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1. INTRODUCTIONSolid Works is a 3D mechanical CAD program that
runs on Microsoft Windows which was developed by Solid Works
Corporation, headquartered in USA, a subsidiary of Dassault
systemes. SolidWorks provides engineers, designers and other
creative professionals with the tools they need to design the
worlds greatest products.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: Precisely
turn creative concepts into 3D design. Create the most ergonomic
designs possible. Produce design iterations in less time. Reduce
prototyping time and cost. Work with customer data. Manage product
information more effectively. Render highly detailed 3D design.
1.1 Modules in SolidWorksSolidWorks extends design applications
through full integration with best in class solutions. The
following modules are mainly used. Part Modeling Assembly Modeling
Surface Modling Sheet Metal Design Drawing
1.2 Features of SolidworksSolidWorks 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:
Feature-based Parametric Solid modeling Constraints
1.2.1 Feature-basedJust 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
features. When you create a model using the solidworks software,
you work with intelligent, easy to understand geometric features
such as bosses, cuts, holes, ribs, fillets, chamfers and draft. The
features are applied directly to the work piece as soon as they are
created.
1.2.2 ParametricThe dimensions and relations used to create a
features are captured and stored in the model. This enables not
only to capture your design intent, but also to quickly 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 ModelingA solid model is the most complete type of
geometry model used in CAD systems. It contains all the wire frame
and surface geometry necessary, to fully describe the edges and the
faces of the model.
1.2.4 ConstraintsGeometric relations such as parallel,
perpendicular, horizontal, vertical, concentric and coincident are
some of the constraints supported by solidworks.2. Graphic User
Interface of SolidWorks and ControlThe format of the SolidWorks
window reflects that of windows itself. The same is true for any
SolidWorks document. Once opened a document appears split into two
panels. The right is the graphics window, where your model or
drawing appears. You can create and manipulate the document in the
graphics window. The Main elements of the SolidWorks user interface
are as follows:FeatureManager design tree: Similar to the windows
explorer tree it lists the structure of the part, assembly or
drawing.
PropertyManager: Appears in the left panel when you select many
of the SolidWorks commands such as sketches, fillet features and so
on. The PropertyManager displays selection icons to enter relevant
command options and boxes/fields to enable the user to enter
relevant design and data parameters.
ConfigurationManager: Appears in place of the FeatureManager
design tree. Helps create, select and view multiple configurations
(variations of parts and assemblies in a single document).
Main Menu: A set of drop down menus (File, Edit, View, and so
on) across the top of the user interface. The menu bar contents are
task dependent based on the active document type. SolidWorks
toolbars display these functions whereas the menu bar contains the
complete set.Standard toolbar: Found just beneath the main menu
this toolbar is consists of a set of the most commonly used command
buttons.View toolbar: Features a series of commonly used command
buttons that allow you to zoom, rotate and view the part in
different orientations.Command Manager: A dynamic toolbar that
lists the command buttons for the type of document you are working
on.
Graphics area: Displays the part assembly or drawing.Quick tips
help: Indicates with a question mark button whether Quick Tips is
on or off. Click the icon to toggleDesign Library: Click to open
the design library. Inside you see the Design Library, Toolbox and
3D Content Central each which contain many standard design elements
you can drag and drop into your design.
File Explorer: Duplicates Windows Explorer in your computer.
Lists recently opened documents and currently opened documents. You
can drag documents from here into the graphics area.Triad: A traid
appears in part and assembly documents to help you orient when
viewing models. The Triads is for reference only. You can not
select it.
2.2 View and OrientationA set of predefined views can be
selected through the Standard view toolbar, a flyout (similar to a
drop down Menu) tool bar that is embedded in the View toolbar. If
you click the Standard View button in the View toolbar, you get a
pull-down menu of several commands that represent standard
engineering views. This enables the user to select views such as
Side, Front, Top, Right and Bottom as well as perspectives:
Isometric, Trimetric and Dimetric which vary in viewing.
2.2.1 OrientationThe orientation section of the View toolbar
offers several tools to enable the user to manually manipulate the
orientation of a model. These manipulation tools include the
following:Zoom to Fit: Zooms in or out so the entire model is
visible. Zoom to Area: Zooms in on a portion of the view that you
select by dragging a bounding box. The centre of the box is marked
with plus (+) sign. Zoom In/Out: Zooms in as you press and hold the
left mouse button and drag the mouse up. Zooms out as you drag the
mouse down. Zoom to Selection: Zooms to the size of a selected
entity. Rotate View: Rotates the view as you press and hold the
left mouse button and drag the mouse around the screen. Pan View:
Scrolls the view so the model moves as you drag the mouse.
2.2.2 Display ModesThe third section of the View toolbar offers
the following display modes for model and drawing view in drawing
documents. These tools include the following:Shaded Shaded with
Edges Hidden Lines Removed Hidden Lines Visible Wireframe (Displays
all edges of the model) Section View
Fig : Section View and PropertyManager
Control Mouse buttonsSolidWorks uses three mouse buttons to
access features, select objects and perform tasks: Left: Selects
menu items, entities in the graphics area, and objects in the
FeatureManager design tree.To select an entity click on the entity
in the graphics window or in the feature manager design tree.
Selected objects become highlighted in both the graphics area and
FeatureManager design tree. To select multiple entities hold down
the Ctrl button while continuing to click on the objects to be
selected. To select a group of objects hold down the mouse button
and drag a window around the objects. To deselect all objects click
anywhere in the document window outside the part or assembly.Right:
Displays context sensitive options and shortcut
menus.Middle:Rotate: Hold down button and move mouse. To rotate
about a vertex edge or axis (other than the origin) click the
middle mouse button on the geometry then hold and move the
mouse.Pan: Hold Ctrl button while holding down button and move the
mouseZoom: Position cursor over the chosen position in the graphics
window and hold shift and mouse button or if available spin roller
button toward you to zoom out and reverse to zoom in
Keyboard ShortcutsListed below are the predefined keyboard
shortcuts options:Arrow Keys . . . . . . . . . . . . . . . . Rotate
the viewShift+Arrow Keys . . . . . . . . . . . Rotate the view in
90 incrementsAlt+Left or Right Arrow Keys .Rotate about normal to
the screenCtrl+Arrow Keys . . . . . . . . . . . Move the
viewShift+z . . . . . . . . . . . . . . . . . . . . Zoom Inz. . . .
. . . . . . . . . . . . . . . . . . . . . . Zoom Outf . . . . . . .
. . . . . . . . . . . . . . . . . . . Zoom to FitCtrl+1 . . . . . .
. . . . . . . . . . . . . . . Front OrientationCtrl+2 . . . . . . .
. . . . . . . . . . . . . . Back OrientationCtrl+3 . . . . . . . .
. . . . . . . . . . . . . Left OrientationCtrl+4 . . . . . . . . .
. . . . . . . . . . . . Right OrientationCtrl+5 . . . . . . . . . .
. . . . . . . . . . . Top OrientationCtrl+6 . . . . . . . . . . . .
. . . . . . . . . Bottom OrientationCtrl+7 . . . . . . . . . . . .
. . . . . . . . . Isometric OrientationCtrl+8 . . . . . . . . . . .
. . . . . . . . . . View Normal ToSpacebar . . . . . . . . . . . .
. . . . . . View Orientation dialogCtrl . . . . . . . . . . . . . .
. . . . . . . . . Hold and select multiple items with mouse
buttonCtrl+c . . . . . . . . . . . . . . . . . . . . . Copy
selected entity/itemCtrl+z . . . . . . . . . . . . . . . . . . . .
. UndoCtrl+y . . . . . . . . . . . . . . . . . . . . . RedoCtrl+Tab
. . . . . . . . . . . . . . . . . . .Switch between
documentsAlt+drag . . . . . . . . . . . . . . . . . . . Select
anywhere in a drawing viewShift+drag . . . . . . . . . . . . . . .
. . Maintains distance between drawing views while draggingCtrl+R .
. . . . . . . . . . . . . . . . . . . .RedrawCtrl+B . . . . . . . .
. . . . . . . . . . . . .Rebuild
Customizing the SolidWorks windowSystem optionsThe options
grouped under the heading System Options are saved on your system
and affect every document you open in your SolidWorks session.
System settings allow you to control and customize your work
environment. For example, you might like working with a coloured
graphics window background. Since this is a system setting, parts
or assemblies opened on your system would have a coloured graphics
window.
Fig: Located on the tools menu the options dialogue box allows
you to customize the SolidWorks software.
3. CREATE A PART (PART MODELING)
3.1 Create Your Part Stages in the Process Create a New part
documentNew parts can be created in inch, millimetre or other
units. Parts are used to create and hold the solid model. Sketch
the profileSketches are collections of 2D geometry that are used to
create solid features. These include lines, circles and rectangles.
Applying Sketch relations and dimensionsGeometric relationships
such as horizontal and vertical are applied to the sketch geometry.
Dimension size the geometry while the relations restrict the
movement of the entities. Extruding the sketchExtruding uses the 2D
sketch to create a 3D solid feature.
3.2 ProcedureThe process in this includes sketching and
extrusions. To begin with, a new part file is created.3.2.1 Create
a New part document1. New part
2. Filing a part.Using the Save option from the File menu or
selecting the Save button on the Standard toolbar; file the part
under the name Candle Holder. The extension, *.sldprt, is added
automatically. Click Save.
3. Select the Plane we want to Sketch on. It is important to
choose the correct plane to sketch on this is done by selecting the
best profile to sketch of the part. The best profile to sketch is
the profile when selected extruded generated the majority or most
complexities of the part.The direction we look at to part to get
the get the best profile whether it be the plan, elevation or end
view will determine sketching on the Top, Front or Right Plane.By
giving careful thought to which plane is used to sketch the
profile, the proper views are easily generated on the detail
drawing.
Fig: Sketching Planes
Sketch toolbar
4. What is Design Intent: Design Intent is our plan as to how
our model should behave when changes are made. How Do we Imbed
Design intent?
We can imbed design intent following the steps below: Choose the
Best Profile Choose the Plane Sketch Rough Sketch Automatic
(sketch) Relations Added Relations Dimensions Equations Link Values
Extrusion Type of extrusion used End Condition Blind Mid Plane
4. Create our sketch by selecting the Top Plane and then the
Sketch Icon
Rule of Thumb When Sketching Rough Sketch Add Relations Add
DimensionsRelations such as parallel, horizontal, vertical and
tangent and so on, can be automatically added to the sketch while
sketching. Link Values / Equations
5. We know we are actively in a sketch by the following
screen
6. Select the Line Command on the sketch toolbar and draw a
rectangle on the screen.The positioning of the sketch in relation
to the origin is important. ( your sketch must be attached to the
origin in some form in order to fully define the sketch)Tip: By
positioning the origin in the centre of the square by using a
construction line the origin is positioned in the centre. This
enables you to place the circle in the centre of the cube later on.
7. Dimension the Sketch using the dimension icon.
8. Conditions of a Sketch.Under DefinedThere is inadequate
definition of the sketch, but the sketch can still be used to
create features. This is good because many times in the early
stages of the design process, there isnt sufficient information to
fully define the sketch. When more information becomes available,
the remaining definition can be added at a later time. Under
defined sketch geometry is blue (by default).
Fully DefinedThe sketch has complete information. Fully defined
geometry is Black (by default). As a general rule, when a model is
completed, the sketches within it should be fully defined.
Over DefinedThe sketch has duplicate dimensions or conflicting
relations and it should not be used until repaired. Unnecessary
dimensions and relations should be deleted. Over defined geometry
is red (by default).
9. Select the Features Icon on the Command Manager.
10. Select the extrude command and extrude the 2d Profile.
Design Intent at extrusion stage. Examples of design intent in
respect of features Base Extrude Revolve Cut Extrudes Shell Fillets
Chamfer Examples of design intent in respect to End Conditions of
features Blind Through all Mid-plane Up to Next Up to Surface
Fig. Extruded 2D sketch
11. Select Top Face of the Cube and create a sketch by selecting
the Sketch icon
12. Select a circle command start the center of the circle at
the origin. 13. Select the Cut Extrude command form the Feature
Tool Bar.
14. Cut Extrude Blind into the cube or as required.
15. Create a Sketch on the Front Face of the Cube.
16. Using the Centre Line command sketch a centre line across
the diagonal
17. Using the Polygon Command, sketch a polygon starting on the
midpoint of the centre line.
18. Select the top line of the polygon and add the relationship
of horizontal in the Property Manager
19. Dimension the top line of the polygon.
20. Cut Extrude the Sketch.
21. Add a chamfer to the Polygon.
Fig. Chamfer options and Projected view of chamfered part.
22. Select all 6 edges of the Polygon.
23. Apply the same chamfer to the edge of the circle.
24. Add Fillet to all 8 edges as can be seen in Picture.
25. Select Fillet command from the Features Tool Bar.
26. Select the options like dimension and angle of fillet.
Projected view of Fillet
27. Apply a material to the part. In the Feature Manager right
click on add material andselect any material(say brass) and say ok.
29. Save the Part File as *.SLDPRT format.
4. REFERENCE GEOMETRYReference geometry 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
interface for various placed and sketched features and so on. Fig.
Reference geometry option in toolbar.
4.1 Types of Reference Geometry4.1.1 Reference PlanesThis
feature allows the user to create additional planes to sketch on
other than the given right, front, and top plane. To create a
reference plane left click on plane and select the desired option
in the property manager for creating the plane. These options
include:1. Through lines/points: creates a plane through a point an
edge, sketch line, three points, or axis.2. Parallel plane at
point: creates a plane through a point parallel to a plane or
face.3. At angle: create a plane through an axis, edge or sketch
line at a specified angle from a face or plane.4. Offset distance:
create a plane parallel to an existing plane and specifying the
desired distance.5. Normal to curve: Create a plane through a
specified point and makes it perpendicular to a desired curve or
edge.6. On surface: creates a plane on a non-planer face or angled
surface.
4.1.2 Reference AxesAllows the user to insert an axis in the
part document. Axes are particularly useful in creating part
features. To create a reference axis left click on axis and select
the desired option in the property manager for creating the axis.
These options include:1. On edge: places an axis on a desired edge
or sketch line of the part.2. Two planes: create an axis at the
intersection of two planes or planar faces.3. Two points/vertices:
create an axis through two selected points, vertices, or midpoints
on a line, edge, or part corner.4. Cylindrical/conical faces:
places an axis through the center of a circular, cylindrical, or
conical face. This axis can also be seen by right clicking on view
and then selecting temporary axes.5. Point and a face: creates an
axis perpendicular to a selected face or plane and through a
selected point, midpoint, or vertex.
4.1.3 Reference Coordinate SystemsCreate an additional
coordinate system on the part by specifying the x, y, and z
directions with the parts geometry. This can be helpful when
integrating a part into an assembly as a reference for directional
part interactions as well as setting up a zero point for machining
and manufacturing the part.
4.1.4 Reference PointAdd a singular location on a part document
that references geometries found on the modeled part. These can be
placed at the center of an arc, the center of a face, an
intersection, along a curve, or projected onto another entity.
These can be helpful in making point clouds to help define and
place three or two dimensional sketches. Most commonly used in
complicated parts such as vehicle frames.
5. ASSEMBLY MODELINGAssembly is a combination of two or more
components using parametric relationship. In solid works, these
relations are called Mates. These mates enable you to constrain
degrees of freedom of the components at their respective work
positions. Components can be part or sub assembly.5.1 Types of
Assembly Design ApproachThere are two approaches for making an
assembly. Bottom-up Design Top-down Design
Bottom-up DesignIt is the traditional method. In bottom-up
design, you can create parts, insert them into an assembly, and
constraint them as required by your design. Bottom-up design is the
preferred technique when you are 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 top-down design.
Top-Down DesignIn top down design you can start your work in the
assembly and built parts to fit in the assembly. You can use the
geometry and built parts to fit in the assembly. You can use the
geometry of one part to help define the other parts or to create
machined features that are added only after the parts are
assembled. You can start with a skeleton model/layout sketch that
defines fixed part locations, planes and so on. Then design the
parts referencing these definations.
5.2 ASSEMBLY MATES Mates create geometric relationships between
assembly components. As you add mates, you define the allowable
directions of linear or rotational motion of the components. You
can move a component within its degrees of freedom, visualizing the
assembly's behavior. Mates are solved together as a system. The
order in which you add mates does not matter; all mates are solved
at the same time. You can suppress mates just as you can suppress
features. These include: Standard mate Advanced mate Mechanical
mate Smart mate Mate reference
5.2.1 Standard mateMates create geometric relationships, such as
coincident, perpendicular, tangent, and so on. Each mate is valid
for specific combinations of geometry. The following tables list
the valid mates for all geometry types. Coincident - The Coincident
mate is applied to make two planar faces coplanar. However, you can
apply the Coincident mate to other entities as well. Concentric -
The Concentric mate is used to align the central axis of one
component with that of the other. You need to select the circular
faces or circular edges to apply the Concentric mate. You can also
apply the Concentric mate between a point and a circular face or a
circular edge. Distance - The Distance button is chosen to apply
the Distance mate between two components. To apply this mate,
invoke the Mate Property Manager and select the entities from both
components. Choose the Distance button from the Mate pop-up
toolbar; the Distance spinner will be displayed in the Mate pop-up
toolbar. Angle - The Angle button is used to apply the Angle mate
between two components. This mate is used to specify the angular
position between the selected plane, planar face, or edges of the
two components. To apply this mate, invoke the Mate Property
Manager and select the entities from the two components. Parallel -
The Parallel button in the Mate pop-up toolbar is used to apply the
Parallel mate between two components. To apply the Parallel mate,
invoke the Mate Property Manager and select two entities from two
components.
Perpendicular - The Perpendicular button in the Standard Mate
rollout is used to apply the Perpendicular mate between the two
components. Invoke the Mate Property Manager and select two
entities from two components.
Tangent - The Tangent button available in the Mate pop-up
toolbar is used to apply the Tangent mate between two components.
To apply the Tangent mate between two components, invoke the Mate
Property Manager and select two components.
5.2.2 Smart MateSmart Mates is the most attractive feature of
the assembly design environment in Solid Works. The Smart Mates
technology speeds up the design process in the assembly environment
of Solid Works. To add smart mates to the components, choose the
Move Component button from the Assemble Command Manager ;the Move
Component Property Manager will be displayed .Now, choose the Smart
Mates button available in the Move rollout; the Move Component
Property Manager will be replaced by the Smart Mates Property
Manager.
5.2.3 Mate ReferenceIn Solid Works, you can define the mate
reference for the part in the Part mode or in the Assembly mode.
The mate references allow you to define the mating references such
as planar surfaces, axes, edges, and so on before assembling the
component. To define the mate references, choose Reference Geometry
> Mate Reference from the Assemble Command Manager; the Mate
Reference Property Manager will be displayed.
5.2.4 Advanced MatesAdvanced mates include limit, linear/linear
coupler, path, symmetry, and width mates. SymmetricA symmetric mate
forces two similar entities to e symmetric about a plane or planar
face of a component or a plane of the assembly. The following
entities are allowed in symmetry mates: Points such as vertices or
sketch points Lines such as edges, axes or sketch lines Planes or
planar faces Spheres of equal radii Cylinder of equal radii
WidthA width mate centers a tab within the width of a groove .
groove width references can include: Two parallel planar faces Two
non-planar faces
PathA path mate constrains a selected point on a component, to a
path. You can define the path by selecting one or more entities in
the assembly. You can define pitch, yaw and roll of the component
as it travels along the path.
Linear/linear CouplerA linear/linear coupler mate established a
relationship between the translation of one component and the
translation of another component.
LinearLimit mates allows components to move within the range of
values for distance or angle as well as a maximum and minimum
value.
5.2.5 Mechanical MatesMechanical mates include cam-follower,
gear, hinge, rack and pinion, screw, and universal joint mates.
CamA type of tangent or coincident mate. Asks the user to select
all of the cam face to which the follower will lie on and the face
of the follower that will touch the cam.
HingeConstrain two components rotational degrees of freedom.
Asks user to input two concentric sections, coincident faces, and
the angle limit (how far the components can move from each other
identical to angle mate).
GearMates two gears or cylindrical faces so that the two
components rotate relative to one another about an axis.Note:
Select the inside bore hole of the gear or the axis, do not select
the face of the gear.
Rack PinionSimilar to the gear mate except that the revolution
of one component corresponds to the linear movement of the mating
component. This mate does not require gear teeth.
ScrewConstrains two components with a concentric mate and
defines a pitch relationship between the rotation of one component
and the translation of another.
Universal JointThe rotation of a component about its axis is
controlled by the rotation of the mating component about its
axis.
5.3 ROTATING INDIVIDUAL COMPONENTSIn SolidWorks, you can rotate
an individual unconstrained component in the assemblydocument
without affecting the position and location of the other
components. The Rotate Component tool is used to rotate the
component.
5.3.1 Rotating Individual Components by DraggingYou can rotate
the component placed in the assembly without invoking any tool. To
rotate an individual component, select the component, press and
hold the right mouse button and then drag the cursor to rotate the
component. Release the right mouse button after attaining the
desired orientation of the individual component.
5.3.2 Rotating Individual Components Using the Rotate Component
ToolYou can also rotate an individual component using the Rotate
Component tool. Torotate an individual component using this tool,
choose Move Component > RotateComponent from the Assemble
Command Manager; the Rotate ComponentProperty Manager will be
invoked. You will notice that the Free Drag option is selected from
the Rotate drop-down list in the Rotate rollout. Therefore, you
will be prompted to select a component and drag it to rotate. The
select cursor will be replaced by the rotate cursor. Select the
component and drag the cursor to rotate the component.
6. DRAWING VIEWSDrawings are essentially a mean to communicate
the design to the manufacturing entity of any organization.
Mechanical drawings are important because they allow those who are
technically trained to reconstruct your 3D geometry from 2D
drawings. Fortunately, SolidWorks makes it very easy for us to
create drawings from a part or assembly file. In fact, if built
properly, SolidWorks will also dimension the entire part and
assembly for us, something that saves a lot of time.
More important than the ability to create a complex lofted
surface is the fact that once you have modeled your design,
multiview drawings are just a few mouse clicks away. BOMs can be
created automatically from the assembly structure, and alternate
position views are generated with a simple drag of the mouse.
6.1 Steps Involved In Creating Drawing Views1. Click New in the
standard toolbar, or click file>> new from the menu bar.2. In
the new solid works document dialog box that is displayed, as
shown, select the drawing option and click ok.
3. Select the desired sheet format in sheet format/size dialog
box as shown in earlier topic and then click ok. Click cancel, if
you do not want to use any sheet format. You can also create custom
sheet size selecting custom sheet size.4. In model view property
manager, select a model from open documents as shown or browse to
part or assembly file.5. Specify options in the Model View Property
Manager, and then place the view in the graphics area.6. Position
the Front Elevation on the drawing sheet and Left click.7. Move
Mouse to the Left of the Front Elevation to Create the Side
Elevation (left click to position view).8. Move Mouse Under the
Front Elevation to Create the Plan View / Top View (left Click to
position View).9. Move Mouse up too the Left Diagonal of the Front
View to Create the isometric view. Hold down the Ctrl key and
position the view under the Side Elevation.10. Hold Down the Ctrl
Key and Select all Drawing Views.11. Select the Hidden Lines icon
from the views toolbar to show hidden lines in all views.12.
Drawing Views Should Look like below.13. Smart dimensions can be
used to apply any missing dimensions manually.14. For saving the
file, click save in the standard toolbar or click file>>save.
The file will be saved with .slddrw.
7. SHEET METALSheet 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 6 mm. 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. Aluminum,
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.
7.1 Sheet Metal ToolsWhen you create a sheet metal operation in
SolidWorks, new feature namely, sheet-metal , base-flange and
flat-pattern, are automatically created. Sheet-metal contains the
bend parameters such as bend radius, bend allowance, bend
deduction, etc. Base-flange is the first solid feature of sheet
metal part. Flat-Pattern flattens the sheet metal part. It is
suppressed by default, as the part is in its bent state. Unsuppress
the feature to flatten the sheet metal part. There are various
tools within the part module that SolidWorks provides to build the
sheet metal parts.7.2 Base FlangeA base flange is the first feature
in a new sheet metal part When you add 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 features
are added to the FeatureManager design tree.
7.3 Edge FlangeEdge Flange is used to add flanges to one or more
edges. You can also select multiple linear edges, which are
contiguous or non- contiguous. With contiguous edges, the software
automatically trims to 45 degrees.
7.4 Miter FlangeA miter flange feature adds a series of flanges
to one or more edges of a sheet metal part. Some items to note
about a miter flange feature are:1. The sketch for a miter flange
must adhere to the following requirements: The sketch can contain
lines or arcs. The miter flange profile can contain more than one
continuous line. For example, it can be an L-shaped profile. The
sketch plane must be normal to the first edge where the miter
flange is created.2. The thickness is automatically linked to the
thickness of the sheet metal part.3. You can create a miter flange
feature on a series of tangent or non-tangent edges.4. Instead of
creating a miter flange across the entire edge of a sheet metal
part, you can specify an offset of the flange.
7.5 HemThe Hem tool adds a hem to your sheet metal part at a
selected edge. The following points are to be noted for Hem
feature.1. The selected edge must be linear.2. Mitered corners are
automatically added to intersecting hems.3. If you select multiple
edges to add a hem, the edges I must lie on the same face.
7.6 JogThe jog tool adds material to a sheet metal part by
creating two bends from a sketched line. Some additional items to
note about the Jog tool are:1. The sketch must contain only one
line. The line does not need to be horizontal or vertical.2. The
bend line does not have to be the exact length of the faces you are
bending.
7.7 Break Corner/Corner TrimThe Break Corner tool cuts away
material from a sheet metal part on an edge or a face. The Corner
Trim tool cuts material away from a flattened sheet metal SB on an
edge or a face.
7.8 Closed CornersYou can add closed corners between sheet metal
flanges. The Closed Comer feature adds material between sheet metal
features. The following are the capabilities of Closed Comer:1.
Close multiple corners simultaneously by selecting the faces for
all the comers that you want to close.2. Close non-perpendicular
corners.3. Apply a closed corner to flanges with bends other than
90.4. Adjust the Gap distance, the distance between the two
sections of material where area is added by the Closed Comer
feature.5. Adjust the Overlap/Underlap ratio. The ratio between the
material that overlaps and the material that underlaps. The value 1
indicates that the overlap and the underlap are equal.6. Close or
open the bend region.Closed corner
7.9 RipA Rip feature 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. You can add a rip feature to any part.
7.10 Sketch BendYou can add bend lines to the sheet metal part,
while; the part is in its folded state with a sketched bend
feature. This allows you to dimension the bend line to other
folded-up geometry. Some items to note about a sketched bend
feature are:1. Only lines are allowed in the sketch. You can add
more than one line per sketch.2. The bend line does not have to be
the exact length of the faces you are bending.
7.11 Unfold/FoldWith the Unfold and Fold tools, you can flatten
and bend one, more than one or all the bends in a sheet metal part.
This combination is useful while adding a cut across a bend. First,
add an Unfold feature to flatten the bend. Next, add your cut.
Finally, add a Fold feature to return the bend to its folded
state.
7.12 Forming Toolsforming tools act as dies that bend, stretch,
or otherwise form sheet metal to create form features such as
louvers, lances, flanges and ribs. The SolidWorks software includes
some sample forming tools to get you started. They are stored in
< mstai/_dir >\data\design library\ forming tools. You can
insert forming tools only from the Design Library and you can apply
them only to sheet metal parts. A sheet metal part has the
Sheet-Metal I feature in the FeatureManager design tree. You can
create your own forming tools using many of the same steps you use
to create any SolidWorks part.Creating a Forming ToolYou can create
forming tools and add them to sheet metal parts. When you create a
forming tool:1. The locating sketch is added to position the
forming tool on the sheet metal part.2. The colors are applied to
distinguish the stopping face from the faces to remove.
7.13 Cross BreakIn HVAC (Heating, Ventilating and Air
Conditioning) or duct work design, cross breaks are used to stiffen
sheet i metal. The Cross Break command allows you to insert [ a
graphical representation of a cross break in a sheet metal part.
Cross break characteristics:1. You can flatten a sheet metal part
with a cross break.2. You can add edge or miter flanges to the edge
of a face that contains a cross break.3. The dimensions of a part
with a cross break are not changed.4. You can edit the cross break
sketch to move comers and change relationships.5. When you create a
part with a cross break, the flattened view is labeled with the
bend direction, bend radius and bend angle.
7.14 Welded CornerThe Welded Comer PropertyManager allows you to
add a weld bead to the corners of a folded sheet metal part,
including miter flanges, edge flanges and closed comers.
7.15 Lofted BendsLofted bends in sheet metal parts use two
open-profile sketches that are connected by a loft. The Base-Flange
feature is not used with the Lofted Bend feature The SolidWorks
software contains several pre-made sheet metal parts created with
lofted bends, locate! in: \Documents and Settings\AIl Users!
Application Data\SolidWorks\SolidWorks 2010\desig* library\
Parts\sheet metal\lofted bends. Characteristics of Lofted Bends:1.
K-Factor or Bend Allowance to calculate bends.2. Cannot be
mirrored.3. Requires two sketches that include: Open profiles
without sharp edges. Aligned profile openings to ensure flat
pattern accuracy.
8. WORKBOOK8.1 Part Modeling Fig. Pivot
Fig. Body of Vice
Fig. Spring
Fig. Screw Rod
8.2 Surface Modeling
Fig. Water Container
Fig. Oil Can
Fig. Helmet
8.3 Sheet Metal
Fig. CPU cover
Fig. Amplifier Cover
8.4 Assembly
Fig. Safety Valve
Fig. Machine Vice