Solidworks Report File 4c5m4o

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1. INTRODUCTION Solid 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 world’s 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 SolidWorks SolidWorks 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

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1.2 Features of Solidworks 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:    

Feature-based Parametric Solid modeling Constraints

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 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 Parametric The 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 Modeling A 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 Constraints Geometric relations such as parallel, perpendicular, horizontal, vertical, concentric and coincident are some of the constraints ed by solidworks.

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2. Graphic Interface of SolidWorks and Control The 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 s. 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 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 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 to enter relevant design and data parameters.

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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 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.

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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 toggle

Design 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.

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2.2 View and Orientation A 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 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 Orientation The orientation section of the View toolbar offers several tools to enable the 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 Modes The 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

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Hidden Lines Removed Hidden Lines Visible Wireframe (Displays all edges of the model) Section View

Fig : Section View and PropertyManager

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Control Mouse buttons SolidWorks 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 design tree.

FeatureManager

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 mouse Zoom: 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 Shortcuts Listed below are the predefined keyboard shortcuts options: Arrow Keys . . . . . . . . . . . . . . . . Rotate the view Shift+Arrow Keys . . . . . . . . . . . Rotate the view in 90° increments Alt+Left or Right Arrow Keys .Rotate about normal to the screen Ctrl+Arrow Keys . . . . . . . . . . . Move the view Shift+z . . . . . . . . . . . . . . . . . . . . Zoom In z. . . . . . . . . . . . . . . . . . . . . . . . . . Zoom Out f . . . . . . . . . . . . . . . . . . . . . . . . . . Zoom to Fit

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Ctrl+1 . . . . . . . . . . . . . . . . . . . . . Front Orientation Ctrl+2 . . . . . . . . . . . . . . . . . . . . . Back Orientation Ctrl+3 . . . . . . . . . . . . . . . . . . . . . Left Orientation Ctrl+4 . . . . . . . . . . . . . . . . . . . . . Right Orientation Ctrl+5 . . . . . . . . . . . . . . . . . . . . . Top Orientation Ctrl+6 . . . . . . . . . . . . . . . . . . . . . Bottom Orientation Ctrl+7 . . . . . . . . . . . . . . . . . . . . . Isometric Orientation Ctrl+8 . . . . . . . . . . . . . . . . . . . . . View Normal To Spacebar . . . . . . . . . . . . . . . . . . View Orientation dialog Ctrl . . . . . . . . . . . . . . . . . . . . . . . Hold and select multiple items with mouse button Ctrl+c . . . . . . . . . . . . . . . . . . . . . Copy selected entity/item Ctrl+z . . . . . . . . . . . . . . . . . . . . . Undo Ctrl+y . . . . . . . . . . . . . . . . . . . . . Redo Ctrl+Tab . . . . . . . . . . . . . . . . . . .Switch between documents Alt+drag . . . . . . . . . . . . . . . . . . . Select anywhere in a drawing view Shift+drag . . . . . . . . . . . . . . . . . Maintains distance between drawing views while dragging Ctrl+R . . . . . . . . . . . . . . . . . . . . .Redraw Ctrl+B . . . . . . . . . . . . . . . . . . . . .Rebuild

Customizing the SolidWorks window System options The 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

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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.

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3. CREATE A PART (PART MODELING)

3.1 Create Your Part Stages in the Process 

Create a New part document

New parts can be created in inch, millimetre or other units. Parts are used to create and hold the solid model. 

Sketch the profile

Sketches are collections of 2D geometry that are used to create solid features. These include lines, circles and rectangles. 

Applying Sketch relations and dimensions

Geometric 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 sketch

Extruding uses the 2D sketch to create a 3D solid feature.

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3.2 Procedure The process in this includes sketching and extrusions. To begin with, a new part file is created.

3.2.1 Create a New part document 1. New part

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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.

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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?

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We can imbed design intent following the steps below:   

 

4.

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

Create our sketch by selecting the Top Plane and then the Sketch Icon

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Rule of Thumb When Sketching – Rough Sketch – Add Relations – Add Dimensions

Relations 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

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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.

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7. Dimension the Sketch using the dimension icon.

8. Conditions of a Sketch. Under Defined There 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 isn’t 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 Defined The 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 Defined The 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.

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10. Select the extrude command and extrude the 2d Profile.

Design Intent at extrusion stage. 

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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

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Fig. Extruded 2D sketch

11. Select Top Face of the Cube and create a sketch by selecting the Sketch icon

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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

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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.

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21. Add a chamfer to the Polygon.

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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.

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Projected view of Fillet

27. Apply a material to the part. In the Feature Manager right click on add material and select any material(say brass) and say ok.

29. Save the Part File as *.SLDPRT format.

4. REFERENCE GEOMETRY

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Reference 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 Geometry 4.1.1 Reference Planes This feature allows the 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 Axes

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Allows the 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 Systems Create 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 Point

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Add 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 MODELING

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Assembly 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 Approach There are two approaches for making an assembly.  

Bottom-up Design Top-down Design

Bottom-up Design It 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 Design In 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

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Smart mate Mate reference

5.2.1

Standard mate

Mates 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. 

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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.

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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.

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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 Mate

Smart 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 Reference

In 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 Mates

Advanced mates include limit, linear/linear coupler, path, symmetry, and width mates. 

Symmetric

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A 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

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Width A width mate centers a tab within the width of a groove . groove width references can include:  Two parallel planar faces  Two non-planar faces

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Path A 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.

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Linear/linear Coupler A linear/linear coupler mate established a relationship between the translation of one component and the translation of another component.

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Linear Limit 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 Mates

Mechanical mates include cam-follower, gear, hinge, rack and pinion, screw, and universal t mates.

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Cam A type of tangent or coincident mate. Asks the 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.

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Hinge Constrain two components rotational degrees of freedom. Asks to input two concentric sections, coincident faces, and the angle limit (how far the components can move from each other – identical to angle mate).

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Gear Mates 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.

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Rack Pinion Similar 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.

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Screw Constrains two components with a concentric mate and defines a pitch relationship between the rotation of one component and the translation of another.

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Universal t The rotation of a component about its axis is controlled by the rotation of the mating component about its axis.

5.3

ROTATING INDIVIDUAL COMPONENTS In SolidWorks, you can rotate an individual unconstrained component in the assembly document 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 Dragging You 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

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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 Tool You can also rotate an individual component using the Rotate Component tool. To rotate an individual component using this tool, choose Move Component > Rotate Component from the Assemble Command Manager; the Rotate Component Property 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 VIEWS Drawings 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.

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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. BOM’s 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 Views 1. 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.

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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.

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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.

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7.

SHEET METAL 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 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 Tools

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When 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 Flange A 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 Flange

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Edge 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 Flange A 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.

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 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.

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7.5 Hem The 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.

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7.6 Jog The 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 Trim The 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.

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7.8 Closed Corners You 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

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7.9 Rip A 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 Bend

You 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.

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7.11 Unfold/Fold With 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.

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7.12

Forming Tools

forming 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 Tool You 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.

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7.13

Cross Break

In 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.

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7.14

Welded Corner

The 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 Bends

Lofted 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 s! 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.

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8. WORKBOOK 8.1 Part Modeling

Fig. Pivot

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Fig. Body of Vice

Fig. Spring

Fig. Screw Rod

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8.2

Surface Modeling

Fig. Water Container

Fig. Oil Can

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Fig. Helmet

8.3

Sheet Metal

Fig. U cover

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Fig. Amplifier Cover

8.4

Assembly

Fig. Safety Valve

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Fig. Machine Vice