Beruflich Dokumente
Kultur Dokumente
For
o Day 2
o Day 3
o Day 4
o Day 5
o Day 6
o Day 7
o Day 8
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Figure 1 - Tools->Options
While we are on the topic, the piece of the SolidWorks interface depicted is the Menu Bar. On my
interface, I will keep the Menu Bar Pull-Downs Pinned open for quick reference. The commands to the
right of the drop down menu are the quick launch. You can completely customize the quick launch
the same way you customize tool bars, but I will cover that later.
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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.
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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.
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Figure 11 - Plate
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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.
Tolerance Class. Sets the part tolerance class.
o
o
o
o
Fine (f)
Medium (m)
Coarse (c)
Very Coarse (v)
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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.
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Click on any one of the large fillets and place the dimension as shown then click Ok.
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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.
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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.
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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.
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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.
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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:
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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.
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Additionally, SolidWorks also provides for Smart Mates and Smart Components as well as Active
Dragging and mating from within the Assembly Drawing area. A note about mates in SolidWorks, mates
should be used sparingly. The more mates in an assembly, the larger the assembly file and the greater
the chance that it will become corrupt or broken.
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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.
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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.
To create a design table, start with a fully modeled part. Go to Tools->Options
and enable the Show Dimension Names option then click OK. Next in the browser
tree, right click on the Annotations folder and ensure the Display Annotations and
Show Feature Dimensions are checked on.
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To re-name a dimension, simple click on the dimension then change the name in the Property Manager.
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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
Figure 61 - Insert a Design Table
Edit Control:
Allow Model Updates Takes any changes made to the
SolidWorks file and updated the values stored in the design table. This can be
very dangerous!
Block Model Updates Forces changes to design table dimensions to occur in the
design table. This is the preferred method.
Options:
I generally leave all of these boxes checked. These options control what
SolidWorks does when you open a design table.
Figure 62 - Design Table Property
Manager
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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 unstable 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
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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.
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Legal Values
(body cell)
$configuration @part_name
configuration name
not evaluated
$configuration @feature_name
configuration name
not evaluated
$comment
empty
$description
configuration name
$partnumber
configuration name
$state @feature_name
Suppressed, S
Unsuppressed, U
Unsuppressed
dimension @feature_name
- or dimension@sketch_name
not evaluated
$hw-size
$parent
property is undefined
$prp @property
property is undefined
$state @equation_number@equations
Suppressed, S
Unsuppressed, U
Unsuppressed
$state @lighting_name
Suppressed, S
Unsuppressed, U
Unsuppressed
$state @sketch_relation@sketch_name
Suppressed, S
Unsuppressed, U
Unsuppressed
$user notes
not evaluated
$color
zero (black)
$sw-mass
$sw-cog
$tolerance @dimension_name
Parts only
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Assemblies only
$displaystate
$fixed
$state
@component_name<instance>
Resolved, R
Suppressed, S
Resolved
$configuration
@component_name<instance>
configuration name
$never_expand_in_BOM
No
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Figure 69 - Load
Macro Toolbar
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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.
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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.
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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.
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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.
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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.
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Use a face fillet to fillet the top face to the side faces as shown. Apply a radius of 25mm to both edges.
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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.
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Next, the following sketch is revolved using the revolved surface command.
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On the Right Plane, sketch the following, then use the fit spline tool again replacing the lines and arc
with the spline.
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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.
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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.
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Figure 115 - Joint Groups before and After with Property Manager
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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You can right click on this chart to customize its 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.
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Set the number of buckling modes to 5 and the solver to Automatic. Click ok, then run the
analysis.
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Repeat these steps with the top two faces setting the temperature to 100C. Mesh and run the
analysis to produce the output as shown.
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Reverse both temperatures by double clicking on them and changing their values from 0C to
100C 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.
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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.
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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.
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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.
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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.
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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.
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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.
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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 thats all we care about. Finally click the selection box
then select the two faces as shown. Click OK to see the results.
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Repeat the steps above to create plots for Velocity and Acceleration.
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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 dont need to import all the loads from my motion analysis, just the first second
since everything is based on 1 Hz.
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Now, right click on the part and select open. At the bottom, you should see a new Simulation
stored in this part.
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Dont set your mesh too fine since the analysis will need to run 26 times. Dont 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.
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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. Dont worry, Simulation will only run Set 7.
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This workforce solution was funded by a grant awarded under Workforce Innovation in Regional Economic
Development (WIRED) as implemented by the U.S. Department of Labors Employment and Training Administration.
The solution was created by the grantee and does not necessarily reflect the official position of the U.S. Department of
Labor. The Department of Labor makes no guarantees, warranties, or assurances of any kind, express or implied, with
respect to such information, including any information on linked sites and including, but not limited to, accuracy of the
information or its completeness, timeliness, usefulness, adequacy, continued availability, or ownership. This solution is
copyrighted by the institution that created it. Internal use by an organization and/or personal use by an individual for
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