Mastering SolidWorks

Ibrahim Zeid, Professor of Mechanical, Industrial and Manufacturing Engineering at Northeastern University, is a Fellow of the American Society of Mechanical Engineers. His research focuses on mechanics, personalized medicine, simulation, and complex networks analysis. His honors include Northeastern's Excellence in Teaching Award and SAE's Ralph R. Teetor National Educational Award. Nathan Brown, research engineer and instructor in the Department of Bioengineering at the University of Louisville, teaches SolidWorks, 3D modeling, and manufacturing processes at the graduate level. A Certified SolidWorks Associate, his extensive CAD experience includes developing custom, anatomically accurate pelvic limb 3D computer models to investigate and correct ligament injuries and deficiencies in dogs.

Preface     vi

PART I:  COMPUTER-AIDED DESIGN (CAD) BASICS     1

Chapter 1  Getting Started     3

1.1 Introduction     3

1.2 Engineering Design Process     4

1.3 CAD Process     4

1.4 Manufacturing Process     5

1.5 CAM Process     6

1.6 SolidWorks Installation and Resources     6

1.7 SolidWorks Overview     8

1.8 Customize SolidWorks     11

1.9 Modeling Plan     12

1.10 Part Creation     14

1.11 Examples     15

1.12 Tutorials     22

    Tutorial 1-1 Create a Flap     22

    Tutorial 1-2 Create a Pin and Bushing Bearing     24

    Tutorial 1-3 Create a Pillow Block     25

    Tutorial 1-4 Create Drawings     28

    Tutorial 1-5 Create an Assembly     29

Problems     32

Chapter 2  Modeling Management     37

2.1 Overview     37

2.2 Types of CAD Models     37

2.3 Planning Part Creation     39

2.4 Part Topology     40

2.5 Parametric Modeling     40

2.6 Customizing SolidWorks     42

2.7 Productivity Tools     43

2.8 Coordinate Systems     43

2.9 Sketch Planes     44

2.10 Sketch Status     46

2.11 Part Feature Tree     47

2.12 Construction Geometry     48

2.13 Reference Geometry     48

2.14 Sketch Entities     50

2.15 Sketch Relations     51

2.16 Equations and Link Values     51

2.17 Geometric Modifiers     53

2.18 Grids     54

2.19 Patterns     54

2.20 Selecting, Editing, and Measuring Entities     58

2.21 Boolean Operations     59

2.22 Templates     61

2.23 Viewing     61

2.24 Model Communication     62

2.25 Tutorials     63

    Tutorial 2-1 Create a Coil Spring     63

    Tutorial 2-2 Create a Mount Plate     65

    Tutorial 2-3 Create a Bracket     66

    Tutorial 2-4 Create a Wheel     67

    Tutorial 2-5 Create a Tire and a Pin     69

    Tutorial 2-6 Create a Caster Assembly     70

Problems     73

Chapter 3  Design Intent     81

3.1 Introduction     81

3.2 Capturing Design Intent     82

3.3 Documenting Design Intent     83

3.4 Comments     83

3.5 Design Binder     84

3.6 Equations     85

3.7 Design Tables and Configurations     85

3.8 Dimension Names     85

3.9 Feature Names     85

3.10 Folders     86

3.11 Tutorials     86

    Tutorial 3-1 Design Intent via Two Modeling Plans     86

    Tutorial 3-2 Design Intent via Three Modeling Plans     89

    Tutorial 3-3 Design Intent via Design Specifications     91

    Tutorial 3-4 Design Intent via Mating Conditions     93

Problems     95

PART II:  BASIC PART MODELING     97

Chapter 4  Features and Macros     99

4.1 Introduction     99

4.2 Features     100

4.3 Spur Gears     103

4.4 Design Library and Library Features     109

4.5 Configurations and Design Tables     110

4.6 Macros     111

4.7 Tutorials     114

    Tutorial 4-1 Create Sweep Features     114

    Tutorial 4-2 Create Loft Features     116

    Tutorial 4-3 Use the Hole Wizard     118

    Tutorial 4-4 Create Compression Spring     119

    Tutorial 4-5 Create Spiral     120

    Tutorial 4-6 Create Features     121

    Tutorial 4-7 Use the Smart Fasteners Wizard     122

    Tutorial 4-8 Create a Bolt     123

Problems     126

Chapter 5  Drawings     135

5.1 Introduction     135

5.2 Engineering Drafting and Graphics Communication     136

5.3 ASME Abbreviation Rules     137

5.4 ASME Drafting Rules     138

5.5 ASME Dimensioning Rules     139

5.6 Dimensions     142

5.7 Drawing Content and Layout     144

5.8 Angles of Projection     145

5.9 Views     146

5.10 Sheets     148

5.11 Title Blocks     149

5.12 Drafting Control     150

5.13 Tolerances     150

5.14 Bills of Materials     151

5.15 Model and Drawing Associativity     151

5.16 Design Checker     151

5.17 Tutorials     152

    Tutorial 5-1 Create Drawing Views     152

    Tutorial 5-2 Insert Annotations     153

    Tutorial 5-3 Fill Title Block     153

    Tutorial 5-4 Create Assembly Drawing with Bill of Materials     154

    Tutorial 5-5 Use Model-Drawing Associativity     155

Problems     156

Chapter 6  Assemblies     157

6.1 Introduction     157

6.2 Assembly Mates     158

6.3 Bottom-Up Assembly Modeling     159

6.4 Top-Down Assembly Modeling     159

6.5 The Assembly Tree     164

6.6 Assembly Drawings     164

6.7 Assembly Exploded Views and Animations     164

6.8 Assembly Motion Study     165

6.9 Interference and Collision Detections     166

6.10 Assembly Design Tables     166

6.11 Tutorials     166

    Tutorial 6-1 Create a Cam and a Follower Assembly     167

    Tutorial 6-2 Create a Working Hinge Assembly     168

    Tutorial 6-3 Mate Two Gears with a Gear Mate     169

    Tutorial 6-4 Create a Functional Rack and Pinion     171

    Tutorial 6-5 Create a Functional Ball Screw     173

    Tutorial 6-6 Study Universal Joint Motion     174

    Tutorial 6-7 Create a Motion Study     176

    Tutorial 6-8 Detect Collision and Interference     178

    Tutorial 6-9 Create a Design Table     179

    Tutorial 6-10 Create a Part in the Context of an Assembly     180

Problems     183

Chapter 7  Rendering and Animation     195

7.1 Introduction     195

7.2 Scenes and Lighting     196

7.3 Rendering Models     197

7.4 Decals     198

7.5 Textures     199

7.6 Materials     199

7.7 Appearance and Transparency     201

7.8 Background and Scenes     201

7.9 Cameras and Camera Sleds     201

7.10 Animation     201

7.11 Tutorials     202

    Tutorial 7-1 Apply Colors to Objects     202

    Tutorial 7-2 Apply a Background and a Scene     203

    Tutorial 7-3 Apply Lights to a Scene     204

    Tutorial 7-4 Add Material and Transparency     205

    Tutorial 7-5 Add a Camera to a Scene     206

    Tutorial 7-6 Create a Motion Study     207

    Tutorial 7-7 Create a Camera-Sled Based

Animation     210

Problems     213

PART III:  ADVANCED PART MODELING     215

Chapter 8  Curves     217

8.1 Introduction     217

8.2 Curve Representation     218

8.3 Line Parametric Equation     219

8.4 Circle Parametric Equation     220

8.5 Spline Parametric Equation     221

8.6 Two-Dimensional Curves     222

8.7 Three-Dimensional Curves     223

8.8 Curve Management     224

8.9 Tutorials     224

    Tutorial 8-1 Create a 2D Curve by Using an Explicit Equation     224

    Tutorial 8-2 Create a 2D Curve by Using a Parametric Equation     225

    Tutorial 8-3 Create a 3D Curve by Using a Parametric Equation     225

    Tutorial 8-4 Create a 3D Curve by Using 3D Points     227

    Tutorial 8-5 Create a 3D Curve by Using 3D Sketching     228

    Tutorial 8-6 Create a 3D Curve by Using Composite Curves     229

    Tutorial 8-7 Create a 3D Curve by Projecting a Sketch onto a Curved Face     231

    Tutorial 8-8 Create a 3D Curve Using Projected Curves     232

    Tutorial 8-9 Create a Stethoscope Model     241

Problems     244

Chapter 9  Surfaces     249

9.1 Introduction     249

9.2 Surfaces     249

9.3 Using Surfaces in Solid Modeling     252

9.4 Surface Representation     254

9.5 Plane Parametric Equation     255

9.6 Ruled Surface Parametric Equation     257

9.7 Surface Visualization     260

9.8 Surface Management     260

9.9 Tutorials     261

    Tutorial 9-1 Create Basic Surfaces: Extrude, Revolve, Loft, Sweep, Knit, and Radiate     261

    Tutorial 9-2 Create Basic Surfaces: Planar, Filled, Boundary, and Offset     263

    Tutorial 9-3 Visualize Surfaces     264

    Tutorial 9-4 Create an Artistic Bowl     265

    Tutorial 9-5 Use Surface Intersections     268

    Tutorial 9-6 Create a Tablespoon     269

    Tutorial 9-7 Create a Computer Mouse     271

    Tutorial 9-8 Create a Baseball Hat     273

    Tutorial 9-9 Create a Hair Dryer     277

    Tutorial 9-10 Create an Oil Container     279

Problems     282

Chapter 10  Sheet Metal and Weldments     289

10.1 Introduction     289

10.2 Sheet Metal     289

10.3 Sheet Metal Features     291

10.4 Sheet Metal FeatureManager Design Tree     296

10.5 Sheet Metal Methods     297

10.6 Weldments     299

10.7 Weldment Features     301

10.8 Weld Symbols     305

10.9 Tutorials     306

    Tutorial 10-1 Create Sheet Metal     306

    Tutorial 10-2 Create a Sheet Metal Drawing     308

    Tutorial 10-3 Create a Sheet Metal Part from a Solid Body     309

    Tutorial 10-4 Create a Sheet Metal Part from a Flattened State     310

    Tutorial 10-5 Create a Weldment     311

    Tutorial 10-6 Create a Weldment Drawing     313

Problems     316

Chapter 11  Sustainable Design     319

11.1 Introduction     319

11.2 Design and Society     321

11.3 Guidelines and Principles     321

11.4 Life Cycle Assessment     323

11.5 Impact Metric     325

11.6 Implementation     327

11.7 Design Activities     327

11.8 Sustainable Design Tools     328

11.9 SolidWorks Sustainability     329

11.10 Tutorials     332

    Tutorial 11-1 Redesign a Steel Washer     332

Problems     335

PART IV:  PART DEVELOPMENT AND ANALYSIS     337

Chapter 1 2 Tolerances     339

12.1 Introduction     339

12.2 Tolerance Types     340

12.3 Tolerance Concepts     340

12.4 ASME Tolerance Rules     343

12.5 Tolerancing Tapers     347

12.6 Limits of Dimensions     348

12.7 Tolerance Accumulation     353

12.8 Statistical Tolerancing     354

12.9 True Position     356

12.10 Geometric Tolerances     357

12.11 Datum Target Symbols     359

12.12 Tolerance Interpretation     360

12.13 Tolerance Analysis     362

12.14 SolidWorks Tolerance Analysis     364

12.15 Tutorials     367

    Tutorial 12-1 Create Conventional Tolerances     367

    Tutorial 12-2 Create Geometric Tolerances     369

    Tutorial 12-3 Define Datum Targets     370

    Tutorial 12-4 Tolerance a Taper     371

    Tutorial 12-5 Perform Tolerance Stack-up Analysis     372

Problems     374

Chapter 13  Analysis Tools     377

13.1 Introduction     377

13.2 Data Exchange     378

13.3 Mass Properties     381

13.4 Animation and Motion Analysis     385

13.5 Flow Simulation     386

13.6 Finite Element Method     386

13.7 Finite Element Analysis     389

13.8 SolidWorks Simulation     391

13.9 Von Mises Stress     391

13.10 Tutorials     396

    Tutorial 13-1 Export Native SolidWorks Files     396

    Tutorial 13-2 Import IGES and STEP Files into SolidWorks     396

    Tutorial 13-3 Calculate Mass Properties of a Solid     397

    Tutorial 13-4 Perform Motion Analysis Using a Motor     398

    Tutorial 13-5 Perform Static Linear FEA on a Part     403

    Tutorial 13-6 Perform Thermal FEA on a Part     405

    Tutorial 13-7 Perform Flow Analysis on a Hose     406

Problems     408

PART V:  PART MANUFACTURING     409

Chapter 14  Rapid Prototyping     411

14.1 Introduction     411

14.2 RP Applications     412

14.3 RP Overview     414

14.4 RP Concepts     414

14.5 SolidWorks Triangulation     417

14.6 RP Steps     418

14.7 RP Building Techniques     419

14.8 Bottle Prototype     420

14.9 Tutorials     421

    Tutorial 14-1 Generate Part Prototype File     421

    Tutorial 14-2 Generate Assembly Prototype File     422

    Tutorial 14-3 Read Back an STL File     423

Problems     425

Chapter 15  Numerical Control Machining     427

15.1 Introduction     427

15.2 Basics of Machine Tools     428

15.3 Basics of Machining     430

15.4 Turning     438

15.5 Drilling     438

15.6 Milling     439

15.7 Electrical Discharge Machining     439

15.8 Manufacturing of Design     441

15.9 SolidWorks DFMXpress     442

15.10 Basics of NC Machining     445

15.11 G-Code and M-Code Programming     447

15.12 CAM Add-In Software     449

15.13 Tutorials     449

    Tutorial 15-1 Drill Holes     450

    Tutorial 15-2 Mill Faces     452

    Tutorial 15-3 Mill Pockets     455

    Tutorial 15-4 Mill Slots     457

Problems     460

Chapter 16  Injection Molding     463

16.1 Introduction     463

16.2 Basics of Injection Molding Machines     464

16.3 Basics of Injection Molding     465

16.4 Basics of Mold Design     467

16.5 Basics of Part Design     470

16.6 Phases of Mold Design     471

16.7 SolidWorks Mold Design     472

16.8 Tutorials     473

    Tutorial 16-1 Create a Block Mold     473

    Tutorial 16-2 Create a Sandbox Mold     477

    Tutorial 16-3 Create a Hemisphere Mold     481

    Tutorial 16-4 Create an Easter Egg Mold     484

    Tutorial 16-5 Generate a Mold Drawing     487

Problems     488

Appendix A  ANSI and ISO Tolerance Tables     491

Appendix B  SolidWorks Certification     505

B.1 Certified SolidWorks Associate (CSWA)     505

B.2 Certified SolidWorks Professional (CSWP)     506

B.3 CSWP-Surfacing     506

B.4 CSWP-Sheet Metal     507

B.5 CSWP-Weldments     507

B.6 CSWP-Simulation     507

B.7 CSWP-Mold Making     508

B.8 Testing Resources     508

B.9 Sample Test Questions     509

Index     517