ul Zz Q a <SolidWorks 2008 Training Manual Table of Contents Introduction Abou hy nis Conirse jerequisites “ Course Design Phildsophy Using this Book 3 About the Training Piles e Conventions Used in this Book x Windows® XP Use of Color Graphies and Graphics Cards z Color Schemes Lesson 1; : Modeling Sheet Metal Parts Sheet Metal Methods a) Stages in the Process. 9 Metal Toolbar i 9 ging with Sheet Metal Features Sheet Metal Gauges ' Base Flange i Metal Features. i Sheet-M cal Feature - 4 Flat-Pattern Peature % 5 Miter Pk . 6 bdge Hanges = 18 Bend Angles : . a Adding a Tah >‘SolidWorks 2008 Training Manual Flat Pattern , 24 Flat Patier Options Comer-T rim Cuts Cuts it the Folded Model Untold and Fold s Shee! Metal Parts in Drawings Sheet Metal Options 32 Exercise 1: Sheet Metal Bends a 35 Exercise 2: Sheet Metal Relief 36 Exercise 3: Shee! Metal Flinues and Bends 3 Exercise 42 Assorted Framing Hangers 40 Lesson 2 Sheet Metal Forming Tools Sheet Metal Forming Tools. 5 Tools eras 45 priming Tool 45 How They Work ; a 43 Creating a Cistiom Forming Tool 18 Update . Exeteise 5: Fornting Tool é Lesson 3: Additional Sheet Metal Features Edge Flanges und Closed Comers 6 Individual Edyes with an Edge Flangs 6 Closing a Corner 02 Hes. . 3 Curved Edge Manges 64 ing in Flat, - 66 70 y 7 tal Reliet Cut 7 Break Com: 3 Jou Feature 74 Fix Projected Length, - a5 Lofied Bendy 7 Bend Deviation, 0 Lxervise 6: Sheet Metal ftom Flat a Exervise 7: Jos and Hems NSSolidWorks 2008 Training Manvial Lesson 4: Converting Parts to Sheet Metal Sheet Metal Topies Stazes in the Process Recognize Bends Method Import Opening IGES F Document Te Report Files, Using the Rip Fe. - Adding Bends in Place of Shurp Comers Sheet Metal Features New Features Switching Between States. . Metal from Shelled Parts Unrolling Cones and Cylinders Process Plans Bends Configurations Exercise 8: Importing and Converting Exercise 9: Process Planning. Lesson 5; Modeling Sheet Metal in the Context of an Assembly Sheet Metal Topics Top-Down Assembly Modeling Stages in the Process InsContext Sheet Metal Pars Adding a Nes Part into un Assembl Results of Insert, Compon Appearance During Part Fait Color ofthe Building Edge Flanges In Context Build In Context Additional Cut Features Edit Assembly Exercise 1: Sheet Metal in an Assembly Exercise 11) U-Bolt In-Comtest Exercise 12: Tube BraveSolidWorks 2008 Training Manual Introduction About This Course Prerequisites Course Design Philosophy Using this Book Laboratory Exercises A Note About Dimensions About This Course The goal of this course is to teach you how to build sheet metal parts, using SolidWorks mechanical design automation software. The sheet metal application in Solid Works 2008 is so robust and feature rich that itis impractical to cover every minute detail and still have the course bea reasonable length. Therefore. the tous of this course. is on the fundamental skilly and concepts central to successfully building sheet metal parts. You should view the training course mara as a supplement to, nota replacement for, the system documentation and on-line hetp. Onee you have developed a skills, you can refer to the on-line help tor information on hess frequently used command options. Students attending this eourse-are expected to have th Mechanical design experience. & Comple mt Experience with the Windows! operating system. This course is designed around a process or task-based approach to maining, Rather than foeus on individual features amd funetions, a process-based training course emphasizes the processes and procedieres you fatlows wo complete & particular task. By utilizing ease studies 0 ‘Mhustrate these processes. you learn the necessary commands, options sind menus in the contest of completing a design task This training manual is intended to be wsed in a elasstoom environment under the guidance of an experienced Solid Works jnstructor. I is not intended to be a sell-paccd tutorial, The examples and ease sludigs are designed to be demonstrated “live” by the instructor Laboratory exercises give you the opportunity to apply and pr material covered during the lectureidémonstration portion of the course. They are designed to represent typical design and modeli ‘tuations While being modest enough to be completed during class time. You should note that many students work at different pac Therefore, we nave included more lab exercises than you eum reasonably expect to complete during the course. ‘This ensures that even the fastest student will not run out of exercises. The drawings and dimensions given in the lab exercises are not intended to reflect any particular drafting standard, In faet, sometimes dimensions are given in-a fashion that would never be considered acceptable in industry, The r or this 3 the labs are designed to encourage You (0 apply the information covered in class ad to. employ: and rein foree certairs teohitig Aga result, he drawings and dimensions in the exercises are done in a way that compliments this abjective.Introduction About the Training Files Conventions Used in this Book Windows” XP. Use of Color SolidWorks 2008 Training Manual A complete set of the various files used throughout this eourse-can be downloaded from the SolidWorks website, wwww.solidworks.com. Click on the tink for Services. then Technical References, then Training You must sign-in ta access the Training page. Onee sig you vill see the link to Download SolidWorks 2008 Training Files. URI ltep:évsww solidhvorks. contpages'services/subseription ts The files are supplied in signed, selbextracting e The files are orgunized by lesson number. The folder within each lesson contains the files your instructor uses while Presenting the lessous. The Exce = css folder contains any files that 2 the laboratory’ ener This manual uses the follow 2 (yp phic conventions: Bold Sans Serif | Sofid\orks communes and oplions appear in this style. For example, Insert, Boss jeans choose the Boss option trom the Insert menu. ure names and file names appear in this style, For example, Double lines precede andl follow sections of the procedures. This provides separation benween the steps of the procedure anid lange blocks of explanatory test. The steps themselves are numbered in sams serif bold. The sereen shots in this masal were made using SolidWorks 2008 running on Wi lows” XP. You may notice differences in the ippearance of the menus und windows: These differences do not afléet the perlormance of the software. the Solid Works user interface makes extensive use of eoloE ty highlight selected geometry and to provide you with visu he innuitiveness and ease of use oF the To take maximune advantage of this, the taining dh, manuals are printed in full color Windows® xPSolidWorks 2008 Training Manual Introduction Also, in some cases, we may have used additional cotor in the illustrations 10 communicate concepts, identity Features, and othenvise convey important information, For example, wwe might show the resulé of an tion in a different eolor, even thouzh by SolidWorks sofissare would to! the results it that way Graphics and SolidWorks 2008 sets a new standard with best-in-elass graphies, The Graphics Cards combination ofa highly reflective material and the realism o RealView Graphics is an efleetive tool for evaluating the quality of axisanced part models andl surlaces. RealView Graphics is hardware (graphics cate) support of udvune shading in real time. For example, if you rotate a part, i retains tty rendered appearance throughout the rotation Color Schemes Out of the bos, SolidWorks 2008 provides several predetined color schemes that control, among other things, the colors used for highlighted items, selected items. sketch relation symbols, and shided previews of Features We have riot used the sante eolor scheme for every ease study and eXercise biccause some calor ore visible ane clear than others shen used With different cotored pares In addition, we have changed the viewport background to pluin white so that the illustrations reprodwee better on white paper As a result, because the color settings on your computer may be different than the ones used by the authors of this book, the images you Soe on Your sereen nity fot exactly mateh thase in the book: Use af ColorIntroduction Displaying Sketch Relations. SolidWorks 2008 Training Manual SolidWorks 2008 has the capability to utomativally display graphic representations of sketch relations as shown in the illustration it. These can be turned on ancl off 12 the command View, Sketch Relatians In snost of the examples in this hook, the graphic display of tl turned off sketch relations has been Use of ColorSolidWorks 2008 Training Manual Lesson 1 Modeling Sheet Metal Parts Upon suecessfil completion of thiy lesson, you will be able 10: a Createa sheet metal part using a base Mange : features such us the ed Add the sheet metal specific flan, miter Manges, and tabs. a Flaten a sheet metal part 10 see the flat pattem, aw Create drawings of'sheet metal parts,SolidWorks 2008 Training Manual Lesson 1 Sheet Metal Methods Stages in the Process Sheet Metal Toolbar ‘Sheet Metal Methods Modeling Shoot tata! Pars Fundamentally, there are twe approaches for building sheet metal part fro starting Sith the yery first feature — the base Mange feature. This incthod takes sdvantage of all the alized tools, commands. sind options in the sheet metal application, This is. vost all parts aad thats winut ths less Wictionality and spe the preferred method for = Transforming a part that was built nventionally into stshrect metal 10 il eat be Mattened, and so that sheet metal-specilic features, ean be applied to it. Converting un imported part intoa sheet metal art ly a typical evample of when this approach makes sense. This method is covered in Lesson 4: Converting Parts 10 Sheet Meta Some key stages in the modeling process are given in the following list Fach of these topics comprises a section in the lesson. Designing with Sheet Metal Features Features that are specifically sheet metal are used to ereate parts. These include several types of Manges. tabs, added bends and fattening wols, Using Forming Tools Use forming tools Lo shape the st metal port, The wols can he used 25 16) odified: or crebied fram sexaich Sheet Metal Drawings (Creating a drawing using a sheet me part has some unique options, Using Symmetry Symmetric models ea Mirror Bodies beereated as partial models and mirrored using Existing Rounds ‘Sketches that contain rounds are processed by the base fla Designing in the Flat Sheet metal purts eun be alesign dasa flat pattern anid folded hater The Sheet Met! toolbar contains shorteuts tor ull the sheet metal commands. These commands can also be accessed via the Insert, Sheet Metal menu.Lesson 1 Moding Shoot Mota! Parts Designing with Sheet Metal Features Sheet Metal Gauges 10 SolidWorks 2006 Training Manual Sheet Metal parts constitute a very specific type of solid model, They have the characteristics of being thin walled with rounded corners. The wall thickness 's constant throughout the model and the Bends are applied using a selected bend radius value, When relief is needed, i¢ is PP ide automatically. SolidWorks takes care of these requirements for you using specific sheet metal tals. Se? D > ‘ Sheet Metal Gauge can be selected (0 set the thickness and limit the choice or radius. Sample tables le steel and aluminum ace i with SolidWorks, User detined tables ean be created canairoa Tape Designing with Sheet Metal FeaturesSolidWorks 2008 Training Manual Lesson 1 Mordting Shoot Hot Parte Flanges The fundamental sheet metal feature is a flange, In this example, different types of flanges will be used to construct a sheet metal part, description of the different Nange types is offered below. SolidWorks Sheet Metal has four different types of Manges that ean be used to create parts, The Manges add material of prede fined thiekness in different ways, Base Flange The Base Flange is used to ereate the base feature for the sheet metal part. It works similarly to-the Extrude feature but it automatically adds, bends using spe Bend Radius Miter Flange ‘The Miter Flange ix used to ereate flanges that connect aban angle to existing edges of the noxtel IL has options follow a tangent set of edges, create rips where needed or aflset the ends. Edge Flange An Edge Flange adels material to eéeate a flange at ai aiale to an existing edge. The angle and the profile sketch can be modified Multiple flanges can be created toweth The Edge Flange can also be ercated with any gombination of nonlinear ans! Linear edues, ILis possible to add ede flangeson arts: such as the linear of lofted or Designing with Shect Metal FeaturesLesson 4 Moding Sheet Metal Parts Procedure SolidWorks 2008 Training Manual Tab A Tab can be used i (Boss Flange) adil a boss f ture that thickness as the re the model, The tab is sketched on an existin face The model to he created i812 cover for a stereo receiver. I uses all four types of Ranges, as well as cuts and forming tools, Base Flange 2 The Base Flange js the base feuture wf'a sheet metal part. Itereates th d for subsseqquent sheet ion on the familiar Bass Extrude New part Create a new part with units millimeters, Nanie the part Sketch. Sketch a ree ngle using the plang. Chane the bottom kine to ometry, anid dimesion as shown. Relate the bottom fine nga Midpoint relation, to the Oni —— 2 —_____ Designing with Sheet Metal FeaturesSolidWorks 2008 Training Manual Introducing: Base Flange Where to Find It Lesson 1 Modeling Sheet Metol Parts The Base Flange is used to create the base feature ola sheet metal part, The flange is ereut Bend Radius. An open ev iS an extrusion with a Thickness value and mnkour is treated like hin feature extrusion, 4 closed contour is treated as the ouiline ofa flat plate. This is usetl if yous to design shu ct mnetal parts trons a Hay pattern, [rom the meni choose: Insert, Sheet Metal, Base Flange: © Or.click the BB) tool on the Sheet Metal toa Base Flange, Click the Base Flange tool and change the sett . = End Condition = Blind = (Depth) = 240mm - = Use gauge table = On = Gauge table = ALUMINUM sists = Gauge 20, Poem Auto Relief=Obround = [arr] Verity that the-thickness is ee Minit = Reverse direction checkbox to, change it ba aes Click OK 10 eFeate the fia Tiemann Note Ihe Override thickness und Override radius options can be used! to overtide the values taken feom the table Designing with Sheet Metal Features 13Lesson ¢ Modeling Soot ital Parte Sheet Metal Features Sheet-Metal Feature iB shone tat Explaining the Bend Parameters “4 Completed base flange. The bs we Tange is Tisted in the PeatureManuger as Base Lange. Note thi other Features have also been bvo, added ae ail and Thes 5 will be explained on the following pages, Certain Specialized features ar mieraved with the Base Flarige that occur only in sheet metal purts, They are used for default settin, eoniral of the part, The sheet ~ hire Contains the Settings REET Twa used for the part, This ineludes the gauge uble, ft SS, how he [Skiba defeull bend radius, the material thick bendollowanceiscalubled, how i bend relief ix generated. The informaion comes jeg ihom the-cholses made inthe bose fonge and other’ (mead defi settings. Use Edit Feature to change i,k 7 ——s ——e For Bend Allowance thiete are four options: m= Bend Table ism: contains bend eateulations based on thickness and bend radius. Bend tables are Excel files and have the * . 21s file extension, Use Insert, Sheet Metal, Bend Table, Fram File or New lo «dd ure They can also be chosen from the Use bend table pull-duwit in the Sheet