Engineering Design and Graphics with SolidWorks® 2016 James D. Bethune 330 Hudson Street, NY NY 10013 Senior Editor: Laura Norman Composition: iEnergizer Aptara®, Inc. Senior Production Editor: Tracey Croom Printer/Binder: RR Donnelley Cover Designer: Chuti Prasertsith Cover Printer: RR Donnelley Full-Service Project Management: Text Font: Bookman Sudip Sinha/ iEnergizer Aptara®, Inc. Credits and acknowledgments borrowed from other sources and reproduced, with permission, in this textbook appear on the appropriate page within the text. Unless otherwise stated, all artwork has been provided by the author. SolidWorks® is a registered trademark of Dassault Systèmes SolidWorks Corp. All rights reserved. Disclaimer: The publication is designed to provide tutorial information about SolidWorks® and/or other Dassault Systèmes SolidWorks Corp computer programs. Every effort has been made to make this publication complete and as accurate as possible. The reader is expressly cautioned to use any and all precautions necessary, and to take appropriate steps to avoid hazards, when engaging in the activities described herein. Neither the author nor the publisher makes any representations or warranties of any kind, with respect to the materials set forth in this publication, express or implied, including with- out limitation any warranties of fitness for a particular purpose or merchantability. Nor shall the author or the publisher be liable for any special, consequential, or exemplary damages resulting, in whole or in part, directly or indirectly, from the reader’s use of, or reliance upon, this material or subsequent revisions of this material. Copyright © 2017 by Pearson Education, Inc., publishing as Peachpit Press. All rights reserved. Printed in the United States of America. This publication is protected by Copyright and permission should be obtained from the publisher prior to any prohibited reproduction, storage in a retrieval system, or transmission in any form or by any means, electronic, mechanical, photocopying, recording, or likewise. For information regarding permissions, request forms, and the appropriate contacts within the Pearson Education Global Rights & Permissions Department, please visit www.pearsoned.com/permissions/. Many of the designations by manufacturers and seller to distinguish their products are claimed as trademarks. Where those designations appear in this book, and the publisher was aware of a trademark claim, the designations have been printed in initial caps or all caps. Library of Congress Cataloging-in-Publication Data Names: Bethune, James D., 1941- author. Title: Engineering design and graphics with SolidWorks 2016 / James D. Bethune. Description: First edition. | Boston : Pearson, [2017] | Includes index. Identifiers: LCCN 2016017519| ISBN 9780134507699 | ISBN 013450769X Subjects: LCSH: Engineering graphics—Data processing. | Engineering models—Data processing. | SolidWorks. | Computer-aided design. Classification: LCC T386.S55 B48 2017 | DDC 620/.0042028553—dc23 LC record available at https://lccn.loc.gov/2016017519 10 9 8 7 6 5 4 3 2 1 ISBN 10: 0-13-450769-X ISBN 13: 978-0-13-450769-9 Preface This book shows and explains how to use SolidWorks® 2016 to create engi- neering drawings and designs. Emphasis is placed on creating engineering drawings including dimensions and tolerances and using standard parts and tools. Each chapter contains step-by-step sample problems that show how to apply the concepts presented in the chapter. The book contains hundreds of projects of various degrees of difficulty specifically designed to reinforce the chapter’s content. The idea is that stu- dents learn best by doing. In response to reviewers’ requests, some more difficult projects have been included. Chapter 1 and 2 show how to set up a part document and how to use the SolidWorks S ketch tools. Sketch tools are used to create 2D part docu- ments that can then be extruded into 3D solid models. The chapters con- tain an explanation of how SolidWorks’ colors are used and of how shapes can be fully defined. The usage of mouse gestures, S key, and origins is also included. The two chapters include 43 projects using both inches and mil- limeters for students to use for practice in applying the various S ketch tools. Chapter 3 shows how to use the F eatures tools. F eatures tools are used to create and modify 3D solid models. In addition, reference planes are covered, and examples of how to edit existing models are given. Chapter 4 explains how to create and interpret orthographic views. Views are created using third-angle projection in compliance with ANSI standards and conventions. The differences between first-angle and third- angle projections are demonstrated. Five exercise problems are included to help students learn to work with the two different standards. Also included are section views, auxiliary views, and broken views. Several of the projects require that a 3D solid model be drawn from a given set of orthographic views to help students develop visualization skills. Chapter 5 explains how to create assembly drawings using the Assembly tools (M ate , exploded V iew ) and how to document assemblies using the D rawing Documents tools. Topics include assembled 3D solid models, exploded isometric drawings, and bills of materials (BOMs). Assembly numbers and part numbers are discussed. Both the A nimate Collapse/Explode and Motion Study tools are demonstrated. In addition, the title, release, and revision blocks are discussed. An explanation of how to use I nterference Detection is given. Chapter 6 shows how to create and design with threads and fasteners. Both ANSI inch and ANSI metric threads are covered. The D esign Library is presented, and examples are used to show how to select and size screws and other fasteners for assembled parts. Chapter 7 covers dimensioning and is in compliance with ANSI stand- ards and conventions. There are extensive visual examples of dimensioned shapes and features that serve as references for various dimensioning applications. Chapter 8 covers tolerances. Both linear and geometric tolerances are included. This is often a difficult area to understand, so there are many examples of how to apply and how to interpret the various types of toler- ances. Standard tolerances as presented in the title block are demon- strated. Many of the figures have been updated. iii Chapter 9 explains bearings and fit tolerances. The D esign Library is used to create bearing drawings, and examples show how to select the cor- rect interference tolerance between bearings and housing, and clearance tolerances between bearings and shafts. Chapter 10 presents gears. Gear terminology, gear formulas, gear ratios, and gear creation using the SolidWorks T oolbox are covered. The chapter relies heavily on the D esign Library . Keys, keyways, and set screws are discussed. Both English and metric units are covered. There is an extensive sample problem that shows how to draw a support plate for mating gears and how to create an assembly drawing for gear trains. The projects at the end of the chapter include two large gear assembly exercises. Chapter 11 covers belts and pulleys. Belts, pulleys, sprockets, and chains are drawn. All examples are based on information from the D esign Library . There are several sample problems. Chapter 12 covers cams. Displacement diagrams are defined. The chapter shows how to add hubs and keyways to cams and then insert the cams into assembly drawings. The chapter also shows how to add springs to followers. Chapter 13 is an online chapter. It includes two large project-type problems. They can be used as team projects to help students learn to work together to share and compile files, or they can be used as end-of-the- semester individual projects. This chapter can be found on the web as a supplement to the Instructor’s Manual at h ttp://pearsonhighered.com/irc. Instructors may distribute to students. The Appendix includes fit tables for use with projects in the text. Clearance, locational, and interference fits are included for both inch and millimeter values. Download Instructor Resources from the Instructor Resource Center To access supplementary materials online, instructors need to request an instructor access code. Go to w ww.pearsonhighered.com/irc to register for an instructor access code. Within 48 hours of registering, you will receive a confirming e-mail including an instructor access code. Once you have received your code, locate your text in the online catalog and click on the Instructor Resources button on the left side of the catalog product page. Select a supplement, and a login page will appear. Once you have logged in, you can access instructor material for all Pearson textbooks. If you have any difficulties accessing the site or downloading a supplement, please contact Customer Service at h ttp://247pearsoned.custhelp.com/. Acknowledgments I would like to acknowledge the reviewers of this text: Peggy Condon-Vance, Penn State Berks; Lisa Richter, Macomb Community College; Julie Korfhage, Clackamas Community College; Max P. Gassman, Iowa State University; Paul E. Lienard, Northeastern University; and Hossein Hemati, Mira Costa College. Thanks to editor Lisa McClain. Thanks to my family—David, Maria, Randy, Sandra, Hannah, Will, Madison, Jack, Luke, Sam, and Ben. A special thanks to Cheryl. James D. Bethune iv Preface Contents CHAPTER 1 Getting Started 1 2- 3 Origins 50 To Show the Origin 50 Chapter Objectives 1 2- 4 Circle 5 1 1- 1 Introduction 1 To Sketch a Circle 51 1- 2 Starting a New Drawing 2 To Sketch a Perimeter Circle Using Three Points 53 To Start a New Drawing 2 To Sketch a Perimeter Circle Tangent to Three Lines 54 To Select a Drawing Plane 3 2- 5 Rectangle 5 5 1- 3 SolidWorks Colors 7 To Sketch a Center Rectangle 55 1- 4 Creating a Fully Defined Circle 7 To Sketch a 3 Point Corner Rectangle 56 To Change an Existing Dimension 9 To Sketch a 3 Point Center Rectangle 57 Fully Defined Entities 10 To Sketch a Parallelogram 58 1- 5 Units 1 2 2- 6 Slots 59 To Change Units 13 To Draw a Straight Slot 60 To Draw a Centerpoint Straight Slot 61 1- 6 Rectangle 13 To Draw a 3 Point Arc Slot 62 To Sketch a Rectangle 13 To Draw a Centerpoint Arc Slot 62 To Exit the Sketch Mode 15 To Reenter the Sketch Mode 15 2- 7 Perimeter Circle 63 To Draw a Perimeter Circle 64 1- 7 Moving Around the Drawing Screen 16 To Zoom the Line 16 2- 8 A rcs 64 To Move the Line 16 To Draw a Centerpoint Arc 65 To Reorientate the Line 17 To Draw a Tangent Arc 65 To Draw a 3 Point Arc 67 1- 8 Orientation 1 7 To Return to the Top View Orientation – View Selector 17 2- 9 Polygons 67 To Return to the Top View Orientation – Top View 18 To Draw a Hexagon 67 To Return to the Top View Orientation – Orientation Triad 18 2- 10 Spline 6 9 1- 9 Sample Problem SP1-1 18 To Draw a Spline 70 To Fix a Line in Place 21 To Edit a Spline 70 Sketch Relations 22 2- 11 Ellipse 71 1- 10 Creating 3D Models 23 To Draw an Ellipse 71 To Create a 3D Model 23 To Draw a Partial Ellipse 72 To Draw a Parabola 73 1- 11 Saving a Document 24 Conic Section 74 To Save a Document 24 To Draw a Conic 75 1- 12 Lines and Angles – Sample Problem SP1-2 25 2- 12 Fillets and Chamfers 77 1- 13 Holes 29 To Draw a Fillet 77 To Create a Hole 29 To Draw a Chamfer 78 Chapter Projects 34 2 - 13 Sketch Text 80 To Add Text 80 CHAPTER 2 Sketch Entities and Tools 41 To Change the Font and Size of Text 80 Chapter Objectives 41 2- 14 Point 83 2- 1 Introduction 41 2- 15 Trim Entities 83 2- 2 Mouse Gestures and the S Key 42 To Use Trim Entities 83 Mouse Gestures 42 2- 16 Extend Entities 84 S Key 46 To Extend Entities in a Sketch 85 v 2- 17 Offset Entities 86 3- 9 Chamfer 147 To Draw an Offset Line 87 To Define a Chamfer Using an Angle and a Distance 147 To Define a Chamfer Using Two Distances 148 2- 18 Mirror Entities 88 To Define a Vertex Chamfer 149 2- 19 Linear Sketch Pattern 90 3- 10 Revolved Boss/Base 1 50 To Create a Linear Sketch Pattern 93 3- 11 Revolved Cut 154 2- 20 Circular Sketch Pattern 93 To Create a Circular Sketch Pattern 94 3- 12 Reference Planes 155 To Create a Reference Plane 155 2- 21 Move Entities 95 To Move an Entity 95 3- 13 Lofted Boss/Base 159 2- 22 Copy Entities 96 3 - 14 Shell 1 62 To Copy an Entity 98 3- 15 Swept Boss/Base 164 2- 23 Rotate Entities 98 3- 16 Draft 166 To Rotate an Entity 99 3- 17 Linear Sketch Pattern 168 2- 24 Scale Entities 99 3- 18 Circular Sketch Pattern 170 To Create a Scale Entity 99 3- 19 Mirror 171 2- 25 Stretch Entities 100 To Stretch an Entity 101 3- 20 Helix Curves and Springs 173 To Draw a Helix 173 2- 26 Split Entities 102 To Draw a Spring from the Given Helix 174 To Use the Split Entities Tool 102 3- 21 Compression Springs 1 75 2- 27 Jog Lines 103 To Create Ground Ends 176 To Use the Jog Line Tool 105 3- 22 Torsional Springs 178 2- 28 Centerline 105 To Draw a Torsional Spring 178 To Use the Centerline Tool 106 3- 23 Extension Springs 181 2- 29 Sample Problem SP2-1 106 To Draw an Extension Spring 182 2- 30 Sample Problem SP2-2 108 3- 24 Wrap 1 85 2- 31 Sample Problem SP2-3 110 To Create Debossed Text 185 Chapter Projects 113 3- 25 Editing Features 189 To Edit the Hole 189 CHAPTER 3 Features 1 23 To Edit the Cutout 190 Chapter Objectives 123 3- 26 Sample Problem SP3-2 1 91 3- 1 Introduction 1 23 To Draw a Cylinder 192 3- 2 Extruded Boss/Base 1 23 To Create a Slanted Surface on the Cylinder 194 To Use the Extruded Boss/Base Tool 124 To Add the Vertical Slot 195 To Create Inward Draft Sides 126 To Add the Ø8 Hole 197 To Create an Outward Draft 127 3- 27 S ample Problem SP3-3 199 3- 3 Sample Problem SP3-1 128 3- 28 Curve Driven Patterns 202 3- 4 Extruded Cut 131 To Use the Curve Driven Pattern Tool – Example 1 202 To Use the Curve Driven Pattern Tool – Example 2 205 3- 5 Hole Wizard 132 Chapter Projects 208 3- 6 A Second Method of Creating a Hole 134 3- 7 Blind Holes 1 36 CHAPTER 4 Orthographic Views 2 25 To Create a Blind Hole – Inches 136 Chapter Objectives 225 To Create a Blind Hole – Metric 138 4- 1 Introduction 225 3- 8 Fillet 1 40 4- 2 Third- and First-Angle Projections 227 To Create a Fillet with a Variable Radius 141 To Create a Fillet Using the Face Fillet Option 143 4- 3 Fundamentals of Orthographic Views 228 To Create a Fillet Using the Full Round Fillet Option 144 Normal Surfaces 229 vi Contents Hidden Lines 230 Release Blocks 332 Precedence of Lines 231 Tolerance Block 333 Slanted Surfaces 232 Application Block 333 Compound Lines 233 5- 13 Animate Collapse 333 Oblique Surfaces 234 5- 14 Sample Problem 5-1: Creating the Rotator Rounded Surfaces 234 Assembly 335 4- 4 Drawing Orthographic Views Using SolidWorks 236 5- 15 Using the SolidWorks Motion Study Tool 338 To Move Orthographic Views 245 Motion 340 To Create Other Views 245 5- 16 Editing a Part within an Assembly 341 4- 5 Section Views 246 5- 17 Interference Detection/Clearance Verification 343 4- 6 Drawing a Section View Using SolidWorks 248 Interference Detection 343 To Change the Style of a Section View 253 To Detect an Interference 344 4-7 Aligned Section Views 254 To Verify the Clearance 347 4- 8 Broken Views 255 To Remove the Interference 347 To Create a Broken View 256 To Verify That a Clearance Exists 349 4- 9 Detail Views 257 Chapter Projects 351 To Draw a Detail View 257 CHAPTER 6 T hreads and Fasteners 3 75 4- 10 Auxiliary Views 259 To Draw an Auxiliary View 259 Chapter Objectives 375 Chapter Projects 263 6- 1 Introduction 375 6- 2 Thread Terminology 375 CHAPTER 5 Assemblies 2 99 Pitch 376 Chapter Objectives 299 6- 3 Thread Callouts—ANSI Metric Units 376 5- 1 Introduction 2 99 6- 4 Thread Callouts—ANSI Unified Screw Threads 377 5- 2 Starting an Assembly Drawing 299 6- 5 Thread Representations 378 5- 3 Move Component 302 6- 6 Internal Threads—Inches 378 5- 4 Rotate Component 303 6- 7 Threaded Blind Holes—Inches 381 5- 5 Mouse Gestures for Assembly Drawings 303 6- 8 Internal Threads—Metric 382 5- 6 Mate 305 6- 9 Accessing the Design Library 3 84 To Create the First Assembly 305 6- 10 Thread Pitch 3 85 To Create a Second Assembly 307 To Create a Third Assembly 310 6- 11 Determining an External Thread Length—Inches 3 85 5- 7 Bottom-up Assemblies 310 6- 12 Smart Fasteners 3 90 5- 8 Creating an Exploded Isometric Assembly Drawing 3 15 6- 13 Determining an Internal Thread Length 393 5- 9 Creating an Exploded Isometric Drawing 6- 14 Set Screws 397 Using the Drawing Format 3 18 6- 15 Drawing a Threaded Hole in the 5- 10 Assembly Numbers 320 Side of a Cylinder 398 5- 11 Bill of Materials (BOM or Parts List) 322 6- 16 Adding Set Screws to the Collar 402 To Edit the BOM 324 Chapter Projects 404 To Add Columns to the BOM 326 To Change the Width of a Column 327 CHAPTER 7 Dimensioning 439 To Change the Width of Rows and Columns 328 Chapter Objectives 439 To Change the BOM’s Font 328 7- 1 Introduction 439 5- 12 Title Blocks 329 Revision Letters 330 7- 2 Terminology and Conventions—ANSI 440 To Edit a Title Block 330 Some Common Terms 440 Contents vii Some Dimensioning Conventions 440 8- 4 Understanding Plus and Minus Tolerances 5 11 Some Common Errors to Avoid 441 8- 5 Creating Plus and Minus Tolerances 512 7- 3 Adding Dimensions to a Drawing 442 To Add Plus and Minus Symmetric Tolerances Using Controlling Dimensions 445 the Dimension Text Box 514 Dimensioning Short Distances 446 8- 6 Creating Limit Tolerances 515 Autodimension Tool 448 8- 7 Creating Angular Tolerances 516 To Create Baseline Dimensions 451 8- 8 Standard Tolerances 518 7- 4 Drawing Scale 451 7- 5 Units 452 8- 9 Double Dimensioning 518 Aligned Dimensions 453 8- 10 Chain Dimensions and Baseline Dimensions 520 Hole Dimensions 453 Baseline Dimensions Created Using SolidWorks 522 7- 6 Dimensioning Holes and Fillets 457 8- 11 Tolerance Studies 522 Dimensioning a Blind Hole 457 Calculating the Maximum Length of A 523 Dimensioning Hole Patterns 459 Calculating the Minimum Length of A 523 7- 7 Dimensioning Counterbored and 8- 12 Rectangular Dimensions 523 Countersunk Holes 460 8- 13 Hole Locations 523 Counterbored Hole with Threads 464 To Dimension Countersink Holes 470 8- 14 Choosing a Shaft for a Toleranced Hole 525 To Dimension the Block 471 For Linear Dimensions and Tolerances 526 7- 8 Angular Dimensions 471 8- 15 Sample Problem SP8-1 526 To Dimension an Evenly Spaced Hole Pattern 476 8- 16 Sample Problem SP8-2 527 7- 9 Ordinate Dimensions 476 8- 17 Nominal Sizes 5 28 To Create Ordinate Dimensions 477 8- 18 Standard Fits (Metric Values) 528 7- 10 Baseline Dimensions 479 Clearance Fits 529 To Create Baseline Dimensions 479 Transitional Fits 529 Hole Tables 481 Interference Fits 529 7- 11 Locating Dimensions 4 83 8- 19 Standard Fits (Inch Values) 529 7- 12 Fillets and Rounds 484 To Add a Fit Callout to a Drawing 530 Reading Fit Tables 530 7- 13 Rounded Shapes—Internal 4 84 8- 20 Preferred and Standard Sizes 531 7- 14 R ounded Shapes—External 485 8- 21 Surface Finishes 533 7- 15 Irregular Surfaces 486 8- 22 Surface Control Symbols 534 7- 16 Polar Dimensions 4 87 8- 23 Applying Surface Control Symbols 5 35 7- 17 Chamfers 4 88 To Add a Lay Symbol to a Drawing 536 7- 18 Symbols and Abbreviations 4 88 8- 24 Design Problems 538 7- 19 Symmetrical and Centerline Symbols 490 Floating Condition 539 7- 20 Dimensioning to a Point 490 Fixed Condition 540 7- 21 Dimensioning Section Views 491 Designing a Hole Given a Fastener Size 542 7- 22 Dimensioning Orthographic Views 491 8- 25 Geometric Tolerances 543 Dimensions Using Centerlines 492 8- 26 Tolerances of Form 543 Chapter Projects 493 8- 27 Flatness 543 CHAPTER 8 Tolerancing 5 09 8- 28 Straightness 544 8- 29 Straightness (RFS and MMC) 545 Chapter Objectives 509 8- 1 Introduction 5 09 8- 30 Circularity 548 8- 2 Direct Tolerance Methods 509 8- 31 C ylindricity 549 8- 3 Tolerance Expressions 511 8- 32 Geometric Tolerances Using SolidWorks 550 viii Contents 8- 33 Datums 5 50 Interference for a Manufactured Bearing 619 To Add a Datum Indicator 552 To Apply an Interference Fit Tolerance Using To Define a Perpendicular Tolerance 553 SolidWorks 619 To Define a Straightness Value for Datum Surface A 554 Using SolidWorks to Apply Standard Fit Tolerances to an Assembly Drawing 620 8- 34 Tolerances of Orientation 5 54 9- 13 Fit Tolerances—Millimeters 6 21 8- 35 Perpendicularity 555 Chapter Projects 622 8- 36 Parallelism 557 8- 37 Angularity 557 CHAPTER 10 Gears 6 39 8- 38 Profiles 558 Chapter Objectives 639 8- 39 Runouts 560 10- 1 Introduction 639 8- 40 Positional Tolerances 561 10- 2 Gear Terminology 640 8- 41 Creating Positional Tolerances 10- 3 Gear Formulas 641 Using SolidWorks 563 10- 4 Creating Gears Using Solid Works 642 To Create the Positional Tolerance 563 To Create a Gear Assembly 643 8- 42 Virtual Condition 5 66 To Animate the Gears 647 Calculating the Virtual Condition for a Shaft 567 10- 5 G ear Ratios 648 Calculating the Virtual Condition for a Hole 567 10- 6 G ears and Bearings 649 8- 43 Floating Fasteners 567 To Add Bearings 649 8- 44 Sample Problem SP8-3 568 10- 7 Power Transmission—Shaft to Gear 651 8- 45 Sample Problem SP8-4 569 10-8 Set Screws and Gear Hubs 651 8- 46 Fixed Fasteners 569 To Add a Threaded Hole to the Gear’s Hub 653 8- 47 Sample Problem SP8-5 570 10- 9 Keys, Keyseats, and Gears 656 8- 48 Design Problems 5 71 To Define and Create Keyseats in Gears 656 To Return to the Assembly Drawing 659 Chapter Projects 575 To Define and Create a Parallel Key 660 To Create a Keyseat in the Shaft 661 CHAPTER 9 Bearings and Fit To Create the Keyseat 663 Tolerances 6 05 To Create the Arc-Shaped End of a Keyseat 663 Chapter Objectives 605 10- 10 Sample Problem 10-1—Support Plates 665 9- 1 Introduction 6 05 To Determine the Pitch Diameter 666 9- 2 Sleeve Bearings 606 To Edit the Bill of Materials 667 To Draw a Sleeve Bearing 606 10- 11 Rack and Pinion Gears 671 To Use a Sleeve Bearing in an Assembly Drawing 607 To Animate the Rack and Pinion 673 9- 3 Bearings from the Toolbox 609 10- 12 Metric Gears 673 9- 4 Ball Bearings 612 To Create a Metric Gear 674 9- 5 Fits and Tolerances for Bearings 614 Chapter Projects 676 9- 6 Fits—Inches 614 CHAPTER 11 Belts and Pulleys 6 99 9- 7 Clearance Fits 614 Chapter Objectives 699 9- 8 Hole Basis 615 11- 1 Introduction 699 9- 9 Shaft Basis 615 11- 2 Belt and Pulley Standard Sizes 699 9- 10 Sample Problem SP9-1 615 To Draw a Belt and Pulley Assembly 700 9- 11 Interference Fits 616 11- 3 P ulleys and Keys 705 9- 12 Manufactured Bearings 617 To Add a Keyway to a Pulley 706 Clearance for a Manufactured Bearing 618 11- 4 M ultiple Pulleys 708 To Apply a Clearance Fit Tolerance Using SolidWorks 618 To Create a Multi-Pulley Assembly 708 Contents ix