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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.......................5 Lesson 2: Using Assemblies.............................................................................6 Creating Parts In-Context ............................................................................................7 Opening an Assembly with Quick View................................................................7 Hiding and Showing Components.........................................................................8 The Assembly FeatureManager design tree...............................................................12 Working In-Context....................................................................................................14 Edit Assembly Mode vs. Edit Part Mode.............................................................14 In-Context Parts and Virtual Parts.......................................................................15 Setup for Using Edit Part.....................................................................................15 Creating a New Part ............................................................................................16 Edit Part Mode............................................................................................................17 Why do the Colors Change?................................................................................17 Controlling the Display........................................................................................17 Understanding the Color Coding.........................................................................23 Extrusions In-Context..........................................................................................26 Edit Assembly Mode..................................................................................................28 Working with Virtual Parts..................................................................................29 Adding Component Instances and Mating.................................................................29 In-Context Part Editing...............................................................................................34 i SolidWorks Engineering Design and Technology Series Opening a Part from an Assembly .............................................................................35 Multi-body Materials...........................................................................................36 Reordering Features.............................................................................................37 Materials.....................................................................................................................38 Pack and Go................................................................................................................40 Work Flow...........................................................................................................40 Lesson 3: Creating a Weldment......................................................................43 Creating Weldment Parts............................................................................................44 Planes and Sketches.............................................................................................44 Structural Members..............................................................................................44 Weldments..................................................................................................................45 Creating a Weldment............................................................................................45 Using Different Planes and Sketches...................................................................48 Using 2D Sketches...............................................................................................50 Renaming and Opening a Virtual Part.................................................................55 Additional Planes and 2D Sketches.....................................................................58 Sketching with Pierce Relations...........................................................................60 Adding Bracing to the Frame.....................................................................................64 Using 3D Sketches......................................................................................................65 Sketching in the X, Y and Z Directions...............................................................65 3D Sketch Dimensions.........................................................................................66 Placing a Component Using Sketch Geometry..........................................................68 Making Changes...................................................................................................70 Working With Sub-Assemblies..................................................................................71 Opening a Sub-assembly from the Assembly......................................................71 Rigid vs. Flexible Sub-Assemblies......................................................................72 Bracing Sketches........................................................................................................74 Remaining Sketches.............................................................................................75 Weldment Structural Members...................................................................................77 Creating Custom Profiles.....................................................................................78 Adding Structural Members.......................................................................................81 Corner Treatments................................................................................................82 Using Trim/Extend.....................................................................................................86 Trimming Boundary.............................................................................................86 Using Folders.......................................................................................................88 Map for Structural Member Types and Trim/Extend..........................................89 Mirroring Structural Members.............................................................................90 Editing.........................................................................................................................91 Editing the Corner Treatment...............................................................................91 Using Locate Profile............................................................................................93 Using Instant 3D..................................................................................................96 ii SolidWorks Engineering Design and Technology Series Checking Clearances............................................................................................98 Interference Detection........................................................................................102 Mounting Plates........................................................................................................104 Creating a Reusable Sketch................................................................................104 Pasting the Sketch..............................................................................................105 Weldment Cut Lists..................................................................................................111 Cut List Properties..............................................................................................112 Save as External File..........................................................................................113 Lesson 4: Using Molds and Surfaces...........................................................114 Molds and Surfaces...................................................................................................115 runner The part..............................................................................................116 Features in the Part.............................................................................................117 Anatomy of a Loft..............................................................................................118 Creating Mold Tooling.............................................................................................119 Surface and Solid Bodies...................................................................................119 Description of the Bodies...................................................................................120 Mold Tools.........................................................................................................121 Using Surfaces...................................................................................................126 Making Use of Symmetry.........................................................................................133 Lesson 5: Brake Rotor Analysis....................................................................136 Brake Rotor Design..................................................................................................137 SolidWorks Simulation Interface.......................................................................138 Transient Thermal Analysis......................................................................................140 Thermal Boundary Conditions.................................................................................141 Convection.........................................................................................................141 Heat Power.........................................................................................................144 Post Processing.........................................................................................................146 Static Study...............................................................................................................148 Temperature Dependent Material Properties.....................................................149 Fixtures.....................................................................................................................149 Loading.....................................................................................................................151 Braking Force...........................................................................................................152 Thermal Loading................................................................................................153 Post Processing.........................................................................................................154 Editing Plots.......................................................................................................155 Chart Options.....................................................................................................155 Settings...............................................................................................................155 Conclusions...............................................................................................................157 iii SolidWorks Engineering Design and Technology Series Lesson 6: Frame Analysis..............................................................................158 Torsional Rigidity.....................................................................................................159 Element Types..........................................................................................................159 Shell Elements....................................................................................................160 Beam Elements...................................................................................................160 Preparing for Analysis..............................................................................................161 Experimental Design................................................................................................162 Beam Meshing..........................................................................................................163 Section Properties...............................................................................................164 End Conditions...................................................................................................164 Trusses................................................................................................................165 Joint Group.........................................................................................................166 Merging Joints Automatically............................................................................168 Fixtures.....................................................................................................................168 Loading.....................................................................................................................170 Post Processing.........................................................................................................172 Cylindrical Coordinates.....................................................................................173 Torsional Rigidity..............................................................................................175 Beam Stresses.....................................................................................................176 Cross Section Directions 1 and 2.......................................................................177 Shear and Bending Diagrams.............................................................................179 Conclusion................................................................................................................180 Lesson 7: Intake Analysis..............................................................................181 Intake Manifold Design............................................................................................182 Model Preparations...................................................................................................182 External Flow Analysis......................................................................................182 Internal Flow Analysis.......................................................................................182 SolidWorks Flow Simulation Interface..............................................................184 Lids.....................................................................................................................184 Check Geometry.................................................................................................186 Creating the Project..................................................................................................186 Engineering Goals..............................................................................................194 Post-Processing.........................................................................................................196 Color Bar............................................................................................................197 Discussion..........................................................................................................199 Conclusions...............................................................................................................199 iv SolidWorks Engineering Design and Technology Series Lesson 1 Introduction When you complete this lesson, you will be able to: (cid:2) Describe the relationship between Parts, Assemblies and Drawings; (cid:2) Identify the principal components of the SolidWorks user interface; (cid:2) Download and extract the required companion files. 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: (cid:2) Lesson 1 - Parts (cid:2) Lesson 2 - Assemblies (cid:2) Lesson 3 - Drawings 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 CAD Instructor Guide: (cid:2) Lesson 1: Using the Interface (cid:2) Lesson 2: Basic Functionality (cid:2) Lesson 3: The 40-Minute Running Start (cid:2) Lesson 4: Assembly Basics (cid:2) Lesson 6: Drawing Basics 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 resources. Click the SolidWorks Resources tab and click Student Curriculum. Conventions Used in This Book 3 SolidWorks Introduction Engineering Design and Technology Series 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. Before You Begin 4