Inside SolidWorks 2003

®

David Murray

T H O M S O N

DELMAR I E A R N I N G Australia Canada Mexico Singapore Spain United Kingdom United States

Contents

Chapter 1: Computer-aided Design 1 Moving into the Digital Age 2 How SolidWorks Fits In 3

Feature-based Modeling 3 Parametric Modeling 4 Solid Modeling 4

Design Intent 5 Boolean Modelers 7 Nonparametric Modelers 8 Parametric Modelers 8 Benefits of Solid Modeling 9 Downstream Benefits of Solid Modeling 11 SolidWorks and the Big Picture 12 SolidWorks API 13 Minimum System Requirements 13 Dual Processors? 14 Memory and Hard Drive Space 15 Graphics Cards 16 Monitor and Screen Size 16 Summary 17 Questions and Topics for Discussion 18 Optional Problem 18

Chapter 2: A SolidWorks Overview 19 Sketching Overview 19 Features Overview 20 Sketched Versus Applied Features 21 The SolidWorks Interface 22

Beginning a New Part 22 Toolbars 23

FeatureManager and the Work Area 25 The Separator Bar 26 PropertyManager 26

FeatureManager Pane Control 29 Renaming Objects 30

Using the Mouse Buttons 31 Selecting Entities 31 The Context-sensitive Menü 31 Middle Mouse Button Functionality 32

Toggling Plane Display 32 Changing Views 35

Using the Orientation Window 35 Using the Standard Views Toolbar 36 The Normal To Function 37

Using Templates 38 Standard File Extensions 38 Template File Extensions 38 Modifying Document Properties and

Saving Templates 39 Deciding on a Sketch Plane 41 Entering Sketch Mode 42 Sketch Color Codes 43 Understanding Error Symbology 44

Overdefined Geometry 44 What's Wrong? 45

The Origin Point 46 Sketch Basics 47

Am I in a Sketch? 47 System Feedback 48 An Introduction to Constraints 49

Summary 52 Questions and Topics for Discussion 53

Chapter 3: Sketching Basics 55 Beginning a Sketch: A Quick Review 55 Sketching 56

vi Contents

Lines 56 Deleting Entities 58 Auto-transitioning to Ares 60 Exiting Commands 61 Dxagging Geometry 61 Command Persistence 62

Sketch Entities 63 Tangent Are 64 3 Point Are 64 Centerpoint Are 65 Circles 65 Rectangles 66 Rectangles at an Angle 66 Parallelograms 66 Polygons 67 Ellipses 68 Centerpoint Ellipses 69 Parabolas 70 Points 70 Centerlines 71

Splines 71 Nonproportional Splines 72 Proportional Splines 73 Adding Control Points 73 Deleting Control Points 74 Simplifying a Spline 74 Spline Tangency Conditions 75 Moving Frames 76 Spline Minimum Radius and Inflection

Points 77 Inspecting Sketch Curvature 77

Construction Entities 78 Sketch Guidelines 79

Contour Select Tool 81 Check Sketch For Feature 82 Keep It Simple 83 Fully Define Your Sketch 83

Units of Measurement 84 Grid/Snap Settings 84

Sketch Plane Indicators 85 Snap Behavior 86

Geometrie Relations 86 Callouts 87 Deleting Relations 88

Dimensioning 89 Automatic Dimensioning 91 Pan and Zoom Commands 92

View Orientation 93 Additional Zoom Options 97 Zoom Limitations in Windows 98

Display Options 99 Wireframe 99 Hidden Lines Visible 99

Summary 104 Questions and Topics for Discussion 105 Optional Problem 106

Chapter 4: Castings 107 Getting Started: A Quick Review 107

Determine the Best Profile 108 Select the Appropriate Plane 108 Fully Define the Sketch 108

Creating Features 109 Base Features 109 Extrusion End Conditions 111

The Pivot Arm: An Overview 112 The Mid Plane End Condition 112 A Common Mistake 115

Editing Techniques 116 Editing a Sketch 116 Editing a Definition 118 Modifying Dimensions 119 Renaming Features 121 The Blind End Condition 121 The Up To Surface End Condition 121 The Through All End Condition 125 Cutting with an Open Profile 126

Mirroring Sketch Geometry 129 Mirroring Sketch Geometry Dynamically . . 130 Mirroring Existing Sketch Geometry 130

Multiple Bodies 134 Creating Planes 137 Starting a Plane 138 Summary 147 Questions and Topics for Discussion 148

Chapter 5: Turned Parts 149 Revolved Features 149

Begin with a Centerline 150

Inside SolidWorks 2003 vii

Rules Governing Revolved Sketch Geometry 151

Revolve Command Panel 152 Diameter Dimensions from Centerlines . . . 154

Dimension Properties 155 Modifying Properties via PropertyManager .157 Dimensioning to a Tangency Point 160 Dual Dimensioning 162

Sketch Fillets 163 Keeping Corners Constrained 164 Adding Virtual Sharps Manually 165

Sketch Chamfers 165 Trimming 166 Extending 167 Converting Entities 168 Offsetting Entities 170 Summary 174 Questions and Topics for Discussion 175

Chapter 6: Molded Parts 177 Thin-walled Parts 178

Thin-feature Parts 178 Shelled Parts 178

The Shell Command 178 Shell Feature Panel 179 Multi-thickness Shell 181

Fillets and Rounds 182 Fillets as Features 183 Fillet Options 188

Selection Techniques 190 Select Midpoint 190 Select Chain 191 Select Loop 191 Select Tangency 191 Select Other 191

Chamfers 193 Angle-Distance 193 Distance-Distance 193 Vertex Chamfer 194

The Hole Wizard 198 Legacy Tab 200 Holes on Nonplanar Faces 200 Adding Favorites 200 Simple Holes 201

Lofted Parts 202

Split Curve Command 204 Correct Selection of Loft Profiles 206 Guide Curves 206 Pierce Constraint 207 Centerline Option 210 Other Loft Options 211 Tangency Conditions 212

Split Lines 215 The Silhouette Method 217 Adding Draft 218

Adding Draft with a Parting Line 218 Adding Draft with a Neutral Plane 220 Step Draft 221 Face Propagation Options 222

Rib Tool 223 Linear Versus Natural 224 Draft Reference for Ribs 226

Draft Analysis 226 Face Classification 227 Draft Analysis Color Settings 229

Summary 232 Questions and Topics for Discussion 234

Chapter 7: Patterns 237 Simple Pattern Alternatives 237

Copying and Pasting Features 238 The Control-Drag Technique 240

Linear Patterns 241 Pattern Seed Only 243 Vary Sketch 243 Deleting Instances from a Pattern 245

Circular Patterns 249 Working with Circular Patterns 250 Equal spacing Option 251

Geometry Patterns 252 Axes 253

Temporary Axes 253 User-defined Axes 254

Sketch-driven Patterns 258 Table-driven Patterns 260

Coordinate Systems 261 Modifying a Table-driven Pattern 263

Curve-driven Patterns 264 Mirroring Feature Geometry 267

Mirroring and Patterning Faces and Bodies. 268

viii Contents

Symmetrical Parts 269 Mirrored Parts, or "Left-Hand" Versions 269 External References 271

Opening Referenced Files 272 Locking References 272 Breaking External References 273

Sketch Step and Repeat Commands 273 Linear Sketch Step and Repeat 274 Circular Sketch Step and Repeat 277

Summary 278 Questions and Topics for Discussion 280 Optional Problem 281

Chapter 8: Sheet Metal 283 Thin-feature Parts 283

Auto Fillet Option 285 Revolving an Open Profile 285 Closed-profile Thin Features 286 Cap Ends Option 287

Defining a Sheet Metal Part 287 Sheet-Metall 288 Base-Flange 292 Flat-Patternl 293

Edge Flange 295 Flange Position 297

Flange Position Offset Option 298 Custom Relief Type and Custom Bend

Allowance 298 Editing the Flange Profile 299

Miter Flange 300 Offset Miter Flange 301 Tabs 302 Sketched Bends 303 Jogs 304 Hems 306 Breaking Corners 307 Closing Corners 308 Lofted Bends 310 Cutting Sheet Metal Parts 311

Link to Thickness 311 Normal Cut 312 Working in the Flattened State 312

Forming Tools 315 Using the Feature Palette 316 Editing Palette Items 326

Modifying Part Color 328 Modify Sketch Command 329

Rotating Using the Mouse 331 Translating 331 Scaling 332 Flipping 332

Converting to Sheet Metal 332 Inserting Bends 333 Reordering Bends 336 Rolled Bends 336 Legacy Sheet Metal Parts 337

Rip Features 338 Summary 340 Questions and Topics for Discussion 341 Optional Problem 342

Chapter 9: Springs, Threads, and Curves . 343 Swept Features 343

Valid Profiles 344 Valid Paths 345 Using Existing Edges as a Sweep Path 347 Align with End Faces Option 348 Additional Sweep Options 349 Orientation and Twist Control 350 Sweeping with Guide Curves 353

Helical Curves 354 Creating Helixes 355 Spirals 357

Springs 357 Phase 1: Starting with a Circle 358 Phase 2: Defining the Helix 358 Phase 3: Creating a Sketch Plane 358 Phase 4: Sketching a Sweep Profile 359 Phase 5: Exiting the Sketch and

Creating the Sweep 359 Composite Curves 359 Threads 364

Creating Threads 364 Rounding Threads 366

Springs and Threads: Final Comments 367 3D Sketcher 368

3D Sketch Relations 370 Drawing Splines in 3D 371

Projected Curves 375 Projecting a Sketch onto a Sketch 375

Inside SolidWorks 2003 I X

Projecting a Sketch onto a Face 376 Curves Through Points 378

Curve Through Reference Points 378 Curve Through Free Points 378 Curve Files 379

Section Properties 380 How Section Properties Work 381 Measurement Options Window Settings. . . 382

Mass Properties 382 Changing the Coordinate System 384 Mass Properties in Assemblies 384 Placing a Point at the Centroid 385

Summary 385 Questions and Topics for Discussion 386 Optional Problem 387

Chapter 10: Part Configurations 389 Reasons for Configurations 389

Assembly Performance 390 Sheet Metal Forming Operations 390 Part Families 390 Application-specific Requirements 390 Design-specific Requirements 390

ConfigurationManager 391 FeatureManager and

ConfigurationManager Descriptions . . 392 Properties for Newly Inserted Items 393 Copying Configurations 394

Suppression States 395 Parent/Child Relationships 395 Other Methods of Changing Suppression . . 398

Dimensional Configurations 399 Other Configurable Objects 399

Configuring End Conditions 400 Configuring Geometrie Relations 402

Nested Configurations 404 Summary 405 Questions and Topics for Discussion 406

Chapter 11: Design Drawings 407 File Associativity 408 New Drawings 408

Drawing Interface 410 Drawing Sheet Formats 413 Drawing Templates 416

Inserting Views 422 Moving Views 424 Modifying View Alignment 425 Right-clicking Precautions 427 Projected Views 427 Auxiliary Views 428 Named Views 429 Relative to Model View Method 430 Section Views 431 Aligned Sections 435 Broken-out Section Views 441 Detail Views 442 Broken Views 444 Cropped Views 446 Empty Views and Creating Tables 447

View Appearance 448 Hiding Individual Edges 448 Tangent Edges 449 Changing a View's Scale 451

Dimensioning 452 Moving Dimensions 457 Dimension Favorites 459 Reference Dimensions 461 Extension Lines 462

Center Marks 463 Creating Center Marks 463 Automatic Center Marks and Centerlines . 464

Layers 465 Making a Layer Current 467 Deleting a Layer 467 Turning Layers On and Off 467 Moving Objects Between Layers 468

Properties of Multiple Objects 469 Line Formatting 469 Annotations 470

Notes 471 Hole Callouts 475 Cosmetic Threads 476 Weld Symbols 479 Geometrie Tolerancing 480 Surface Finish Symbols 481 Datum Features 481 Datum Targets 482 Multi-jog Leaders 482 Dowel Pin Symbols 484

X Contents

Blocks 484 Creating and Editing Blocks 484 Exploding Blocks 486 Inserting Blocks 486 Saving and Linking Block Files 487 Imported Block Attributes 487

RapidDraft Files 488 Creating RapidDraft Drawings 489 Synchronizing Model Geometry 490

Tabulated Drawings 491 Summary 492 Questions and Topics for Discussion 494 Optional Problem 496

Chapter 12: Assemblies 497 Starting a New Assembly 498 Inserting Components 499

Fixed or Floating? 500 FeatureManager Symbology 501

Moving and Rotating Components 502 Moving Components in Specific Directions. . 504 Mating Relationships 505

Mate Options 507 Finding Mates 513 Viewing Mates with PropertyManager 514 Smart Mates 514 Inserting Components with Smar tMates . . . 515 Mate References 516

Palette Parts and Palette Assemblies 517 Component Patterns 519

Creating Component Patterns 519 Deleting Patterned Components 523

Hiding Components 523 Component Suppression States 524

Lightweight Components 524 Resolving Components 527

Working with Subassemblies 528 Component Subassemblies 528 Component Properties 529

Component Replacement 533 Reloading Components 535 Mate Troubleshooting and Repair 536

Missing References 537 Overdefined Mates 537 Improper Alignment 538

Mate Diagnostics 538 Component Editing 539

Opening Component Files 540 Editing Components in Context 540

Interference Checking 544 Collision Detection 545 Dynamic Clearance 547 Physical Dynamics 548 Simulation 549 Assembly Features 551

Feature Scope 551 Assembly Feature Patterns 554

Assembly Drawings 554 Assembly Section Views 555 Hiding Components in Drawing V i e w s . . . . 556 Show Hidden Edges 557

Bill of Materials 558 Bill of Materials Properties Window

Options 559 Editing a BOM 563 Customizing a BOM Template 564 BOM Properties 565 Overriding BOM Part Number 566

Exploded Views 567 Editing an Exploded View 569 Expanding and Collapsing an Exploded

View 570 Copying Exploded Views 570 Exploded Views in Drawings 571

Balloons 572 Working with Balloons 572 Balloons and Component Names 574

Summary 575 Questions and Topics for Discussion 576

Chapter 13: Cavities, Cores, and Mold Making 579 The Cavity Command 579

Creating the Die 580 Creating the Cavity 581

Inserting Parts 582 Referencing Configurations 585 Creating the Mold 585 Open-profile Cutting 586

Derived Parts 587

Inside SolidWorks 2003 xi

Splitting Parts 589 Creating a Core and Cavity 591

Scaling 592 Creating Shutoff Surfaces 593 Radiated Surfaces 596 Lofted Surfaces 598 Creating the Mold Assembly 600 Inserting a New Part into an Assembly . . . . 601 InPlace Mates 601 Knitting Surfaces 603 The Cavity Base Feature 605 Completing the Core 607 Final Touches 607

Summary 608 Questions and Topics for Discussion 609

Chapter 14: Welded Assemblies 611 Adding Weld Beads 611

Weld Bead Mate Surfaces 615 Weld Bead Special Situations 616 Weld Bead Associativity 617

The Join Command 619 A Common Mistake When Joining 622 Disassociating Joined Components 623 Multiple Bodies in Joined Parts 623

Saving Assemblies as Part Files 623 Summary 626

Questions and Topics for Discussion 627

Chapter 15: Assembly Configurations 629 Adding Assembly Configurations 629 Assembly Configuration Properties 630

Use configuration specific color Option . . . 631 Suppress features and mates Option 632 Hide component modeis Option 632 Suppress component modeis Option 632 BOM-related Options 632

Controlling Component Configurations 633 Using Assembly Configurations

Successfully 635 Showing Alternate Components 639

Controlling Configurations in Drawings 639 Summary 641 Questions and Topics for Discussion 642

Chapter 16: Design Tables 643 Linking Versus Embedding 644 Preparations for Design Table Creation 644

Turning on Dimension Names 645 Displaying All Model Dimensions 646

Creating a Design Table 646 Adding a Blank Design Table 649 Feature Suppression in Design Tables 650 Design Table Options 653 Adding Rows and Columns Automatically. 653 Saving and Linking to Design Table Files. . 654 ConfigurationManager Symbology 655

Design Table Editing 656 Deleting a Configuration 657 Assembly Design Tables 658

Controlling Assembly Feature and Mate Dimensions 659

Controlling Component Suppression 660 Controlling Assembly Feature and

Mate Suppression 661 Controlling Component Visibility 662 Specifying a Component's Configuration . . 662 Adding Notes and Controlling Part

Numbers 663 Controlling Subassembly Expansion

in a BOM 663 A Pictorial Overview 664

Showing Design Tables in Drawings 666 Design Table Summary and Recommendations 667

Custom Properties 667 Configuration-specific Properties 672 Defining Custom Properties in Design

Tables 672 Associative Custom Properties 673 Custom Properties and BOMs 675

Summary 675 Questions and Topics for Discussion 676 Optional Problem 677

Chapter 17: Equations 679 Preparatory Work 679 The Equation Creation Process 681

Equations in Action 683

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Link Values 684 Equations Window Buttons 688

Summary 692 Questions and Topics for Discussion 692 Optional Problem 692

Chapter 18: Advanced Assembly Modeling 693 System Performance 693

Large Assembly Mode 694 Performance Options 696

Assembly Restructuring 700 Reorganize Components Command 702 Multi-user Environments and Copying Files. . 703

Scenario 1: Working Independently 704 Scenario 2: Working Over a Network 708

Envelopes 718 Envelope Selection Techniques 720 Advanced Selection Techniques 721 Summary 723 Questions and Topics for Discussion 724

Chapter 19: Advanced Feature Types 725 Domed Features 725 Shape Command 729 Advanced Filleting 732

Variable Radius Fillets 732 Utilizing Movable Fillet Points 734 Setback Fillets 734 Face Blends 736 Füll Round Fillets 739 Continuous Curvature Fillets 740

Face Curvature 740 Rolling Back FeatureManager 741 Reordering 743 Summary 744 Questions and Topics for Discussion 745

Chapter 20: Working with Surfaces 747 Surfaces Versus Solids 748 Creating Surfaces 748 Trimming and Extending Surfaces 750

Deviation Analysis 751 Untrimming Surfaces 751 Trimming Surfaces 752 Surface Lofting Techniques 754

Solidifying Surfaces 754 Offset Surfaces 755 Planar Surfaces 756 Manipulating Bodies 756 Moving, Copying, and Rotating Bodies 757 Cutting with Surfaces 759 Hiding and Showing Bodies 760 Summary 761 Questions and Topics for Discussion 762

Chapter 2 1 : Engraved and Embossed Text 763 Adding Text as a Feature 763

Aligning Text on a Curve 765 Sketch Text Options 766

Sketch Text as a Feature 768 Text Features on Curved Surfaces 771 Wrapping Text Around a Cylinder 773 Embossed Text on a Curved Surface 776 Summary 778 Questions and Topics for Discussion 779 Optional Problem 780

Chapter 22: Importing and Exporting Files 781 Importing Files 781

AutoCAD Drawing and DXF Files 784 Parasolid Files 785 IGES Files 786 STEP Files 788 ACIS SAT Files 788 Virtual Reality Markup Language 788 Stereolithography Files 789 Proprietary Formats 790 Dynamic Link Libraries 791

Exporting Files 791 DWG and DXF Export Options 793 Creating a Map File 795 Parasolid Export Options 798 IGES Export Options 799 STEP Export Options 801 ACIS Export Options 801 VDAFS Export Options 802 VRML Export Options 802 Stereolithography Export Options 803 Exporting Proprietary Formats 805

Saving Image Files 806

Inside SolidWorks 2003

TIFF Files 806 TIFF Export Options 807

eDrawings 810 Summary 811 Questions and Topics for Discussion 811

Chapter 23: Customizing SolidWorks . . . .813 Customize Window 814

Toolbars 814 Commands 815 Resetting Toolbars and Customized

Settings 816 Menüs 817 Keyboard 820

Transferring Hot Keys 821 Macros 822 Feature Palette 826 New SolidWorks Document Tabs 828 Gradient or Image Backgrounds 829

Using Background Images 830 Manager Backgrounds and Scheines 831

Lighting 832 Advanced Shading Properties 833 Light Sources 834

Summary 843 Questions and Topics for Discussion 844

Index 845