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An Instructional Manual for Basic Modeling and Analysis
Using Dassault Systemes SolidWorks
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1-2-3 Block
The first part we will model is a simple 1-2-3 block, so called because its
dimensions are 1 inch by 2 inches by 3 inches. This simple block is a staple part in
machining. It is often assigned to new machinist both to teach them useful skills in its
manufacture, and for its usefulness in setting up parts. We will use this block to teach the
basics of sketching and dimensioning as well as the use of the extrude feature. Later this
block will be used for some of our basic force simulations. We will also use this part to
teach the basics of opening a new part file which will be used for all subsequent modeling
examples.
After opening SolidWorks a blank screen should be displayed as below.
(Image: Fotofast, 2013)
In order to model our block we must open a new part file. This can be done one of two
ways. A new file can be opened by pressing the key combination of Ctrl+n, or by going
to the file menu in the top left corner, and selecting new. Either of these methods should
bring up one of the two screens below, for our model we will select “Part”.
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(Images: Fotofast, 2013)
After selecting part the screen should look the same as below with only menus and
nothing in the main modeling area.
(Image: Fotofast, 2013)
For the 1-2-3 block we will go to the sketch tab of the top bar, and select
“sketch”.
(Image: Fotofast, 2013)
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3 planes labeled front plane, top plane and right plane, should appear as below.
(Image: Fotofast, 2013)
Next click the front plane; your view should shift so that the origin is the only point on
the screen. Your screen should look like the image below.
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(Image: Fotofast, 2013)
Next we will click the rectangle tool .
The default rectangle type requires that we define two corners of the rectangle.
First we will click on the origin, and then move the mouse to an arbitrary point up and to
the right, while doing this a rectangle should be seen with its bottom left corner at the
origin and the top right corner at the arbitrary point.
(Image: Fotofast, 2013)
Significant of the origin. The selection of the origin as a corner of the rectangle
is not arbitrary, while it has no impact on the individual component we are
modeling; it has implications for the use of parts in assemblies as well as the
manufacture of these parts. It is important to remember that the ultimate goal of
CAD is to produce designs for components and devices that will actually be
produced.
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The most important thing to notice at this point is that the rectangle we have made
is blue in color; this indicates that its dimensions are not sufficiently defined. At this
point we must add dimensions to the sketch to define its size. In this example our model
has dimensions of 1”x2”x3”. At this point one may be wondering how this two-
dimensional sketch will produce a 3-dimensional block. The creation of 3D objects from2D sketches is one of the biggest conceptual hurdles that must be overcome in CAD
modeling. In this case we need to define a cross section, which we subsequently will
extrude to create a 3D shape. For the 1-2-3 block we can chose 3 cross sections, 1”x2”,
1”x3”, or 2”x3”, each of which will require an extrude with a dimensional value of the
missing dimension. We will chose a 1”x3” cross section, which will later require a 2”
extrude. To set these dimensions we will use the “SmartDimension” tool.
To do this first click the SmartDimension icon, . Then select one of the
vertical lines making up the perimeter of the rectangle. Next click the other vertical line.
After making these two selections a box should appear; its current value is of no
significance. In this box input 3 and hit enter. Doing this defines two lines as being 3
inches apart from each other. Adding this dimension should turn the vertical lines black
with blue points at the top ends, this indicates that the lines are in a position which is
constrained side to side, but not vertically. While still using the SmartDimension tool,repeat the previous steps but this time click the horizontal lines and input 1 for the
dimension. Your sketch should now be entirely black, this indicates that it is fully defined
and has the dimensions of the sketch in the image below.
(Image: Fotofast, 2013)
Had we not anchored the corner of the rectangle at the origin, the sketch would still be
blue because while the rectangles dimensions would be fixed and the location of the
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rectangle on the plane would be unrestricted. Since our sketch is now fully defined we
can exit the sketch, this is done by clicking the exit sketch icon at the top left of your
screen.
Having fully defined our sketch it is time to turn the 2D sketch into a 3D object.
As mentioned earlier we will use the extrude feature for this model. To create the extrudeclick on the features tab, and then click the extrude boss/base button. A dialogue box
should appear on the left. The sketch we made before will automatically be selected.
Next select “Mid Plane” for the type of extrusion. This is another choice that is made so
the model is more usable. Mid plane will extrude the part in each direction with the plane
we sketched on in the center, this makes mating in assemblies much easier, which we will
cover later. The last input we must make is for the thickness of the extrude, in our case, 2
inches. After inputting 2 in. the dimension box you model should look like the image
below with the extrude fields filled to match the image and the same yellow preview.
(Image: Fotofast, 2013)
Click either the green check mark at the top of the extrude options, or the green
checkmark in the top right of the screen to finish the extrude. We now have a finished
part, save the part under the name 1-2-3 block and open a new part file for the next
model.
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Simple Cap
Our next part is a simple cap for which we will use the revolve feature. The
revolve feature takes a sketch and traces it around an axis of revolution defined by us. To
start, create a new sketch on the front plane. Next select the line tool and create a hollow
L shape starting from the origin; your sketch should look like the image below and
consist of 6 lines.
(Image: Fotofast, 2013)
Again we see that our sketch is blue meaning we must add relations and dimensions to
define the sketch. Before we add dimensions we are going to create a few relations
between the lines. This is an important feature when defining sketches. By using more
relations and fewer dimensions, parts are easier to edit should the need for changes arise.
Click the line tool again to exit the tool; you should have an arrow with no icon next to it.
Next, while holding the control button, click the two short lines that make up the top and
end of the L, a box should appear on the left as below.
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(Image: Fotofast, 2013)
Select the “=” sign, this will make the two lines equal in length, lastly click the green
check mark. Next select the top of the L and the far left, again holding the control button
to select multiple lines. Once again we are going to click the equal sign. We are also
going to click the perpendicular symbol . When sketching, SolidWorks
will automatically create some references; these are the symbols in green you see if you
hover the mouse over a line or other feature. The automatic references made when
sketching the L mean that defining the two lines as perpendicular is not necessary, but it
is a good practice. Our last reference will be with the two lines that make the inside of the
L. For these lines we will only define them as perpendicular, this will constrain their
length as well, as it is dictated by the other lines when we define the direction of these
two. Lastly we must add dimension. Click the smart dimension tool and dimension one of
the short lines as 0.25 and the vertical line on the outside as 1.0; your sketch should be
black and look like the image below.
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(Image: Fotofast, 2013)
Notice that we fully dimensioned this sketch with only 2 dimensions due to our
references. Without the references we put in place, we would have needed to dimension
every line which would be a bit cumbersome. Now that we have a fully defined sketch
we will exit the sketch.
Select the features tab and click revolved boss/base . Similar to the extrude
feature, a set of boxes will appear on the left of the screen. The revolve tool requires that
we select an axis of revolution and a shape as well as how many degrees we want it to
revolve. The axis of revolution is the axis about which the shape will be revolved; in our
case this is the short bottom of the L. The box for the axis of revolution should
automatically be highlighted. Click the bottom of the L to define it as the axis of
revolution.
(Image: Fotofast, 2013)
The sketch we made earlier should automatically be selected as the shape to
revolve. As a default the revolution should be 360 degrees, if for some reason it is not
input 360 in the revolution field. All fields should match the image below as should the
yellow preview.
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(Image: Fotofast, 2013)
Click the green check mark to finish the revolve. We now have a cap, but the sharp
corner on the inside and outside are not ideal. To fix these we are going to use the Fillet
feature.
Click the Fillet button . To add a fillet we must select the edge we wish to
Fillet, to do this simply hover over the edge until only the ring around the outside is
highlighted in orange in the first image below.
(Images: Fotofast, 2013)
We also want to Fillet the inside of our shape, do this we must rotate the shape.
To manipulate the shape simply press down on your mouse’s scroll wheel and move the
mouse, the shape will spin in 3D space. Once you have a view of the inside, repeat the
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previous step of hovering your mouse and clicking once only the orange ring is
highlighted as in the second image above. Fillets can be applied to a number of edges at
once given that they are to have the same radius Fillet, in our case we will make both a
radius of 0.10. Input this dimension in the box named fillet radius, you should have two
yellow previews of the fillets. Click the green check mark to apply the fillets. Our part isnow finished, save it as “Simple Cap”.
Creation of Basic Assembly Components
Now that we understand the two most frequently used modeling features, we are
going to do a very simple assembly. An assembly is as the name suggests, an assembly of
parts related to each other through things called mates. Mates are nothing more than
references between two different parts. For out simple assembly we are going to modify
our 1-2-3-block and create a simplified bolt.
Modified 1-2-3 block. First we will modify our 1-2-3-block, by adding 8 holes.
To do this, start by opening the model file we created earlier. Next click the sketch tab
and start a new sketch. Rather than selecting one of the 3 planes, we are going to select
one of the 2”x3” faces as highlighted below.
(Image: Fotofast, 2013)
Select the circle tool from the sketch bar, and create a circle that is contained on the
face and near the corner, its exact location is unimportant, after drawing the circle it
should be blue and your model should look roughly like the image below. You may wish
to spin the part for easier sketching.
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(Image: Fotofast, 2013)
Next select the line tool and draw one line from the vertical edge of the face to the center
of the circle, and another from the center of the circle to the bottom edge of the face as
illustrated below.
(Image: Fotofast, 2013)
We are going to use these lines to define the position of the circle, but we do not want
SolidWorks to think that the lines are part of the shape that makes up the hole. We can
tell SolidWorks that these lines are “construction lines.” To do this simply deselect the
line tool and select both lines while holding control. A box with relation options should
pop up on the left as before, in this case we want the two lines to be equal in length, we
also want to check the box next to “for construction” and like before we click the =
symbol. To finalize the position of the circle simply dimension one of the lines, we will
make them ! of an inch, 0.25in. The center of the circle should now be black but the
outside will still be blue. This is because we have defined its location but not its size. Add
a dimension of .125 for the diameter by clicking the outside of the circle while using
smart dimension. Your fully defined circle sketch should look like the image below.
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(Image: Fotofast, 2013)
Now that our sketch it fully defined, exit the sketch and go to the features tab. Select the
extrude cut feature. You may have a blank dialogue box, if this is the case simply click
the circle sketch which should be grey, and set the depth to “through all” as shown below.
Lastly click the green check mark.
(Image: Fotofast, 2013)
Now we have one hole, but we want 8 holes. While we could have sketched 8 holes thereare much more efficient ways to make more holes. We are going to use a linear pattern
and then a mirror to get our 8 holes. This is not the absolute fastest way to do this, but it
allows us to explore two very useful features, and is still much faster than creating 8
individual holes.
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First we will use the linear pattern tool . This is found in the features toolbar
at the top of the screen. The extrude cut we just made should auto select as the feature to
pattern, we must still specify a direction, the spacing, and the number of instances. The
direction is established by clicking the 3 in edge highlighted below.
(Image: Fotofast, 2013)
We need 8 total holes but for this step we want 4, thus for instances we input 4. To define
the spacing we will make use of a handy feature in SolidWorks. Any dimensional box
can be filled with an equation. In this case we need 3 equal gaps to separate the 4 holes,
subtracting the space from the edge from the total length. We understand that the holes
must be 2.5 to 3 in apart, so we simply input that in the spacing box and click the green
checkmark. Your screen should look as below with all fields matching those of the image
before clicking the check mark.
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(Image: Fotofast, 2013)
To turn the 4 holes we have made into 8 we are going to use the mirror tool. To start this
step just click the mirror tool in the feature bar . The mirror tool requires a plane or
face to mirror about and the feature we wish to mirror. You may recall that we used a
Mid Plane extrusion earlier, that choice makes this mirror much easier. Since we
extruded the 2 in. dimension equally from our sketch plane, which was the front plane,
we must now simply select the front plane. To do this click the “+” pointed to below, this
will show the “feature tree”.
(Image: Fotofast, 2013)
Click the field named Mirror face/plane and select the front plane in the tree. Next, click
the field named Features to Mirror and then the linear pattern from in the tree. Your
screen should match the image below, if so click the green check mark and you will have
8 holes in your 1-2-3-block. Save your new model as 1-2-3-block with holes.
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FEA Force Simulation of the 1-2-3 Block
As briefly explained before FEA is a powerful analysis tool built into
SolidWorks. SolidWorks is capable of preforming a number of different design studies
but for this manual we will focus on two simple types of study. Using the 1-2-3-block
and the simple cap we made before, we will do two different static studies using a force
and a pressure. First we will do the force study on the 1-2-3-block.
To start the force study we need to open the model of the 1-2-3-block we made earlier.
Once the model is open go to the “office products” tab and select SolidWorks simulation.
(Image: Fotofast, 2013)
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This will create a new tab at the top called simulation. Click on this new tab. You should
see an icon labeled study with a drop down arrow under it. Click the drop down arrow
and select new study.
(Image: Fotofast, 2013)
A number of study types should come up on the left. We want to select “static” as shown
below and then the green check mark.
(Image: Fotofast, 2013)
To do a study we must define a few things for SolidWorks to use in its analysis.
We must define the material out of which the part is made as well as the load we are
placing on it and in what way it is fixed. This last one is a bit tricky but very important. It
is easiest to explain in the context of physical testing, after all, FEA is a simulation
method and thus correlates to real testing. If we were to put a force on the side of out
block, it would simply slide unless we somehow held it in place. The fixtures in a
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simulation are simply our way of telling SolidWorks how we would like to hold the part.
In this case we are going to use what is called a fixed geometry, which means
SolidWorks will keep the face we select completely fixed while applying force as we
define. To set the fixture right click on the fixtures icon as pointed to below. This will
give a dropdown menu; select fixed geometry from this menu.
(Image: Fotofast, 2013)
The last step is to pick what face we wish to fix, we will use one of the two 1”x3” faces,
it is arbitrary which one we use. Your screen should look like the one below, with green
arrows on the face we selected.
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(Image: Fotofast, 2013)
Next we will define the material. To do this, right click the field pointed to below,
this will give a drop down menu much like for fixtures. Select Plain Carbon Steel from
this menu, SolidWorks has a large library containing the relevant properties for most
commonly used material however we will not address more advanced material
assignments in this manual.
(Image: Fotofast, 2013)
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Now we must define the force we wish to apply to the block. To do this, simply
click the external load dropdown and select force as shown below.
(Image: Fotofast, 2013)
We are going to apply a 1000lb force to the 1”x3” face across from the face we
fixed earlier, this simulation would be analogous to applying 1000lbs. of crushing force
in a physical test. Units will need to be changed to imperial; this is done in the units
dropdown menu. The dialogue box on the left should match that of the image below.
(Image: Fotofast, 2013)
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Creating a mesh is the last thing we must do before we can run the test. The mesh
is the basis for Finite Element Analysis. The method works by breaking the model into a
large number of small elements and evaluating each, the mesh defines these small
elements. We create the mesh by right clicking the “mesh” field and selecting “createmesh”.
(Image: Fotofast, 2013)
A slider will be displayed with bounds of course and fine, a finer mesh will
produce more accurate results but the simulation will take longer to run. We will leave
the slider at the default position since our study is being performed only for our
education.
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(Image: Fotofast, 2013)
Finally we can run the simulation, to do this simply click the “run” button at the
top of the screen.
Your model should look the same as the image below. Notice that the results
folder has 3 fields under it, each of these represents a different engineering measurement
which provides information about the models performance in the simulation. The
meaning and manipulation of these outputs is well beyond the scope of this manual and
will not be covered.
(Image: Fotofast, 2013)
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FEA Pressure Simulation of Simple Cap
Now we will run FEA on the simple cap modeled earlier. This simulation will
have many similar features to the last one but we will apply a different load type. Instead
of applying a force like last time, we are going to apply a pressure. Just like last time we
must apply a material, a load, a fixture condition and a mesh. Refer to the last section if
you need guidance on the location of each option. Start by repeating the material
assignment from the 1-2-3-block simulation, again choosing Plain Carbon Steel for the
material. We again are going to use fixed geometry for our fixture. This time we will
select the rim around the open end of the cap as highlighted in the image below.
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(Image: Fotofast, 2013)
Next we need to apply our load, click the drop down and select “pressure”.
(Image: Fotofast, 2013)
Select the 3 internal faces highlighted below and specify a pressure of 1000 psi,
units again will have to be changed to imperial. You should have the same faces
highlighted and your input fields should match the image.
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(Image: Fotofast, 2013)
Like the last simulation we will use a medium mesh. After meshing simply click
“run” and wait for the results to come up, they should look like the image below.
(Image: Fotofast, 2013)
Conclusion
In this brief manual we have covered some of the basic features of SolidWorks.
We modeled a part using the extrude tool, and two parts with the revolve tool. In the
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course of modeling these parts we learned how to sketch using some of the basic sketch
tools. We also learned how to dimension and relate sketch elements in order to constrain
the size and location of our sketch. We made use of some more advanced tools, linear
pattern and mirror, while modeling our modified block. Assemblies were also covered via
out example assembly using the simplified bolts and modified 1-2-3 blocks. Lastly we performed two static simulations of the first two parts we made. Throughout the manual a
number of seemingly arbitrary choices were made, these were made in order to establish
good modeling habits. The last point that should be made is to remember at all times that
modeling is a tool for the creation of actual parts. Hopefully this manual has provided
some insight into the use of SolidWorks for basic tasks. The skills taught in this manual
should allow a user to do much of the simple modeling they would like.