Beruflich Dokumente
Kultur Dokumente
For
John P. Greiner
jpgreiner@gmail.com
SolidWorks and Simulation Training
Topics:
o Day 1
Basic SolidWorks overview
DimXPert
o Day 2
Moldtools
Sheet Metal
o Day 3
Assemblies
o Day 4
Design Tables
Macros
o Day 5
Surfacing
Lofting
Weldments
o Day 6
Beam Analysis
Fatigue Analysis
o Day 7
Other Simulation
o Day 8
Motion Analysis
About Me:
John P. Greiner
10 Years SolidWorks Experience
3 Years teaching SolidWorks Basic and Advanced at both Clark College in Vancouver and
Portland Community College.
Senior Mechanical Engineer at Key Knife, Inc. in Tualatin, Or. (7 years)
SolidWorks Training:
o Basic SolidWorks, Advanced Part Modeling, Advanced Assembly Modeling, SolidWorks
Drawings, Simulation Basic, Simulation Advanced, Simulation Non-Linear
Day 1:
Terminology
Dictionary.com defines terminology as the system of terms belonging or peculiar to a science, art, or
specialized subject. The terminology surrounding SolidWorks, while not difficult, does require at least a
review to help me communicate with you more
effectively and vice versa.
The area immediately below the Menu bar is the command manager. The command manager is
SolidWorks version of the infamous “Ribbon” popular with the new Microsoft Office. The command
manager is there to simplify your interface by displaying only the toolbars you need when you can use
them. The scuttlebutt is that in the next couple of versions of SolidWorks, the toolbars will go away, so
you might as well get used to using the Command Manager now! The tabs on the bottom of the
command manager can be added or removed with some pre-sets created by SolidWorks. Additionally,
any menu you have can also be turned into a tab.
The SolidWorks Document window is where all the magic happens. A few items of note are the ‘Heads
Up View Toolbar’ and the ‘Feature Manager Design Tree’. We will be referring to both of these items
quite a bit throughout our time together. Note the ‘Property Manager’, ‘Configuration Manager’ and
the ‘DimXpert Manager’ also located in the same area as the ‘Feature Manager Design Tree’.
The final piece of the puzzle then is the ‘Task Pane’ and the
‘Status Bar’. The Task Pane contains items like the Toolbox, Design
Library, Custom Properties, Search and File Explorer. Usually, I will not
pin this section open since it takes up valuable Graphics Area on my
screen.
SolidWorks Files
SolidWorks uses a complex system of linking and embedding to store data in files. Linking
involves storing the data in one file and referencing it from another file. No data is duplicated; instead
the path to the referenced document is stored in the SolidWorks database. When you open a
SolidWorks file that has linked references, it opens/loads data from each linked document. This is
advantageous if the file you are linking is subject to change. Embedding is the exact opposite of linking.
When you embed information into a SolidWorks file, that data is copied from the original location to the
new file. Updating the source file will have no effect on the embedded data. Some examples of Linked
data: A drawing file referencing a part or assembly file, an assembly file with multiple parts, an in-
context part created inside an assembly. Example of embedded data: Design binder files, library
features, internally stored design table.
Properties
SolidWorks basically has two different types of
settings, Document Properties and System Options.
Document Properties apply only to the open document
or template while system properties persist between
documents. To get to these settings, go to Tools-
>Options. You immediately see the ‘System Options’
dialog box. Everything on this tab is a system setting.
These settings are saved to the Windows System
Registry upon exiting SolidWorks. Some examples of
settings that are system wide include:
Document Units
Drafting Standard
Dimension Arrow Length
Material Properties
Image Quality
Dim Xpert Settings
As you can see, there are a whole lot of settings available to the user. To customize SolidWorks, you
could easily spend an hour or more going thru each setting. Knowing that your settings are stored in the
Windows Registry, not exactly a Fort Knox of security, a back-up of your setting could save you many
hours of setup and configuration time if for example you get a new computer or you somehow corrupt
your user profile. You can export your setting following these simple steps:
1. Modify all the System Settings you want then close SolidWorks.
2. Under Programs->SolidWorks 2009->SolidWorks 2009 SPX.X-
>SolidWorks Tools you will find a utility called ‘Copy Settings Wizard’
3. The Copy Settings Wizard is very easy to use. Simply click the Save
Settings Button followed by the Next button
4. Browse to a location to store the registry file. I recommend a network
location that is backed up regularly. Then click finish.
To restore your settings simply locate the registry file and double click on it to launch the Copy
Settings Wizard in restore mode. Follow the simple instructions and away you go. Be sure that
SolidWorks is not open when you perform these steps.
Introduction to Sketching
o Create a new part
o Insert a new sketch
o Add sketch geometry
o Establish sketch relations between pieces of geometry
o Understand the state of a sketch.
o Use sketch tools to add fillets.
o Extrude the sketch into a solid.
Basic Part Modeling
o Choose the best profile for sketching.
o Choose the proper sketch plane.
o Extrude a sketch as a cut.
o Create Hole Wizard holes.
o Insert fillets on a solid.
o Make a basic drawing of a part.
o Make a change to a dimension.
o Demonstrate the associatively between the model and its drawings.
Modeling a Casting or Forging
o Use the view display and modification commands.
o Copy and paste features.
o Edit the definition and parameters of a feature and regenerate the model.
o Use Up To Next and Mid Plane end conditions to capture design intent.
o Use symmetry in the sketch.
Patterning
o Create a linear pattern.
o Add a circular pattern.
o Use geometry patterns properly.
o Create a mirror pattern.
o Use the pattern seed only option with a linear pattern.
o Add a sketch driven pattern.
o Automate the process of fully defining a sketch.
Revolved Features
o Create revolved features.
o Apply special dimensioning techniques to sketches for revolved features.
o Use the multi-body solid technique.
o Create a sweep feature.
o Calculate the physical properties of a part.
o Perform rudimentary, first pass stress analysis.
Shelling and Ribs
o Apply draft to model faces.
o Perform shelling operations to hollow out a part.
o Create planes.
o Use the rib tool.
o Create thin features.
Editing: Repairs
o Diagnose various problems in a part.
o Repair sketch geometry problems.
o Repair dangling relations and dimensions.
o Use the FeatureXpert to repair filleting problems.
o Use the FilletXpert and DraftXpert to add fillets and draft.
Editing: Design Changes
o Understand how modeling techniques influence the ability to modify a part.
o Utilize all the available tools to edit and make changes to a part.
o Use Sketch Contours to define the shape of a feature.
Configurations of Parts
o Use configurations to represent different versions of a part within a single SolidWorks
file.
o Use configure feature to create and edit configurations.
o Suppress and un-suppress features.
o Change dimension values by configuration.
o Suppress features by configuration.
o Understand the ramifications of making changes to parts that have configurations.
o Use the design library to insert features into a part.
Design Tables and Equations
o Link dimension values together to capture design intent.
o Create equations.
o Automatically create design tables.
o Use existing design tables to create families of parts.
o Make detail drawings using more advanced types of drawing views.
DimXpert
The DimXpert software is used to create a fully tolerance model that can be used with
TolAnalyst stack analysis. The results can also be used for:
The model is treated as an imported body with topological, not SolidWorks, features. It is
considered to be in an under constrained state unless enough dimensions are added to fully constrain
the features. Dimensions and tolerances can be added manually or automatically and conform to the
ASME Y14.41-2003 standard.
DimXPert Features
DimXPert features are used to describe the feature geometry of the part. These features are
based solely on geometry, no on the dimensions and features that were created in building the part.
The feature types are listed below:
Plane features are recognized from planar faces in the model. Multiple related planes may be
recognized as Width Features or Compound Planes.
Boss features
Cylinder features can be recognized instead of a circular boss.
Fillet Features
Fillet Pattern – a collection of fillet features of the same size but disconnected.
Fillet Chain – a connected set of fillets.
Simple Hole
Countersink Hole
Counterbored Hole
Hole Pattern
Slot
Pocket
Notch
DimXPert Examples
Simple Plate
Model the plate as shown.
Figure 11 - Plate
Tools->Options->Document Settings->DimXpert
Block Tolerance
A common form of tolerance used with inch units. The
tolerance is based on the given precision of each
dimension, so you must specify trailing zeroes.
General Tolerance
A common form of tolerance used with metric units in conjunction with the ISO drawing standard.
General Tolerance is based on ISO 2768-1 Tolerances for linear and angular dimensions without
individual tolerance indications.
o Fine (f)
o Medium (m)
o Coarse (c)
o Very Coarse (v)
Since this is not a revolved part, select prismatic and since we are going to
use GD&T type dimensioning, select Geometric from the settings box.
Select the Primary, Secondary and Tertiary datums. The primary datum is
the bottom of the plate, the secondary datum is the short end and the
Figure 14 - Auto Dimension
tertiary datum is one of the long ends as shown below. Scheme
In the Scope box, select Selected Features and then click inside one of the holes. Notice how
DimXpert adds a hole pattern since it recognized the pattern of the same sized holes. Next click on faces
opposite our datum 2 and datum 3. These planar datums will be used to define the length and width of
our part. Next, click OK to let the DimXpert go to work on your part.
Expand all the features in the DimXpert Feature Manager. Spend a minute or two reviewing what the
DimXpert created. Notice that when you click on a feature, it highlights in the Graphics Area.
Click on any one of the large fillets and place the dimension as shown then click Ok.
If your Show Tolerance Status is still on, you should see the fillets change to green indicating that they
are now constrained.
At this point, be sure to save the model. From the Heads Up View Toolbar, select ‘Top’ view.
Notice how some of the dimensions disappear. This is because you are now only seeing the dimensions
assigned to the Top View. Spend a moment cleaning up the dimensions like you would want them to
show on paper.
Do the same thing but with the part viewed from the front.
Click File->Make Drawing From Part. Before dropping a view onto your page, make sure the
Import Annotations, DimXpert Annotations, Include items from hidden features and Auto-start
projected view is checked. Then drop the Top and Front views onto the sheet.
Week 1 Assignment:
Pick a single part file and use the DimXpert to fully define your part. Create a drawing using only
DimXPert dimensions.
*If Allowed, upload your part and drawing to the www.drop.io/AAEngineering. (This way I can
answer specific questions based on your models.)
Day 2
Mold Tools
Objectives
Know how to locate and identify the Mold Tools in SolidWorks 2009
Understand how to use the existing mold tools.
Walk thru a simple mold tool design.
In order to be efficient with the mold tools, you must first understand a little something about
injection molds. Molds are made up of a core and a cavity that when sandwiched together allow for the
exact thickness of plastic to be injected into the mold creating the desired shape. The core duplicates
the inner surface of the model while the cavity duplicates the outer surface. Ensuring that the part will
eject from the mold once it has dried is half the battle when it comes to designing molds. I will guide
you thru a simple example using the SolidWorks Telephone file.
Once the file is open, the first step is to check the part with the draft analysis tool. We are trying
to verify that each of the surfaces contain sufficient draft. In this part, the direction of pull is normal to
the TOP plane, so go ahead and select that plane. This defines the direction of movement of the mold
during the part ejection
process. We want the
white arrow to point up as
shown to the right. Set the
draft angle to 0.5° and
check the face classification
check box. The green faces
indicate positive draft while
the red faces indicate
negative draft. The yellow
faces are the faces that we
need to be concerned
about since these are the
faces that will prevent our
part from ejecting from the
mold easily. Clicking the
green check box
maintains these colors Figure 29 - Draft Analysis
without adding a feature to the design tree. An Undercut analysis can be performed the same way only
it indicates trapped areas which prevent the part from leaving the mold. To add draft to this yellow
surface, click the Draft button on the mold tools
or features toolbar. Again, select the top plane
as the pull direction, but flip the direction so
that the arrow points down. Next select the
Parting Line option and set the angle to 1°.
Right click on the outer edge of the yellow face
and click Select Tangency. This should select
the entire perimeter of the part on the yellow
face. Click the green check to add the draft.
The entire yellow surface disappears.
All of the thru holes appear in the edges box. Make sure Knit, Filter Loops and Show Callouts is
checked then click ok. A new surface is created that is coincident with the existing surface, but contains
no holes.
Parting surfaces extrude from the parting line and are used to separate the mold cavity from the
core. Select the parting surfaces tool, set the distance to 10mm and check Knit All Surfaces and click OK.
Next, create a parting plane parallel to the rectangular surface with an offset of 20mm as shown.
Sheet Metal
Objectives
Refresh (As Needed) on specific Sheet Metal Features
Often, it is easier to create a solid model in context of an assembly then convert that part to a sheet
metal part. Take a look at these two examples:
Other times, we may need to convert some volume shape into a sheet metal part.
Review
This section is meant to be a refresher course on sheet metal modeling using SolidWorks. Listed
below are the Sheet Metal commands. After a quick review, an example can be done on any feature or
features you would like to see demonstrated.
Base Flange
Convert to Sheet Metal – Lets you specify the thickness, bends and rips necessary o convert a
solid part to a sheet metal part.
Lofted Bend – Allows you to loft together two separate open profiles as a sheet metal part.
Edge Flange
Miter Flange
Hem – adds a hem to a linear edge.
Jog
Sketched Bend
Cross Break
Chamfer
Fillet
Forming Tool
Extruded Cut
Simple Hole
Vent
Unfold
Fold
Flatten
No Bends – Rolls Back a sheet metal part containing Flatten-Bends and Process-Bends to show
the part with bends removed.
Rip – Rips the corner of a solid part for use in changing the solid part into a sheet metal part.
Insert Bends – Creates a sheet metal part from an existing part.
Day 3
Assemblies
Objectives
Motion Manager
Top-Down Assembly Modeling
Advanced Mate Techniques
Large Assemblies
SpeedPak
Motion Manager
The Motion Manager is a tool used to create animations from SolidWorks parts and assemblies.
It can also work with Photo Works to produce photorealistic animations to add visual impact to
presentations and documents. Additionally, the Motion Manager is used to perform simulations with
Cosmos Motion.
Alternately, you can animate using Basic Motion. In a basic motion animation, you apply gravity,
contact, springs, dampers and motors to your assembly and observe the behavior. The basics of the
animation are the same as above. Note that this is not a simulation, this is only showing basic motion. A
simulation must be run using Cosmos Motion.
Large Assemblies
Working with large assemblies in SolidWorks requires a strategy to minimize the time required
to load and edit the components in the assembly. There are several different strategies offered using
lightweight, hidden and suppressed components.
Lightweight Components offer reduced file sizes on open to increase speed. They must be fully
loaded to perform some operations. A lightweight component can:
o Speed Up Assembly Work
o Keep Mates Intact
o Maintain Placement
o Keep Orientation
o Be Moved and Rotated
o Be Displayed in Shaded, Hidden Line or Wireframe Modes
o Have their edges, faces, or vertices selected or mated to.
o Have Mass Properties or Interference Detection performed on them.
Large assembly mode is used to invoke a set of options based on an assembly with the minimum
number of components. The threshold for the number of components is user defined. When
opening an assembly with Large Assembly Mode active, the software checks to see if it qualifies
as a “large” assembly. If so, appropriate settings are chosen to make the large assembly faster.
o Automatically Load Components Lightweight
o Do not save auto recover info
o Hide all planes, axes, sketches, curves, annotations etc.
o Do not display edges in shaded mode.
o Suspend automatic rebuild.
Selective Open option allows components to be selected, hidden and not loaded into memory
prior to opening. It makes extensive use of Display States. When opening a large assembly, click
the Quick View option. Next hold down ‘CTRL’ and select the components that you need to
work with. Click ok and the parts not selected will not be loaded. A new display state is created
which you can re-name for later use.
SpeedPak
SpeedPak is new to SolidWorks 2009 and is used to create a simplified configuration of an
assembly without losing references. A SpeedPak configuration is a subset of the parts and faces of an
assembly. Unlike regular configurations, where you can simplify an assembly only by suppressing
components, SpeedPak simplifies without suppressing. Therefore, you can substitute a SpeedPak
configuration for the full assembly in higher level assemblies without losing references. SpeedPak
configurations must be manually updated when changes occur to the assembly.
Day 4
Design Tables
Objectives
Creating a New Design Table
Best Practices and Common Mistakes
SolidWorks design tables enable the user to rapidly create a family of parts based
on a well defined model or assembly. Design tables are especially useful when you need
a part that is exactly like a previous part, only with a dimensional change like hardware,
motor mounting frames and other generally “Purchased” parts. You must have
Microsoft Excel installed on your computer to use SolidWorks design tables.
At this point you should be able to see all of the dimensions that you created to
make your part. By default, SolidWorks names the dimensions D1, D2..etc. in each
sketch. Since D1 doesn’t really mean anything to us unless we are looking at a sketch or
a part, I recommend re-naming the dimensions. In the example provided, I am using the
diagram and chart below to generate a configured chain. I therefore name the
dimensions in SolidWorks the column name from the table to make creating the design
table easier.
To re-name a dimension, simple click on the dimension then change the name in the Property Manager.
Once your dimensions are named, you can go ahead and create the
design table. Click Insert->Table->Design Table to bring up the Design
Table Property Manager. From the property manager, we have several
options.
Source:
Blank – Creates a completely blank design table. To finish the
design table double click on each dimension and it will
automatically be entered into the proper column in Excel.
Auto-Create – SolidWorks queries the model and any created
configurations. It then adds any changed dimensions directly to
the design table upon creation.
From File – Allows the user to specify an Excel document to use as
the design table.
o Link to File – Keeps the design table saved external to the
SolidWorks File
Options:
I generally leave all of these boxes checked. These options control what
SolidWorks does when you open a design table.
Click “OK” to create the design table. Since I had only one configuration created, the “Dimensions”
dialog box comes up. Hold down ‘Shift’ and click on the dimensions you want controlled in the design
table, then click “OK”.
The SolidWorks interface now changes to look like Excel. Additionally, an Excel Worksheet is
opened up in the drawing area of SolidWorks as shown below. This appears to be one of the most un-
stable ways to use SolidWorks. For some reason, I have had SolidWorks crash on my whenever I try to
work in this mode.
Figure 64 - Excel/SolidWorks
Click in the drawing area to close the design table. Then go to the Configuration Manager, right
click on the new Design Table and select “Edit Table in New Window”. This will open Excel so you can
work with the design table separately from SolidWorks. Occasionally the “Add Columns and Rows”
dialog box will appear. This is SolidWorks attempt to notify you of changes to the model since the last
time the design table was opened. Just click “OK” so you can take a look at the design table. (If the
design table does not open fully and SolidWorks is blinking in your Windows Taskbar, click SolidWorks to
reveal this dialog box. You cannot edit SolidWorks or the Design Table while this box is open.)
Now it is a simply a matter of typing in the values from our source to Excel. The first row is
simply a reference back to the SolidWorks file. The second row is a list of all the dimensions or
properties that the design table controls. All the following rows are simply data used to update the
model.
SolidWorks reads the design table from top to bottom left to right. It continues reading until it
hits a blank column, then it goes to the next row. It then continues reading until it hits a blank row. We
can use this to our advantage. You can add notes, pictures or equations to the right of the design table
as long as you leave a blank row between your calculations and the area SolidWorks will read. To
generate the created configurations, simply close Excel.
The dimensions controlled by the design table turn pink. Since I set the option to “Block Model
Updates” you cannot change the values from SolidWorks, you must open the design table to modify the
number.
The table below shows what exactly can be controlled from design tables. (This is the “Summary of
Design Table Parameters” from the SolidWorks help.)
Parts only
$configuration @part_name configuration name not evaluated
dimension @feature_name any legal decimal value for the dimension not evaluated
- or -
dimension@sketch_name
$hw-size any value listed in Size in the Hole Wizard smallest hole size available
PropertyManager
$sw-mass any legal decimal value for the mass The calculated value of mass in the Mass
Properties dialog box.
$sw-cog any legal decimal value for the coordinates of The calculated value of mass in the Mass
the center of gravity, in the format x, y, z Properties dialog box.
$tolerance @dimension_name See Tolerance Keywords and Syntax in NONE, or for a derived configuration, the
Design Tables. tolerance value of its parent.
Assemblies only
Macros
Objectives
Record a Macro
Edit a Macro
SolidWorks Application Programming Interface (API)
Assign a Macro to a Button
Recording a Macro
Recording a macro in SolidWorks is simple. Right click on the toolbar region and select the
Macro toolbar. Press the red record button then do something in SolidWorks. This record is
not like recording on a VHS tape or a DVD. The macro recorder only records actions within
SolidWorks, time is not recorded. Once you have completed your task, click the “Stop”
button on the same toolbar. A dialog box will show up asking you where you would like to
store your newly recorded macro.
To view/edit your macro, click the edit button then browse to the macro file you just
created. Click open to see the SolidWorks VBA interface. A sample macro is shown below as
it was recorded by SolidWorks.
Figure 69 - Load
Macro Toolbar
Ok, time to talk code. For those of you that have no idea how to program, I’m sorry, but here I
go anyway. For some reason the recorder does not use the proper declarations when recording a
macro. First off, you should always have the setting “Option Explicit” at the top of the code. This
requires you to declare a variable before trying to use it. Second, you will notice that the recorder
declared the variable ‘swApp’ and ‘part’ as object. While this works, it makes debugging and modifying
more difficult. I recommend changing the declarations of ‘swApp’ and ‘part’ as shown:
This declares swApp as a class type SldWorks and Part as a class type ModelDoc2 which is what
they are. This gives you more direct access to the methods and members of the classes while modifying
the code. Additionally, this will speed up the macro during run-time since the code is not wasting the
step of converting a generic class ‘Object’ to a class ‘SldWorks’. The SolidWorks API is well documented
under Help->API Help.
To assign a macro to a button, first right click on the
macro toolbar and choose customize. Click on the
“Commands” tab then select “Macro” from the list on the left.
You can drag the “New Macro” button down onto the macro
toolbar which will then launch the “Customize Macro Button”
dialog box. The tooltip it the bold lettering shown in the
bubble when you hold your mouse over a button. The
prompt is some sort of short description of what the button
does.
Macro Ideas
Toggle document units between Inches, Millimeters or Dual Dimensioning
Toggle between ANSI and ISO drafting Standards.
One button print 8.5” x 11” paper.
One button print 11” x 17” paper.
Auto-Fill Custom/Document Properties
One Button save as eDrawing, PDF, Step, Iges….etc.
Create a better interference checker using the Combine feature.
One click Pack and Go
Day 5
Weldments
Objectives
Create a Weldment
Create a Weldment Profile
Break a weldment up into sub-weldments.
Most weldments consist of 3D-Sketches and Structural Member features. The 3d sketch is
usually the center of a frame, but can also be the
outside or inside by simply changing the pierce point
on the profile sketch. Let’s start by creating the 3D
sketch seen here. This is to create an evaporator
support weldment.
Now select the other three lines and clear the Apply
Corner Treatment check box. This gives a nice rectangular
box made of C Channel.
Now add a sketch on the back side of the reinforcing plate as shown below. This will be the
length of the angle brace. Add the angle brace as shown using the structural members command.
Mirror the leg components with respect to the front reference plane. Create two cross braces
connecting the two legs. One brace is located on the inside of the leg, while the other on the outside of
the leg geometry. Extrude the braces to a thickness of ¼”.
Use the hole wizard to create a clearance hole for a 7/16” bolt thru the two cross braces. Then
mirror both legs about the Right Plane.
Using the hole wizard once again and starting on the selected face below, create more 7/16”
thru holes as shown.
Before clicking ok on the property manager to create the holes, check the feature scope. Check
selected bodes then select the ones shown below. Once done, mirror the bolt holes across the right
plane.
Right click on Cut List item 3 and add the weight property as shown. Repeat for Cut List item 4.
Right click on Cut List Item 1 and add the Description field with a value of “Leg Assembly”. Because this
is a Sub-Weldment, it will not pull any data forward like length or weight.
Lofting
Lofting enables the user to create features that are defined by multiple cross sectional profiles.
The system constructs the feature – a boss, a cut or a surface feature – by building the feature between
the sketches. Lofts interpolate face geometry between the profiles.
Initiate the loft command then select the two vertexes shown. SolidWorks tries to merge the
two shapes as quickly and efficiently as possible. To get the desired shape open the centerline
parameters box and click the arc connecting the two sketches as shown. Set the start constraint and
end constraint to normal to profile then click OK to build the feature. This forces the feature to hold the
shape of the sketches for a little while before beginning its conversion to the alternate sketch.
Next we need to make a sketch on the semi-circle face and convert the entities of the underlying
sketch. Right click on the arc and select “Split Entities” then click the arc two times to create 3 co-radial
arcs. Add the construction geometry to constrain the arcs as shown.
Next create a loft from this new sketch to the square. The additional points that were created in
the previous step are used to help normalize the loft. Again set the start and end condition to normal to
profile and select the centerline arc.
Creating these two lofts has created several surface artifacts. To clean up these artifacts, begin
by selecting all the good faces in the model. Once done right click and select Invert Selection. This
ensures you get all the artifact surfaces.
From the surfaces toolbar, click delete face and check delete and patch then click ok to clean up
all the artifact surfaces.
Use a face fillet to fillet the top face to the side faces as shown. Apply a radius of 25mm to both edges.
On a plane located 100mm above the bottom sketch the following rounded rectangle then
extrude the sketch up to next with a 5° draft.
To finish the part, add a 12.5mm fillet around the new boss feature at the intersection with the
existing lofts. Then shell the entire part with a wall thickness of 2mm.
Surfacing
Objectives
Understanding Surfaces
Introduction to Surfacing
Understanding Surfaces
In SolidWorks, solid bodies and surface bodies are very nearly the same. This is one of the
reasons it is so easy to use them together in advanced modeling. To understand their differences, and
their similarities, it helps to know what exactly it is that constitutes a surface or solid body. Solid and
surface bodies are made up of two types of information Geometry and Topology.
Geometry describes shape. Something can be flat or warped, straight or curved. A point is a
specific, unique location in space.
The inside versus the outside of a solid. This is defined by the face normal.
Which edges meet at which vertices.
Which edges form the boundaries of which face.
Which edge is the common boundary between two adjacent faces.
In a solid body, every edge is the boundary between exactly two faces. In a surface body, we
can have edges that bound only one face. This is why you cannot create two squares that share exactly
one edge as a single solid body since the edge would be shared by four surfaces. When SolidWorks
builds solid models it is really automating a lot of surface modeling tasks by creating surface bodies and
assembling them to form a closed volume.
All surfaces in SolidWorks can be described by a parameterized mesh of curves. These are called
iso-parameter or U-V curves. The curves along one side of a four-sided surface are the U curves. Those
in the perpendicular direction are the V curves. The parameter is the number representing the position
along the length of the edge between 0 and 1. You can see the U-V mesh by using the Face Curves
commands.
There are several classes of surface geometry used in SolidWorks. Algebraic surfaces can be
described with simple algebraic expressions. Ruled surfaces are surfaces where every point on the
surface has a straight line that passes through it and lies on the surface. Developable surfaces are a
subset of rules surfaces, and can be flattened without stretching the surface. NURBS (non-uniform
rational b-spline) is a surfacing technology widely used by CAD and computer graphics software. NURBS
surfaces are defined by parameterized U-V curves where the curves are splines, and the surface is
interpolated between the splines.
Introduction to Surfaces
Starting a surface model is the same as a solid model. Begin with the sketch below and use a
surface extrude to extrude a surface 90mm from a mid plane.
Next, the following sketch is revolved using the revolved surface command.
Create an offset plane 10.5 mm in the negative Y direction parallel to the top plane. The
following sketch is first created then the fit spline tool is used to create a single spline to the profile.
On the Right Plane, sketch the following, then use the fit spline tool again replacing the lines and arc
with the spline.
On the front reference plane, sketch the following geometry then extrude it with a surface
extrude. Use an up to vertex end point and select the vertex from the first surface you created.
Using the trim function, select the surfaces shown and set the trim type to Mutual. Next select
the purple faces shown below to be removed.
Use the mutual trim again to trim the previous surface and the swept surface. This time, keep
the purple section shown below.
The third and final mutual trim will require removing the purple faces shown below.
Finally, click Insert, Boss/Base, Thicken and set the thickness to 1mm
Day 6
Beam Analysis
Objectives
Setting up and running a static analysis
Difference between Static Analysis and Beam Analysis
Apply Loads and Restraints
Understanding Results
I used ANSI 3” C-Channel and 2” x 2” square tubing to create my table. I then added clearance
holes for ½” bolts as shown below. I will not add the bolt, washer or nut to the assembly because it
would add unnecessary complexity to the mesh which will increase the time required for analysis.
Now we are ready to start setting up our analysis. On the Simulation tab, click study. In the
property manager give the study a name and select “Static”.
Figure 115 - Joint Groups before and After with Property Manager
As a general rule, you want to apply as few restraints as possible to your model. The more
restraints you add the more “Stiffness” you add to the matrix. Since a table generally sits on the ground
I will use the “Referenced Geometry” option when restraining my table. Notice how the animation at
the top of the property manager applies a visual representation of the restraint. Next, select the joints
at the bottom of each of the legs. These are the joints that we will be applying the restraint to. In the
next box, select the bottom face of one of the legs as a reference plane, then ensure the normal to
option is turned on at the bottom. This restraint adequately resembles the actual restraints a table may
see sitting on the floor.
Click OK to apply the restraints. Next add a fixed restraint to just one of the 4 legs.
Unfortunately, this is required when performing a beam type analysis using SolidWorks Simulation.
Let’s assume that this table is holding a 5000 lb piece of equipment with its center of gravity
exactly positioned in the middle of the table. Right click on External Loads and select Force. Click the
Beams button then select the top four beams as shown in blue below. Select the top face of one of the
beams as the reference plane, apply a normal force of 5000 lb.
Meshing a beam analysis is fully automated by SolidWorks. Right click on Mesh and choose
“Create Mesh”. To run the analysis, right click on the name of the analysis and click Run.
Double clicking on the results files gives the following two charts.
Right click on results and click “Define Beam Diagram” to create the Shear-Moment plot below.
Apply similar fixtures to the bottom of the table, do not apply the fixed
restraint. Apply the same 5000 lb load to the top of the plate using External
Loads.
Mesh using the default settings. You will notice that this mesh takes significantly longer to
create than the last one. Save your file, then Run the analysis as before. I had to change my solver to
the Direct Sparse method in order to get my simulation to solve. This simulation takes longer to solve
than the previous but also gives more detailed results.
So, the real question is, which one is correct? The answer is, as one may put it “Yes”. Both
simulations are correct given the method with which they were solved. According to SolidWorks, if the
length of the member is greater than 10x the cross section length, the beam method is more accurate
and faster.
Go back to the previous study and change the Global Contact to No Penetration. Right click on
Contact and select the Bolt option. Select the circular edge of the thru hole on the C-Channel as the
reference edge for the bolt head and the circular edge on the far side of the leg as the nut reference
edge. Since the bolt size is ½”, set the head size to 0.866” and the diameter to 0.5”. Set the material to
Alloy Steel and the torque to 1440 lb-in. Note that the torque is Inch Pounds and not foot pounds.
Before clicking OK, click the pin so you can re-use the settings on all the bolts.
Click OK and select the next bolt and so on until you have defined all 8 bolts for the assembly.
Re-Mesh the assembly and run the analysis again. This run should take much longer to process due to
the additional solving of the contact and constraints.
As a general rule of FEA, the displacement plots are more accurate since they are calculated
directly from the stiffness matrix. The stress and strain plots are then derived from the displacement
results.
Fatigue Analysis
Objectives
Run a Fatigue Analysis
In the Fatigue study, right click on loading and select the Add Event button.
Set the cycles to 100000 and select the proper loading type. Click OK, then right
click on the study and select Run. It should not take very long for you to get results.
So how accurate it the Fatigue Plot? In my experience, using the “Derived” S-N curve the Total
Life plot is usually within about 30%. I suspect that with more accurate S-N data this could be improved
drastically.
Day 7
Other Simulations
Objectives
Provide an overview of the other simulation types available using SolidWorks Simulation
Frequency Analysis
A quick refresher on un-damped systems:
If a design in subjected to dynamic loading, static studies cannot be used to evaluate the
response. Frequency studies can help to avoid resonance in your design. They are also required to
form the basis for evaluating the response of linear dynamic systems. Real models have an infinite
number of natural frequencies, however, generally we only need the first few modes for most
purposes.
To demonstrate, let’s consider a tuning fork like the one below. Create a new Frequency using
SolidWorks Simulation.
Set the material to Alloy Steel (SS), fix the small end then mesh the part.
If no restraint is provided, then SolidWorks solves for the ridgid body modes of vibration. The
first six modes correspond to the six degrees of freedom, so adjust the number of modes to calculate to
11 or more and re-run the study. The model must be restrained for linear dynamic studies.
Dynamic Analysis
Static studies assume that loads are constant or applied very slowly. Because of this
assumption, the velocity and acceleration of each particle of the model is assumed to be zero. As a
result, static studies neglect inertial and damping forces. For many practical cases, loads are not applied
slowly or they change with time or frequency. For such cases, the Dynamic Analysis is required for more
accurate results. Linear dynamic studies are based on frequency studies and therefore a frequency
study must be completed before setting up a linear dynamic study.
Using the tuning fork: Create a new study and name it Dynamic_1. Select
Linear Dynamic as the type and set the option at the bottom to “Modal Time History”.
(Use Modal Time History when the variation of each load is known explicitly and you
are interested in the response as a function of time. Use Harmonic Analysis to
calculate the peak steady state response due to harmonic loads or base excitations.
Use a Random Vibration Analysis to calculate the response due to non-deterministic
loads.) You can duplicate the material and the fixed constraints by dragging the
material from the frequency study to the new Dynamic_1 tab. Repeat by dragging the
Fixed constraint down to the Dynamic_1 tab.
Apply a 50lb load to the end of the tuning fork as shown below. Under the Variation with time
box, choose curve then edit to bring up the Time Curve dialog. I want to simulate flicking or hitting the
tuning fork. Once you have entered the values below, click view to see the graph then click ok twice to
apply the load to the model.
Right click on the Results Options, then click Ok to accept the defaults. Copy the mesh from the
Vibration Analysis as was done before. Run the analysis. On my laptop, this analysis took about 5
minutes to complete. In order to create a graph of the response we need to locate a node in our mesh.
Right click on the mesh and show the mesh. Right click on mesh again and select probe. Change the
advanced option to node then select the tip of the part to identify a node. Remember the node
number, for my model, it is node 537.
To create a graph of the system response, right click on Results and choose Define Response
Graph. Depending on the complexity of your mesh, this could take a few minutes to open up. Locate
your node in the all nodes list, then for the ‘Y’ axis, choose displacement, URES and inches. Click ok to
see your graph.
You can right click on this chart to customize it’s appearance or click File->Save at the top of the
chart to export the data as a .CSV file which you can then import to Excel. You can use this method to
export the Accelerations and Velocities as well.
For this analysis, I am using a 1” x 1” x 60” long steel bar with ø4” Circular plates
that are 0.25” thick on each end. The material is Alloy Steel (SS) from the SolidWorks
material library. On the top, I create a split line offset from the centerline of the part to
ensure buckling occurs. This is where I will apply the load.
Create a new Simulation Study, name the study Buckling and select the Buckling
Analysis then click OK. Fix the bottom and apply a 100,000 lb load in the split line area
created above. Mesh the part, then right click on the study and select properties.
Set the number of buckling modes to 5 and the solver to Automatic. Click ok, then run the
analysis.
Again, use the animate feature to visualize each of the 5 modes. You can get the critical load
factor from the information at the top of each plot.
Thermal Analysis
A thermal analysis calculates the temperature distribution in a body due to Conduction,
Convection and or Radiation. In each of these mechanisms of heat transfer, heat energy flows from the
medium with higher temperature to the medium with lower temperature.
Our tuning fork is held between two surfaces at constant temperatures. The temperature at the
base of the handle is 0°C while the temperature at the opposite end is 100°C. Determine the Steady
State temperature distribution of the tuning fork.
Create a new study name Steady State Heat Transfer and select Thermal as the type of study.
Copy the material from one of the previous studies. Right click on Thermal Loads and select
Temperature. Select the bottom face and enter the temperature of 0°C then click Ok.
Repeat these steps with the top two faces setting the temperature to 100°C. Mesh and run the
analysis to produce the output as shown.
Now that the tuning fork is at a steady state condition, the temperatures are flipped such that
the 0°C Face is now 100°C and vice-versa. Determine the temperature distribution at 2, 4 and 6 seconds
after the switch.
In order to leverage what we have already done, right click on the Steady State Heat Transfer
Study tab at the bottom of the screen and select Duplicate. Provide a new name of Transient Heat
Conduction. Right click on the study name in the browser tree and select properties. In the thermal
properties box, select Transient, set the total time to 6 seconds and the time increment to 0.5 seconds.
Check the box next to Initial Temperatures and ensure the Steady State Heat Transfer study is selected.
Click OK to continue.
Reverse both temperatures by double clicking on them and changing their values from 0°C to
100°C and vice-versa. Delete the results plot then run the analysis. Create 3 new plots showing the
temperature distribution at 2, 4 and 6 seconds.
Design Optimization
Optimization studies help you automate the search for the optimum solution. In optimizing a
design, you need to define your objective, the dimensions of the design that can change, and the
conditions that the design must satisfy.
Let’s say we have an aluminum plate like the one below. We know that this plate will see an
equal force on the mounting holes of 50 lbs (combined) and we want to minimize the weight
maintaining a safety factor of 4. The outer holes in the plate are used to attach the plate to the
structure and are of no concern during this analysis. The thickness of the plate can range from 0.0625”
to 0.1875”. The hole in the center of the plate starts at a 1” diameter and can go up to 3” in diameter.
The starting weight of the part made of 6061-T4 is 0.178 lbs.
Create a new static study and call it Static. Add fixed hinge constraints to the six holes on either
side of the plate. Add a single load from the inside surface of the 4 thru holes at 50 lb. Mesh and run
the analysis. Create a factor of safety plot using the default parameters.
Save the analysis and create a new one called Optimization. Right click on Objective and click
Add. Set the choose Minimize, Mass then select Static and click Ok.
Right click on Design Variable and click Add. Find the center hole diameter and click it. Set the
minimum to 0.5” and the maximum to 3.0” then click OK. Add a second design variable for the thickness
of the material. Allow it to range from 0.0625” to 0.1875” then click OK.
Right click constraints, then click Add. Ensure Static is selected from the drop down, then click
on the Static Study in the grey box. Set the Result Type to Nodal Stress and the Component to VON: von
Mises Stress. Set the units to PSI, the lower bound to 0 and the upper bound to 7500. Where did I get
the 7500? From out static analysis we had a minimum factor of safety of 12 with a maximum von
Misses stress of 2500 psi. Since I want to decrease my weight, I will also need to decrease my minimum
safety factor to around 4. If my stress increases by a factor 3, my Safety Factor should decrease by the
same factor. Thus multiply 2500 psi by 3 to get 7500 psi as an upper limit.
Save the part and run the analysis. SolidWorks will go thru multiple iterations before finding the
optimum. The maximum von Mises Stress in the optimized design is 5887 psi which results in a new
minimum safety factor of 5.6. The final weight of the part is 0.082 lbs. That’s more than a 50%
reduction in weight!
After careful examination you will find that the thickness is now set to .098 in. A bit of research
and engineering can further optimize the design for both weight and manufacturing.
For this study let’s simulate crashing the engine mount into the ground. Assume the mount
does not hit normal to the flat surface but instead skids off the bottom face with a horizontal velocity of
50MPH. Start a new study, name it Drop Test and pick Drop Test as the type of Study.
Right Click on Setup and click Define. Select Velocity at impact then pick one of the top two
edges to define a velocity direction. Set the velocity to 73.3 ft/sec. Pick the Top Plane as a gravity
reference and the Front Plane as the Target reference, click OK.
Right click Result Options and click Define. The number next to the clock is the solution time
after the impact occurs. Leave all the defaults alone and click OK. This tells Simulation to look at the
first 78.88 microseconds after impact, begin saving the data from time 0 and store 25 sets of results.
Copy the mesh from one of the previous studies then run the analysis.
This analysis should be fairly quick though it does use the non-linear solver. Take a look at the
stress plot, animate it to see exactly what is happening.
Day 8
Motion Analysis
Objectives
Setup and run a Motion Analysis.
Export Force/Moment loads from Motion to Simulation.
Run an analysis in Simulation based on the Motion analysis.
Verification that you did in fact design the fixture properly and you will receive 1” of horizontal
movement.
Velocity and Acceleration graphs of the horizontal pin.
In operation, the horizontal pin will see from 0-1000 lbf of resistance to motion. The resistance
is proportional to velocity like a damper. Determine if this design will work?
Once the assembly is constructed and moving as you expect, click the Motion Study 1 tab at the
bottom of the SolidWorks interface. In Tools->Options, make sure that SolidWorks Motion is turned on.
In this case, I turned off SolidWorks Simulation to conserve memory.
Change the study type to Motion Analysis in the upper left corner of the Motion Study Frame.
The other types of simulations were discussed in the Assemblies chapter of this guide.
In the SolidWorks view, orient your assembly model in a way that makes applying motors and
forces easier. Then right click on the Orientation and Camera Views key and select Replace Key. This
will set the current view as the starting view for the simulation.
Next, add a motor to the upper pin as shown. Set the type of motor to linear and select the
vertical edge of the pin. Change the motion to Oscillating and set the distance to 0.500 in. The
frequency should default to 1 Hz. Click ok to create the motor.
At this point, the simulation will run. Go ahead and click on the calculate button. This should
run pretty quick. Creating the motor made the simulation last 5 seconds. This is probably not
necessary, but It solves fast so we will leave it alone for now.
Once the simulation is solved, hit the play button to watch the assembly move. Kind of cool, but
basically just an animation. What we can do from here is get the horizontal displacement, velocity and
acceleration graphs. Click the Results and Plots button at the end of the Motion Study toolbar. Set the
Category to Displacement/Velocity/Acceleration then set the Sub-Category to Linear Displacement. In
the third drop down, select X Component since that’s all we care about. Finally click the selection box
then select the two faces as shown. Click OK to see the results.
The chart provided shows absolute displacement between the fixed base and the end of the pin.
In my graph, the distance ranges from 3 in. to 4 in. which does in fact give me a total of 1 inch
displacement. Remember that you can right click on any of the graphs and export the data as a CSV file
which you can then import into Excel and manipulate.
Repeat the steps above to create plots for Velocity and Acceleration.
Now let’s apply our load based on the information we have learned from the graphs. We want
to apply a 1000 lbf load when the velocity is at its maximum and we want the force to be opposing the
velocity. Click the force button on the Simulation Toolbar and make sure Action Only is selected. Click
on the face of the horizontal pin, this is where the force is applied. Under Force Function, click on
Harmonic then set the Amplitude to 1000 lbf. If we leave everything else alone it should work out for
us. Make sure the arrow is pointing toward the assembly, since this defines the direction of the Positive
force value. Click OK, then re-run the Motion Analysis.
Take a second look at the plots you created before. They are located at the bottom of the
Motion Study Tree. You will notice that nothing changed. What does this mean? Did SolidWorks
Motion even take our new force into consideration? The answer is yes and no. Yes the force was
considered, but it had no effect on the motion simulation. What this means is, we have to do more
work in order to see the effects of the load we applied. Start by saving the assembly, for some reason
this step is required, it is also highly recommended. Create a new Static Study of the assembly. Once
done go to the Simulation menu item and select Import Motion loads. This brings up the Import Motion
Load dialog box. For the next part we have to think a bit. Using our in-depth knowledge of Engineering,
Statics and Dynamics we have to decide which parts to look at and for what time frame.
Based on my in-depth knowledge, I think we should take a look at the rocker piece in the middle
of the assembly. Also, I don’t need to import all the loads from my motion analysis, just the first second
since everything is based on 1 Hz.
In the Import Motion Load Dialog Box select the part or parts that you are interested in and add
them to the right side of the dialog box. Next, click on Multiple Frame Study and set the start frame to 1
and the end frame to 26. Notice how this also corresponds to a time frame of 0 to 1 second. Leave the
step at 1 then click OK. This took my computer quite a while to chug thru.
Now, right click on the part and select open. At the bottom, you should see a new Simulation
stored in this part.
What is interesting about this simulation is that it contains multiple design scenarios. One for
each time segment imported from your motion analysis. Right-Click on the design scenario and click
edit. So what happened is Simulation created a bunch of remote loads and is using the design scenario
to carry the value of the loads at each time segment. All we have to do is mesh the part then run the
analysis on all the design scenarios.
Don’t set your mesh too fine since the analysis will need to run 26 times. Don’t forget to set the
material. Once done right click on the study name and click Run Design Scenarios. I suspect this analysis
will take some time to complete. When done go ahead and hide all of the Loads to make analysis easier.
The only real data we can get from this is the new graph at the end of the results tree. Any
other plot you could see would only show the loading in the last step that was processed. Double click
on the graph to show it. Stretch the graph out so you can see it. The graph shows local maximums of
von Mises Stress for each set. This makes it easy to decide which sets need to be looked at closely.
According to the graph below we should be looking at Sets 7 and 20.
The easiest way to analyze Set 7 is to right click on the Study Tab and select Duplicate. Name it
Set 7 then click Ok. Right click on the design scenario and select edit. At the bottom in the Run Options,
select One Scenario then select Set7. Click Ok then re-mesh with a fine mesh then run the Design
Scenarios again. Don’t worry, Simulation will only run Set 7.
Once the analysis is done, view the results and make any necessary design changes to the part.
Mates were used to define the relationship between components instead of 3D Contact. This
reduces the overall solution time without significantly changing the actual loading on the parts.
Any changes to the part or assembly will require re-running the Motion Analysis then re-
importing the motion loads to the individual part followed by re-running any necessary set(s).
This workforce solution was funded by a grant awarded under Workforce Innovation in Regional Economic
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