regeneration behavior are simpler than in topdown design. Working with bottom-up design enables to focus on the individual parts. It is good method to use if there is no need to create references that control the size or the shape of the parts with respect to each other. 4.1.2. Top-down design: It allows starting work in the assembly and built parts to fit in the assembly. Geometry of one part helps to define the other parts or to create machined features that are added only after the parts are assembled. It can start with a skeleton model/layout sketch that defines fixed part locations, planes and so on. Then design the parts referencing these definitions. For example, inserting a part in an assembly and then, build a fixture based on this part. Working with top-down, creating the fixture in context, enables to reference model geometry. It can control the dimensions of the fixture by creating geometric relations to the original part. If dimension of the part is changed in this way then the fixture is automatically updated. 4.2. Assembly mates: Mates enable to control part movement with respect to each other. They create a geometric relation between assembly components. As mates are added allowable directions of linear or rotational motion of the components can be defined. A component can be moved within its degrees of freedom, visualizing the assemblys behavior. Most commonly mates used in SolidWorks are: 4.2.1. Standard mates: It mates following valid relationships: 4.2.1.1. Coincident: It positions selected faces, edges and planes so that they share the same infinite plane. It positions two vertices, so that they touch Align axes. 4.2.1.2. Parallel: It places the selected items, so that they remain at constant distance apart from each other.

12

4.2.1.3. Perpendicular: It places the selected items at a 900 angle to each other. 4.2.1.4. Tangent: it places the selected items tangent to each other (at least one selection must be a cylindrical, conical or spherical face). 4.2.1.5. Concentric: It places the selections so that they share the same centre line. 4.2.1.6. Lock: It maintains the position and orientation between two components. The components are between fully constrained relative to each other. A lock mate has the same effect as forming a sub-assembly between the two components and making the sub-assembly rigid. 4.2.1.7. Distance: It places the selected items with the specified distance between them. 4.2.1.8. Angle: It places the selected items at the specified angle to each other mate alignment. 4.2.2. Advanced mates: 4.2.2.1. Symmetric: A symmetric mate forces two similar entities to be symmetric about a plane or planar face of a component or a plane of the assembly. The following entities are allowed in symmetric mate: i. Points such as vertices or sketch points. ii. Lines such as edges, axes or sketch lines. iii. Planes or planar faces. iv. Spheres of equal radii. v. Cylinders of equal radii. 4.2.2.2. Width: A mate centers a tab within the width of a groove. Groove width references can include: i. Two parallel planar faces ii. Two non-parallel planar faces. Tab references can include: i. Two parallel planar faces. ii. Two non-parallel planar faces. iii. One cylindrical face or axis. 4.2.2.3. Path: A path mate constrains a selected point on a component, to a path. The path can be defined by selecting one or more entities in the assembly. Also defining pitch, yaw and roll of the component as it travels along the path. 4.2.2.4. Linear/Linear coupler: It establishes a relationship between the translation of one component and the translation of another component. 4.2.2.5. Limit: It allows components to move within a range of values for distance and angle mates as starting distance or angle as well as a maximum and minimum value can be specified. 4.2.3. Mechanical mates: 4.2.3.1. Cam: A cam follower mate is a type of tangent or coincident mate. It allows mating a cylinder, plane, or point to a series of tangent extruded faces, such as the one find on a cam. A cam profile can be created from lines, arcs and splines, as long as they are tangent and form a closed loop.

13

4.2.3.2. Gear: Gear mates force two components to rotate relative to one another about selected axes. Valid sections for the axis of rotation for gear mate include cylindrical and conical faces, axes and linear edges. 4.2.3.3. Hinge: A hinge mate limits the movement between two components to one rotational degree of freedom. It has the same effect as adding a concentric mate plus a coincident mate. It allows limiting the angular movement between the two components. Advantages of hinge mates: i. When modeling, it is required to apply only one mate. ii. If an analysis such as with SolidWorks Simulation is run, the reaction forces and results are associated with the hinge mate, not one particular concentric or coincident mate. 4.2.3.4. Rack and pinion: With rack and pinion mates, linear translation of one component (the rack) causes circular rotation in another component (the pinion), and vice-versa. It can mate any two components to have this type of movement relative to each other. The components do not need to have gear teeth. 4.2.3.5. Screw: A screw mate constrains two components to be concentric, and also adds a pitch relationship between the rotation of one component and the translation of the other. Translation of one component along the axis causes rotation of the other component according to the pitch relationship. Likewise, rotation of one component causes translation of the other component. 4.2.3.6. Universal joint: The rotation of one component (the output shaft) about its axis is driven by the rotation of another component (the input shaft) about its axis. 4.2.4. Mate references: Mate reference specify one or more entities of a component to use for automatic mating. While dragging a component with a mate reference into an assembly, the SolidWorks software tries to find other combinations of the same mate reference name and mate type. If the name is same, but the type does not match, the software does not add the mate. 4.2.5. Editing mates: Mates can be edited to incorporate the changes in relationships applied to the assembly. 4.2.5.1. Deleting mates: When a mate is deleted, it is deleted in all configurations of the assembly. 4.2.5.2. Diagnosis: MateXpert is a tool that allows identifying mating problems in an assembly. It can examine the details of mates that are not satisfied, and identify groups of mates which over define the assembly. 4.2.5.3. Collision detection: It can detect collisions with other components when moving or rotating a component. The software can detect collisions with the entire assembly or a selected group of components. It can find collisions for

14

either the selected components or for all the components that move as a result of mates to the selected components. 4.3. Assembly pattern: In the assembly mode parts can be pattern in the same manner as patterning feature in a part. It can create the following types of pattern in an assembly: linear, circular and derived pattern. The procedure for creating a linear or a circular and derived pattern. 4.4. Creating exploded view: After the product is designed, the manufacturer needs to know how to assemble it and how to maintain it. It creates a view of the assembly showing the components pulled apart, so that it is visible how components fit together. 4.5. Physical simulation: It enables to simulate the effects of motor, springs and gravity on assemblies. It combines simulation elements with SolidWorks tools such as, mates and physical dynamics to move components around assembly. 4.5.1. Motors: Linear and rotary motors are simulation elements that move components around an assembly using physical simulation. Physical simulation combines simulation elements with other tools such as, mates and physical dynamics to move components in a realistic manner within the components degrees of freedom. Type of motion can be selected and the corresponding values can be given: 4.5.1.1. Constant speed: In order to keep motor speed constant just enter the speed value. 4.5.1.2. Distance: It allows motor to operate for a set distance and time frame. 4.5.1.3. Oscillating: It allows entering values for amplitude and frequency.

15

CHAPTER 5

SURFACE MODELING
Surface body is a general term that describes connected zero-thickness geometries such as single surfaces, knit surfaces, trimmed and filleted surfaces etc. it can have multiple surface bodies in a single part. SolidWorks is truly hybrid design software. It allows users to work with both surface and solids in the same environment. Surface tools include: loft, sweep, and radiate, offset, fill, extend, trim, untrim and knit. There are a number of different situations when it is necessary to work with the surfaces. One is while importing a data either using IGES, where collection of surfaces to work with is present. Another is when the shape is best built using freeform surface and then converted to solid. Surfaces define the shape of the face of a solid. Solid models are intelligent. The system knows what space lies inside the solid and what lies outside the solid. Surface bodies can include: i. ii. iii. Single face surfaces Multiple face surfaces Knit surfaces: it combines two or more faces and surfaces into one. The following points should be noted about knit surfaces: a. Edges of the surfaces must be adjacent and should not overlap. b. Surfaces need not be on the same plane. c. Surfaces need not be on the same plane. d. The entire surface body or one or more adjacent surface bodies can be selected. e. Knit surfaces do not absorb the surfaces which were created earlier. f. It can create a solid body when the knit surfaces from a closed volume, or leave it as a surface body. Filled surfaces: the filled surface feature constructs a surface patch with any number of sides, within a boundary defined by existing model edges, sketches or curves. It can be used to construct a surface to fill a gap in a model. Trimmed and extended surfaces: it allows using a surface, plane or sketch as a trim tool to trim intersecting surfaces. It also uses a surface in conjunction with additional surfaces, as mutual trim tools. Imported surfaces Planar surfaces and mid surfaces: planar surface is used to create to create a planar surface from either a closed single contour non-intersecting sketch or a closed set of planar edges. Mid surface enables to create mid surfaces between suitable selected face pairs on solid bodies. Suitable face pairs should be offset from each other. The faces must

iv.

v.

vi. vii.

16

viii.

belong to the same body. Examples of suitable face pairs include two parallel planes, or two concentric cylindrical faces. Mid surface tool is useful for generating meshes of two dimensional elements in finite element modeling. Surfaces made by extrude, revolve, loft, sweep, offset, radiate or fill.

17

CHAPTER 6

SHEET METAL DESIGN

Sheet metal is simply metal formed into thin and flat pieces. It is one of the fundamental forms used in metalworking, and can be cut and bent into a variety of different shapes. The main feature of sheet metal is its ability to be formed and shaped by a number of processes. Each process does alter the metal, finally giving it a different shape or size. Sheet metal is generally sheets less than 6mm.Sheet metal is formed by reducing the thickness of a long metal work piece by compressive forces applied through a set of rolls. It is characterized by its thickness or gauge of the metal and ranges from 30 gauge to about 8 gauge. The higher the gauge, the thinner is the metal. There are many different metals that can be made into sheet metal. Aluminium, brass, copper, cold rolled steel, mild steel, tin, nickel and titanium are just a few examples of metals that can be made into sheet metal. Sheet metal has applications in car bodies, airplane wings, etc. 6.1. Fundamental concepts: There are many different methods which sheet metal designers and shops employs to determine the flat length of sheet stock which will give desired dimensions to the finished bent part. Some of these methods are simply rules of thumb which individuals use based on experience. Often these rules of thumb relate to the material type and thickness, bend radius and angle, machine type, process speeds, and many more. There are two most widely accepted analytic representations of simple sheet metal bending. One representation is based on bend allowance and the other on bend deduction. SolidWorks software can employ both the bend allowance and the bend deduction methods. 6.1.1. Bend allowance: This method describes the flattened length of the part as the sum of the lengths of each of the flat portions of the part plus the length of the flattened bend region. The length of the flattened bend region is represented by the value bend allowance (BA). In SolidWorks, there is scope of providing one or more tables with BA values or use another means to calculate BA which is K-factor. y K-factor: It is a single value which can be used to represent how sheet metal bends fold/unfold over a wide range of geometric parameters. It is the ratio which represents the distance that the neutral sheet is into the sheet metal. A neutral sheet is defined as an imaginary section through the bend region where there is no stretching or compression. It represents the only location within the bend region which does not deform. 6.1.2. . Bend deduction: It also referred to as setback & is simply a different means to represent the sheet metal bending process. Bend deduction is similar to bend

18

allowance in which bend value is determined from sheet metal suppliers, experimental data, experience, or handbooks with equations or tables for different materials. 6.2. Sheet metal tools: 6.2.1. Base flange: A base flange is the first feature in a new sheet metal part. When a base flange feature to a SolidWorks part, the part is marked as a sheet metal part. Bends are added wherever appropriate, and sheet metal specific feature are added to the FeatureManager design tree. 6.2.2. Edge flange: It adds flanges to one or more edges. 6.2.3. Miter flange: It adds series of flanges to one or more edges of a sheet metal part. 6.2.4. Closed corners: It adds closed corners between sheet metal flanges by adding material between sheet metal features. 6.2.5. Rip: It is a cut that is used to saw a part along a specified line or edge. SolidWorks creates a rip feature, along selected internal or external model edges, from linear sketch entities or by combining model edges and single linear sketch entities. A rip feature is commonly used to create sheet metal parts. 6.2.6. Unfold/Fold: With these tools one can flatten and bend one or more than one or all the bends in a sheet metal part. 6.2.7. Flattening bends: It flattens the entire part. 6.2.8. Forming tools: It act as dies that bend, stretch, or otherwise form sheet metal to create form features such as louvers, lances, flanges and ribs. A forming tool can be made using customer specifications and can be stored in forming tools data design library, which enables to use later whenever required. In order to use an already saved forming tool first drag the tool from design library then select the stopping face of forming tool and then faces to remove of sheet metal part. 6.2.9. Welded corner: It adds a weld bead to the corners of a folded sheet metal part, including miter flanges, edge flanges and closed corners. 6.2.10. Lofted bends: It uses two open-profile sketches that are connected by a loft. The base-flange feature is not used with the lofted bend feature. 6.2.11. Converting solid body into sheet metal part: It converts a solid part into sheet metal; thus allowing usage of all sheet metal features.

19

CHAPTER 7

PROJECT ON ASSEMBLY OF CAM AND FOLLWER

The project is divided into four parts: 7.1. Base for inserting Follower: 7.1.1. Simple sketch designs by first creating centre lines, then using simple lines to create part as shown below.

7.1.2. Dimension is given to the sketch by smart dimension.

20

7.1.3. The sketch is further modified by providing fillet.

7.1.4. Sketch need no further editing thus after exiting sketch the sketch appear as shown below.

21

7.1.5. Sketch profile is then extruded; here it is extruded by 30mm thickness and through mid plane direction.

7.1.6. Extruded feature looks like as shown below.

22

7.1.7. In order to create a sketch on solid part surface; first select the face of the part, a pop-up window will appear then select sketch to create a circle on the face.

7.1.8. Then applying extrude cut feature to create a hole.

23

7.1.9. After extruded cut the final base part appears as below.

7.2. Follower 7.2.1. In order to create a round part like follower there is no need to create full sketch as shown below.

24

7.2.2.

Again smart dimension is used for dimensioning.

7.2.3.

Exiting sketch once it is finished.

25

7.2.4. Then revolve command allows to create round feature about a non-intersecting axis or line.

7.2.5. Revolve part looks as shown below.

26

7.3. Cam 7.3.1. Cam sketch is created by using spline tool.

7.3.2. Complete sketch part looks like this after exiting sketch.

27

7.3.3. Then using extrude feature to extrude cam of thickness larger than diameter of follower face.

7.3.4. Extruded cam looks like this.

28

7.3.5. In order to create a sketch on solid part surface; first select the face of the part, a pop-up window will appear then select sketch to create circles on the face.

7.3.6. For create motor spindle it is required to cut solid portion to create slot around spindle.

29

7.3.7. After extrude cut the slot appears as shown below.

7.3.8. Then select the inner circle to extrude to extend it as motor spindle.

30

7.3.9. Final cam part looks like this.

7.4. Assembly of Base, Follower and Cam 7.4.1. To assemble all three parts open a new document and select assembly and then press ok.

31

7.4.2. Since all three parts are designed recently show browse file option automatically shows all part otherwise each part has to be browsed separately.

7.4.3. In assembly first part selected is fixed so always choose non-movable part that is base.

32

7.4.4. After positioning base next part selected is follower.

7.4.5. Then mate tool is selected to mate base with follower.

33

7.4.6. Mate selection is done in two parts first one is shown below in which surface to surface mating is done so that follower upper face comes in datum line of surface of base.

7.4.7. Next mate selection is cylindrical part of follower and inner hollow face of base so that the follower is inside the hole present on base surface.

34

7.4.8. Then cam part is selected.

7.4.9. Move component tool is then used to directly put the cam below the follower face.

7.4.10. In order to achieve the relative motion between the cam and follower; mechanical mate under mate tool is used. As discussed earlier mechanical mate allows simulating relative motion between standard features like cam, gears, rack and pinion, screw and universal

35

joint.

7.4.11. After applying mechanical mate the cam and follower shows relative motion as shown below.

36

CHAPTER 8

GEOMETRIC DIMENSIONING & TOLERANCING

GD&T stands for geometric dimensioning and tolerancing. It is a system of symbols, rules and definitions used to define the geometry of mechanical parts. GD&T is one of the most powerful tools available that can improve quality, reduce cost and shorten delivery time. All of this is possible when the concurrent engineering team is involved with the creation of the drawing. The drawing is a common thread that ties these groups together. They all are involved with the engineering drawing. GD&T on the drawing must first and foremost capture design intent. However, the best design in the world is worthless if it cannot be produced. That is why it is necessary for production/vendors and quality to be involved with the requirements that are placed on the drawing. When they are not involved, the drawings often have overly tight tolerances and result in non-producible parts. At least these are not producible at the quality level, cost and timeliness expected by industry. 8.1. Scope: Use of Geometric dimensioning and tolerancing (GD&T) depends on ones discipline. To the designer it is a way to describe the design intent of individual parts. To someone in production it is the language of modern print reading. To someone working in metrology it is a guide to the inspection of parts. To management it is a concurrent engineering tool that provides clear communication across the enterprise. 8.2. Geometric Characteristic Symbols: Straightness A condition where all points is in a straight line, the tolerance specified by a zone formed by two parallel lines.

Flatness All the points on a surface are in one plane, the tolerance specified by a zone formed by two parallel planes.

Roundness or Circularity All the points on a surface are in a circle. The tolerance is specified by a zone bounded by two concentric circles.

Cylindricity All the points of a surface of revolution are equidistant from a common axis. A cylindricity tolerance specifies a tolerance zone bounded by two concentric cylinders within which the surface must lie.

Profile A Tolerancing method of controlling irregular surfaces, lines, arcs, or normal planes. Profiles can be applied to individual line elements or the entire surface

37

of a part. The profile tolerance specifies a uniform boundary along the true profile within which the elements of the surface must lie.

Angularity The conditions of a surface or axis at a specified angle (other than 90) from a datum plane or axis. The tolerance zone is defined by two parallel planes at the specified basic angle from a datum plane or axis.

Perpendicularity The condition of a surface or axis at a right angle to a datum plane or axis. Perpendicularity tolerance specifies one of the following: a zone defined by two planes perpendicular to a datum plane or axis, or a zone defined by two parallel planes perpendicular to the datum axis.

Parallelism The condition of a surface or axis equidistant at all points from a datum plane or axis. Parallelism tolerance specifies one of the following: a zone defined by two planes or lines parallel to a datum plane or axis, or a cylindrical tolerance zone whose axis is parallel to a datum axis.

Concentricity The axes of all cross sectional elements of a surface of revolution are common to the axis of the datum feature. Concentricity tolerance specifies a cylindrical tolerance zone whose axis coincides with the datum axis.

Position A positional tolerance defines a zone in which the center axis or center plane is permitted to vary from true (theoretically exact) position. Basic dimensions establish the true position from datum features and between interrelated features. A positional tolerance is the total permissible variation in location of a feature about its exact location. For cylindrical features such as holes and outside diameters, the positional tolerance is generally the diameter of the tolerance zone in which the axis of the feature must lie. For features that are not round, such as slots and tabs, the positional tolerance is the total width of the tolerance zone in which the center plane of the feature must lie.

38

Circular Runout Provides control of circular elements of a surface. The tolerance is applied independently at any circular measuring position as the part is rotated 360 degrees. A circular runout tolerance applied to surfaces constructed around a datum axis controls cumulative variations of circularity and coaxiality. When applied to surfaces constructed at right angles to the datum axis, it controls circular elements of a plane surface.

Total Runout Provides composite control of all surface elements. The tolerance applied simultaneously to circular and longitudinal elements as the part is rotated 360 degrees. Total runout controls cumulative variation of circularity, cylindricity, straightness, coaxiality, angularity, taper, and profile when it is applied to surfaces constructed around a datum axis. When it is applied to surfaces constructed at right angles to a datum axis, it controls cumulative variations of perpendicularity and flatness.

39

BIBLIOGRAPHY:
y y www.caddcentre.co.in SOLIDWORKS Reference Guide

40