BY CHRISTOPHER F.

SIKORA

© Copyright 2017 Christopher Sikora

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COURSE SYLLABUS
SolidWorks Basics 120

Course Description:
SolidWorks Basics
3 credit hours
Exploration of the theory and application of solid modeling
techniques for product design and manufacturing. Prerequisite:
Intro to Engineering Drawings 101 or consent of instructor.
(1 lecture hours, 2 lab hours)
Course Objectives:
Provide the student with the knowledge and practical experience in
the areas of 3D CAD modeling of parts, assemblies, and the
creation of mechanical drawings from the models.
Textbook
SolidWorks Basics free/pdf. and videos provided on YouTube
http://www.youtube.com/user/vertanux1
Or simply search the exercise number (example: E5 SolidWorks)

Evaluation Scale:
A 90% to 100%

B 80% to 89%

C 70% to 79%

D 60% to 69%

F Below 60%

Points:
Exercises 300 pts
Mid Term 300 pts
Final 300 pts
Participation/Attendance 100 pts
Total 1000 pts

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General Course Outline
Date Week Topic

1. Introduction to the Interface Lecture

Modeling Theory - Sketching and Base Feature
Geometry Creation.
2. Revolved Features and Mirroring
3. Part Modeling
Secondary Features. Fillets, Chamfers, Draft,
Patterns, Mirroring.

4. Sweeps, and Circular Patterns

5. Modeling Quiz and CAD Administration

6. Building Assemblies (Bottom-Up method “BU”)

7. Creating Drawings. Review for Mid Term

8. Mid Term Exam

9. 3D Curves and Sweeps

10. Swept Blends/Lofting

11. Assemblies Creation (Top-Down Method “TD”)

12. Assembly/Part Editing (“TD” & “BU” Methods)

13. Q2 Assembly Project

14. Q2 Assembly Project (continued)

15. Lab time, Review for Final Exam

16. Final Exam

Recommended Hardware
Flash Drive (>8 GB)

Software (Recommended)
SolidWorks Educational Edition

Instructor Information

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STUDENTS WITH DISABILITIES
We welcome students with disabilities and are committed to
supporting them as they attend college. If a student has a
disability (visual, aural, speech, emotional/psychiatric, orthopedic,
health, or learning), s/he may be entitled to some accommodation,
service, or support. While the College will not compromise or
waive essential skill requirements in any course or degree,
students with disabilities may be supported with accommodations
to help meet these requirements.

The laws in effect at college level state that a person does not
have to reveal a disability, but if support is needed, documentation
of the disability must be provided. If none is provided, the college
does not have to make any exceptions to standard procedures.

All students are expected to comply with the Student Code of

Conduct and all other college procedures as stated in the current
College Catalog.

PROCEDURE FOR REQUESTING ACCOMMODATIONS:

1. Go to SRC108 and sign release to have documentation sent to the
college, or bring in documentation.
2. Attend an appointment that will be arranged for you with the
ADA coordinator or designee.

CLASSROOM PROCEDURES:
1. Attendance of each scheduled class meeting is required unless
otherwise specified by the instructor.
2. Daily work problems and hand-outs will be maintained in a
notebook and turned in upon the instructor’s request.
3. Reading assignments will be made prior to discussing the
material.
4. Keep your drafting workstation clean and free of
miscellaneous materials.
5. Please report any malfunctioning equipment to the instructor.

LABORATORY UTILIZATION:
1. Regular daytime hours. The room is open for your use starting at
9:00AM daily. Even though classes are being held, you are
encouraged to find an open area and work in the laboratory.
2. There are evening classes, but you may use the lab up to 10:00PM.
3. On weekends, the lab will be available on Saturdays from
9:00AM to 4:00PM. The lab will be closed on Sundays.

INSTRUCTOR’S RESPONSIBILITY:
1. Present material in a manner that can be understood by each
student.
2. Respect each student as an individual, to be of assistance in any
way possible, and to help solve problems, but not to solve
problems for the student.

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3. Keep records of your progress and to summarize your learning
experiences with a final

Attendance and Cheating Policies

Introduction: Drafting is a technical profession in our society;
consequently, presentations in this course are factual and
technical, and final grades represent the student’s
accomplishment of the learning activities.

Attendance: Attendance at each class meeting is required.

Attendance may be a factor when determining the final grade.
Your instructor will specify his/her policy concerning the
relationship of attendance and the final grade.

Each instructor has the option of taking attendance for his/her

personal use. If a student misses class because of illness, a field
trip, or any other AUTHORIZED reason, the student is obligated to
determine what was missed, and will be held responsible for that
work. If a student is absent without an excused absence, he/she
will also be held responsible, and must obtain all information
from some source other than the class instructor. Instructors DO
NOT have to accept any make-up work, do individual tutoring, or
make special test arrangements for any UNEXCUSED ABSENCE.

Cheating: Cheating in this department is interpreted to mean the

copying, tracing, or use of another person’s work for the purpose
of completing an assignment.

Individual initiative and personal performance in completing all

assignments is required of all students. This course may seem to
offer situations that are conducive to cheating. However, evidence
of cheating on the part of any student will be sufficient cause for
an assignment of an “F” for the course.

Instructors reserve the right to change a grade after the end of

the semester if there is evidence to warrants.

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 Exercises

SolidWorks 2016 Basics Tutorials

 vertanux1
 14 videos

E1 SolidWorks 2016 - Basic Modeling 1 Tutorial

1:12:40
o

E2 SolidWorks 2016 - Basic Modeling 2 Tutorial

39:46
o

E3 SolidWorks 2016 - Basic Modeling 3 Tutorial 39:20

o

E4 SolidWorks 2016 - Basic Modeling 4 Tutorial 44:08

o

E5 SolidWorks 2016 Assembly Basics 1 25:37

o

E6 SolidWorks 2016 - Detailing Basics 1 Tutorial

16:19

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 SolidWorks 2016 Basics Midterm Exam Review 14:30
o

E7 SolidWorks 2016 - Basic Modeling 5 Tutorial

34:10
o

E8 SolidWorks 2016 - Basic Modeling 6 Tutorial

46:08
o

E9 SolidWorks 2016 - Assembly Basics 2 Tutorial

18:08
o

E10 SolidWorks 2016 - Assemblies 3 Tutorial

26:07
o

E11 SolidWorks 2016 Sheet Metal I Tutorial

27:25
o

SolidWorks 2016 Final Exam Review

17:08
o

HOW TO MAKE A PORTFOLIO

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CAD 120 TOTALS (E – Exercise, L-Lab, Q-Quiz)
 E1 - 10pts
o L1 – 5pts

o L1b – 5pts

 E2 – 30pts
o L2 – 5pts

 Q1 - 10pts
 E3 – 30pts
o L3 - 5pts

o L3b – 5pts
 E4– 30pts
o L4 – 5pts
 E5– 30pts
o L5b - 10pts

 E6– 30pts
o L6 - 10pts
 E7– 30pts
o L7 - 5pts
 E8– 30pts
o L8 – 5pts
 E9– 30pts
o L10 – 5pts
 E10– 30pts
o L11 – 5pts
o L11c - 5pts
 E11– 30pts
o L11d – 5pts

MIDTERM – 300pts
FINAL – 300pts
TOTAL - 1000pts
NOTE: Q2 and IMT Projects may be used as special projects (credit distributed at teachers discretion)

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CAD 120 - COURSE MATERIALS and FILE CONTENTS

Every student is provided with a Training Manual.doc, Lecture Videos, and Sample Files.

These files are located on www.vertanux1.com or

W:CAD Classes/Sikora/SolidWorks/CAD120 folder.
You can copy and paste the entire folder onto your USB Flash Drive.

The first folder contains the training

manual and syllabus and subfolders
containing the training videos and
work files needed to complete some
of the exercise, as well as practice
labs.
The Training Manual is in MS Word
format so students have the ability to
edit and add notes to it.

The video folder contains all

the chapter lecture exercises
so students can review the
lecture. These videos are all
produced in Apple
QuickTime, and Windows
Media Format.

The Work Files folder contains all

the part and assembly files needed
to construct the exercises, labs and
Midterm and Final exams.

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Introduction to SolidWorks
2016-17 Educational Interface
Task Pane

Icons –
Ribbon Pull-down menus
Bar

Origin (Axis Center x-0, y-0, z-0)

Feature Manager

View port

Mouse Buttons
Left Button - Most commonly used for selecting objects on the screen or sketching.

Right Button – Used for activating pop-up menu items, typically used when editing.

Center Button – (option) Used for model Rotation, Pan when holding Ctrl key, and
Zoom when holding Shift key.

Center Scroll Wheel – (option) same as Center Button when depressed, only it activates
Zoom feature when scrolling wheel.

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Options menu “The heart of SolidWorks”…
Selecting the Grid Icon opens the Options Menu or the Tools/Options pull down can
be used.

System Options – (Global Settings) are setting that affect all documents.

 Screen Background Color

 Performance Settings
 Interface Preferences

Document Options – (Individual Settings) are setting that adjust only the
currently active document.

 Units (metric or inches)

 Note and Dimension Fonts
 Part Color

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Sketching Polygon Trim
Rectangle Spline Mirror Pattern/Array
Point
Circle Ellipse Offset
Start Sketch

Fillet Text
Dim
Arcs Convert
 3 Point Entities
Line  Tangent (Projection)
 Centerpoint

NOTE: If you do not see all of these icons on your interface you can customize the toolbars to bring them
up. Right mouse button click on the top grey frame of the window and locate the “customize” option.

Where do you start a sketch?

Sketches can be created on any Plane or Planar Face or Surface. SolidWorks provides
you with three planes centralized at the Origin (your zero marker in space)
NOTE: Planes can also be created and will be discussed in more detail in the future.

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To start a sketch Pre-select the plane or face you desire to sketch on and then select the Sketch
Icon. NOTE: You can select the planes from the “Feature Manager”.

Special Note: You can identify what plane you are sketching on by the X and Y arrows displayed on the red origin.

Normal To Not Normal To

“Good” “Bad”

Controlling your geometry…

SolidWorks uses two methods for constraining geometric entities.
Relations and Dimensions

Relations can be referred to as common elements of geometry such as Tangency,

Parallelism, and Concentricity. These elements can be added to geometric entities
automatically or manually during the design process.

Here is an example of
adding a relationship
between two geometric
entities.

By selecting both entities

SolidWorks will
automatically activate the
properties menu on the
right side of the screen
enabling the user to input
the desired relation.

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 Cautious sketching can save time
Here are some tips to avoid modeling errors.

This is acceptable because it is a closed contour.

Use the “Trim” tool to cut and extend.

This is unacceptable because it has untrimmed geometry.

This is unacceptable because it has multiple contours share a common entity.

There are 3 primary file types in SolidWorks, which include…

1. Part (.sldprt)
Single part or volume.
2. Assembly (.sldasm)
Multiple parts in one file assembled.
3. Drawing (.slddrw)
The 2D layout containing views, dimensions, and annotations.

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Sketch Relations

Dimension SKETCH COLORS

BLUE - Under Defined

BLACK – Fully Defined

YELLOW – Over Defined

Start a
new sketch
BROWN – Dangling

Controlling your geometry with dimensions

Dimensioning this way will

enable the length of the
bracket to change but the
holes will always remain
positioned to 1.5” off each
side.

Dimensioning this way will

enable the length of the
bracket to change but the
holes will always remain
positioned to the left side.

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Solid Modeling Basics
Layer Cake method

Extruded Boss/Base (Creates/Adds material)

Extruded Cut (Removes material)

Ingredients:
 Profile

Revolve method

Revolve Boss/Base (Creates/Adds material)

Revolve Cut (Removes material)

Ingredients:
 Profile
 Center Line (Note: The profile cannot cross over the center line!)

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EXERCISE 1
Introduction to basic part modeling

Base Extrude Features create a 3D solid representation by extruding a 2 dimensional

profile of the entity.

Objective:
Create a
solid
model.

This will create a hole.

This will fail to extrude.

1. Start a new “part”

file. 6. Select to add
the dimensions.

4. Select the
Rectangle tool.
3. Select the
Sketch icon.

2. Select the
“Front” plane.

5. Click and drag

across.

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 7. Select Boss
Extrude.

8. Set to Blind
@ .5”.

9. Hit “Enter”
two times or
the green
check mark to
finish.

10. To sketch the next feature select the front face

of the model and then select the “Sketch” icon.

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 Toggle views using
the “View
Orientation” toolbar
or
Fast Key: Spacebar

11. Go to the
Features tab,
and then select
“Extrude Boss.

Adding the hole

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1. Select this face
and start a sketch.

2. Select the circle

icon, and begin by
locating the center
of the circle, LMB
(left mouse button)
click, and drag out
the circle by LMB
clicking again.

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3. Using “Smart
Dimension” add
the shown
dimensions.

4. Select the
Extrude Cut
icon.

5. Select the
“Through All”
option.

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 Update or Regenerate model
changes using the “Rebuild”
button. Although it is
unnecessary in this instance
it is still a very important
tool. It will update only
dimensional or feature
changes made to the model.
Fast Key: Ctrl Q
Ctrl-Q is a forced complete
rebuild of the model tree.

Go to file save and save-as “E1”

FINISHED

Now try LAB1…

NOTE: Patterns/Arrays and Mirroring will be covered in the next three chapters.
Please try to model LAB 1 without using them. It’s good practice to just
dimension and sketch all geometry when first starting out learning this software.

Please understand that I don’t want to overwhelm you with too much information
the first day. It is my goal to help you succeed, not to fail.

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EXERCISE 2
Revolved Features

Revolved Feature - creates features that add or remove material by revolving

one or more profiles around a centerline. The feature can be a solid, a thin
feature, or a surface.

Tips…
Profile

Centerline, Edge, or
Axis of Revolution

The profile should never cross over the centerline, nor should there be profiles on
both sides of the centerline. Note: Since SolidWorks 2004 Centerlines are not
always necessary if there is an available sketch edge which can be used as an
axis of revolution.

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1. Create a new part file (E2) and then start a sketch on the “Front” plane.

2. Sketch the following. Ctrl select the profile and the horizontal centerline,
then using the “Mirror” tool to create a ¼ of the geometry and then mirror it
to the other side. Make sure you finish adding the dimensions.

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3. Select the Revolve feature icon. Then select the axis/centerline.

4. Select the top and bottom faces and add a .100” fillet.

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EXERCISE 3
Secondary Feature Modeling

1. Sketch the geometry as show below on the “Front” plane.

2. Extrude Boss/Base. Select Mid-Plane, 1” and add 7 of draft.

Mid-Plane

1”

7 degrees

3. Select the front face of the model and start a sketch on it.

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4. Use the “Offset Entities” icon to offset sketch geometry .125” from the
outside edges. NOTE: The face or edges must be selected to see dynamic offsetting.

5. Cut Extrude at .125” deep.

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6. Select the base of the pocket and start a sketch on it.

7. Go “normal to” and sketch the following. Draw 2 circles on the center points of
the outside arcs (Note: You can wake the center points up by gliding the tip of the pointer over
the edge of the arc before sketching) Use the trim tool (trim to closest check option) to
remove intersections.

9. Extrude cut .75” deep.

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10. Select the base of the new pocket and start a sketch on it.

11. Sketch the following, and extrude cut “Through-all”.

12. Hold the “CTRL” key and drag a plane below the “Top” plane. Release
control after you have released the mouse button. Double click on the
new plane to see dimension it has been dragged. Then double click on
the dimension to change it to 4.00”.

The “Plane”
icon can offset
as well as
several other
options for
creating
planes.

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13. Start a sketch on “Plane 1” and draw a .5” dia. circle centered on the
origin.

14. Extrude boss and use the “Up to next” option.

15. Start a sketch on the “Front” plane and sketch the following rectangle.

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16. Extrude boss using the mid-plane option and .750 thick with 7° draft.

17. Using the fillet tool select the following edges and put a .125” radius on them.

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18. Add additional fillets of .06” on the following edges.

19. Short-Cut fillet is applied by selecting the entire face of the transition.
SolidWorks then fillets any and all edges that face comes in contact with.

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41
EXERCISE 4
Secondary Feature Modeling

1. Sketch the geometry as show below on the “Front” plane.

7. Base-Revolve.

One Direction

360 °

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8. Select the “Front” plane and start a sketch on it. Rebuild after completion.

9. Create a plane using the “Plane” tool located under “Reference Geometry”.
Note: The 2 ingredients for creating a plane perpendicular to a curve are the Curve and a
Point (in this case the end point of the curve). Rebuild when completed.

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10. Select the new plane and sketch the following on it. Rebuild.

11. Select the Sweep Icon. Then select the Path and Profile.

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12. Add .188” Fillets on the bottom edges of the spoke.

13. Add .25” fillets to the intersection of the Spoke and Center.

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14. Creating the Circular Pattern/Array: Go to View/and Check on Temporary
Axis. Note: This is not necessary in SolidWorks 2008 as new functionality allows you to select
the edge of the cylinder as the pattern axis.

15. Select the Circular Pattern Icon. Then select the Axis or the cylinder edge
located at the center and the Spoke. Enter 3 for the number of spokes. Note:
be sure to select the fillets as well, or they will not show up on the instances .

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11. Select the “Front” plane and start a sketch on it. Draw the following and don’t
forget the Centerline.

16. Select the Boss-Revolve Icon, and revolve 360 “One-Direction”.

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17. Add .188” fillets around the intersections of the handle and spokes”.

Remember! You can select

the whole handle face and
it will automatically fillet
every edge it contacts.

18. You are finished.

19.

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EXERCISE 5
Bottom-Up Assembly Creation

1. Go to “File/New and select the Assembly Template”.

2. Assemblies Toolbar.

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3. To insert a part into the assembly go to Insert Components.

4. Select “Browse” then search for the “Sheet Metal Bracket.sldprt” in the Exercise 5
folder provided to you. Then move the pointer to the Origin and click the LMB to
insert. NOTE: This will drop the origin of the part coincident to the assemblies’ origin
matching all planes. Notice the Part name now appears in the feature tree.

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5. Go thru the insert steps again to bring in the “Yoke Male”, drop it to the left of the
“Bracket”.

6. Select the “mate” icon and then select the side face of the boss sticking out at
the top of the Yoke. Then select the inside face of the hole on the bracket.

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 Select the concentric option and apply. The part should now move into place.

7. Select the mate icon again and attach the top face of the Yoke with the underside
face of the bracket. Note: To select thru a body RMB click over the surface and select
the “Select Other” option. LMB click to toggle faces RMB to accept face.

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8. Insert the “Spider” part next and mate it between the legs on the yoke, you may
need to select flip mate alignment in order to rotate the part 180 degrees. Note:
The aligned /anti-aligned option can reverse the direction to the model face.

9. Use a concentric mate to align the center hole with the holes on the yoke.

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12. Attach the remainder of the components.

20. After completion you should be able to use the Move Component icon to
dynamically rotate the assembly.

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EXERCISE 6
Fundamental 2D Drawing Creation

1. Open the “Exercise 6” part file.

2. View Layout/Drawing Toolbar.

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3. One method of inserting a part (E6) into a drawing is to first open the desired
part file. Next, go to the new document icon and find and click on the arrow
to its right. Select the Make Drawing form Part option.

4. Notice the options for Sheet Format/Size will pop up. Select A- Landscape
and hit OK.

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5. Inserting a View: You should now see the paper border and the “View
Palette” to the right.

6. Grab the “Front” view by moving the pointer over it and hold the left mouse
button down. Drag it onto the sheet and release the LMB. Hit “ESC”.

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7. Editing the Scale/Paper size: RMB click on the “Sheet1” tab at the bottom
left corner, and select “Properties”

8. This dialog box contains many useful options for editing the drawing. Change
the 1:2 scale to 1:3 and hit ok. Also select the “Third Angle” option.

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9. Projected (Unfolding) Views: Select the “View Layout” tab and then the
“Projected view” option. Then select the front view and move your pointer
up, LMB click, then move your pointer right and LMB click and then 45
Degrees from the front view and LMB click to get your isometric view
unfolded.

10. How to move views: Move pointer over a view border and once the border
highlights in red LMB click and hold on the border ling. Drag pointer to
desired location. Most projected views are locked into the original view they
are projected from, and their movement is limited to either horizontal or
vertical to the source view. If you wish to disconnect a view from its source
then simply RMB click on the desired view and find the “Alignment”/”Break
alignment” option to disconnect the view.
11. Model View: Can also be used to create standard views individually in a
drawing by selecting the icon.

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12. Section Views: Select the “Section View” icon and then locate the left side
quadrant edge of the top view. While a short distance away from contacting the
edge LMB click and drag a line horizontally through the entire view. (Don’t stop in
the middle).

13. Once through release the LMB and you should be able to now drag off a section
view and drop it just above the “Top” view by LMB clicking again.

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14. Detail Views: Select the “Detail View” icon. The circle tool is automatically
activated so then you can draw a circle surrounding the region you wish to
create a detail view from.

15. Move the view to the desired location and LMB click to release/drop it.
Note: the view scale can be changed by simply double clicking on the “scale” text and typing in a new
value, and the position and diameter of the circle can be changed dynamically by LMB clicking and
dragging its center or diameter.

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16. Auxiliary Views: Can be created by selecting an edge of the part and then
select the Auxiliary view icon.

17. Then drag out the view and LMB click to drop it into position.

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18. Editing the Sheet and Sheet Format: The “Sheet” is the transparent top level
containing the model views, dimension and notes. The “Sheet Format” is the
lower level that contains the border, title block, and notes.

19. RMB click on the “SHEET1” tab located at the bottom left corner of the
screen, and select “edit sheet format”.

20. Once in the sheet format you can draw lines, add or edit notes and with the
line format toolbar you can change individual line colors, styles, and
thicknesses.

Note: The line Format toolbar can be opened by RMB clicking on the top grey border of the
SolidWorks screen and locating it on the pull down list.

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21. Dimensions and Annotations: To add independent and non-parametric
dimensions you can select the “Smart Dimension” icon. Then just add
dimensions the way you would in the sketcher. Otherwise you can use the
“Model Items” option in the “Annotation” tab.

22. The “Model Items” are dimensions and annotations added to the model
during its construction by the designer. These annotations can be inserted
automatically into the drawing. These are true, editable, parametric
dimensions.
23. Try using some of the other annotations like Note, Surface Finish, Welds, and
GD&T.

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EXERCISE 7
Projected Curves and Sweeping

1. Sketch this on the “Front” plane.

24. Hit Rebuild to exit the sketch.

25. Select the “Right” plane and start a sketch on it.
26. Draw the following.

27. Rebuild to exit sketch.

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28. If you rotate the view you should see 2 gray sketched on top of each other.
Our intent is to combine the profiles from both the ”Front” and “Right” views
to make 1 standalone 3 dimensional profile.

29. From the feature manager select both sketches. Then go to

Insert/Curve/Projected.

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30. You should now have a single 3 Dimensional curve.

9. Create a ½” circle on the “Top” plane.

10. Rebuild and Sweep using the curve as the Path and the circle as the Profile.

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21. Start a sketch on the “Front” plane. Draw the following.

22. Rebuild to exit the sketch. Select the end face and start a sketch. While
the end face is still highlighted green select the Convert Entities icon.
Rebuild.

Convert Entities
Creates one or more curves in a
sketch by projecting an edge, loop,
face, curve, or external sketch
contour, set of edges, or set of sketch
curves onto the sketch plane.

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23. Sweep using the new path and converted entity as the profile.

14. Select the end face and go to Insert/Pattern/Mirror/Mirror Body.

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Now using the tools you have learned over the past 5 weeks finish the remainder of the
model.

Hints to complete the model…

Boss Revolve “Two Directions”

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The completed part; check to see if your feature tree looks the same as this one.

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EXERCISE 8
Lofting

Loft creates a feature by making transitions between profiles. A loft can be a base, boss,
cut, or surface.

Objective: Create
a boat hull by
lofting multiple
section profiles.

1. Create 4 planes beginning from the “Front” plane and offset from each other as
shown.
Plane 1 – 6.00”
Plane 2 – 8.00”
Plane 3 – 1.00”

2. Sketch 1 on the “Front” plane should look like this… use the Spline tool.

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3. Sketch 2 on “Plane 1” should look like this…

4. Sketch 3 on “Plane 2” should look like this…

5. Sketch 4 on “Plane 3” should look like this… A single point at the origin.

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6. If you rotate the view it should appear like this…

7. Select the Loft icon and begin to select the top left corner of each profile.

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8. You should have ½ a boat now…

9. Use the Mirror-Body feature and select the flat side face as the plane to
mirror from.

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10. You are finished with the boat Hull.

11. (Optional) Now, dress it up for the contest…

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EXERCISE 9
Top-Down Assembly Modeling

Top Down Assembly Modeling is creating parts inside an assembly.

Objective: Create
an assembly of a
pencil sharpener. If
the width is
changed all parts
must update.

1. Create a new assembly file. Save it as E9.

2. Go to insert/components and select new part.

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3. Save it as E9 Front and drop it on the “Front” plane. Create the following part from
the drawing.

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4. When finished select the Edit Component icon to exit part editing mode.

5. Insert another new component and save it as E9 Reservoir.

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6. Create the following model in the context of the assembly-using offset or convert
entities from the E9 Front model.

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 91
INSTRUCTIONS: RECREATE THIS DRAWING
EXERCISE 10
Assembly Editing

This exercise will include both Bottom-Up and Top-Down Assembly Modeling.

Objective: To update the

MP3 Assembly with the
changes requested by the
boss as noted on the
drawing.

1. Open the E10 assembly file and modify according to the instructions noted
on the drawing provided. You will have to mate the Battery part file.

92
93
94
EXERCISE 11
Sheet Metal Design

Sheet Metal part files can be very useful for extracting a flat pattern.

Objective: Model a
sheet metal
enclosure using
Top-Down Assembly
methods, and
flatten it.

2. Open the Exercise 11.sldasm and hide the cover (RMB click on the cover and select
the Hide icon (eye glasses)).

Jog Insert Bend

Lofted Unfold
Break Corner

Hem
Rip
Miter Trim
No Bends
Extend
Edge Flange Flatten
Sketch Bend
Base Flange Fold

95
3. Insert a new part into the assembly; drop it on the “Front” plane of the assembly.
Name it “E11 Cover” (This will be the enclosure) then select the front outside face.
Convert Entities.

4. Extrude up to vertex.

96
5. Once open the assembly should look like this. Right Mouse click on the surface of
the enclosure and select “open E12.sldprt”.

6. Go to an isometric view and “ctrl” select the four faces as shown.

97
Rotate the view to select the fourth face.

98
Select the shell command. Set it to .06”, and select “Shell outward”.

7. Select the bottom face and select the “insert bends” icon.

99
8. Go to the right view orientation and you should have this section view…

9. Click on the Rip parameters and select the two inside edges. Use the arrows to
control rip face direction. Hit apply.

100
10. Right mouse button click on any portion of one of the slots and “select chain”. Hit
the CTRL-C buttons to copy.

11. Select the flatten icon.

101
12. Return to the assembly.

13. Add holes and additional features.

14. The enclosure is now completed. Recreate the attached drawing for your Lab 11.

102
L11

103
 104
L10b
EXERCISE 11B
Alternatives, using base flange sheet metal tool

1. Draw the following sketch.

2. Trim the inside.

105
3. Use the base flange tool.

4. Insert a hem feature on both front edges.

5. Sketch a .5” circle on the top flange.

106
6. Extrude cut through-all.

107
 7. Flatten to verify. Refold.

8. Make a drawing from the part. Bring in the “Flat-Pattern” view. Rotate 90°.

FINISHED

108
109
EXERCISE 11C
Computer Aided Manufacturing (CAD/CAM) with Mastercam and SolidWorks files.

1. Model the drawing on pg. 113

2. Save the part as E11c.

3. Start Matercam and import the SolidWorks E11c.sldprt. be sure to set your “Files of
type” filter to SolidWorks part files.

110
4. Select the Machine type (AKS: Post or Postprocessor)/ Mill/ “Default”
NOTE: You can select from a number of generic posts in the “Manage List” area.

5. Select stock setup from the feature tree.

111
6. Select all solids.

7. Selecting Material: Go to the Tool Settings tab and select Mill Library at the bottom and
find Aluminum 6061.

112
8. Select Properties and Mill Default in the Feature tree, and select Drill.

9. Select the bottom floor surfaces for the drill. Select the green checkbox.

113
10. Select the Tool option, and then select the Library Tool

11. Select a 1/2” (#6) DIA. Drill. Hit the two green check boxes.

114
12. Repeat the same steps to add a ¼” DIA (#5) drill for the second hole. Hit the two green
check boxes.

13. Pockets: Select the Pocket tool

115
14. Select solids, and then select the floor of each pocket. Select the green check box.

15. Select Tool, Select Tool. Select the ½” FLA (FLAT) (#239). Select the green check box.

116
16. Select Roughing, and Constant overlap Spiral. Hit the green check box. Set Corner
Smoothing Radius to .001

17. Select Machine Group 1 from the top of the feature tree, then select the Backplot
icon.

117
18. Adjust the setting as seen below and select the Machine icon to begin the toolpath
simulation.

19. Watch the simulation.

20. G-Code Program Output – Select Post to have Mastercam generate the program.

118
Finished

119
120
EXERCISE11D

Finite Element Analysis (F.E.A.)

In this exercise we will look at a basic stress analysis using SolidWorks Simulation
Express.

Model the paperclip using the sweep feature. Draw the following on the “Front” plane.
Use tangent arcs.

ORIGIN
Sketch the .175 DIA. circle on the “Right” plane.

121
Use Swept Boss Base

R.M.B. select Material/Edit/Aluminum Alloy/1060 Alloy

122
Select Evaluate tab, SolidWorks Simulation Express

Select MMGS, and Options/SI (Lower right corner of screen).

123
Select Next/Next/Add Fixtures

Select cylindrical face shown on picture. Select the green check.

124
Select Next and Add a Force. Select the end face of the clip, Set to English IPS, 15 lbf.

Select Next/Run Simulation/Yes/Set Factor of Safety to 3.0

125
Select show von Mises Stress

Select show Displacement

Complete

126
127
Quiz 2 Special Project

Q 2
20 Points

1. MODEL THE PARTS

2. ASSEMBLE
3. RECREATE THE DRAWINGS

128
129
130
131
132
133
134
135
136
137
138
139
140
CAD 120
Mid-Term Exam

1. Model the BOTTLE drawing (50 Points)

2. Model the CAP drawing (50 Points)

3. Create the BOTTLE assembly and attach the cap to the

bottle. (100 Points)

4. Recreate the MEDICINE BOTTLE assembly drawing (100 Points)

Note: Do not forget to insert your name on the drawing.

Print only the completed assembly drawing and turn it in.

1
2
3
4
CAD 120
Final Exam

1. 3D Model the clock body.

2. Create an assembly and mate all the components as

shown in the provided clock assembly drawing.

3. Re-create the assembly drawing as shown on page 3.

4. Print out your assembly drawing and turn in.

1
2
3
 BY C.F. SIKORA

© Copyright 2016 Christopher Sikora

1
This manual is for educational purposes only. It may be printed, but not resold for profit for its content.

SolidWorks is a registered trademark of Dassault Systèmes SolidWorks Corp.

SolidWorks is a product name of Dassault Systèmes SolidWorks Corp.

ACIS is a registered trademark of Dassault Systèmes SolidWorks Corp.

IGES™ Access Library is a trademark of IGES Data Analysis, Inc.

Other brand or product names are trademarks or registered trademarks of their respective holders.

The information discussed in this document is subject to change without notice and should not be considered commitments by
Christopher F. Sikora.

The software discussed in this document is furnished under a license and may be used or copied only in accordance with the terms
of this license.

2
CAD 121 COURSE SYLLABUS
SolidWorks Advanced

Course Description:
SolidWorks Advanced
3 credit hours
Exploration of the theory and application of solid modeling techniques for product
design and manufacturing. Prerequisite: SolidWorks Basics CAD 120 or consent of
instructor.

Course Objectives:
Provide the student with the knowledge and practical experience in the areas of 3D CAD
modeling of parts, assemblies, and the creation of mechanical drawings from the
models.

Textbook
SolidWorks Advanced (Free/pdf. provided)
Instructional videos of lecture provided at www.vertanux1.com

Evaluation Scale:
A 90% to 100%
B 80% to 89%
C 70% to 79%
D 60% to 69%
F Below 60%

Points:
Exercises 300 pts
Mid Term 300 pts
Final 300 pts
Attendance & Participation 100 pts
Total 1000 pts

3
General Course Outline

Date Week Topic

1. Import and Export – 2D and 3D Translation,

2. Advanced lofting exercise

3. Mold Tools, Cast part, complex draft, setback fillets, and draft
analysis.

4. Design Tables

5. SolidWorks Administration

6. Equations

7. Modeling complex parts using sweeps

8. Advanced Sheet Metal Fabrication. Review for Mid Term

9. Mid Term Exam

10. (No Class) Spring Break

11. Cylindrical and Conical Sheet Metal Parts, Palette forming tools.

12. Assembly Automation methods for the workplace.

13. Freeform Surfacing

14. Weldments & Structural Steel

15. IGES Translation Repair. Review for Final

16. Final Exam

Required Hardware
16+ Gigabyte USB Flash / Thumb Drive

Software
SolidWorks Educational Edition

4
STUDENTS WITH DISABILITIES
We welcome students with disabilities and are committed to supporting them as they
attend college. If a student has a disability (visual, aural, speech, emotional/psychiatric,
orthopedic, health, or learning), s/he may be entitled to some accommodation, service,
or support. While the College will not compromise or waive essential skill requirements
in any course or degree, students with disabilities may be supported with
accommodations to help meet these requirements.

The laws in effect at college level state that a person does not have to reveal a disability,
but if support is needed, documentation of the disability must be provided. If none is
provided, the college does not have to make any exceptions to standard procedures.

All students are expected to comply with the Student Code of Conduct and all other
college procedures as stated in the current College Catalog.

PROCEDURE FOR REQUESTING ACCOMMODATIONS:

1. Go to SRC108 and sign release to have documentation sent to the college, or bring in
documentation.
2. Attend an appointment that will be arranged for you with the ADA coordinator or
designee.

CLASSROOM PROCEDURES:
1. Attendance of each scheduled class meeting is required unless otherwise specified by
the instructor.
2. Daily work problems and hand-outs will be maintained in a notebook and turned in
upon the instructor’s request.
3. Reading assignments will be made prior to discussing the material.
4. Keep your drafting workstation clean and free of miscellaneous materials.
5. Please report any malfunctioning equipment to the instructor.

LABORATORY UTILIZATION:
1. Regular daytime hours. The room is open for your use starting at 8:00AM daily. Even
though classes are being held, you are encouraged to find an open area and
work in the laboratory.
2. There are evening classes, but you may use the lab up to 10:00PM.
3. On weekends, the lab will be available on Saturdays from 9:00AM to 4:00PM. The
lab will be closed on Sundays.

5
INSTRUCTOR’S RESPONSIBILITY:
1. Present material in a manner that can be understood by each student.
2. Respect each student as an individual, to be of assistance in any way possible, and to
help solve problems, but not to solve problems for the student.
3. Keep records of your progress and to summarize your learning experiences with a
final

Attendance and Cheating Policies

Introduction: Drafting is a technical profession in our society; consequently,
presentations in this course are factual and technical, and final grades represent the
student’s accomplishment of the learning activities.

Attendance: Attendance at each class meeting is required. Attendance may be a factor

when determining the final grade. Your instructor will specify his/her policy concerning
the relationship of attendance and the final grade.

Each instructor has the option of taking attendance for his/her personal use. If a
student misses class because of illness, a field trip, or any other AUTHORIZED reason,
the student is obligated to determine what was missed, and will be held responsible for
that work. If a student is absent without an excused absence, he/she will also be held
responsible, and must obtain all information from some source other than the class
instructor. Instructors DO NOT have to accept any
make-up work, do individual tutoring, or make special test arrangements for any
UNEXCUSED ABSENCE.

Cheating: Cheating in this department is interpreted to mean the copying, tracing, or

use of another person’s work for the purpose of completing an assignment.

Individual initiative and personal performance in completing all assignments is required

of all students. This course may seem to offer situations that are conducive to cheating.
However, evidence of cheating on the part of any student will be sufficient cause for an
assignment of an “F” for the course.

Instructors reserve the right to change a grade after the end of the semester if there is
evidence to warrants.

6
General Course Outline

Date Week Topic

1. Import and Export – 2D and 3D Translation,

2. Advanced lofting exercise

3. Mold Tools, Cast part, complex draft, setback fillets, and draft
analysis.

4. Design Tables

5. SolidWorks Administration

6. Equations

7. Modeling complex parts using sweeps

8. Advanced Sheet Metal Fabrication. Review for Mid Term

9. Mid Term Exam

10. Lab

11. Cylindrical and Conical Sheet Metal Parts, Palette forming tools.

12. Assembly Automation methods for the workplace.

13. Freeform Surfacing

14. Weldments & Structural Steel

15. IGES Translation Repair. Review for Final

16. Final Exam

7
 EXAMS
Midterm and Final exams are to be taken on-site with the teacher or proctor present.
All exams are closed book, note, and video.
Absolutely no cell/smart phones or tables are permitted while taking the exams.
Headphones and music are not permitted during the exams.
LABS
Labs are there to help challenge and sharpen your skills, and are a great resource for additional
training. It is recommended you try to complete the labs on your own. “Self-discovery is the best
method of educational retention.” ~ unknown
EXERCISES
All exercises must be completed before the end of the semester as a portfolio.

1. To create a portfolio at the end of each exercise, take a screen capture using ‘ctrl-
print screen’ keys on the keyboard.

2. Then open a word document and paste the image using ‘ctrl-v’. Type in the Exercise
number next to the image.

3. Send the completed portfolio with your name on the front cover to me via email or
hard copy. No more than two exercise images per page.

COMPLETE THE FOLLOWING EXERCISES

1. 13:07
E12 SolidWorks 2012
Exercise 12 - DWG and DXF conversion to 3D model

2. 26:11
E13 SolidWorks 2012
Exercise 13 - Lofting with guide curves, Threads, Curvature Continuos Face Blend Fillets

3. 18:05
E14 SolidWorks 2012
Exercise 14 - Part editing, Molding prep, Draft

8
4. 11:33
E15 SolidWorks 2012
Exercise 15 - Mold Design, Cavity and Core creation, using cavity feature, creating drawings with
layers.

5. 11:02
E16 SolidWorks 2012
Exercise 16 - Design Tables

6. 8:59
E17 SolidWorks 2012
Exercise 17 - Introduction to Equations inside SolidWorks

7. 15:18
E18 SolidWorks 2012
Exercise 18 - Sweeps with guide curves, embossed text, multi - thickness shelling

8. 14:50
E19 SolidWorks 2012
Exercise 19 - Sheet Metal in Top-Down assembly approach

9. 24:21
E20 SolidWorks 2012
Exercise 20 - Assembly Library Component Automation, Rendering

9
10. 23:21
E21 SolidWorks 2012
Exercise 21 - Introduction to Surfacing, importing a jpeg image file and tracing around it

11. 16:28
E22 SolidWorks 2012
Exercise 22 - IGES - IGS - STEP import repair. FeatureWorks

12. 4:10
E23 SolidWorks 2012
Exercise 23 - Cylindrical Sheet Metal parts, Linear sketch patterns

13. 2:57
E24 SolidWorks 2012
Exercise 24 - Conical Sheet Metal parts using the old 90's method, before the loft option became
available. It still works.

14. 3:43
E25 SolidWorks 2012
Exercise 25 - Lofted Sheet Metal parts

15. 13:53
E26 SolidWorks 2012
Exercise 26 - Weldments, Structural Steel

10
CAD 121 TOTALS
E12 – 20pts
L12 - 10
E13 – 20pts
L13 - 10
E14 – 20pts
L14 - 10
E15 – 20pts
L15 - 10
E16 – 20pts
L16 - 10
E17 – 20pts
L17 - 10
E18 – 20pts
L18 - 10
E19 – 20pts
L19 - 10
E20 – 20pts
E21 – 20pts
L21 - 10
E22 – 20pts
E23 – 20pts
E24 – 20pts
E25 – 20pts
E26 – 20pts
L26 - 10
EXERCISES TOTAL 300
LAB TOTAL 100pts
MIDTERM – 300pts
FINAL – 300pts
TOTAL – 1000pts

11
EXERCISE 12
Importing 2D DXF/DWG files

DWG and DXF files can be very useful if imported into SolidWorks.

Objective:
Create a 3D
wheel from an
imported 2D
DWG file.

1. Go to file/open and select DWG from the options. Locate the Wheel Hub file.

12
1. Import to a new drawing.

2. The next screen should look like this… Select the show preview box.

13
3. Once open the drawing should look like this…

4. Go to the layer icon located on the Line Format toolbar, to disable all but the
geometry layer.

14
5. Once the other layers are disabled your drawing should look like this… Drag a
fence around the bottom section view and be sure to include the centerline.
Hit CTRL-C to copy the geometry.

6. Go to File/New part. Click on the “Right” plane and hit CTRL-V to paste the
geometry into the new part file.

15
7. Go to the right view orientation and you should have this section view…

8. Click on the centerline and select the revolve feature. Hit okay.

16
9. Right mouse button click on any portion of one of the slots and “select
chain”. Hit the CTRL-C buttons to copy.

10. Open the part file and select the “Front” plane. Hit CTRL-V to paste the slot.
It may appear to the right of the wheel. Just edit the sketch and window
around the slot sketch. Hold down the CTRL key and drag the main center
point to the center of the wheel.

17
12. Extrude cut through all.

13. Add .125” fillets around the edges of the cutout. Then create a circular pattern
from the one cutout.

14. The wheel is now completed.

18
L12 HOSE BASKET PROJECT
KUPEC METALS INC.
Import the KUPEC DXF File and create a sheet metal garden hose enclosure. .125” Thick.
Aluminum, Water-jet cut through glyphs.

19
20
EXERCISE 13
Lofting with Guide Curves

1. Sketch the geometry as show below on the “Front” plane. Rebuild. (5 spline
points) Use ordinate dimensions for simplicity.

2. Offset a plane 8” from the front plane.

21
3. Sketch the following on Plane 1. (5 spline points)

4. Start a sketch on the top plane, and draw the following. (3 spline points)

22
5. Start a new sketch on the top plane and draw the following. (5 spline points)

6. Loft

23
7. Loft completed.

8. Creating Curvature Continuous Face Blend Fillets. Select the bottom

face and side face of the bottle. Select the fillets icon. Input .250” radius and
check curvature continuous.

24
What are Curvature Continuous fillets?
Click Curvature continuous to resolve
discontinuity problems and create a smoother
curvature between adjacent surfaces. To verify
the effect of the curvature continuity, you can
display Zebra Stripes. You can also analyze the
curvature using the curvature tool.

Curvature continuous fillets differ from standard

fillets in the following ways. They have a spline
cross-section as opposed to a circular cross-
section. Curvature continuous fillets are smoother
than standard fillets because there is no jump in
curvature at the boundary. Standard fillets include
a jump at the boundary because they are tangent
continuous at the boundary.

9. Select the back flat face and go to Insert/Mirror all.

25
10. Insert the neck of the bottle as shown below.

11. Creating a Thread - Select the top face of the neck and go to the plane
wizard. Offset a plane .125” from the top.

26
12. Start a sketch on the new offset plane. Select the top face of the neck and
convert entities.

13. Go to Insert, Curve, Helix/Spiral. Apply the following parameters.

27
14. Now select the sketch tool and click on the portion of the helix closest to the
top end point. This automatically creates a new plane perpendicular to the
helix and starts a sketch on it.

15. Now just draw the geometry of the thread.

28
16. Rebuild, and go to the Sweep feature. Select Path and Profile. Finish.

17. Select the end face of the thread, start a sketch and Convert Entities. Draw a
vertical centerline .110” offset from the edge.

29
18. Revolve 56.

19. Complete the other side the same way. Add additional features to finish
bottle. Shell at .050”.

30
31
EXERCISE 14
Draft and Filleting

Cast parts can be some of the most difficult to modify if draft and complex fillets have
not been inserted early on with design intent.

Objective:
Modify the
casting to
enable mold
creation.

11. Using the Mold Tools toolbar.

32
 12. Draft Angle Analysis.

Face Classification (source: SolidWorks help)

In the graphics area, each face displays a color based on the Draft angle you selected.

Draft analysis results listed under Color Settings are grouped into four categories,

when you specify Face classification:

Positive draft. Displays any faces with a positive draft, based on the reference draft angle you specified.
A positive draft means the angle of the face, with respect to the direction of pull, is more than the reference angle.

Negative draft. Displays any faces with a negative draft, based on the reference draft angle you specified.
A negative draft means the angle of the face, with respect to the direction of the pull, is less than the negative reference angle.

Draft required. Displays any faces that require correction.

These are faces with an angle greater than the negative reference angle, and less than the positive reference angle.

Straddle faces. Displays any faces that contain both positive and negative types of draft.
Typically, these are faces that requires you to create a split line.

NOTE: Display colors may vary. The first time you use draft analysis, the system uses default colors.
If you modify the colors, the system will use the new colors you specified.

33
13. Here we can see that no draft is present on the current part.

14. Applying Draft. Select the Draft icon, and then select the top planar face of
the object.

34
 15. Applying “setback” fillets. Select the three intersecting edges, and then select
the intersection vertex.

6. Apply the following parameters.

35
16. Add draft and fillets where required. Run a draft check to ensure all faces
have draft. Typical Radii - .125”, .060”. Typical Draft 1.

17. This is how the finished model should appear after rendering.

36
37
EXERCISE 15
Cavity & Core Creation

Cavities and Cores can be created using SolidWorks.

Objective:
Create a Cavity
and Core from
the Cast part
used in E14.

18. Start a new assembly and name it E15. Insert the E14 Finished part file into
the new assembly at the origin. Insert a new part, name it Cavity, and drop it
onto the “Top” plane of the E15 assembly. Draw the following. Note the
origin location.

38
19. Extrude-boss 6”.

20. Select the Cavity Icon. The next screen should look like this… Select the E14
part file either from the screen or feature tree.

39
21. Once the cavity has been initiated you will get the “Resolve Result
Ambiguity” box. Just hit okay. This allows you to select the cavity or core
separations available.

22. Hide the E14 component and you should now see the cavity.

40
41
EXERCISE 16
Configurations with Design Tables

Design Tables can be very useful for designing multiple variations of the same part.

Objective: Create
a small, medium,
and large
configuration
using an Excel
Table.

1. Sketch the following on the “Front” plane. Extrude 2”.

2. Sketch the circle and extrude cut through all.

42
3. RMB click on the Annotations folder in the tree. Select “Show feature
dimensions”.
4. Also, go to, “View/Dimension Names”

5. You should now zoom out and see all the dimensions. Arrange them so they
are clear to see.

43
6. Go to “Insert/Design Table and select New”.

7. Type in the Small thru Large text in the left column. Then select cell 2-B and
then double click on the dimension you wish to enter into the table.

44
8. Once the four cells are filled in, type the following specification into the cells
below.

9. It should look like this when complete. Click in the view area and you will
receive the following message if it was successful.

45
10. Click on the configurations manager tab and you will see the new
configurations. Double click on any of the configurations to see it.

11. You are finished with the model. Make the Drawing.

46
47
48
EXERCISE 17
Advanced Equations

1. Here is an example of how to use equations. The images below represent the
same model, but can easily be changed by double clicking on a dimension,
and typing in a new value. This normally would create rebuild errors because
the rib stack would need to be adjusted as well. Equations can be set up to
automatically perform this task.

Objective: Using
equations create a
living hinge
package, which can
adapt to change
easily.

20. Sketch the following on the “Front” plane. Dimension in the order as show.

49
21. Extrude 1.5”. Add 1 of draft when ready. (Note: Do not extrude with draft)

22. Start a sketch on the bottom surface, and draw the following. Extrude with
1 of draft when ready.

50
23. Create a linear pattern.

24. Create a new sketch; Draw the following with coincident relations on both
sides of the cylinder. Let it become a driven dimension. Rebuild. Rename
sketch to “Target gap distance”.

51
25. Activate the “View Feature Dimensions” and “Show Dimension Names”.
26. Rename the dimensions as seen below. This can be done by simply RMB click
on any dimension you would like to change. Go to Properties and entering
different names in the box on the top right.

27. Creating Equations. Go to Tools/Equations. Then select double click in the

cell below “Equations”. Click once on the desired dimensions to have the
names automatically insert into the equations editor.

52
53
What are Equations inside SolidWorks?

They create mathematical relations between model

dimensions, using dimension names as variables.
When using equations in an assembly, one can set
equations between parts, between a part and a sub-
assembly, with mating dimensions, and so forth.

When deleting a feature or dimension that is used in

an equation, you have the option of deleting the
equation or not.

NOTE: Dimensions driven by equations cannot be

changed by editing the dimension value in the model.

28. Here is an index of functions.

54
29. Add the same equations on the left side of the model.

30. Mirror all, both sides.

55
56
EXERCISE 18
Using Sweeps with Guide Curves

Sweeps can be beneficial when creating symmetric freeform geometry.

1. Start a sketch on the “Front” plane and draw a vertical line at 8” from the
origin. Rebuild.
2. Using a spline draw the following on the “Front” plane. Rebuild.
3. Using a spline draw the following on the “Right” plane. Use the same vertical
dims as in step 3.Rebuild.

57
4. Sketch an Ellipse on the “Top” plane. This will be the profile.

5. Hold CTRL and select the spline curve and the point on the Ellipse. Add a
Pierce relationship. Rebuild

A Pierce relation is when

the sketch point is
coincident to where the
axis, edge, or curve pierces
the sketch plane. The
pierce relation is used in
Sweeps with Guide Curves.

58
6. Repeat step 5. Using the right side spline.

7. Sweep

59
8. Sweep completed.

9. Creating Curvature Continuous Face Blend Fillets. Select the top

face and side face of the bottle. Select the fillets icon. Input .250” radius and
check curvature continuous.

60
What are Curvature Continuous fillets?
Click Curvature continuous to resolve
discontinuity problems and create a smoother
curvature between adjacent surfaces. To verify
the effect of the curvature continuity, you can
display Zebra Stripes. You can also analyze the
curvature using the curvature tool.

Curvature continuous fillets differ from

standard fillets in the following ways. They have
a spline cross-section as opposed to a circular
cross-section. Curvature continuous fillets are
smoother than standard fillets because there is
no jump in curvature at the boundary. Standard
fillets include a jump at the boundary because
they are tangent continuous at the boundary.

10. Variable Radius Filleting. Select Fillet tool, then select the Variable fillet.
Select desired edge and it will break the edge into quadrants. Enter dims as
shown.

61
11. The fillet should appear as shown.

12. Create a Thread – Shell at .1”, and add embossed text. You are finished.

62
63
EXERCISE 19
Advanced Sheet Metal Design

Sheet Metal part files can be very useful for extracting a flat pattern.

Objective: Model a
sheet metal
enclosure using
Top-Down
Assembly methods,
and flatten it.

1. Go to file/open and select “E19”. Hide the existing cover.

Sheet Metal Tool Bar:

To activate the toolbar on the ribbon simply RMB click on any ribbon tab and check the
Sheet Metal box.

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2. Insert a new part into the assembly; drop it on the “Front” plane of the
assembly. Name it “Cover” (This will be the enclosure). Then select the inside
shelled face. Convert Entities.

3. Sketch the bottom ends as shown.

65
4. Use the Base Flange icon to extrude as follows.

5. Use the “Hem” icon to remove sharp edges from the bottom of the cover.

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EXERCISE 20
Assembly and Drawing Automation

Assembly and Drawing creation can be virtually automated through the use of many
techniques capable in the SolidWorks software.

Objective: Create the

desk assembly and
implement automation
techniques.

Creating a Hardware Library using the Design Library

1. Install the Desk Parts sub folder (this contains all the hardware required for
assembling the desk) into the E20 directory.

2. Then go to tools/options/system options/file locations and select Design

Library from the pull down menu. Once selected click on the “add” button.
This will enable you to browse to your Desk Parts folder.

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3. By doing this you have now enabled your parts to be accessed through the
Design Library, Desk Parts folder. Enabling easy drag and drop access.
Otherwise you can just use the Insert Component tool.

4. Now start a new part file and begin to create the attached parts.
NOTE: The drawings are missing dimensions. You can use the desk components in the
Design Library to attain the proper measurements.

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5. When all the parts are finished, start an assembly and begin to assemble the
components as shown in the assembly drawing provided.

6. Create a catalog image using Photoview 360. This is his how the finished
model should appear after rendering.

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EXERCISE 21
Introduction to Surfacing

1. Here is an example of how to use surfaces. The spoon model will be used to
introduce the user to the primary surfacing tools available in SolidWorks.

Objective: Create a
spoon using the
surfacing tools.

2. Sketch the following on the “Front” plane.

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3. Sketch the following on the “Right” plane.

4. Go to Insert/Curve/Projected and select the two sketches to create a 3D

projected curve. Change the feature name to “Guide”.

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5. Draw the “Path” on the right plane.

6. Create a new plane Normal to curve.

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7. Start a sketch on the new plane and draw the following using a spline. Use
relations to constrain the sketch.

Pierce
Pierce

Vertical

Horizontal

Midpoint

8. Add a surface sweep.

78
9. Check for surface flaws by right mouse clicking on the surface and select display
curvature. Trim off the bad end by sketching a line on the front plane.

9. Select the trim surface icon.

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10. Select the Base-Thicken tool. Add .050”.

11. You should now have a solid. Try and make the end on your own now.

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EXERCISE 22
Imported 3D Model Repair

IGES files can be very useful for importing files from other systems.

Objective:
Repair the
imported IGES
file, by knitting
it into a solid.

1. Go to File/Open, and select IGES.

Select IGES from “Files of type”.

IGES – Initial Graphics Exchange

Standard.
2. Once imported you will receive a message asking if you would like to run
“Import Diagnostics”. Select “Yes”. Essentially in order to make use of this

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 (make a cavity/mold) it is imperative that it be knit into a solid. This is an
indication that there may be gaps in the surfaces.

3. Note: If you fail to select Import Diagnostics you can simply RMB click on the
surface in the feature tree, and select Import Diagnostics.

4. Select the Attempt to Heal in order to try and correct the gaps.

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5. First try to have SWX automatically close the gaps by selecting the close All
Gap Button. This works sometimes, but don’t count on it. In this case it fails
to close the gaps.
6. Now we must manually address the problem by creating surfaces to close the
gaps. Use your surfacing toolbar.
7. Before canceling out of diagnosis be sure to locate and memorize the gaps.
Changing the surface colors behind or around each gap easily does this.

8. Activate the Surfaces tab and use the “Surface loft” tool. Select edges to use
as Profiles and Guide Curves.

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9. Once all gaps are patched use the “Knit” tool to stitch them together. Be sure
to select all surfaces and the main body.
10. Then you can go to insert/base/thicken.
11. Be sure to select “Create solid from enclosed volume. You should now have a
solid.

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86
EXERCISE 23
Sheet Metal
Cylinders

Sheet Metal part files can be very useful for extracting a flat pattern.

Objective: Model a
sheet metal cylinder
and add cut outs.

12. Go to file/new and select new part and save as “E23”.

Sheet Metal Tool Bar:

To activate the toolbar on the ribbon simply RMB click on any ribbon tab and check the
Sheet Metal box.

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13. Draw the following sketch on the “Front” plane, use the “center point arc”
tool. Make both ends of the arc symmetric to a vertical centerline. Space @
.001”

14. Boss Extrude blind 2.5”. Notice that it should be creating a thin feature and
set the thickness to .060”.

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15. Select the edge of the cylinder and select Insert Bends. Set radius to “0”. Hit
OK.

16. Select the “Flatten” icon to verify. Then select the flatten icon to fold back
up.

17. To create a cut pattern on the sheet metal in the flattened state you must
first flatten it using the Unfold tool. And select the break edge to be fixed.

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 Draw a rectangle as seen below. Use the Sketch pattern tool to pattern
rectangle.

18. Select the “Fold” icon, to refold it. Then you can use “Flatten” to verify.

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EXERCISE 24
Sheet Metal
Modeling Conical Parts

Sheet Metal part files can be very useful for extracting a flat pattern.

Objective: Model a
sheet metal cone and
add cut outs.

1. Go to file/new and select new part and save as “E24”.

2. Draw the following sketch on the “Front” plane, use the “circle” tool.

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3. Boss Extrude blind 2.5” and add 13° Draft.

4. Select the front and back planar faces, then select the Shell feature. Set
thickness to “.060”. Hit OK.

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5. Select the “Front” plane and start a sketch on it. Draw the following angled
cutout. Dimension the edges and set the thickness to .005”.

6. Cut Extrude Through All.

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7. Select the cut edge of the part and then select the “Insert bends” icon.

8. Select the Flatten icon to unfold.

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EXERCISE 25
Sheet Metal Lofts

Lofted Sheet Metal creation can be very useful for complex sheet metal fabrication.

Objective: Model a
lofted sheet metal
part.

1. Begin by offsetting a plane 6” forward from the Front plane.

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2. Sketch the following on the front plane. Leave a small open gap of .1 in the
center top edge. Rebuild

3. Sketch the following on the offset plane. 1” Radius. Rebuild

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4. Select the Sheet Metal Loft tool, and select the sections.

5. Flatten to verify.

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EXERCISE 26
Weldments

Weldment creation can be very useful for automating layout designs and extracting cut
lists.

Objective: Create the

structural steel model
using the weldment
tools.

1. Start a new part file (ANSI inch) and save it as E25.

2. Activate the Weldments tool bar by RMB clicking on any ribbon tab, and
select the “Weldments” checkbox.

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 3. Start a sketch on the “Top” plane and draw the following.

4. Select the Weldments Icon to convert the part to a weldment entity.

5. Select the structural member icon. Also select one sketch line. Input values.

6. Select the other three sketch lines. Notice the end but settings.

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7. Offsetting a plane parallel to a point. Select the front plane and a corner of
the layout sketch you created in step 3. Go to the Plane Wizard.

100
8. Sketch the layout of the leg. Start a sketch on the new plane and draw the
following. Rebuild

9. Select the Structural Members icon. Select the vertical and 45 degree angled
line. Use the same settings as before. Hit the green check to apply.

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10. Select the Trim/Extend icon. Then select the Bodies and Boundaries.

11. It should look like the image below.

102
12. Select the bottom cut surface of the leg. Draw the following and extrude
.75”.

13. Select the Fillet Weld icon and input the following information.

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 14. Select the gusset icon and input the following information.

15. Use the mirror bodies’ tool to mirror the other legs into place. Finished.

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 105
GOAL:
FIND THE INTERNAL
VOLUME OF THE BOTTLE.
106
107
SUPPLIMENT
SolidWorks - CAD Administration

Finding adequate computer hardware to run Solidworks can be challenging, this lesson
looks at the multiple aspects of selecting hardware as well as modifying settings inside
SolidWorks to allow it to run efficiently and trouble free.

Selecting an Operating System (OS).

Windows 7
Windows 8
Windows 10

Virtual Memory Settings inside the OS. It may be a good idea to increase or adjust your
virtual memory setting. The norm would be x2 – x3 your current amount of ram.

Example 512MB of Ram 1000 – 1500 MB Virtual Ram. And keep the initial size the same
as the maximum size. It is said that this prevents write errors.

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Processors (CPU)
BUDGET
Intel
Atom
MID-RANGE
Celeron
Pentium
Core i3 HIGH END
Core i5
Core i7
Xeon PROFESSIONAL

AMD
Sempron
Athlon II
Phenom X2,3,4,6
VISION A4,6,8,10
FX Series
Opteron

109
Multiprocessing

Most CPU manufacturers are beginning to deliver multiple core processors. This can be
seen with the AMD FX which has up to eight processing cores.

Which one will run SolidWorks fastest? You can find benchmarks at www.spec.org
specifically for SolidWorks or you can look for the generic OpenGL benchmark results
that usually use an OpenGL video game.

The question is: “Can SolidWorks benefit from multiple cores?” Currently one might find
an average of 10 – 15% performance increase with general modeling. This is because
SolidWorks is not fully written to take advantage of multithreaded processes. However,
using the SolidWorks Simulation, CFD, or Photoview rendering solutions one may
discover 2x – 12x faster performance versus a single core processor. This is because
these SolidWorks applications do take full advantage of multithreaded processing.
The biggest benefit one might find is the ability to multitask while working with an FEA
analysis. This is a long process and you could actually open up another window of
SolidWorks or Outlook and continue working while the analysis is running with little
slow down in performance.

To check out what your computer has inside without opening the case download the
free version of CPUID – CUP-Z http://www.cpuid.com/softwares/cpu-z.html
Or ctrl-alt-del and start task manager to see how many threads your CPU has, as well as
how much RAM.

110
Graphics Cards
Here are a few brands that are in the Professional Category and actually have specific
drivers that are written to run SolidWorks at its best.
 NVIDIA Quadro series (not NVS series)
 Quadro FX 600 erp.$159 (erp- estimated retail price)
 Quadro FX 2000 erp.$499
 Quadro FX 4000 erp.$799

 ATI FirePro series (not FireMV series)

 FirePro 3900 erp.$159
 FirePro 5900 erp. $499
 FirePro 7900

 Intel Xeon
 P4000 HD integrated graphics (“P” = Professional rated)

These cards are considerably more expensive that mainstream cards but the benefits of
experiencing less crashes or visual problems with Pro/E outweigh the cost.
If you are using SolidWorks at work, DON’T SKIMP! Buy a professional grade video card.
For home use the nVidia Geforce or AMD Radeon series are fair, but you will still
experience some graphical glitches.
GRAPHICS CARD – SolidWorks BENCHMARK (source: www.tomshardware.com)

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With all SolidWorks documents closed go to Tools/Options/System and turn on software
OpenGL.

If your graphics rotation of models is slow try adjusting the image quality. This is located
in the document properties.

MEMORY (RAM)
4.0 – 16.0 GB From simple machined parts to complex assemblies. The more RAM the
better.
3.0 GB+ Requires Windows XP/Vista/7 64 Bit Editions

112
File Translation for the CAD/CAE/CAM Industries
Outline

1. History of Translation in the industry (What is it, why was it needed?)

a. 1979 Society of Manufacturing Engineers (SME) meeting.
b. General Electric challenges the CAD industry.

2. Primary/Neutral translators
a. STEP (Standard for the Exchange of Product Model Data)
i. AP (Application Protocols)
ii. Configurations
iii. Parametric Data
b. IGES (Initial Graphics Exchange Specification)

3. Types of data
a. Raster
b. Vector
i. 2D Geometry
ii. 3D Geometry
1. Curves
2. Surfaces
3. Solids (B-Rep)
c. Configurations
d. PD (Parametric Data)

4. Extracting information from translators.

a. Variation
b. Application

5. What the future holds.

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 With the growing number of software applications available in the Computer

Aided Design, Analysis, and Machining community (CAD/CAE/CAM), one might discover

communication between applications to be difficult, because of incompatibilities

between each application. Translators have been developed for this reason.

In the beginning CAD/CAE/CAM applications where primarily used in the

Scientific, and Aerospace communities. This CAD technology was developed in 1969 and

within a decade had reached a point where various companies had developed multiple

CAD applications. Users of these applications quickly discovered transferring data

between systems was very difficult. Specialized programs had been written to address

the task but no standards had been set. Frustration finally peaked at a Society of

Manufacturing Engineers (SME) meeting in the fall of 1979. An attendee from General

Electric (GE) challenged a panel of CAD vendors to create a universal translator to be

used between the various CAD applications. Soon after the meeting, the panel had

determined that such a task was possible, and set in motion the collaborative

foundation to what would later be recognized as the Initial Graphics Exchange

Specification (IGES). The IGES format is the most common translator used today, and it

continues to evolve and improve with help of user feedback. For more information on

IGES visit the web page. http://www.nist.gov/iges/

Since IGES there have been several other translator. One in particular named

STEP (Standard for the Exchange of Product Model Data) was developed specifically by

the Aerospace industry. Boeing and McDonald Douglas had been attempting to share

data between their CAD systems. They discovered IGES was not adequate, and not well

114
regulated. Variation was becoming an issue between CAD vendors due to poor

regulation of the translator. They decided quality had to be better enforced to eliminate

and reduce variation. They employed the International Organization for Standardization

(ISO) to develop, regulate, and manage the initiative. A team consisting of Boeing,

McDonald Douglas (Unigraphics), Catia, and Computer Vision was formed to assist with

laying the foundation. They assembled scalable algorithms that could be transplanted

into the base code known as Application Protocols (AP). These AP’s are used to identify

the specific tasks available in the translator. For example AP 203 is the most common in

that it has the ability to translate Solids data between systems. Another AP is the 214,

which was later added to enhance the ability to transfer configuration information for

manufacturing and inspection purposes. General Motors (GM) frequently uses the AP

214.

Visual CAD data comes in many forms. A basic break down of this reveals two

types. Raster and Vector. Raster data consists of multiple microscopic dots, which make

up an image. Much like a photograph this method proves inadequate for CAD because

of inaccuracy and it is limited to only two dimensional (2D) representation and

manipulation capabilities.

Raster Vector

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 Vector geometry on the other hand proves robust in its ability to provide both

2D and three dimensional (3D) attributes, making it the criterion form for translating

data. Vector geometry consists of continuous lines, arcs, splines, surfaces, or solid

geometry representations. Dimensional attributes are applied to identify position and

proportions. Enabling them to be easily modified, translated or scaled by simply

changing values.

The ultimate goal of the translator is to eventually enable all data created

on one CAD system to be flawlessly translated into another. This capability is currently

being worked on by ISO to be introduced into the STEP translation algorithm sometime

in the future. No date or deadline has been set until the CAD industry can come up with

a reasonable standard to do so. Several CAD vendors already have methods of either

reading in native CAD files from other systems and rebuilding from scratch the

Parametric Data (PD) or even directly translating the information.

The following is a list of common translators and native CAD formats capable of

being translated between SolidWorks. The list details if the file can be imported or

exported, and what specific data can be obtained by it.

116
TRANSLATOR EXTENSION IMPORT EXPORT VECTOR RASTER 2D 3D PD*
PARASOLID X_T, X_B X X X X
ACIS SAT X X X X
DW G DW G X X X X
DXF DW G X X X X X
IGES IGES, IGS X X X X X
STEP STEP, STP X X X X
VDAFS VDA X X X X
CGR W RL X X X X
HCG HCG X X X
CADKEY PRT X X X
SOLIDEDGE PAR X X X
UGII PRT X X X
MDT DW G X X X X
INVENTOR IPT X X X
PRO/ENGINEER PRT,XPR,ASM,XAS X X X X X
HOOPS HSF X X X
VRML W RL X X X X
VIEW POINT MTS X X X
REALITY W AVE ZGL X X X
EDRAW ING EPRT,EASM,EDRW X X X X
JPEG JPEG,JPG X X X
TIFF TIFF X X X
STL STL X X X
ADD-INS DLL X

Parasolid – Is the core-modeling kernel utilized inside SolidWorks. Two types of

parasolid translation are supported – standard (.x_t) and binary (.x_b); both translate
data flawlessly between native parasolid based systems. However, binary files are
typically smaller in size.

ACIS – Developed by Spatial Technologies – a DASSAULT SYSTEMES company. Portions of

this kernel are seamlessly integrated within SolidWorks. For example Spatials
deformable surface husk technology is recognized as SolidWorks “Shape” feature. ACIS
is the core-modeling kernel for many 3D CAD applications and is a good choice for
translating clean and efficient models between systems using this kernel. A complete list
of current ACIS kernel partners can be found at the internet address listed below.

DWG/DXF – Drawing Exchange File. Support for versions AutoCAD R12 – R2011.

117
IGES – Initial Graphics Exchange Specification. A common translator type, works with
most systems. However, incomplete translations are frequent due to lack of strict
regulations on software developer’s data creation.

STEP 203/214 – Standard for the Exchange of Product model data. A well-regulated
format – software developers must follow strict regulations to offer STEP as a certified
integrator. AP203 (Application Protocol) supports 3D geometry only. AP214 has
additional support for configurations, commonly used by General Motors.

VDAFS – Verband der Automobilindustrie (German Automotive Specification)

CGR – Catia Graphics format

HCG – Highly Compressed Graphics format

CADKEY – Imports native Cadkey part file solids data only.

SolidEdge – Imports native SolidEdge part file solids data only.

UGII – Imports Unigraphics (Siemens NX) native part file solids data only.

MDT – Mechanical Desk Top, (MDT 6.0 installed required to operate) has support for
parametric entities. Will not import 2D drawing data.

Inventor - Imports native Inventor part file solids data only.

Pro/Engineer-Creo – Imports Part and Assembly files. Capable of exporting v.20 part
files. Has support for parametric entities from versions 16 – Creo 1.0.

118
 In the past three years, data translation has made massive leaps in capabilities,

which help end users communicate more efficiently with one another. Unfortunately

there are still some CAD vendors holding back the progress made to have flawless data

communication between all users. These vendors believe empowering any and all

individuals to access data generated on proprietary CAD applications can be detrimental

to the bottom line of their company. They actually have been known to encrypt their

native files to prevent others who have not purchased the native CAD application from

accessing the data, forcing them (usually tier 2 and 3 vendors) to purchase the

application in order to better serve the customer.

In summary, there have been vast improvements in translation between systems

over the past decade. One can assume the final goal will eventually be attained, which

will break down the communications barriers, enabling virtually all CAD systems to

communicate flawlessly between one another.

119
CAD 121
Mid-Term Exam

1. Create an assembly and begin to mate the

components as shown in the Gearbox Assembly
Drawing.

2. Model the gasket as shown on page 4.

3. Model the Rear Casting part.

You may want to model it using the top-down assembly method. It’s much faster.

4. Re-Create Gearbox Exploded Assembly Drawing on

page 2.
The drawing view and appearance must be as close as possible.

1
2
 3
EXTRA CREDIT (10PTS.): FIX INTERFERENCE
 4
NOTE: ALL INTERNAL ESGES REQUIRE .06” FILLETS
CAD 121
Final Exam

1. Model the Communicator with the intent of

efficiency. In other words your goal is to build it using
the smallest number of features on the tree. Use any
method you wish, it can even be unorthodox.

Exceptions: The model must be 100% accurate to the print

provided. Also you cannot export it and re-import, nor use
assemblies to remove features.

NOTES: 20 points will be subtracted for every additional

feature (less one) that was not on master model.
I have a set number of features required to build this through
experience. This number is secret until after you turn in the
test.

1
2