SAE® Design and Analysis Project with SolidWorks® Software Put Picture Here

200 Pages·2011·12.24 MB·English

Engineering Design
and Technology Series
SAE® Design and Analysis Project
with SolidWorks® Software
Put Picture Here
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Document Number: PME1119-ENG
SolidWorks
Engineering Design and Technology Series
Table of Contents
Lesson 1: Introduction.......................................................................................1
Using This Book...........................................................................................................2
What is SolidWorks Software?.....................................................................................2
Prerequisites..................................................................................................................2
Conventions Used in This Book...................................................................................3
Before You Begin.........................................................................................................3
Analyzing a Structure Using SolidWorks and SolidWorks Simulation.......................4
Lesson 2: Using Assemblies.............................................................................5
Creating Parts In-Context ............................................................................................6
Opening an Assembly with Quick View................................................................6
Hiding and Showing Components.........................................................................7
The Assembly FeatureManager design tree...............................................................10
Working In-Context....................................................................................................11
Edit Assembly Mode vs. Edit Part Mode.............................................................11
In-Context Parts and Virtual Parts.......................................................................12
Setup for Using Edit Part.....................................................................................12
Creating a New Part ............................................................................................13
Edit Part Mode............................................................................................................14
Why do the Colors Change?................................................................................14
Controlling the Display........................................................................................14
Understanding the Color Coding.........................................................................20
Extrusions In-Context..........................................................................................24
Edit Assembly Mode..................................................................................................26
Working with Virtual Parts..................................................................................26
Adding Component Instances and Mating.................................................................27
In-Context Part Editing...............................................................................................31
Opening a Part from an Assembly .............................................................................32
Multi-body Materials...........................................................................................33
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SolidWorks
Engineering Design and Technology Series
Reordering Features.............................................................................................34
Materials.....................................................................................................................35
Pack and Go................................................................................................................37
Work Flow...........................................................................................................37
Lesson 3: Creating a Weldment......................................................................40
Creating Weldment Parts............................................................................................41
Planes and Sketches.............................................................................................41
Structural Members..............................................................................................41
Weldments..................................................................................................................42
Creating a Weldment............................................................................................42
Using Different Planes and Sketches...................................................................45
Using 2D Sketches...............................................................................................47
Renaming and Opening a Virtual Part.................................................................51
Additional Planes and 2D Sketches.....................................................................54
Sketching with Pierce Relations...........................................................................56
Adding Bracing to the Frame.....................................................................................60
Using 3D Sketches......................................................................................................61
Sketching in the X, Y and Z Directions...............................................................61
3D Sketch Dimensions.........................................................................................62
Placing a Component Using Sketch Geometry..........................................................64
Making Changes...................................................................................................66
Working With Sub-Assemblies..................................................................................67
Opening a Sub-assembly from the Assembly......................................................67
Rigid vs. Flexible Sub-Assemblies......................................................................68
Bracing Sketches........................................................................................................70
Remaining Sketches.............................................................................................71
Weldment Structural Members...................................................................................73
Creating Custom Profiles.....................................................................................74
Adding Structural Members.......................................................................................77
Corner Treatments................................................................................................78
Using Trim/Extend.....................................................................................................82
Trimming Boundary.............................................................................................82
Using Folders.......................................................................................................84
Map for Structural Member Types and Trim/Extend..........................................85
Mirroring Structural Members.............................................................................86
Editing.........................................................................................................................87
Editing the Corner Treatment...............................................................................87
Using Locate Profile............................................................................................89
Using Instant 3D..................................................................................................92
Checking Clearances............................................................................................94
Interference Detection..........................................................................................97
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SolidWorks
Engineering Design and Technology Series
Mounting Plates..........................................................................................................99
Creating a Reusable Sketch..................................................................................99
Pasting the Sketch..............................................................................................100
Weldment Cut Lists..................................................................................................106
Cut List Properties..............................................................................................107
Save as External File..........................................................................................108
Lesson 4: Using Molds and Surfaces...........................................................109
Molds and Surfaces...................................................................................................110
The runner part..............................................................................................111
Features in the Part.............................................................................................112
Anatomy of a Loft..............................................................................................113
Creating Mold Tooling.............................................................................................114
Surface and Solid Bodies...................................................................................114
Description of the Bodies...................................................................................115
Mold Tools.........................................................................................................116
Using Surfaces...................................................................................................121
Making Use of Symmetry.........................................................................................127
Lesson 5: Brake Rotor Analysis....................................................................130
Brake Rotor Design..................................................................................................131
SolidWorks Simulation Interface.......................................................................132
Transient Thermal Analysis......................................................................................134
Thermal Boundary Conditions.................................................................................135
Convection.........................................................................................................135
Heat Power.........................................................................................................138
Post Processing.........................................................................................................140
Static Study...............................................................................................................142
Temperature Dependent Material Properties.....................................................143
Fixtures.....................................................................................................................143
Loading.....................................................................................................................145
Braking Force...........................................................................................................146
Thermal Loading................................................................................................147
Post Processing.........................................................................................................148
Editing Plots.......................................................................................................149
Chart Options.....................................................................................................149
Settings...............................................................................................................149
Conclusions...............................................................................................................151
Lesson 6: Frame Analysis..............................................................................152
Torsional Rigidity.....................................................................................................153
Element Types..........................................................................................................153
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SolidWorks
Engineering Design and Technology Series
Shell Elements....................................................................................................154
Beam Elements...................................................................................................154
Preparing for Analysis..............................................................................................155
Experimental Design................................................................................................156
Additional Model Modifications........................................................................157
Beam Meshing..........................................................................................................158
Section Properties...............................................................................................158
End Conditions...................................................................................................159
Trusses................................................................................................................160
Joint Group.........................................................................................................160
Merging Joints Automatically............................................................................163
Fixtures.....................................................................................................................163
Loading.....................................................................................................................165
Post Processing.........................................................................................................167
Cylindrical Coordinates.....................................................................................168
Torsional Rigidity..............................................................................................170
Beam Stresses.....................................................................................................171
Cross Section Directions 1 and 2.......................................................................172
Shear and Bending Diagrams.............................................................................174
Conclusion................................................................................................................175
Lesson 7: Intake Analysis..............................................................................176
Intake Manifold Design............................................................................................177
Model Preparations...................................................................................................177
External Flow Analysis......................................................................................177
Internal Flow Analysis.......................................................................................177
SolidWorks Flow Simulation Interface..............................................................179
Lids.....................................................................................................................179
Check Geometry.................................................................................................181
Creating the Project..................................................................................................181
Engineering Goals..............................................................................................189
Post-Processing.........................................................................................................191
Color Bar............................................................................................................192
Discussion..........................................................................................................194
Conclusions...............................................................................................................194
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SolidWorks
Engineering Design and Technology Series
Lesson 1
Introduction
When you complete this lesson, you will be able to:
Describe the relationship between Parts, Assemblies and Drawings;
(cid:81)
Identify the principal components of the SolidWorks user interface;
(cid:81)
Download and extract the required companion files.
(cid:81)
1
SolidWorks Introduction
Engineering Design and Technology Series
Using This Book
The SAE Design and Analysis Project with SolidWorks Software
helps you learn the principles of assembly design and structural analysis using
SolidWorks and SolidWorks Simulation as an integral part of a creative and
iterative design process.
For this project, You will “learn by doing” as you complete modeling and
structural analysis lessons.
What is SolidWorks Software?
SolidWorks is design automation software. In SolidWorks, you sketch ideas and
experiment with different designs to create 3D models using the easy to learn
Windows® graphical user interface.
SolidWorks is used by students, designers, engineers and other professionals to
produce single and complex parts, assemblies and drawings.
Prerequisites
Before you begin the SAE Design and Analysis Project with
SolidWorks Software you should complete the following online tutorials that
are integrated in the SolidWorks software:
Lesson 1 - Parts
(cid:81)
Lesson 2 - Assemblies
(cid:81)
Lesson 3 - Drawings
(cid:81)
You can access the online tutorials by clicking Help, SolidWorks Tutorials, All
SolidWorks Tutorials (Set 1). The online tutorial resizes the SolidWorks window
and runs beside it.
As an alternative, you can complete the following lessons from An Introduction to
Engineering Design With SolidWorks:
Lesson 1: Using the Interface
(cid:81)
Lesson 2: Basic Functionality
(cid:81)
Lesson 3: The 40-Minute Running Start
(cid:81)
Lesson 4: Assembly Basics
(cid:81)
Lesson 6: Drawing Basics
(cid:81)
Using This Book 2
SolidWorks Introduction
Engineering Design and Technology Series
Conventions Used in This Book
This manual uses the following typographical conventions:
Convention Meaning
Bold Sans Serif SolidWorks commands and options appear in this style.
For example, Insert, Boss means choose the Boss option
from the Insert menu.
Typewriter Feature names and file names appear in this style. For
example, Sketch1.
17 Do this step. The steps in the lessons are numbered in sans serif bold.
Before You Begin
If you have not done so already, copy the companion files for the lessons onto
your computer before you begin this project.
1 Start SolidWorks.
Using the Start menu, start the SolidWorks application.
2 SolidWorks Content.
Click Design Library to open the design library
task pane.
Click on SolidWorks Content to show the
folders below it.
Click on SolidWorks Educator Curriculum.
Click SAE Project Files - English.
Note: There may be more curriculum folders listed in
addition to the SAE Project Files.
The lower pane will display an icon representing a
Zip file that contains the companion files for this
project.
Conventions Used in This Book 3
SolidWorks Introduction
Engineering Design and Technology Series
3 Download the Zip file.
Press Ctrl and click the icon.
You will be prompted for a folder in
which to save the Zip file.
Ask your teacher where you should
save the Zip file. Usually the
C:\Temp folder is a good location.
Click OK.
Tip: Remember where you saved it.
4 Open the Zip file.
Browse to the folder where you saved the Zip file in step3.
Double-click the SAE Project Files.zip file.
5 Click Extract.
Click Extract and Browse to the location where you want to save the
files. The system will automatically create a folder named
_SAE_Project_ENG in the location you specify. For example, you might want
to save it in My Documents. Check with your teacher about where to save the
files.
You now have a folder named SAE Project Files on your disk. The data in this
folder will be used in the exercises.
Tip: Remember where you saved it.
Analyzing a Structure Using SolidWorks and SolidWorks Simulation
During this session, you will learn how to analyze a structure using SolidWorks
and SolidWorks Simulation.
Once you have had a chance to see how easy it is to use SolidWorks solid
modeling software, you will use an assembly to check whether components fit
properly.
You will then make a drawing of one of the components, complete with a cut list.
If a printer is available, you can print out a hardcopy of your drawing.
Analyzing a Structure Using SolidWorks and SolidWorks Simulation 4