Lab Demonstrations

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Lab Demo l - Counter Block

Open a new part file and save it as LabDemol. Right click Right Plane: Sketch: Line. Starting at the origin, draw a line approximately 4.4 horizontally inches to the left, 1.4 inches up, 3 inches to the right, up at a 45 deg angle, 1.4 inches to the right, 1.4 inches down, and back to the origin at about a 45 deg angle. Smart Dimensions: click on left most vertical line and right most vertical line and make the distance between them 5.8 inches. Make both vertical lines 1.4 inches, the right top horizontal line 1.4 inches and the left horizontal line 3.0 inches. Make the horizontal dimension of the right angled line 1.4 inches, and make the total vertical dimension 2.8 inches. The drawing should be fully defined. If not, type escape, click on the starting point, control click on the origin and make them coincident. Feature Tab: Extrude Boss/Base: 3 inches, MidPlane (to keep the origin in the plane of symmetry). OK Rename feature to "CB Base." Check Point 1, Save file. Right click top left face. Sketch: Top View. (Use the transparent Heads Up toolbar at the top of the work area to set the views.) With circle tool, draw a circle in the middle of the face. With Smart Dimensions make the circle 1.6 diameter, and 1.5 inches up and to the right from the lower left comer. Feature Tab: Extrude Cut .4 inches, blind. OK Rename to "CounterBore Top" (Since this in not a standard counterbore for a fastener, Hole Wizard will not be used.) Right click bottom of hole just extruded, sketch, top view. Select circle tool, tickle the edge of the circle until the center mark appears. Draw a circle concentric with the previous one and

make it .6 in diameter. Feature Tab: Extrude cut - Through All. OK. Rename to "CounterBore Thru". Right click on top left face again: sketch: top view. With corner rectangle tool draw a vertical rectangle across the width of the face, centered on the hole. Make it .4 wide. Select center line tool. Draw a center line from origin to the mid point of the top horizontal line of the rectangle. Escape: select center line and make it vertical. Extrude cut: up to surface: select bottom of counter bore, OK. Rename to "CounterBore Slot." Check Point 2, Save file. Isometric view: Right click right face: Sketch: right view. Draw a circle on the selected face: Dimensions: .8 diameter, .8 from bottom and 2.1 from far right side. Extrude Cut: Through All. Rename to "Side Hole." Isometric View: Right click top right face: Sketch: Top View. Line Tool: draw a horizontal line: Start drawing from end point, go back and retouch this end point and you will switch to a tangent arc tool. Draw a half circle starting at right end point of line and going to me right and down to make a half circle. Draw a line to the left to right under the starting point: Start drawing from end point, go back and retouch this end point and you will switch to a tangent arc tool and complete the slot. Dimension slot: .6 from left edge, .7 from top (these are to centers of arc) 1.8 center-to-center and .3 radius. Extrude Cut: 1.1 inches: Blind: OK. Rename "Top Slot."

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Click on Fillet Tool. Set radius to .4 inches. Select the two vertical front edges. OK. Rename to "Rounds." Save part to prepare to bring into a drawing. Check Point 3, Save file. Open a landscape title block (TBLand). Save as LabDemol. Select View Layout Tab: Standard three view. Bring in a standard three view drawing of the part. Make sure tangent edges are removed and hidden lines are visible. Set the default scale to 1:2. View : Open Layer Properties (found at lower left of screen): New: Dimensions. Make the color Royal Blue. Click OK. Insert: Model Items: Import From: Change to Entire Model. OK. Annotations Tab: Smart Dimensions: Add dimensions to the depths on the slots in the front view. These are to hidden lines, but these dimensions will not be visible when you are done. Move all the dimensions (shift drag) for the counterbore hole to the top view. Annotations Tab: Select Note Icon: Click on big hole. Click on .60 dimension and the diameter sign and value are entered in the note. Pick counter bore symbol (under Add Symbols: Hole Symbols), click on 1.60 dimension, pick depth symbol (hole symbols), click on .40 depth in front view. Highlight all text and change font size to 10 point. OK. Right click on each of the three CB dimensions and select hide. Do not delete these dimensions. Repeat for top slot. Pick Note Icon, click on arc of slot, click to set note, click on .30 radius dimension, pick depth symbol, click on 1.10 depth dimension in front view. Highlight all text and change font size to 10 point. OK. Right click on each of these dimensions and select hide. Do

not delete these dimensions. Check Point 4, Save file. To add center marks to the slot arcs select Annotations Tab: Center Marks. Uncheck Use Document Defaults and then Extended Lines. This will add only center marks. Clock on both arcs to add marks then hit escape to close box. Drag all the dimensions for the side hole to the right view. If the diameter dimension is a linear dimension rather than a leader, right click on the dimensions, Display Options and select “Display as Diameter.” Select the R.4 dimension for the rounds. In the property manager click before R<dim> and type “2X ”. Click on all the dimensions and check to see that the extensions lines are the correct length. Many of the dimensions will go to the center of the block since the first extrusion was MidPlane so the grips of the extension lines will have to be moved off the body. Clean up and align the dimensions. Adjust the leaders of the two notes so that they point to the center of the arc they are attached to. Click on View Layout Tab: Model View, select LabDemol, click on blue arrow and select isometric view. Move cursor to upper right of drawing and click to set view. With the isometric view selected (green border around it) select "Hidden Lines Removed" in the view menu to eliminate the hidden lines. Check Point 5, Save file. To add items to the title block, right click on a white area of the drawing and pick "Edit Sheet Format". Carefully double click on "Drawing by", set the cursor to the right of the colon and type in your name. For the drawing title type in "Counter Block", Drawing Number

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"A24785", tolerance ±.01 and Scale "1:2". The other items may be added in a like manner. When you are done right click in the drawing area and select "Edit Sheet" to get back to the drawing. Check Point 6, Save file. When printing out, make sure the printer is set to print black and white, not gray scale or color. The drawing's borders should be a dark black and not a light

gray. A printout of a completed drawing is shown on a later page. You will have two files at the completion of this demo – a part file and a drawing file. They are linked. You must have the part file available in order to open the drawing file so keep them together.

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Lab Demo 2 – Counter Block Configurations In the folder LabDemo2 open the part file LabDemo2. Right click on CB Base and select Edit Sketch. To make dimensions parametrically dependent on another one use an equation. In the Menu Bar select Tools: Equations. In the dialog box, select Add. Click on the vertical 1.4 dimensions on the left. In the box you will see something like “D3@Sketch1”. This is the name of that dimension. Then type in “=.5*” and click on the 2.8 vertical dimension. OK The front height now will always be 1/2 the total height. Close the equation box and click on OK (the purple check mark) to accept the sketch. The equations may also be entered directly without opening a sketch. Right click on Annotations in the Feature Manager and select Show Feature Dimensions. Tools: Equations: Add. To keep the counter bore in the center of the face, click on the 1.5 front back dimension, type “=.5*”, then click on the 3.0 length dimension. OK. Add. Click on the 1.5 width dimension, type “=.5*” then click on the 3.0 width dimension. This will be blue as it arose from an extrusion. OK. OK. Right click on Annotations in the Feature Manager and select Show Feature Dimensions to toggle the dimensions off. Check Point 1. Save Demo. We may want to have other parts like this one with different dimensions and or features. We can put these in the same part file by using different configurations. In the feature manager, click on the third tab over at the top to get to the configuration manager. Right click on the top line and select Add Configuration. Give the new configuration a name “Big Block”. OK. Double click on the Big Block name to select that configuration. Return to the feature manger by clicking on the left-most tab at the top.

Double click on the CB Base to view that feature’s dimensions. Change the 2.8 height to 4.8, and in the right-most pull-down change All Configurations to This Configuration, OK Also change the 5.8 length to 8, the 3.0 width to 4.0 and the 3.0 length to 5.0 selecting This configuration each time. Click the rebuild icon (the red-green traffic light in the menu bar) to update the sketch. The slot is no longer centered. We can use an equation to keep that centered. Right click on Annotations in the Feature Manager and select Show Feature dimensions. Tools: Equations: Add. Click on the .6 spacing dimension, type “=.5*(“, click on the blue width dimension. “-“, click on the width of the slot, “)”. OK. OK. Rebuild. The slot will be centered. Right click on Annotations in the Feature Manager and select Show Feature Dimensions to toggle the dimensions off. Check Point 2. Save Part. Return to the configuration manager. Double click on Default configuration, then right click on the top line and select add configuration. Call this configuration “Altered Block.” Return to the Feature Manager. Right click on Top Slot and choose suppress (the third icon from the left on top.) Expand Slot in the tree and select its sketch. Type Control C to copy it, click on the top face and type Ctrl-V to paste it. A new sketch is in the feature tree. Right click and edit sketch. Add the .6 and .7 dimensions to position the slot. Extrude Boss/Base: 1.1 inches up. OK. This inverts the slot. Rename feature “Outer Slot” and drag it up under Top Slot. Double click on CounterBoreTop and change the diameter for This Configuration to 2.0. Finally right

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click on the angled face: Sketch: Normal To. Draw a vertical center line. Circle: draw a circle on the right half. Dimension it .75 diameter, .75 from outside edge and 1.0 from the edge where the origin is. Sketch Mirror: select circle to be mirrored and the center line as the mirror line. Feature Tab: Extrude Cut: through All: OK. Rename Eye Holes. Check Point 3. Save Part. If you return to the configuration manager you can double click on the three different configurations and see the changes that have been made. If the slots are not correct go to each part configuration and make sure the slot is unsuppressed and Outer Slot is suppressed in Default and Big Block and the reverse for altered Block. For another review on adding and cleaning up dimensions, open LD2CkPt4. This is a three view of the Big Block configuration with a dimension layer already active. Change the layer to none and turn on the origins. Delete the right view. (View: Origins) Select a center line from the sketch tool bar. Place the cursor over the origin on the front view and “tickle it” move the cursor over the origin to activate it. Carefully move the cursor down getting a dashed blue line and place it about where the purple box is. Click and drag up to the upper purple line and release. Select View Layout Tab: Section and place the new section to the right of the front view. Make sure that the arrows point away from the section view and make sure that the section view has hidden lines removed. Shut off the origins. Activate the dimension layer. Deselect all views. Annotations Tab: Model Items: Change selected features to entire model:

OK. You will find most of the dimensions in the section and the top and right views and none in the front. Move the dimensions around so that they are in the best view for them. The dimensions for the two circles of the counter bore should be in the top view. If these dimensions have extension lines, right click on the dimension, select Display Options: Display as Diameter. OK. Add center marks to the slot arcs as was done in the last demo. Drag all the dimensions for the side hole to the right view. Select the R.4 dimension for the rounds. In the property manager click before <dim> and type “2X ”. Click on all the dimensions and check to see that the extensions lines are the correct length. Many of the dimensions will go to the center of the block since the first extrusion was MidPlane so the grips of the extension lines will have to be moved off the body. Clean up and align the dimensions. Adjust the leaders of the two notes so that they point to the center of the arc they are attached to. Also check to see that you are not dimensioning to any hidden lines. As there are two decimals places in the units the tolerance should be ±.01. Right click in a white area of the drawing: Edit Sheet Format. Double click on Tolerance, place the cursor to the right , select add symbol and under modifying symbols select plus-minus. OK. Type .01 and click in drawing. Right click on drawing: Edit Sheet to return to the model view. Add an isometric view without hidden lines to the drawing. Check Point 5. Save drawing.

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Lab Demo 3 – Design Tables

When many different configurations of a part are needed the dimensions are put into a design table for simplicity, rather than changing the dimensions for each different configuration. Open a new part file and save it as labdemo3. Right click Front Plane: Sketch. Center Line. Draw a horizontal center line through the origin. Line: starting at the origin, go up .125, right 1, up .08, right .25, down to the centerline, back to the origin to finish. Smart Dimension Click on 1 inch line, click on centerline, drag across centerline set diameter dimension: .25. Click on edge of head, click on centerline, drag across centerline to set diameter: .375. Make length of body 1 inch and length of head .25. Feature Tab: Revolved Boss/Base. OK. Rename “Screw Body.” Right click on right end of head: Sketch: Right View. On the menu bar: Tools: Sketch Entities: Polygon. Make sure parameter box has a 6 (hexagon). Click on origin and drag to the right, release. Dimension the inscribed circle to 3/16. Escape: Click on right vertex, control click on the origin, pick horizontal. Extrude cut .120 deep. OK. Rename “Hex Socket.” Check Point 1. Save File. Click on bottom end edge of screw. On Menu Bar: Insert: Annotations: Cosmetic Threads. Make minor diameter .2 and the length of threads .67. OK. For shaded cosmetic threads: right click on Annotations in the Feature Manager, pick details and check shaded cosmetic threads. Click on Bottom Edge of Screw. Fillet pull-down icon: Chamfer. Set distance to .025 and angle to 45º. OK. Rename “End Chamfer.” The screw is done. Check Point 2. Save File. To simplify and clarify the design table we will now rename the dimensions. Right click on Annotations in the Feature Manager and

select Show Feature Dimensions. Grab the dimensions and move them off the part so they are clearly seen. Right click on the φ.25 dimension and pick properties. Near the top is a box labeled name and D1 is in the box. Change it to “Major Diameter.” Likewise change φ.38 to “Head Diameter”, 1.00 to “Length” .25 to “Head Height”, φ.19 to “Hex Size”, .12 to Hex Depth”, .67 to “Thread Length”, .20 to “Minor Diameter and .03 to “Chamfer.” To insert the design table, Insert: Design Table. Pick Auto Create, OK. For “Dimension to Include” select everything except D1@screw base and D2@Chamfer as these dimensions – the rotation angle and chamfer angle – will not change. OK. The design table will appear with all the dimensions except the minor diameter and thread lengths. These are not used in the part construction so SolidWorks does not add them. We will insert them. Close the table by clicking in the drawing. Move the part so that the .20 and .67 dimensions will be visible when the table opens. You may have toplay with it a bit ti get the minor diameter to show, or even edit the cosmetic thread feature a couple of times. Check Point 3. Save Part. In the Configuration Manager right click on Design Table and select Edit Table. This is a standard Excel table and is edited as such. Click on the blank box next to Chamfer@End Chamfer (I2) then double click on the .20 dimension in the part. That dimension will be added to the table. Repeat for .67 dimension (thread length.) Adjust the column order so they are major diameter, length, head diameter, head height, hex size, hex depth, chamfer, minor diameter and thread length. Some of these dimensions are proportional to other dimensions so we will put these relations into the table. Click on the .2 minor diameter. Type in “=.8*” and click on the .25 major

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diameter. Enter. Click on the chamfer .025 and type in “=(“, click on the major diameter, type “-“, click on the minor diameter, type “)/2”. Enter. For this screw the head height is equal to the major diameter. Click on the head height - .25 and type “=”, click on the major diameter, enter. The head diameter of this screw is 1.5 times the major diameter. Click on the head diameter, type “=1.5*”, click on the major diameter, enter. Finally click on the thread length .67 type “=2/3*” click on the length, enter. Feature Manager. Right click on Annotations in the feature manager and turn off the dimensions. Check Point 4. Save Part. To enter new configurations, just add new lines to the table. Configuration Manager, right click on Design Table, Edit Table. In the left column box below default (do not change the name of default) add “1-4X1”, below that add “1-4X1.5”, below that add “3-8X1.5” and below that add “1-2X2” to depict the four screws that we will have. (SolidWorks does not allow a “/” in the configuration name so we will use the – instead.) Copy the top row of numbers down to the next four rows. The default is the same as the 1/4 screw so those numbers are correct. For the second 1/4 inch screw, change the length to 1.5. For the other two change the diameters to .375 and .5 respectively, the lengths to 1.5 and 2, the hex size to 5/16 and 3/8 and hex depth to .182 and .245. The table is complete. Click in the drawing to close the design table. Go to the configuration manager and double click on the different size screws to make sure everything look OK. Double click on default and return to the Feature Manager. Check Point 5. Save File. Open a landscape title block. Save it as LabDemo3. Model View: Select LabDemo3, Blue Arrow: Right View. Place the view near the top right of the page. OK. Draw a centerline through the right view and create a sectioned front view. View: Origins to shut off origins. Layer Properties: Create a dimension layer. OK Model Items: OK. Move the

dimensions around so they are well placed. We want to change the dimensions so that they are generic names instead of number. Click on the major diameter .25. In the property manager highlight < mod diam> <dim> and Type “Major φ” a dialog pop up will appear warning that you are eliminating the link to the dimension as soon as you type the first character. Check the ”Don’t ask me again” box, OK, and continue typing. In a similar manner change the length, head φ and head height. Use two lines for the name when necessary. You should now have generic dimensions. Check Point 6. Save Drawing. To bring in the table, select the screw (green border) Annotations Tab: Table: Design Table. Drag it to a clear spot on the sheet. The table needs cleaning up. Go back to the part and edit the table. Click on the row marker 3. Right click and select insert to put in a new row. Type in the dimension names using diam for diameter and leaving out the @... part. Highlight the numbers, type control-1 to get to the format box, select numbers and three decimals. Select all the columns: Format: Column Width: 7 OK. Select the top two rows, right click and hide. Do not delete or change these rows as the table may become inoperative. Move the grips on the right and bottom so that only the cells with values appear. Highlight all the visible boxes. In the menu bar select the borders about each cell. To set the font size, while the table is highlighted pick a 10 point font. (For a larger table use a smaller font.) Click outside the table to close it and save the part. Control-Tab to the drawing and rebuild if necessary. OK Move the items on the sheet around until they look good. Fill in the Title Block and you are done. Check Point 7. Save File.

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Lab Demo 4 – Valve Lifter Assembly

In this demo an animated assembly of a valve lifter will be created. Open SolidWorks and then open the files Cam, Rocker Arm, Valve, Lifter, and Support. Open a new assembly file. Insert components will open automatically. Click on the push pin to keep the box visible. View: Origins to turn on origins. Bring in the following parts in this order: Support, Cam, Rocker Arm, Valve, Lifter. OK to shut box. when you bring in the first part, place your cursor over the origin already on the assembly and the part will snap to the origin. Note that the first part brought into an assembly will be fixed. To unfix a part, right click on its name in the feature manager and select “Float”. View Origins. In the Feature Manager, right click on Cam. Then select the appearance callout icon, and click on the box under color and beside Cam. Make the cam blue and the emissivity between .2 and .6. OK. Select the rocker arm and make it Red. Likewise make the valve green, the lifter yellow and the support gray. This will make the parts stand out a bit more in the assembly. To turn off the origins select view: origins. Check Point 1. Save Assembly as ValveLifter. Select Mate – the paper clip icon. Select the inside face of the left hole in the support (not the edge) and the outside face of the lifter. Check the strawberry field in the property manager to make sure both are faces. Concentric: OK. Do the same with the right hole and valve. Select the inside face of the cam hole and the outside face of the lower left peg. Concentric OK. Repeat with the rocker arm and the upper peg. Click and

drag the valve to center it on the support. Do likewise with the lifter. Note that in reality the valve and lifter would never be able to be assembled with the holes as both of their ends are larger than the holes.. They would have to be two pieces, but for this demonstration they will work. Click on the face of the rocker and the end face of its peg. Make this a distance mate with a .25 distance. Flip the dimension if the peg does not stick out beyond the rocker arm. OK. Create a .50 distance mate between the cam and its peg’s face. Click OK a second time to close mate property box. Check Point 2. Save Assembly. Mate: zoom in on left end of rocker arm: down arrow: select the top face of the lifter: up arrow twice: select the bottom curved face on the rocker arm peg: tangent mate. OK. Scroll over to the right end of the rocker arm and create a tangent mate between the valve top and the rocker arm peg. Type F to zoom out and fill screen. Click and drag the lifter up and down to observe the working so far. Move the cursor off the parts before releasing the mouse so as not to select any parts. In the Property Manager Select the Mechanical Mate box. Click on the cam mate. A Mate Selections dialog box appears. Carefully select all four side faces of the cam. Do not select the front or back face. Click on the Cam Follower Box. Click in a blank area of the drawing region – not on a part. Use the Cursor Arrows to rotate the assembly until you can select the bottom face of the lifter. OK. OK a second time to close

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the Mate Property Manager. Grab the cam with the mouse and rotate it observing the motion of the parts. Check Point 3. Save Assembly. To automate the motion, click on the Motion Study 1 tab just below the work area. A new box will appear at the bottom. In the upper left of this Motion Box change “Assembly Motion” to “Physical Simulation.” On the top bar of the Motion Box is a Motor Icon. Select this and in the property manager pick rotary motor. Click on the front face of the cam and use the reversing arrow in the Property Manager to have the rotation clockwise. OK. In the timing box, drag the top diamond out to 20 seconds. Then click the Calculate Simulation button just to the left of Physical simulation. Let it run for 20 seconds (It will stop automatically.) Pick the Play from Start button to begin the replay. You can pick a continuous loop, single loop, have it reverse direction at the end of the cycle as well as select the speed. Select the Model Tabs to return to the assembly. Check Point 4. Save Assembly. These simulations are neat to do, but real engineering requires assembly and detail drawings to be done so that the parts may be reproduced. In the Assembly Tab select Exploded View. Click in the component box and select the cam and rocker arm in the assembly; click in the direction box, then click on the z direction arrow on the part; make the distance 5. Click “Done” to move to the next step. Click on the component box and pick the Cam to move; click on the up arrow in the drawing and the reverse direction; make the distance 6. Click “Done”. Follow these sequences to move the rocker arm up 5 inches, the valve and

lifter out 3 inches, the valve and lifter down 5 inches and finally the lifter 2 inches to the left (-x direction.). OK to close explosion box. To add assembly lines to the exploded view: Explode Line Sketch. Click on inside face of cam hole: click on front face of cam peg on the support. Make sure the arrow points into the cam hole and not outwards. OK (Click green arrow.) Do the same with the rocker arm. Click on the top face of the lifter: click on the bottom inside face of the lifter hole. Do the same with the valve. OK: Accept Sketch (purple arrow in upper right corner.) The explosion is complete. You may have to edit and redo the cam mate after the explosion to make it work properly again. You may always collapse the assembly and replay the simulation. One last step need to be done before going into a drawing. In the feature manager, drag the support down below the lifter so that the order of parts is Cam, Rocker Arm, Valve, Lifter, Support. Check Point 5. Save Assembly. Open a landscape titleblock. Save as: Valve Lifter. Model View: Select Assembly: OK: Isometric View: Click in drawing to set assembly. View: Origins to turn off origins. Right click on sheet away from assembly: Properties: Set Scale to 1:4: OK. Annotations Tab: Balloons: click on edge of each piece to attach balloon and then in the drawing to set the balloon. Do for all five parts. OK. Click on any balloon that needs to be placed better and adjust.

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Select Assembly (green border.) Tables: Bill of Materials: Click OK to accept defaults. Click in drawing area to set BOM. Drag to select entire table. Click on “A” icon. Set font size to 8 pt. Make the justification centered for the whole table. Click outside table to deselect it. Grab each vertical line in table aside from leftmost and move to the left as much as possible to minimize column width. Click and drag on the upper left corner and move BOM table to upper right corner of title block border. All the items have the correct part numbers and part names except for the cam. Right click on the cam and select Open Part, if the cam is not already open. Click on the Configuration Manager tab, right click on default and select properties. At the bottom of the dialog box, pull down and select User

Specified Name. In the white bar above type in 25224 for the part number. Click on Custom Properties: In dialog box, select property name and pick Description from the pull down menu. Type in “Cam”: Add: OK: OK. Save part. The part numbers for the other parts are: Rocker Arm – 25268, Valve, 25142, Lifter 25230, and Support 12874. Control-Tab back to the assembly drawing and the BOM should be complete. Now all that has to be done to complete the drawing is to fill in the title block with the correct information. In a normal final assembly, Material, Tolerance and Next Assembly are left blank. All the other boxes are filled in. Check Point 6. Save Drawing.

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Lab Demo 5 – Assemblies and Interference

Many parts are originally designed to fit well with other pieces, but when they have to move with respect to their fits, the interfere with the other parts and cannot perform the required motion. This demo will show how to detect these interferences and correct for them. However nothing beats careful planning in the design before hand to avoid these interferences. Open the two parts – “Piers” and “Span” in LabDemo4 folder. Open a new assembly file; the insert components manager opens automatically. Click on the push pin to keep it open. View: Origins to turn on origins. Select the piers, place the cursor over the origin and click in the assembly drawing area to fix the part. Select the span and bring it into the area. OK. Save the assembly as LabDemo5. View: Origins to shut off origins. Mates: Select inside face of hinge hole on both the pier and span: Concentric: OK. Select the front faces of both: Coincident: OK. Select the front top edge of the span and the front left top edge of the pier. (These are colinear lines right now): Pick an angle mate: 90º: enter: Advanced Mate: Down near the bottom of the Advanced dialog box make the minimum 0º. OK. OK again to close the mate box. The span is fully mated to the pier, but may rotate through a 90º angle. Check Point 1. Save Assembly. Front View. Grab and lift the span. You will notice the bottom right corner passes through the pier. The span is the exact same width as the opening between the piers so it should not move. Double click on the span, double click on the 6.00 dimensions and make it 5.98

– allowing for .02 clearance. OK. Rebuild (The green light in the top menu bar.) Now there is a little clearance between the parts, but they still interfere as the span is lifted. Control-Tab to the span part. Push and hold the control key, press the tab key and select the open part, assembly or drawing you wish. Front view: right click front face: Sketch: Line. Draw a line starting at the far right edge about 3/8 inch down and draw it down to the bottom edge about 3/8 inch to the left of the lower right corner. Draw in the rest of the right triangle along the edges of the part. Smart Dimensions: make the vertices of the triangle .375 from each one’s respective corner: Extrude Cut: Through All: OK. Rename Feature “Edge Slope.” Save: Control-Tab to the Piers. Add a triangular boss to the respective corner of the pier again having the vertices .375 from the corners. Rename “Edge Slope”. Control-Tab back to the assembly. Now when you move the span there is always a clearance at the right edge. Isometric View: Click on Move Component. Click on collision detection. Move the span and notice the top faces of both the pier and span change color implying that they are interfering. The interference is taking place at the hinges. No opening was made to allow for the rotation of the hinges. Check Point 2. Save Assembly. Control-Tab to the piers. Right click the face just below the hinges: Sketch: Right View: Hidden Lines Visible. Rectangle tool. Draw a rectangle from the left midpoint of the left hinge up to the upper

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left corner of the pier. Draw another rectangle from the right side midpoint of the left hinge to the upper left corner of the right hinge. Isometric View: Extrude Cut: Blind: .375: OK. Rename “Hinge Clearance.” Save part. Control-Tab to the Span and repeat the cuts in that part’s hinges. Follow the steps for the pier. Save part and Control-Tab back to the assembly. Now when you move the span with collision detection on the motion will be free of interference. Check Point 3. Save Assembly. To create the archway for the lift mechanism we will use the sweep command. Open a new part. Right click Right Plane: Sketch. Line: Draw a vertical line starting to the left of the origin, 11.5 inches up: 3 Point Arc: Click on end of line: click on point horizontal to right of line’s end: click to set arc: Line: draw a line down to the right of the origin. Escape. Make the two vertical lines equal and the center point of the arc vertical with the origin. Draw a center line between the two bottom edge points and make this line midpoint with the origin. Smart dimensions: Make the lines 11.5 high, 4 apart and the center of the arc 10.5 above the origin. Click on purple arrow to accept sketch. Right click Top Plane: Sketch: Bottom View: Rectangle tool. Sketch a rectangle and make the sides .5 wide by .25 thick. Make the inside edge midpoint with the end of the previous sketch. You mah need ot hit the right cursor key once to be able to select the end of the line of the previous sketch. Accept sketch. Sweep Icon: the profile is the rectangle and the path is the arc: OK. Rename Archway. Front View: Front Face: Sketch: Circle.

Draw a circle near the top of the front face. Set the center vertical with the origin, the diameter .25 and the center .58 below the top break edge. Extrude .25. OK Rename “Peg”. Front Plane: Mirror: select peg: OK. Rename “Other Peg.” Make the arch light orange. Check Point 4. Save part as Arch. Open LiftRod. Control-Tab to assembly. Insert components: bring in Arch and two LiftRods in that order. Right click on the second lift rod and select the Component Properties icon. In the lower part of the dialog box select the Connector configuration. OK. This rod should now be a connector – shorter than the lift rod. Mates: Make the front face of the span and the inside face of the arch coincident, the bottom faces of both parts coincident and the left faces of both coincident; You may have to rotate the pieces 90º to get the left face of the span. Make the inside face of the bottom hole of the LiftRod and the outside face of the peg on the pier concurrent and make the outer faces of both of these coincident. Do the same with the peg on the arch and the hole on the connector. Finally make the last two holes (LiftRod and Connector) concurrent. Close the mate box. Check Point 5. Save Assembly. Here we have a simple lift bridge with no interference between the parts. To complete this assembly, another set of arms may be placed on the other side. In practice a large counter weight is placed at the intersection of the LiftRod and the Connector to aid in lifting of the bridge. The weight would go down to close to the roadway, but as the bridge is open no traffic would be passing through. Also a

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full truss structure would be across the span for strength and stability. Open the file LD5CkPt5 if it not already open. To have an exploded view for bringing into a drawing, click on exploded view icon. Click on the Span, Arch & Connector to select components to move: click in direction box: Select up arrow (y direction): Distance 6, Click apply to make sure direction is right: Done. Click in components box in settings: click on arch and span: direction box: click right (red arrow, x direction): distance 4: Apply: Done. Repeat moving arch 4 inches up (y direction) and then move lift rod 4 inches out (z direction). Finally move the connector 2 inches in the z direction. OK. To undo explosion right click in drawing area and select “Collapse”. To re-explode click on explode icon. Add exploded line sketches. Join the hinge holes in the span to the hinge holes in the piers. Join the bottom face on the arch to the back bottom corner of the span, the hole in the connector to the peg on the arch, the other hole in the connector to the hole in the lift rod and the hole in the lift rod to the peg on the piers. Make sure that the arrows point in the correct direction as you select the parts. Check Point 6: Save Assembly. Before bringing the assembly into a drawing check the order of the parts in the feature manager. Are they in the order you want them to be in the bill of materials. If not change the order now. Open Landscape title block: Save as LabDemo5. Model View: LabDemo5: Blue Arrow: Isometric View: Click in drawing to set view. Right click in blank space of drawing: Properties: Scale 1:4:

OK. View: Origins to turn off origins if they are on. Annotations Tab: Balloons: click on edge of each part and click to set each balloon. OK. Select Assembly (green border.) Tables: Bill of Materials: Click OK to accept defaults. Click in drawing area to set BOM. Drag over all the cells to select the entire table. In the fly-out that appears click on the Icon with an A on a sheet. Set the font size to 8 points and the justification to center. Grab each vertical line in table aside from leftmost and move to the left to minimize column width. Click and drag on blue bar and move BOM table to upper right corner of title block border. All the items have the correct part numbers and part names except for the arch, which we created. Right click on the arch and select Open Part. Click on the Configuration Manager tab, right click on default and select properties. At the bottom of the dialog box, pull down and select User Specified Name. In the white bar above type in 3562 for the part number. Click on Custom Properties: In dialog box, select property name and pick Description from the pull down menu. Type in “Archway”: Add: OK: OK. Save part. The other parts are: Piers #3554, Span #3543, Lift Rod #3572 and Connector #3576. Control-Tab back to the assembly drawing and the BOM should be complete. Now all that has to be done to complete the drawing is to fill in the title block with the correct information. Check Point 7. Save Drawing.

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Lift Bridge Model

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Lab Demo 6 – Mass and Volume Properties

In this lab demo you will find how to use the loft and shell commands and how to determine the physical properties (mass, volume, center of mass, etc.) of the part. Open file LD6CkPt1 to start. This is a 5 x 6 block centered on the origin, extruded 3 midplane. The face edges are filleted .75 and the top and bottom edges are filleted 1 inch. Right click on the top face: sketch: convert entities: accept sketch (purple check in upper right corner.) Click on top face again: insert: reference geometry: plane: .75 inch: OK. Right click on new plane: Sketch: Top View. Tools: Sketch Entities: Ellipse. Click on origin: drag to right of origin: click: click on origin, drag above origin: click to set ellipse. Smart dimensions: major axis (click on both horizontal end points) 2.75: Minor axis (click on both vertical end points 1.25. Escape: click on origin: control click on right end point: horizontal. Accept sketch. Loft: click on sketch 2 and sketch 3 for profiles. OK. Rename to “Neck.” Check Point 2. Click on right face: Insert: reference geometry: plane: .5 OK. Repeat this with a separation of .25 to the plane just created. Repeat 8 more times using previous plane as the starter. Then do two more planes .5 apart. Open file LD6CkPt3. This has all the planes. Right click right face – not a plane: Sketch: right view. Circle tool. Draw a circle below origin. Smart dimensions: .75 diameter: 1.6 below origin. Escape: set center of circle vertical with origin. Accept Sketch. Right click Plane 2: Sketch: Tools: Sketch Entities: Ellipse. Sketch ellipse below origin. Smart dimensions: Vertical major axis 1.25: horizontal minor axis .75: center of ellipse coincident with

circumference of circle, i.e. (1.6 - .375) below origin. Escape: set center of ellipse vertical with origin: set bottom of ellipse vertical with center. Accept sketch. Repeat eight more times on successive planes with each ellipse centered at the top edge of the previous one. An easier method to do the repeated ellipses is to select the sketch in the feature manager copy it using control-c, select the next plane, paste with control-v. You get a new sketch of a fully dimensioned ellipse. Right click on the new sketch: edit sketch. Select the center of the ellipse, control click on the upper vertex of the ellipse below it and make the points coincident. Do this for planes 3 to 10. Then there is an ellipse with vertical semi axis .5 on plane 11 followed by two .75 circles on planes 12 and 13. The final circle is 5.0 above origin. Open LD6CkPt4 to see all the sketches. Loft: expand part feature tree in upper left corner. Pick the twelve sketches of the spout. Move the selected joining points so they are all on the top or all on the bottom. OK. Rename feature “Spout.” View: Planes to hide planes. Select the top ellipse on the pitcher and the end face of the spout: Shell: thickness .07: OK. Rename “Insides.” Select section view to see hollowed insides. Check Point 5. To attach handle: Right click Front Plane: Sketch: Front View. Hidden Lines Visible. Line. Draw a horizontal line starting at left side of body out about .75 inch. 3 Point Arc: click on end of line: click above body right above end of line: click to make concave part face right. Click on end of arc: click on curved inside hidden upper left edge of body click to make concave part face down. Escape. Make end of line and arc tangent and the two arcs tangent. Make ends

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of big arc vertical, make the right end of the line coincident with the outside face and the small arc end coincident with the inside face of the curved edge. Smart dimensions: line is .75 long and 1.75 below origin. Big arc is R2.50 and small arc is R1.50. The sketch should be fully defined. Accept sketch. Click on left face of base: Sketch: Left View. Circle: draw a circle close to end of handle line, but not right on it. Diameter .5. Escape: rotate view around so the circle and the end of handle are visible. Select both and make coincident. Accept sketch. Sweep. The circle is the profile and the handle line is the path. Under options check align with end faces. Check thin feature box. Click on direction arrow beside one direction so the feature will expand in. Make wall thickness .07. OK. Rename “Handle.” Check Point 6. In the Feature Manager, right click on Material and select edit material. In the Property Manager material window click on Aluminum alloy and pick 1060 aluminum. OK To find the physical properties – Evaluate Tab: Mass Properties. You will see the mass

is .89 pounds, the volume is 9.11 in3, surface area is 260 in2, and the center of mass is located at (0, .29, 0) The volume is the volume of the material. To find the amount of water this pitcher will hold, the roll back feature has to be used. In the Feature Manager, there is a horizontal bar at the bottom of the feature tree. If you place the cursor over it, the cursor becomes a hand with curved fingers. Click and drag the bar up until it is just above the shell command and release. Tools: Mass Properties. You will find that the volume is 86.9 in3. Close the dialog box. Pull the roll bar down to just below the first shell command and reopen the Mass Properties. The volume is now 8.2 in3. The difference is 78.7 in3 which is the total inside volume. This is about 1.4 quarts. Since you cannot fill both the body and spout to the brim this would probably be called a 1.25 quart pitcher or a 5 cup pitcher. Principle axes and mass moment of inertial are also given. These are important in order to determine rotational dynamics of parts.

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Lab Demo 7 – Sub-Assemblies

In many cases there are just too many parts to try to group in one assembly. Instead subassemblies are used to simplify the assembling and the drawings. A subassembly is treated like a single part when it is included into another assembly. In today’s demonstration we will use a model of an old fashioned lift pump to show how sub assemblies are used. Open SolidWorks and open the assembly file LD7LiftValve. This assembly contains the parts Plunger, Valve Flap and Hinge Pin. Pick Save As and save assembly as Lift Valve. Four mates, are already inserted: a concentric mate between the flapper hole and the holder hole, a distance mate of .02 between the side face of flapper and adjacent face of holder, a concentric mate between the pin and the holder hole and a coincident mate between the pin and holder face. Select the mate tool. Click on the bottom face of the flap and the top inside face of the plunger. Select an angle mate and make it 20°. Click on the advanced mate and make the minimum angle 0°. This is called a limit mate. Check Point 1. Save the Assembly as Lift Valve. Open the other files for the full assembly: Right Housing, Handle, Lift Rod and Handle Pin. Create a new assembly and bring in the Right Housing to fix this part. Make sure it snaps to the origin when you place it. We need a mirror image of this housing to complete the pump. Control-Tab, continue to hold down the tab key and select Right Housing. Select the Front Plane. Menu Bar: Insert: Mirror Part (about halfway down.) Check plane and solid body and uncheck everything else in the dialog box that comes

up. OK. A new part is created linked to the former part. Shut off all the planes that are showing: View: Planes. Save this as Left Housing. Control-Tab back to the assembly and bring in the parts Left Housing, Lift Valve, Handle, lift Rod and Handle Pin in that order. Mate the two housings by making their curved insides concentric, the flat faces coincident and the top faces coincident. Close the mate manager. Right click on Left Housing in the property manager and select suppress icon to hide that part. Mate the lift valve to the Right Housing using a concentric mate. Click on the bottom of the Lift Valve and the bottom face of the Housing. Make a distance mate of 10 inches, then Advanced Mates and pick the minimum distance as 1 inch (Limit Mate.) Mate the handle to its support using a concentric and a coincident mate. Mate the Lift rod to the handle with a concentric mate and have the end face coincident with the side face of the handle. Mate the Lift Rod and the Lift Valve with a concentric mate. The mating should be complete. Close the Mate Manager and move the handle of the pump to observe the mechanism. The valve flap of the Lift Valve will not work in this particular assembly. Unsuppress (Set to Resolve)) the Left Housing to complete the assembly. Check Point 2. Save Assembly as Pump. Place the handle all the way down and select mass properties. The weight of the assembly is 7.26 lb using the default material properties and the center of mass is

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at (.027, 8.39, 0.00). These values will differ if the handle is not all the way down or if you did not snap the first part to the origin. Explode the assembly to prepare it for insertion into a drawing. Step 1: Click on Left Housing: Move 12 Inches left (Z direction): Done. Step 2: Lift Rod – 10 inches left ( Z direction.) Step 3: Lift Rod – 12 inches up (Y direction): Step 4: Handle – 8 inches left (Z). Step 5: Handle – 12 inches front (X), Step 6: Lift Valve – 12 inches up (Y). Step 7: Handle Pin 6 inches right (-Z). Insert – Exploded Line Sketch. Click on pairs to show exploded lines clicking on OK after each set. Starting at the left end of handle pin click in sequence Pin Hole in Right Housing, Pin Hole in Handle (line going through handle back to front,) & Pin Hole in Left Housing. OK. Top hole in Handle & Top Edge of Lift Rod. Bottom Edge of Lift Rod & Hole in top of Lift Valve. Bottom edge of Lift Valve & Bottom inside edge of Right Housing. Left Housing to Right Housing. Click OK, Click on purple arrow in upper right corner to accept sketch. Check Point 3. Save Assembly. Open landscape title block. Model view: Pump assembly: Isometric view. Turn off hidden lines and origins. Right click in blank area of drawing sheet: Properties: Scale 1:8. Annotation Tab: Balloons: Click on each of the parts. Select Assembly: Tables: BOM. Drag across the whole table to select everything. In the fly-out dialogue select center justify. Click on the ”A” icon and make sure the font is at 8 points. OK. Reduce BOM columns to be as narrow as possible, but still readable. Set BOM. Set Left Housing part number to 2832 and the Lift Valve sub-assembly to 4652. Check the

box titled “Don’t show child components in BOM when used as a subassembly.” The two housings are to be welded. Create a new layer labeled Weld and make it a color different from black. Click on the vertical right edge of the left housing. Then click on the weld icon in the annotation tool bar. On the Weld symbol button select square weld below the line. Make the depth (to the left of the weld symbol) .25. OK. Do the same for the left outside edge of the right housing below the spout. To get multiple leader lines, select the weld, control click on the grip (green square) on the end of the arrow and drag to the point where a new leader is to go. Do enough leaders so the entire outside edges are selected. The drawing number of the full assembly is 4925 and there is no next assembly. Check Point 4. Save drawing as Pump. Open the Lift Valve assembly (LD7CkPt5) and select exploded view to get the pre-done exploded and line sketch if these are not already displayed. Open landscape title block. Model view: Lift Valve assembly: Isometric view. Turn off hidden lines and origins. Right click in blank area of drawing sheet: Properties: Scale 1:2. Annotation Tab: Balloons: Click on each of the parts. Select Assembly: Tables: BOM. Drag across the whole table to select everything. In the fly-out dialogue select center justify. Click on the ”A” icon and make sure the font is at 8 points. OK. Reduce BOM columns to be as narrow as possible, but still readable. Set BOM. The drawing number of the sub-assembly is 4652 and the next assembly is 4925. Check Point 6. Save Drawing as Lift Valve.

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Lab Demo 8 – Bevel Gears In this demo we will look at the gear mating of two bevel gears. Bevel gears are used for 90º intersection shaft applications. As was done with threaded fasteners where the actual threads are not drawn, the gear teeth are not drawn in CAD. A flat face is drawn at the pitch diameter. In real life, the gear teeth extend beyond this face and the gaps extend into the face. To create a simple bevel gear, open a new part file and save it as LabDemo8. Right click Front Plane: Sketch: center line tool. Draw a vertical center line through the origin to be used for a rotational extrude. Line: Starting below the origin draw a line vertically up about 1 inch, right about 5 inches, down to the right at a 45º angle about .5 inches, left about 4 inches down .5 inches left to starting point. Center line: draw a line from the origin to the center of the angled face. Escape: select the center line just drawn and make it horizontal. Smart dimensions: right height .5 inches, angle of edge 45º, lower height .5 inch. Select point on angled face where center line intersects and then select vertical center line. Drag mouse to left of centerline to set dimension as a diameter and make the diameter 10. Select vertical line of shaft tie in, select center line drag left of center line, set diameter to 1.5 inch. Escape: select vertical center line: Revolved Boss/Base: OK. Rename feature to “Gear Body.” Right click top face: Sketch: Top View. Circle tool: draw a circle centered at the origin, .5 inches in diameter. Extrude cut through all. Rename “Shaft Hole.” Right click top face: sketch: rectangle: draw a rectangle with left edge on origin and right edge past face. Escape: Select left edge and origin: midpoint. Smart Dimensions: height .125, length 5. Extrude cut: .0625. OK.

Rename “Groove.” Right click groove in the feature Manager: Select appearance icon, select the groove color box. Make its color red with an emissivity of .25. The only purpose of the groove is to make the gear motion visible. Check Point 1. Save file. Right click on Annotations: Show Feature Dimensions: select the diameter 10 dimension: in the property manager under primary value rename dimension “Diameter.” OK. Right click on Annotations: Show Feature Dimensions to turn off dimensions. Insert: Design table: OK: just select diameter dimension: OK. In the column under default, type in 10,9,8,7,6,5,4,3,2 in succeeding rows to give configuration names.. Do the same in the next column to give different diameter dimensions. Click in the drawing to close the box. Click on configuration manager and check out the nine new configurations. Return to the feature manager. Check Point 2. Save File. Open the parts Shaft and Base. Open a new assembly. Insert Components opens as a default: depress the push pin: Bring in the base first and fix it to the origin and then bring in two gears (LabDemo8) and two shafts. OK. In the Feature Manager, move the base to the last place in the assembly so the order will be correct for the BOM. Right click on one gear: component properties: (top right icon) configuration specific property box: “10”: OK. Right click on other gear: component properties: select configuration “2”: OK. Check Point 3. Save as LabDemo8. Mate: Select inside face of vertical hole: select outside face of a shaft: concentric. If the flag on the shaft is not downward,

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change Mate Alignment. OK. Do the same with the other shaft and horizontal hole – the flag is to the outside. Make the holes in the gears concentric with each shaft. The beveled faces facing up and to the right, and the 10 inch gear is horizontal. OK. Make the end faces of each shaft coincident with the outer face of each gear. To lock each gear to its shaft, expand the feature tree in the upper left corner. Make the top plane of a shaft coincident to the right plane of its corresponding gear. OK to close mate box. Check Point 4. Save Assembly. Mate: Use a distance mate to make the top face of the big gear 2.75 inches above the top face of the base and the small gear’s left face 1.75 from the left face of the base upright. This places the gears in contact. Finally open the Mechanical Mate box. Select Gear Mate. Select the beveled faces of the two gears for the mate selection. To have the proper ratio click on the larger gear face first. If you click in the reverse order, the large gear will go through five rotations

for every rotation of the small gear – an impossibility – except in SolidWorks. In the ratio box make the ratio 5 to 1. The ratio refers to the diameters or radii of the two gears. OK. OK to close mate box. To create the simulation, click on the Motion Study 1 tab on the bottom of the page. Change Assembly Motion to Physical Simulation. Click on Motor Icon. In the property manager make motor type Rotary, the component is the horizontal shaft, constant speed, 50 RPM. OK. In th emotion box, drag the top black diamond to the 30 second mark. Click on calculate icon and let it run for the full time. Replay simulation to observe motion. Check Point 5. Save Assembly. Save and retain the gears for next week’s lab so that you do not have to recreate them. They will be part of the Rube Goldberg Assembly you will create.

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Bevel Gear Examples

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Lab Demo 9 COSMOSXpress

COSMOSXpress is a quick and easy to use program, which will test the strength of various parts that you have built. It is built right into SolidWorks and is a light version of COSMOSWorks, a full blown FEA (Finite Element Analysis) program. Begin by creating a rectangle 1 inch by 1 inch on the right plane with the origin at the center of the rectangle. Do not use the equal relation, but dimension each side, as we will be changing the dimensions. Extrude it 12 inches to the right so that the origin is on the left face. Call this only feature “Bar.” Right click on the material button in the Feature Manager and make the material Chrome Stainless Steel. Save the part as LabDemo9. Check Point 1. A quick check of the mass properties has the weight as 3.38 pounds. We want to know if this bar can support 500 pounds hung on its right end. Open COSMOSXpress: Tools: COSMOSXpress Analysis Wizard. (If you get an error message that it cannot open due to COSMOSWorks being active go to Tools: Add-ins and uncheck COSMOSWorks. OK. Pick options and set the units to English (IPS).Check the show annotations… box as well. Next. The material should already be selected. If not select it now. Next. Next. To set the restraints, scroll around until you can select the left face. You will see the restraint arrows on the face. Next. Next. Next. Select the radio button for Force. Next. Select the right face for the load application. Next. Select normal to a reference pane. Select the top plane and reverse the force direction. Make the

force 500 pounds. Next. Next. Pick radio button for yes. Next. Click on Run. COSMOSXpress will create a mesh and do a FEA stress analysis and give the load safety factor. Anything less than 1 is bad. Next. Select radio button to no. we do not want to optimize the design just yet. Next. Click “Show me the stress distribution. Next. The stresses are shown in colors with red being the highest stress. The maximum stress is 3.74E4 psi which is greater then the yield stress of 2.5E4 psi. the arrow on the von Mises table shows the yield strength. This bar will not withstand the 500 pounds. We will need a thicker bar. If you press the play button you will see the stresses develop as the bean is flexed. Stop that and pick next and choose the displacement plot. Again you will see an exaggerated plot of the displacement in color with red being the greatest displacement. Cancel COSMOSXpress, without saving any results. double click on Bar in the feature manager, change the height of the bar to 1.5 inches and rebuild. Reopen COSMOSXpress and do all the same settings we did previously and then run the simulation. Again select not to optimize and look at the stress diagram. the maximum stress now is 1.7 E4 psi which is below the yield strength. Click on Back until you come to dialog box where you can select optimize the design. Click yes Next. Select a Factor of Safety of 1. Next. Double click on the 1.5 inch height since this is the dimension we want to optimize. Make

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the lower limit 1 and the upper limit 1.5 since we know the result is between these two. Next. Optimize. COSMOSXpress analyzes several different thicknesses until it finds the optimal one. Iin this case it sheds 17% off the weight of the part making it lighter and cheaper. Next. Select the stress distribution and look at the stress. The maximum stress is just below the yield stress and the thickness is 1.25 inches. The maximum displacement is .0614 inches which is about 5% of the thickness. However the diagram you see expands the displacement scale by a

factor of 20 so you can see what is happening. So now you have a quick and easy way to test the strength of parts you have created. In actual applications you would not use a safety factor of 1 as you would be just at the yield point and any extra forces of jolts will put a permanent set into the material. Utilizing this analysis you can also observe quickly where a part is most apt to break and strengthen just that region. This is especially critical with irregular parts and non uniform loadings.

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