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Document Number: PME1119-ENG SolidWorks Engineering Design and Technology Series Table of 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.......................4 Lesson 2: Using Assemblies.............................................................................5 Creating Parts In-Context ............................................................................................6 Opening an Assembly with Quick View................................................................6 Hiding and Showing Components.........................................................................7 The Assembly FeatureManager design tree...............................................................10 Working In-Context....................................................................................................11 Edit Assembly Mode vs. Edit Part Mode.............................................................11 In-Context Parts and Virtual Parts.......................................................................12 Setup for Using Edit Part.....................................................................................12 Creating a New Part ............................................................................................13 Edit Part Mode............................................................................................................14 Why do the Colors Change?................................................................................14 Controlling the Display........................................................................................14 Understanding the Color Coding.........................................................................20 Extrusions In-Context..........................................................................................24 Edit Assembly Mode..................................................................................................26 Working with Virtual Parts..................................................................................26 Adding Component Instances and Mating.................................................................27 In-Context Part Editing...............................................................................................31 Opening a Part from an Assembly .............................................................................32 Multi-body Materials...........................................................................................33 i SolidWorks Engineering Design and Technology Series Reordering Features.............................................................................................34 Materials.....................................................................................................................35 Pack and Go................................................................................................................37 Work Flow...........................................................................................................37 Lesson 3: Creating a Weldment......................................................................40 Creating Weldment Parts............................................................................................41 Planes and Sketches.............................................................................................41 Structural Members..............................................................................................41 Weldments..................................................................................................................42 Creating a Weldment............................................................................................42 Using Different Planes and Sketches...................................................................45 Using 2D Sketches...............................................................................................47 Renaming and Opening a Virtual Part.................................................................51 Additional Planes and 2D Sketches.....................................................................54 Sketching with Pierce Relations...........................................................................56 Adding Bracing to the Frame.....................................................................................60 Using 3D Sketches......................................................................................................61 Sketching in the X, Y and Z Directions...............................................................61 3D Sketch Dimensions.........................................................................................62 Placing a Component Using Sketch Geometry..........................................................64 Making Changes...................................................................................................66 Working With Sub-Assemblies..................................................................................67 Opening a Sub-assembly from the Assembly......................................................67 Rigid vs. Flexible Sub-Assemblies......................................................................68 Bracing Sketches........................................................................................................70 Remaining Sketches.............................................................................................71 Weldment Structural Members...................................................................................73 Creating Custom Profiles.....................................................................................74 Adding Structural Members.......................................................................................77 Corner Treatments................................................................................................78 Using Trim/Extend.....................................................................................................82 Trimming Boundary.............................................................................................82 Using Folders.......................................................................................................84 Map for Structural Member Types and Trim/Extend..........................................85 Mirroring Structural Members.............................................................................86 Editing.........................................................................................................................87 Editing the Corner Treatment...............................................................................87 Using Locate Profile............................................................................................89 Using Instant 3D..................................................................................................92 Checking Clearances............................................................................................94 Interference Detection..........................................................................................97 ii SolidWorks Engineering Design and Technology Series Mounting Plates..........................................................................................................99 Creating a Reusable Sketch..................................................................................99 Pasting the Sketch..............................................................................................100 Weldment Cut Lists..................................................................................................106 Cut List Properties..............................................................................................107 Save as External File..........................................................................................108 Lesson 4: Using Molds and Surfaces...........................................................109 Molds and Surfaces...................................................................................................110 The runner part..............................................................................................111 Features in the Part.............................................................................................112 Anatomy of a Loft..............................................................................................113 Creating Mold Tooling.............................................................................................114 Surface and Solid Bodies...................................................................................114 Description of the Bodies...................................................................................115 Mold Tools.........................................................................................................116 Using Surfaces...................................................................................................121 Making Use of Symmetry.........................................................................................127 Lesson 5: Brake Rotor Analysis....................................................................130 Brake Rotor Design..................................................................................................131 SolidWorks Simulation Interface.......................................................................132 Transient Thermal Analysis......................................................................................134 Thermal Boundary Conditions.................................................................................135 Convection.........................................................................................................135 Heat Power.........................................................................................................138 Post Processing.........................................................................................................140 Static Study...............................................................................................................142 Temperature Dependent Material Properties.....................................................143 Fixtures.....................................................................................................................143 Loading.....................................................................................................................145 Braking Force...........................................................................................................146 Thermal Loading................................................................................................147 Post Processing.........................................................................................................148 Editing Plots.......................................................................................................149 Chart Options.....................................................................................................149 Settings...............................................................................................................149 Conclusions...............................................................................................................151 Lesson 6: Frame Analysis..............................................................................152 Torsional Rigidity.....................................................................................................153 Element Types..........................................................................................................153 iii SolidWorks Engineering Design and Technology Series Shell Elements....................................................................................................154 Beam Elements...................................................................................................154 Preparing for Analysis..............................................................................................155 Experimental Design................................................................................................156 Additional Model Modifications........................................................................157 Beam Meshing..........................................................................................................158 Section Properties...............................................................................................158 End Conditions...................................................................................................159 Trusses................................................................................................................160 Joint Group.........................................................................................................160 Merging Joints Automatically............................................................................163 Fixtures.....................................................................................................................163 Loading.....................................................................................................................165 Post Processing.........................................................................................................167 Cylindrical Coordinates.....................................................................................168 Torsional Rigidity..............................................................................................170 Beam Stresses.....................................................................................................171 Cross Section Directions 1 and 2.......................................................................172 Shear and Bending Diagrams.............................................................................174 Conclusion................................................................................................................175 Lesson 7: Intake Analysis..............................................................................176 Intake Manifold Design............................................................................................177 Model Preparations...................................................................................................177 External Flow Analysis......................................................................................177 Internal Flow Analysis.......................................................................................177 SolidWorks Flow Simulation Interface..............................................................179 Lids.....................................................................................................................179 Check Geometry.................................................................................................181 Creating the Project..................................................................................................181 Engineering Goals..............................................................................................189 Post-Processing.........................................................................................................191 Color Bar............................................................................................................192 Discussion..........................................................................................................194 Conclusions...............................................................................................................194 iv SolidWorks Engineering Design and Technology Series Lesson 1 Introduction When you complete this lesson, you will be able to: Describe the relationship between Parts, Assemblies and Drawings; (cid:81) Identify the principal components of the SolidWorks user interface; (cid:81) Download and extract the required companion files. (cid:81) 1 SolidWorks Introduction Engineering Design and Technology Series 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 online tutorials that are integrated in the SolidWorks software: Lesson 1 - Parts (cid:81) Lesson 2 - Assemblies (cid:81) Lesson 3 - Drawings (cid:81) You can access the online tutorials by clicking Help, SolidWorks Tutorials, All SolidWorks Tutorials (Set 1). The online tutorial resizes the SolidWorks window and runs beside it. As an alternative, you can complete the following lessons from An Introduction to Engineering Design With SolidWorks: Lesson 1: Using the Interface (cid:81) Lesson 2: Basic Functionality (cid:81) Lesson 3: The 40-Minute Running Start (cid:81) Lesson 4: Assembly Basics (cid:81) Lesson 6: Drawing Basics (cid:81) Using This Book 2 SolidWorks Introduction Engineering Design and Technology Series Conventions Used in This Book This manual uses the following typographical conventions: Convention Meaning Bold Sans Serif SolidWorks commands and options appear in this style. For example, Insert, Boss means choose the Boss option from the Insert menu. Typewriter Feature names and file names appear in this style. For example, Sketch1. 17 Do this step. The steps in the lessons are numbered in sans serif bold. 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 Content. Click Design Library to open the design library task pane. Click on SolidWorks Content to show the folders below it. Click on SolidWorks Educator Curriculum. Click SAE Project Files - English. Note: There may be more curriculum folders listed in addition to the SAE Project Files. The lower pane will display an icon representing a Zip file that contains the companion files for this project. Conventions Used in This Book 3 SolidWorks Introduction Engineering Design and Technology Series 3 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. 4 Open the Zip file. Browse to the folder where you saved the Zip file in step3. Double-click the SAE Project Files.zip file. 5 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. Tip: Remember where you saved it. Analyzing a Structure Using SolidWorks and SolidWorks Simulation During this session, you will learn how to analyze a structure using SolidWorks and SolidWorks Simulation. Once you have had a chance to see how easy it is to use SolidWorks solid modeling software, you will use an assembly to check whether components fit properly. You will then make a drawing of one of the components, complete with a cut list. If a printer is available, you can print out a hardcopy of your drawing. Analyzing a Structure Using SolidWorks and SolidWorks Simulation 4