1

INTERNSHIP TRANING REPORT

ON

SOLIDWORKS

BENGAL COLLEGE OF POLYTECHNIC

DURGAPUR

Submitted By – JATIN DEO

DEPARTMENT- ELECTRICAL ENGINEERING

REGISTRATION NO-D212202038

YEAR -3rd

SEMESTER-5th

ROLL NO- 215212

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1. INTRODUCTION
Solid Works is a 3D mechanical CAD program that runs on Microsoft Windows which was developed by Solid Works
Corporation, headquartered in USA, a subsidiary of Dassault systemes. SolidWorks provides engineers, designers and
other creative professionals with the tools they need to design the world’s greatest products.

SolidWorks provides a full range of integrated modeling, simulation, visualization; communication and validation
tools that product designers need to develop better products faster and at lower cost. In addition, its unique
capabilities enable the mechanical designer to concentrate on the product design.

SolidWorks enable the design engineer to:

• Precisely turn creative concepts into 3D design.

• Create the most ergonomic designs possible.

• Produce design iterations in less time.

• Reduce prototyping time and cost.

• Work with customer data.

• Manage product information more effectively.

• Render highly detailed 3D design.

1.1 Modules in SolidWorks

SolidWorks extends design applications through full integration with best in class solutions. The following modules
are mainly used.

• Part Modeling

• Assembly Modeling

• Surface Modling

• Sheet Metal Design

• Drawing

1.2 Features of Solidworks

SolidWorks is software developed for mechanical design engineers and contains many features that facilitate the
engineers to easily create and manage designs. Some of the important features of solidworks are as follows:

• Feature-based

• Parametric

• Solid modeling  Constraints

1.2.1 Feature-based
Just as an assembly is composed of a number of individual piece parts, a solidWorks model also consists of individual
constituent elements. These elements are called features. When you create a model using the solidworks software,
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you work with intelligent, easy to understand geometric features such as bosses, cuts, holes, ribs, fillets, chamfers
and draft. The features are applied directly to the work piece as soon as they are created.

1.2.2 Parametric
The dimensions and relations used to create a features are captured and stored in the model. This enables not only
to capture your design intent, but also to quickly and easily make changes to the model. In the revolved body, hole
size is reduced parametrically since all the circles are driven by relation and dimension. A change in one hole reflects
the others.

1.2.3 Solid Modeling

A solid model is the most complete type of geometry model used in CAD systems. It contains all the wire frame and
surface geometry necessary, to fully describe the edges and the faces of the model.

1.2.4 Constraints
Geometric relations such as parallel, perpendicular, horizontal, vertical, concentric and coincident are some of the
constraints supported by solidworks.

2. Graphic User Interface of SolidWorks and Control

The format of the SolidWorks window reflects that of windows itself. The same is true for any SolidWorks document.
Once opened a document appears split into two panels. The right is the graphics window, where your model or
drawing appears. You can create and manipulate the document in the graphics window. The Main elements of the
SolidWorks user interface are as follows:

FeatureManager design tree: Similar to the windows explorer tree it lists the structure of the part,
assembly or drawing.
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PropertyManager: Appears in the left panel when you select many of the SolidWorks commands such as
sketches, fillet features and so on. The PropertyManager displays selection icons to enter relevant command options
and boxes/fields to enable the user to enter relevant design and data parameters.

ConfigurationManager: Appears in place of the FeatureManager design tree. Helps create, select and view
multiple configurations (variations of parts and assemblies in a single document).
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Main Menu: A set of drop down menus (File, Edit, View, and so on) across the top of the user interface. The
menu bar contents are task dependent based on the active document type. SolidWorks toolbars display these
functions whereas the menu bar contains the complete set.

Standard toolbar: Found just beneath the main menu this toolbar is consists of a set of the most commonly
used command buttons.

View toolbar: Features a series of commonly used command buttons that allow you to zoom, rotate and view
the part in different orientations.

Command Manager: A dynamic toolbar that lists the command buttons for the type of document you are
working on.

Graphics area: Displays the part assembly or drawing.

Quick tips help: Indicates with a question mark button whether Quick Tips is on or off. Click the icon to toggle

Design Library: Click to open the design library. Inside you see the Design Library, Toolbox and 3D Content
Central each which contain many standard design elements you can drag and drop into your design.

File Explorer: Duplicates Windows Explorer in your computer. Lists recently opened documents and currently
opened documents. You can drag documents from here into the graphics area.

Triad: A traid appears in part and assembly documents to help you orient when viewing models. The Triads is for
reference only. You can not select it.
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2.2 View and Orientation

A set of predefined views can be selected through the Standard view toolbar, a flyout (similar to a drop down Menu)
tool bar that is embedded in the View toolbar. If you click the Standard View button in the View toolbar, you get a
pull-down menu of several commands that represent standard engineering views. This enables the user to select
views such as Side, Front, Top, Right and Bottom as well as perspectives: Isometric, Trimetric and Dimetric which
vary in viewing.

2.2.1 Orientation
The orientation section of the View toolbar offers several tools to enable the user to manually manipulate the
orientation of a model. These manipulation tools include the following:

Zoom to Fit: Zooms in or out so the entire model is visible.

Zoom to Area: Zooms in on a portion of the view that you select by dragging a bounding box.

The centre of the box is marked with plus (+) sign.

Zoom In/Out: Zooms in as you press and hold the left mouse button and drag the mouse up.

Zooms out as you drag the mouse down.

Zoom to Selection: Zooms to the size of a selected entity.

Rotate View: Rotates the view as you press and hold the left mouse button and drag the mouse around the screen.

Pan View: Scrolls the view so the model moves as you drag the mouse.

2.2.2 Display Modes

The third section of the View toolbar offers the following display modes for model and drawing view in drawing
documents. These tools include the following:

Shaded

Shaded with Edges

Hidden Lines Removed
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Hidden Lines Visible

Wireframe (Displays all edges of the model)

Section View

Fig : Section View and PropertyManager

Control
Mouse buttons
SolidWorks uses three mouse buttons to access features, select objects and perform tasks:

Left: Selects menu items, entities in the graphics area, and objects in the FeatureManager design tree.

To select an entity click on the entity in the graphics window or in the feature manager design tree. Selected objects
become highlighted in both the graphics area and FeatureManager design tree. To select multiple entities hold
down the Ctrl button while continuing to click on the objects to be selected. To select a group of objects hold down
the mouse button and drag a window around the objects. To deselect all objects click anywhere in the document
window outside the part or assembly.

Right: Displays context sensitive options and shortcut menus.

Middle:

Rotate: Hold down button and move mouse. To rotate about a vertex edge or axis (other than the origin) click the
middle mouse button on the geometry then hold and move the mouse.
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Pan: Hold Ctrl button while holding down button and move the mouse

Zoom: Position cursor over the chosen position in the graphics window and hold shift and mouse button or if
available spin roller button toward you to zoom out and reverse to zoom in

Keyboard Shortcuts
Listed below are the predefined keyboard shortcuts options:

Arrow Keys . . . . . . . . . . . . . . . . Rotate the view

Shift+Arrow Keys . . . . . . . . . . . Rotate the view in 90° increments

Alt+Left or Right Arrow Keys .Rotate about normal to the screen

Ctrl+Arrow Keys . . . . . . . . . . . Move the view

Shift+z . . . . . . . . . . . . . . . . . . . . Zoom In

z. . . . . . . . . . . . . . . . . . . . . . . . . . Zoom Out

f . . . . . . . . . . . . . . . . . . . . . . . . . . Zoom to Fit

Ctrl+1 . . . . . . . . . . . . . . . . . . . . . Front Orientation

Ctrl+2 . . . . . . . . . . . . . . . . . . . . . Back Orientation

Ctrl+3 . . . . . . . . . . . . . . . . . . . . . Left Orientation

Ctrl+4 . . . . . . . . . . . . . . . . . . . . . Right Orientation

Ctrl+5 . . . . . . . . . . . . . . . . . . . . . Top Orientation

Ctrl+6 . . . . . . . . . . . . . . . . . . . . . Bottom Orientation

Ctrl+7 . . . . . . . . . . . . . . . . . . . . . Isometric Orientation

Ctrl+8 . . . . . . . . . . . . . . . . . . . . . View Normal To

Spacebar . . . . . . . . . . . . . . . . . . View Orientation dialog

Ctrl . . . . . . . . . . . . . . . . . . . . . . . Hold and select multiple items with mouse button

Ctrl+c . . . . . . . . . . . . . . . . . . . . . Copy selected entity/item

Ctrl+z . . . . . . . . . . . . . . . . . . . . . Undo

Ctrl+y . . . . . . . . . . . . . . . . . . . . . Redo

Ctrl+Tab . . . . . . . . . . . . . . . . . . .Switch between documents

Alt+drag . . . . . . . . . . . . . . . . . . . Select anywhere in a drawing view

Shift+drag . . . . . . . . . . . . . . . . . Maintains distance between drawing views while dragging

Ctrl+R . . . . . . . . . . . . . . . . . . . . .Redraw

Ctrl+B . . . . . . . . . . . . . . . . . . . . .Rebuild
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Customizing the SolidWorks window
System options
The options grouped under the heading System Options are saved on your system and affect every document you
open in your SolidWorks session. System settings allow you to control and customize your work environment. For
example, you might like working with a coloured graphics window background. Since this is a system setting, parts or
assemblies opened on your system would have a coloured graphics window.

Fig: Located on the tools menu the options dialogue box allows you to customize the SolidWorks software.
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3. CREATE A PART (PART MODELING)

3.1 Create Your Part

Stages in the Process

• Create a New part document

New parts can be created in inch, millimetre or other units. Parts are used to create and hold the solid model.

• Sketch the profile

Sketches are collections of 2D geometry that are used to create solid features. These include lines, circles and
rectangles.

• Applying Sketch relations and dimensions

Geometric relationships such as horizontal and vertical are applied to the sketch geometry. Dimension size the
geometry while the relations restrict the movement of the entities.  Extruding the sketch

Extruding uses the 2D sketch to create a 3D solid feature.

3.2 Procedure
The process in this includes sketching and extrusions. To begin with, a new part file is created.

3.2.1 Create a New part document

1. New part
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2. Filing a part.

Using the Save option from the File menu or selecting the Save button on the Standard toolbar; file the part
under the name Candle Holder. The extension, *.sldprt, is added automatically. Click Save.
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3. Select the Plane we want to Sketch on.

It is important to choose the correct plane to sketch on this is done by selecting the best profile to sketch of the part.
The best profile to sketch is the profile when selected extruded generated the majority or most complexities of the
part.

The direction we look at to part to get the get the best profile whether it be the plan, elevation or end view will
determine sketching on the Top, Front or Right Plane.

By giving careful thought to which plane is used to sketch the profile, the proper views are easily generated on the
detail drawing.
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Fig: Sketching Planes

Sketch toolbar

4. What is Design Intent:

Design Intent is our plan as to how our model should behave when changes are made. How Do we Imbed Design
intent?

We can imbed design intent following the steps below:

• Choose the Best Profile

• Choose the Plane

• Sketch

 Rough Sketch

 Automatic (sketch) Relations

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 Added Relations

 Dimensions  Equations

 Link Values
• Extrusion

 Type of extrusion used

• End Condition

 Blind

 Mid Plane

4. Create our sketch by selecting the Top Plane and then the Sketch Icon

• Rule of Thumb When Sketching

– Rough Sketch
– Add Relations

– Add Dimensions

Relations such as parallel, horizontal, vertical and tangent and so on, can be automatically added to the sketch
while sketching.

• Link Values / Equations

5. We know we are actively in a sketch by the following screen

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6. Select the Line Command on the sketch toolbar and draw a rectangle on the screen.

The positioning of the sketch in relation to the origin is important. ( your sketch must be attached to the origin in
some form in order to fully define the sketch)

Tip: By positioning the origin in the centre of the square by using a construction line the origin is positioned in the
centre. This enables you to place the circle in the centre of the cube later on.

7. Dimension the Sketch using the dimension icon.

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8. Conditions of a Sketch. Under Defined

There is inadequate definition of the sketch, but the sketch can still be used to create features. This is good
because many times in the early stages of the design process, there isn’t sufficient information to fully define the
sketch. When more information becomes available, the remaining definition can be added at a later time. Under
defined sketch geometry is blue (by default).

Fully Defined

The sketch has complete information. Fully defined geometry is Black (by default). As a general rule, when a
model is completed, the sketches within it should be fully defined.

Over Defined

The sketch has duplicate dimensions or conflicting relations and it should not be used until repaired.
Unnecessary dimensions and relations should be deleted. Over defined geometry is red (by default).

9. Select the Features Icon on the Command Manager.

10. Select the extrude command and extrude the 2d Profile.

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Design Intent at extrusion stage.

• Examples of design intent in respect of features

– Base Extrude

– Revolve

– Cut Extrudes

– Shell

– Fillets

– Chamfer

• Examples of design intent in respect to End Conditions of features

– Blind
– Through all

– Mid-plane

– Up to Next

– Up to Surface

Fig. Extruded 2D sketch

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11. Select Top Face of the Cube and create a sketch by selecting the Sketch icon

12. Select a circle command start the center of the circle at the origin.

13. Select the Cut Extrude command form the Feature Tool Bar.

14. Cut Extrude Blind into the cube or as required.

15. Create a Sketch on the Front Face of the Cube.

16. Using the Centre Line command sketch a centre line across the diagonal
17. Using the Polygon Command, sketch a polygon starting on the midpoint of the centreline.

18. Select the top line of the polygon and add the relationship of horizontal in the Property
Manager
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19. Dimension the top line of the polygon.

20. Cut Extrude the Sketch.

21. Add a chamfer to the Polygon.

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Fig. Chamfer options and Projected view of chamfered part.

22. Select all 6 edges of the Polygon.

23. Apply the same chamfer to the edge of the circle.

24. Add Fillet to all 8 edges as can be seen in Picture.

25. Select Fillet command from the Features Tool Bar.

26. Select the options like dimension and angle of fillet.

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Projected view of Fillet

27. Apply a material to the part. In the Feature Manager right click on add material and

select any material(say brass) and say ok.

29. Save the Part File as *.SLDPRT format.

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4. REFERENCE GEOMETRY
Reference geometry assist in creating the CAD models. Reference geometry includes planes, axes, points and
coordinate systems. These reference geometries act as a reference for drawing the sketches in sketched features,
defining the sketch planes and assembling the components.

They also serve as a interface for various placed and sketched features and so on.

Fig. Reference geometry option in toolbar.

4.1 Types of Reference Geometry

4.1.1 Reference Planes

This feature allows the user to create additional planes to sketch on other than the given right, front, and top plane.
To create a reference plane left click on plane and select the desired
option in the property manager for creating the plane. These options
include:

1. Through lines/points: creates a plane through a point an edge,

sketch line, three points, or axis.

2. Parallel plane at point: creates a plane through a point parallel to a

plane or face.

3. At angle: create a plane through an axis, edge or sketch line at a

specified angle from a face or plane.

4. Offset distance: create a plane parallel to an existing plane and

specifying the desired distance.

5. Normal to curve: Create a plane through a specified point

and makes it perpendicular to a desired curve or edge.

6. On surface: creates a plane on a non-planer face or angled

surface.

4.1.2 Reference Axes

Allows the user to insert an axis in the part document. Axes are
particularly useful in creating part features. To create a reference axis left
click on axis and select the desired option in the property
manager for creating the axis. These options include:
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1. On edge: places an axis on a desired edge or sketch line of the part.

2. Two planes: create an axis at the intersection of two planes or planar faces.

3. Two points/vertices: create an axis through two selected points, vertices, or midpoints on a line, edge, or
part corner.

4. Cylindrical/conical faces: places an axis through the center of a circular, cylindrical, or conical face. This axis
can also be seen by right clicking on view and then selecting temporary axes.

5. Point and a face: creates an axis perpendicular to a selected face or plane and through a selected point,
midpoint, or vertex.

4.1.3 Reference Coordinate Systems

Create an additional coordinate system on
the part by specifying the x, y, and z
directions with the parts geometry. This can
be helpful when integrating a part into an
assembly as a reference for directional part
interactions as well as setting up a zero point
for machining and manufacturing the part.

4.1.4 Reference Point

Add a singular location on a part document that
references geometries found on the modeled part.
These can be placed at the center of an arc, the center of a face, an intersection, along a curve, or projected onto
another entity. These can be helpful in making point clouds to help define and place three or two dimensional
sketches. Most commonly used in complicated parts such as vehicle frames.
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5. ASSEMBLY MODELING
Assembly is a combination of two or more components using parametric relationship. In solid works, these relations
are called Mates. These mates enable you to constrain degrees of freedom of the components at their respective
work positions. Components can be part or sub assembly.

5.1 Types of Assembly Design Approach

There are two approaches for making an assembly.

 Bottom-up Design  Top-down

Design

Bottom-up Design

It is the traditional method. In bottom-up design, you can create parts, insert them into an assembly, and constraint
them as required by your design. Bottom-up design is the preferred technique when you are using previously
constructed, off-the-shelf parts. An advantage of bottom up design is that, because components are designed
independently, their relationships and regeneration behavior are simpler than in top-down design.
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Top-Down Design

In top down design you can start your work in the assembly and built parts to fit in the assembly. You can use the
geometry and built parts to fit in the assembly. You can use the geometry of one part to help define the other parts
or to create machined features that are added only after the parts are assembled. You can start with a skeleton
model/layout sketch that defines fixed part locations, planes and so on. Then design the parts referencing these
definations.

5.2 ASSEMBLY MATES

Mates create geometric relationships between assembly components. As you add mates, you define the
allowable directions of linear or rotational motion of the components. You can move a component within its
degrees of freedom, visualizing the assembly's behavior. Mates are solved together as a system. The order in
which you add mates does not matter; all mates are solved at the same time. You can suppress mates just as you
can suppress features. These include:

• Standard mate
• Advanced mate
• Mechanical mate
• Smart mate
• Mate reference

5.2.1 Standard mate

Mates create geometric relationships, such as coincident,

perpendicular, tangent, and so on. Each mate is valid for
specific combinations of geometry. The following tables list the
valid mates for all geometry types.

• Coincident - The Coincident mate is applied to make two

planar faces coplanar. However, you can apply the
Coincident mate to other entities as well.

• Concentric - The Concentric mate is used to align the central

axis of one component with that of the other. You need to
select the circular faces or circular edges to apply the
Concentric mate. You can also apply the Concentric mate
between a point and a circular face or a circular edge.

• Distance - The Distance button is chosen to apply the Distance

mate between two components. To apply this mate, invoke
the Mate Property Manager and select the entities from
both components. Choose the Distance button from the Mate
pop-up toolbar; the Distance spinner will be displayed in the
Mate pop-up toolbar.
• Angle - The Angle button is used to apply the Angle mate
between two components. This mate is used to specify the
angular position between the selected plane, planar face, or
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edges of the two components. To apply this mate, invoke the Mate Property Manager and select the
entities from the two components.

• Parallel - The Parallel button in the Mate pop-up toolbar is used to apply the Parallel mate between two
components. To apply the Parallel mate, invoke the Mate Property Manager and select two entities from
two components.

• Perpendicular - The Perpendicular button in the Standard Mate rollout is used to apply the
Perpendicular mate between the two components. Invoke the Mate Property Manager and select two
entities from two components.

• Tangent - The Tangent button available in the Mate pop-up toolbar is used to apply the Tangent mate
between two components. To apply the Tangent mate between two components, invoke the Mate
Property Manager and select two components.

5.2.2 Smart Mate

Smart Mates is the most attractive feature of the assembly design

environment in Solid Works. The Smart Mates technology speeds up the
design process in the assembly environment of Solid Works. To add smart
mates to the components, choose the Move Component button from the
Assemble Command Manager ;the Move Component

Property Manager will be displayed .Now, choose the Smart Mates button
available in the Move rollout; the Move Component Property Manager
will be replaced by the Smart Mates Property Manager.

5.2.3 Mate Reference

In Solid Works, you can define the mate reference for the part in the Part
mode or in the Assembly mode. The mate references allow you to define
the mating references such as planar surfaces, axes, edges, and so on before
assembling the component. To define the mate references, choose
Reference Geometry > Mate Reference from the Assemble
Command Manager; the Mate Reference Property Manager will be
displayed.

5.2.4 Advanced Mates

Advanced mates include limit, linear/linear coupler, path,

symmetry, and width mates.

• Symmetric
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A symmetric mate forces two similar entities to e symmetric about a plane or planarface of a
component or a plane of the assembly. The following entities are allowed in symmetry mates:

 Points such as vertices or sketch points

 Lines such as edges, axes or sketch lines

 Planes or planar faces  Spheres of equal radii

 Cylinder of equal radii

• Width
A width mate centers a tab within the width of a groove . groove width references caninclude:
 Two parallel planar faces  Two non-
planar faces

• Path
A path mate constrains a selected point on a component, to a path. You can define thepath by
selecting one or more entities in the assembly. You can define pitch, yaw and roll of the component as it
travels along the path.

• Linear/linear Coupler
A linear/linear coupler mate established a relationship between the translation of onecomponent and
the translation of another component.

• Linear
Limit mates allows components to move within the range of values for distance or angle as well as a
maximum and minimum value.

5.2.5 Mechanical Mates

Mechanical mates include cam-follower, gear, hinge, rack and pinion,

screw, and universal joint mates.

• Cam
A type of tangent or coincident mate. Asks the user toselect all
of the cam face to which the follower will lie on and the face of the
follower that will touch the cam.

• Hinge
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Constrain two components rotational degrees of freedom. Asks user to input two concentric sections,
coincident faces, and the angle limit (how far the components can move from each other – identical to
angle mate).

• Gear
Mates two gears or cylindrical faces so that the two components rotate relative to one another about an
axis.

Note: Select the inside bore hole of the gear or the axis, do not select the face of the gear.

• Rack Pinion
Similar to the gear mate except that the revolution of one component corresponds to the linear
movement of the mating component. This mate does not require gear teeth.

• Screw
Constrains two components with a concentric mate and defines a pitch relationship between the
rotation of one component and the translation of another.

• Universal Joint
The rotation of a component about its axis is controlled by the rotation of the mating component about
its axis.

5.3 ROTATING INDIVIDUAL COMPONENTS

In SolidWorks, you can rotate an individual unconstrained component in the assembly document without
affecting the position and location of the other components. The Rotate Component tool is used to
rotate the component.

5.3.1 Rotating Individual Components by Dragging

You can rotate the component placed in the assembly without invoking any tool. To rotate an individual
component, select the component, press and hold the right mouse button and then drag the cursor to
rotate the component. Release the right mouse button after attaining the desired orientation of the
individual component.

5.3.2 Rotating Individual Components Using the Rotate Component Tool

You can also rotate an individual component using the Rotate Component tool. To rotate an individual
component using this tool, choose Move Component > Rotate Component from the Assemble Command
Manager; the Rotate Component
Property Manager will be invoked. You will notice that the Free Drag option is selected from the Rotate
drop-down list in the Rotate rollout. Therefore, you will be prompted to select a component and drag it
to rotate. The select cursor will be replaced by the rotate cursor. Select the component and drag the
cursor to rotate the component.
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6. DRAWING VIEWS
Drawings are essentially a mean to communicate the design to the manufacturing entity of any organization.
Mechanical drawings are important because they allow those who are technically trained to reconstruct your 3D
geometry from 2D drawings. Fortunately, SolidWorks makes it very easy for us to create drawings from a part or
assembly file. In fact, if built properly, SolidWorks will also dimension the entire part and assembly for us,
something that saves a lot of time.

More important than the ability to create a complex lofted surface is the fact that once you have modeled your
design, multiview drawings are just a few mouse clicks away. BOM’s can be created automatically from the
assembly structure, and alternate position views are generated with a simple drag of the mouse.

6.1 Steps Involved In Creating Drawing Views

1. Click New in the standard toolbar, or click file>> new from the menu bar.
2. In the new solid works document dialog box that is displayed, as shown, select the drawing option and click
ok.
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3. Select the desired sheet format in sheet format/size dialog box as shown in earlier topic and then click ok.
Click cancel, if you do not want to use any sheet format. You can also create custom sheet size selecting
custom sheet size.

4. In model view property manager, select a model from open documents as shown or browse to part or
assembly file.

5. Specify options in the Model View Property Manager, and then place the view in the graphics area.
6. Position the Front Elevation on the drawing sheet and Left click.
7. Move Mouse to the Left of the Front Elevation to Create the Side Elevation (left click to position view).
8. Move Mouse Under the Front Elevation to Create the Plan View / Top View (left Click to position View).
9. Move Mouse up too the Left Diagonal of the Front View to Create
the isometric view. Hold down the Ctrl key and position the view
under the Side Elevation.

10. Hold Down the Ctrl Key and Select all Drawing Views.
11. Select the Hidden Lines icon from the views toolbar to show hidden
lines in all views.

12. Drawing Views Should Look like below.

13. Smart dimensions can be used to apply any missing dimensions manually.

14. For saving the file, click save in the standard toolbar or click
file>>save. The file will be saved with .slddrw.
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7. SHEET METAL
Sheet metal is simply metal formed into thin and flat pieces. It is one of the fundamental forms used in
metalworking, and can be cut and bent into a variety of different shapes. The main feature of sheet metal is its
ability to be formed and shaped by a number of processes.

Each process does alter the metal, finally giving it a different shape or size.

Sheet metal is generally sheets less than 6 mm. Sheet metal is formed by reducing the thickness of a long metal
work piece by compressive forces applied through a set of rolls. It is characterized by its thickness or gauge of
the metal and ranges from 30 gauge to about 8 gauge. The higher the gauge, the thinner is the metal.

There are many different metals that can be made into sheet metal. Aluminum, brass, copper, cold rolled steel,
mild steel, tin, nickel and titanium are just a few examples of metals that can be made into sheet metal. Sheet
metal has applications in car bodies, airplane wings, etc.

7.1 Sheet Metal Tools

When you create a sheet metal operation in SolidWorks, new feature namely, sheet-metal , base-flange and
flat-pattern, are automatically created. Sheet-metal contains the bend parameters such as bend radius, bend
allowance, bend deduction, etc. Base-flange is the first solid feature of sheet metal part. Flat-Pattern flattens the
sheet metal part. It is suppressed by default, as the part is in its bent state. Unsuppress the feature to flatten the
sheet metal part. There are various tools within the part module that SolidWorks provides to build the sheet
metal parts.
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7.2 Base Flange 7.3 Edge Flange

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A base flange is the first feature in a new sheet metal part When you add a base flange feature to a SolidWorks
part, the part is marked as a sheet metal part. Bends are added wherever appropriate, and sheet metal specific
features are added to the FeatureManager design tree.

Edge Flange is used to add flanges to one or more edges. You can also select multiple linear edges, which are
contiguous or non- contiguous. With contiguous edges, the software automatically trims to 45 degrees.

7.4 Miter Flange

A miter flange feature adds a series of flanges to one or more edges of a sheet metal part. Some items to note

about a miter flange feature are: 1. The sketch for a miter flange must adhere to the following requirements:

 The sketch can contain lines or arcs.

 The miter flange profile can contain more than one continuous line. For example, it can be an L-
shaped profile.
 The sketch plane must be normal to the first edge where the miter flange is created.
2. The thickness is automatically linked to the thickness of the sheet metal part.
3. You can create a miter flange feature on a series of tangent or non-tangent edges.
4. Instead of creating a miter flange across the entire edge of a sheet metal part, you can specify an offset of
the flange.
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7.5 Hem
The Hem tool adds a hem to your sheet metal part at a selected edge. The following points are to be noted for
Hem feature.

1. The selected edge must be linear.

2. Mitered corners are automatically added to intersecting hems.
3. If you select multiple edges to add a hem, the edges I must lie on the same face.
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7.6 Jog
The jog tool adds material to a sheet metal part by creating two bends from a sketched line. Some additional
items to note about the Jog tool are:

1. The sketch must contain only one line. The line does not need to be horizontal or vertical.
2. The bend line does not have to be the exact length of the faces you are bending.
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7.7 Break Corner/Corner Trim

The Break Corner tool cuts away material from a sheet metal part on an edge or a face. The Corner Trim tool
cuts material away from a flattened sheet metal SB on an edge or a face.

7.8 Closed Corners

You can add closed corners between sheet metal flanges. The Closed
Comer feature adds material between sheet metal features. The following
are the capabilities of Closed Comer:
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1. Close multiple corners simultaneously by selecting the faces for all the comers that you want to close.
2. Close non-perpendicular corners.
3. Apply a closed corner to flanges with bends other than 90°.
4. Adjust the Gap distance, the distance between the two sections of material where area is added by the
Closed Comer feature.

5. Adjust the Overlap/Underlap ratio. The ratio between the material that overlaps and the material that
underlaps. The value 1 indicates that the overlap and the underlap are equal.

6. Close or open the bend region.

Closed corner

7.9 Rip
A Rip feature is a cut that is used to "saw" a part along a specified line or edge. SolidWorks creates a rip feature,
along selected internal or external model edges, from linear sketch entities or by combining model edges and
single linear sketch entities. A rip feature is commonly used to create sheet metal parts. You can add a rip
feature to any part.

7.10 Sketch Bend

You can add bend lines to the sheet metal part, while; the part is in its folded state with a sketched bend feature.
This allows you to dimension the bend line to other folded-up geometry. Some items to note about a sketched
bend feature are:

1. Only lines are allowed in the sketch. You can add more than one line per sketch.
2. The bend line does not have to be the exact length of the faces you are bending.
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7.11 Unfold/Fold

With the Unfold and Fold tools, you can flatten and bend
one, more than one or all the bends in a sheet metal
part. This

combination is useful while adding a cut across a bend. First, add an Unfold feature to flatten the bend. Next,
add your cut. Finally, add a Fold feature to return the bend to its folded state.

7.12 Forming Tools

forming tools act as dies that bend, stretch, or otherwise form sheet metal to create form features such as
louvers, lances, flanges and ribs. The SolidWorks software includes some sample forming tools to get you
started. They are stored in < mstai/_dir >\data\design library\ forming tools. You can insert forming tools only
from the Design Library and you can apply them only to sheet metal parts. A sheet metal part has the Sheet-
Metal I feature in the FeatureManager design tree. You can create your own forming tools using many of the
same steps you use to create any SolidWorks part.

Creating a Forming Tool

You can create forming tools and add them to sheet metal parts. When you create a forming tool:

1. The locating sketch is added to position the forming tool on the sheet metal part.
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2. The colors are applied to distinguish the stopping face from the faces to remove.

7.13 Cross Break

In HVAC (Heating, Ventilating and Air Conditioning) or duct work
design, cross breaks are used to stiffen sheet i metal. The Cross Break
command allows you to insert [ a graphical representation of a cross
break in a sheet metal part. Cross break characteristics:

1. You can flatten a sheet metal part with a cross break.

2. You can add edge or miter flanges to the edge of a face that
contains a cross break.

3. The dimensions of a part with a cross break are not changed.

4. You can edit the cross break sketch to move comers and change
relationships.

5. When you create a part with a cross break, the flattened view is labeled with the bend direction, bend
radius and bend angle.
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7.14 Welded Corner
The Welded Comer PropertyManager allows you to add a weld bead to the corners of a folded sheet metal part,
including miter flanges, edge flanges and closed comers.

7.15 Lofted Bends

Lofted bends in sheet metal parts use two open-profile sketches that are connected by a loft. The Base-Flange
feature is not used with the Lofted Bend feature The SolidWorks software contains several pre-made sheet metal
parts created with lofted bends, locate! in:
<install_dir>\Documents and Settings\AIl Users! Application Data\SolidWorks\SolidWorks 2010\desig* library\
Parts\sheet metal\lofted bends.

Characteristics of Lofted Bends:

1. K-Factor or Bend Allowance to calculate bends.

2. Cannot be mirrored.
3. Requires two sketches that include:

 Open profiles without sharp edges.

 Aligned profile openings to ensure flat pattern accuracy.

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8. WORKBOOK
8.1 Part Modeling

Fig. Pivot

Fig. Body of Vice

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Fig. Spring

Fig. Screw Rod

 44
8.2 Surface Modeling

Fig. Water Container

Fig. Oil Can

 45

Fig. Helmet

8.3 Sheet Metal

Fig. CPU cover

 46

Fig. Amplifier Cover

8.4 Assembly

Fig. Safety Valve

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Fig. Machine Vice