Engineering Design and Technology Series ® SAE Design and Analysis ® Project with SolidWorks Software Put Picture Here Dassault Systèmes SolidWorks Corporation, Outside the U.S.: +1-781-810-5011 175 Wyman Street Fax: +1-781-810-3951 Waltham, Massachusetts 02451 USA Email: [email protected] Phone: +1-800-693-9000 Web: http://www.solidworks.com/education © 1995-2013, Dassault Systèmes SolidWorks Corporation, a Copyright Notices for SolidWorks Standard, Premium, Dassault Systèmes S.A. company, 175 Wyman Street, Waltham, Professional, and Education Products Mass. 02451 USA. All Rights Reserved. Portions of this software © 1986-2013 Siemens Product Lifecycle Management Software Inc. All rights reserved. The information and the software discussed in this document are subject to change without notice and are not commitments by This work contains the following software owned by Siemens Dassault Systèmes SolidWorks Corporation (DS SolidWorks). Industry Software Limited: D-Cubed™ 2D DCM © 2013. Siemens Industry Software No material may be reproduced or transmitted in any form or by Limited. All Rights Reserved. any means, electronically or manually, for any purpose without D-Cubed™ 3D DCM © 2013. Siemens Industry Software the express written permission of DS SolidWorks. Limited. All Rights Reserved. The software discussed in this document is furnished under a D-Cubed™ PGM © 2013. Siemens Industry Software license and may be used or copied only in accordance with the Limited. All Rights Reserved. terms of the license. All warranties given by DS SolidWorks as to the software and documentation are set forth in the license D-Cubed™ CDM © 2013. Siemens Industry Software agreement, and nothing stated in, or implied by, this document or Limited. All Rights Reserved. its contents shall be considered or deemed a modification or D-Cubed™ AEM © 2013. Siemens Industry Software amendment of any terms, including warranties, in the license Limited. All Rights Reserved. agreement. Portions of this software © 1998-2013 Geometric Ltd. Patent Notices Portions of this software incorporate PhysX™ by NVIDIA 2006- SolidWorks® 3D mechanical CAD software is protected by U.S. 2010. Patents 5,815,154; 6,219,049; 6,219,055; 6,611,725; 6,844,877; Portions of this software © 2001-2013 Luxology, LLC. All rights 6,898,560; 6,906,712; 7,079,990; 7,477,262; 7,558,705; reserved, patents pending. 7,571,079; 7,590,497; 7,643,027; 7,672,822; 7,688,318; Portions of this software © 2007-2013 DriveWorks Ltd. 7,694,238; 7,853,940, 8,305,376, and foreign patents, (e.g., EP 1,116,190 B1 and JP 3,517,643). Copyright 1984-2010 Adobe Systems Inc. and its licensors. All rights reserved. Protected by U.S. Patents 5,929,866; 5,943,063; eDrawings® software is protected by U.S. Patent 7,184,044; U.S. 6,289,364; 6,563,502; 6,639,593; 6,754,382; Patents Pending. Patent 7,502,027; and Canadian Patent 2,318,706. Adobe, the Adobe logo, Acrobat, the Adobe PDF logo, Distiller and Reader are registered trademarks or trademarks of Adobe U.S. and foreign patents pending. Systems Inc. in the U.S. and other countries. Trademarks and Product Names for SolidWorks Products For more DS SolidWorks copyright information, see Help > and Services About SolidWorks. SolidWorks, 3D ContentCentral, 3D PartStream.NET, eDrawings, and the eDrawings logo are registered trademarks and Copyright Notices for SolidWorks Simulation Products FeatureManager is a jointly owned registered trademark of DS Portions of this software © 2008 Solversoft Corporation. SolidWorks. PCGLSS © 1992-2013 Computational Applications and System Integration, Inc. All rights reserved. CircuitWorks, FloXpress, PhotoView 360, and TolAnalyst, are trademarks of DS SolidWorks. Copyright Notices for SolidWorks Enterprise PDM Product FeatureWorks is a registered trademark of Geometric Ltd. Outside In® Viewer Technology, © 1992-2012 Oracle © 2011, Microsoft Corporation. All rights reserved. SolidWorks 2014, SolidWorks Enterprise PDM, SolidWorks Workgroup PDM, SolidWorks Simulation, Copyright Notices for eDrawings Products SolidWorks Flow Simulation, eDrawings, Portions of this software © 2000-2013 Tech Soft 3D. eDrawings Professional, SolidWorks Sustainability, Portions of this software © 1995-1998 Jean-Loup Gailly and SolidWorks Plastics, SolidWorks Electrical, and Mark Adler. SolidWorks Composer are product names of DS SolidWorks. Portions of this software © 1998-2001 3Dconnexion. Other brand or product names are trademarks or registered Portions of this software © 1998-2013 Open Design Alliance. All trademarks of their respective holders. rights reserved. Portions of this software © 1995-2012 Spatial Corporation. COMMERCIAL COMPUTER SOFTWARE - PROPRIETARY The Software is a "commercial item" as that term is defined at 48 The eDrawings® for Windows® software is based in part on the C.F.R. 2.101 (OCT 1995), consisting of "commercial computer work of the Independent JPEG Group. software" and "commercial software documentation" as such Portions of eDrawings® for iPad® copyright © 1996-1999 Silicon terms are used in 48 C.F.R. 12.212 (SEPT 1995) and is provided Graphics Systems, Inc. to the U.S. Government (a) for acquisition by or on behalf of civilian agencies, consistent with the policy set forth in 48 C.F.R. Portions of eDrawings® for iPad® copyright © 2003-2005 Apple 12.212; or (b) for acquisition by or on behalf of units of the Computer Inc. department of Defense, consistent with the policies set forth in 48 C.F.R. 227.7202-1 (JUN 1995) and 227.7202-4 (JUN 1995). In the event that you receive a request from any agency of the U.S. government to provide Software with rights beyond those set forth above, you will notify DS SolidWorks of the scope of the request and DS SolidWorks will have five (5) business days to, in its sole discretion, accept or reject such request. Contractor/Manufacturer: Dassault Systèmes SolidWorks Corporation, 175 Wyman Street, Document Number: Waltham, Massachusetts 02451 USA. Contents Lesson 1: Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Using This Book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 What is SolidWorks Software? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Prerequisites. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Conventions Used in This Book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Before You Begin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Analyzing a Structure Using SolidWorks and SolidWorks Simulation. . . . . . . . . . . . . . . . . . . 5 Lesson 2: Using Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Creating Parts In-Context . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Opening an Assembly with Quick View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Hiding and Showing Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 The Assembly FeatureManager design tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Working In-Context . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Edit Assembly Mode vs. Edit Part Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 In-Context Parts and Virtual Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Setup for Using Edit Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Creating a New Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Edit Part Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Why do the Colors Change? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Controlling the Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Understanding the Color Coding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Extrusions In-Context. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Edit Assembly Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Working with Virtual Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Adding Component Instances and Mating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 SolidWorks SAE Design and Analysis Project i Contents In-Context Part Editing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Opening a Part from an Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Multi-body Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Reordering Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Pack and Go. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Work Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Lesson 3: Creating a Weldment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Creating Weldment Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Planes and Sketches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Structural Members. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Weldments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Creating a Weldment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Using Different Planes and Sketches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Using 2D Sketches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Renaming and Opening a Virtual Part. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Additional Planes and 2D Sketches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Sketching with Pierce Relations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Adding Bracing to the Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Using 3D Sketches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Sketching in the X, Y and Z Directions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 3D Sketch Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Placing a Component Using Sketch Geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Making Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Working With Sub-Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Opening a Sub-assembly from the Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Rigid vs. Flexible Sub-Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Bracing Sketches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Remaining Sketches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Weldment Structural Members . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Creating Custom Profiles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Adding Structural Members . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Corner Treatments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Using Trim/Extend. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Trimming Boundary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Using Folders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Map for Structural Member Types and Trim/Extend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Mirroring Structural Members . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Editing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Editing the Corner Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Using Locate Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 ii SolidWorks SAE Design and Analysis Project Contents Using Instant 3D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Checking Clearances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Interference Detection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Mounting Plates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Creating a Reusable Sketch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Pasting the Sketch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Weldment Cut Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Cut List Properties. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Save as External File. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Lesson 4: Using Molds and Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Molds and Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 The runner part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Features in the Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Anatomy of a Loft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Creating Mold Tooling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Surface and Solid Bodies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Description of the Bodies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Mold Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 What Does This Mean?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Using Surfaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Making Use of Symmetry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Lesson 5: Brake Rotor Analysis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Brake Rotor Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 SolidWorks Simulation Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Transient Thermal Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 Thermal Boundary Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 Convection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 Heat Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 Post Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 Static Study . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 Temperature Dependent Material Properties. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 Fixtures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 Braking Force. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 Thermal Loading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 Post Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 Editing Plots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 Chart Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 Conclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 SolidWorks SAE Design and Analysis Project iii Contents Lesson 6: Frame Analysis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 Torsional Rigidity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 Element Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 Shell Elements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 Beam Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 Preparing for Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 Experimental Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 Beam Meshing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 Section Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 End Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 Trusses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 Joint Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 Merging Joints Automatically. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152 Fixtures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 Post Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 Cylindrical Coordinates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 Torsional Rigidity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158 Beam Stresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 Cross Section Directions 1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 Shear and Bending Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161 Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 Lesson 7: Intake Analysis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163 Intake Manifold Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164 Model Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164 External Flow Analysis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164 Internal Flow Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164 SolidWorks Flow Simulation Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 Lids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 Check Geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 Creating the Project . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167 Engineering Goals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173 Post-Processing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 Color Bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176 Discussion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178 Conclusions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178 iv SolidWorks SAE Design and Analysis Project 1 Lesson 1: Introduction When you complete this lesson, you will be able to:  Describe the relationship between Parts, Assemblies and Drawings.  Identify the principal components of the SolidWorks user interface.  Download and extract the required companion files. SolidWorks SAE Design and Analysis Project 1 Lesson 1: Introduction Using This Book The SAE Design and Analysis Project with SolidWorks Software helps you learn the principles of assembly design and structural analysis using SolidWorks and SolidWorks Simulation as an integral part of a creative and iterative design process. For this project, you will “learn by doing” as you complete modeling and structural analysis lessons. What is SolidWorks Software? SolidWorks is design automation software. In SolidWorks, you sketch ideas and experiment with different designs to create 3D models using the easy to learn Windows® graphical user interface. SolidWorks is used by students, designers, engineers and other professionals to produce single and complex parts, assemblies and drawings. Prerequisites Before you begin the SAE Design and Analysis Project with SolidWorks Software you should complete the following tutorials that are integrated in the SolidWorks software:  Lesson 1 - Parts  Lesson 2 - Assemblies  Lesson 3 - Drawings You can access the tutorials by clicking Help, SolidWorks Tutorials. The tutorial resizes the SolidWorks window and runs beside it. As an alternative, you can complete the following lessons from CAD Student Guide:  Lesson 1: Using the Interface  Lesson 2: Basic Functionality  Lesson 3: The 40-Minute Running Start  Lesson 4: Assembly Basics  Lesson 6: Drawing Basics 2 SolidWorks SAE Design and Analysis Project Lesson 1: Introduction Conventions Used in This Book This manual uses the following typographical conventions: Convention Meaning Bold Arial SolidWorks commands and options appear in this style. For example, Insert, Boss means choose the Boss option from the Insert menu. Courier Feature names and file names appear in this style. For New example, Sketch1. 17 Do this The steps in the lessons are numbered in Bold Arial. step. Before You Begin If you have not done so already, copy the companion files for the lessons onto your computer before you begin this project. 1 Start SolidWorks. Using the Start menu, start the SolidWorks application. 2 SolidWorks resources. Click the SolidWorks Resources tab and click Student Curriculum . SolidWorks SAE Design and Analysis Project 3 Lesson 1: Introduction 3 SolidWorks Content. Expand the SolidWorks Educator Curriculum folder. Expand the proper Curriculum <year> folder. Click Design Library to open the design library task pane. Click the SAE Car Design Project folder. The lower pane will display an icon representing a Zip file that contains the companion files for this project. 4 Download the Zip file. Press Ctrl and click the icon. You will be prompted for a folder in which to save the Zip file. Ask your teacher where you should save the Zip file. Usually the C:\Temp folder is a good location. Click OK. Tip: Remember where you saved it. 5 Open the Zip file. Browse to the folder where you saved the Zip file in step 4. Double-click the SAE Project Files.zip file. 6 Click Extract. Click Extract and Browse to the location where you want to save the files. The system will automatically create a folder named _SAE_Project_ENG in the location you specify. For example, you might want to save it in My Documents. Check with your teacher about where to save the files. You now have a folder named SAE Project Files on your disk. The data in this folder will be used in the exercises. 4 SolidWorks SAE Design and Analysis Project