Mastering SolidWorks®

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 Mastering SolidWorks®
The Design Approach

Third Edition

Ibrahim Zeid
Nathan Brown

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 Mastering SolidWorks

Copyright © 2021 Pearson Education, Inc.

The authors and publisher have taken care in the preparation of this book, but make no
expressed or implied warranty of any kind and assume no responsibility for errors or omis-
sions. No liability is assumed for incidental or consequential damages in connection with or
arising out of the use of the information or programs contained herein.

Many of the designations used by manufacturers and sellers to distinguish their products are
claimed as trademarks. Where those designations appear in this book, and the publisher was
aware of a trademark claim, the designations have been printed with initial capital letters or in
all capitals.

SOLIDWORKS is a registered trademark of Dassault Systemes. Dassault Systemes SolidWorks

Corporation, a corporation, having its principal place of business at 175 Wyman Street,
Waltham, Massachusetts, 02451, UNITED STATES.

AutoCAD is a registered trademark of Autodesk, Inc. Pro/Engineer is a registered trademark of

Parametric Technology Corporation (PTC). CATIA is a registered trademark of Dassault
Systèmes SA.

“ANSI” and the ANSI logo are registered trademarks of ANSI.

The publication is designed to provide tutorial information about the SolidWorks computer
program. Every effort has been made to make this publication complete and as accurate as
possible. The reader is expressly cautioned to use any and all precautions necessary, and to
take appropriate steps to avoid hazards, when engaging in the activities described herein.

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ISBN-13: 978-0-13-688726-3
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 Features of Mastering SolidWorks®:
The Design Approach
Tutorials
Tutorial 4–6: Create Features
This tutorial covers the creation of these features: chamfer, fillet, slot, shell, draft, and
rib. All dimensions are inches. Here are useful observations:
1. Make sure to pay attention to the visual clues shown in the left pane while creating
these features.
2. For example, the box symbol under Chamfer parameters indicates that you can
chamfer a face, an edge, or a vertex (corner point). As expected, chamfering a face
chamfers all its edges. Chamfering a corner chamfers the three edges that meet
there.
3. A rib requires a profile sketch (e.g., a line or stepwise line) and a thickness.

p 1: Step 5:Shell Block

q p ( g, p )
Step-by-Step Instructions
Step 1: Step 5: Shell Block
Create Sketch1 feature: Shell on Fea-
and Block tures tab > select top
feature: File > face of Block > enter 0.1
New > Part > for wall thickness D1 >
OK > Top .
Plane >
Extruded
Boss/Base on Features tab > Center Rectangle on
Sketch tab > click origin and sketch and dimension as Step 6:Draft Block
shown > exit sketch > reverse extrusion direction > feature: Delete the
enter 0.5 for thickness D1 > > File > Save As > chamfer, fillet, and shell
tutorial4.6 > Save. features > Draft on
Features tab > enter 10
Step 2: Chamfer an degrees for Draft Angle >
edge of Block feature: select top face of Block as
Fillet dropdown on Neutral Plane > select Block four side faces to draft > .
Features tab > Chamfer
> select Block edge
shown > use 0.1 for D
d 45 d f l

p
Hands-on for Tutorials
HANDS-ON FOR TUTORIAL 12–1. Edit the title block to add a tolerance general note in the
Commentsbox of the title block. The note should read:
GENERAL TOLERANCE
.X { .030
.XX { .010
.XXX { .005
.XXXX { .0005

Create Geometric Tolerances

Equation (12.5) should confirm that observation (a d dsmax).

Examples and Solutions
Example 12.1 Calculate the limits and tolerance zones for the following three
fits: clearance of RC3, transition of LT4, and interference of FN2.
Use a basic size of 5.0000 in.
Solution Following the above four steps, Table 12.2 shows the results.

TABLE 12.2 Limits for Basic Size d 5.000 in.

Fit dhmin dhmax dsmin dsmax h s A
RC3 (H7/f6) 5.0000 5.0016 4.9974 4.9984 0.0016 0.0010 0.0016
LT4 (H8/k7) 5.0000 5.0025 5.0001 5.0017 0.0025 0.0016 0.0017
FN2 (H7/s6) 5.0000 5.0016 5.0035 5.0045 0.0016 0.0010 0.0045

Th li i h i T bl 12 2 i h h S lidW k l h i Fi 12 8

Problems
problems

1. List the sources of variability in manufacturing.

2. Why do we need tolerances?
3. List the two types of tolerances. What does each type control?
4. Inspection gauges are used to check whether a part is within its tolerance
limits. Perform an in-depth research study on inspection gauges including
their types, their design, and how they are used during part inspection.
5. What is the difference between a nominal and a basic size? Give an example.
6. Three types of tolerances exist: unilateral, bilateral, and symmetric. Describe
each type. Give a numerical example for each type.
7 List the three types of material conditions Explain each type

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 Preface
The target audience for this book is college students in courses that use
SolidWorks to learn and master CAD/CAM for design, visualization,
prototyping, and manufacturing. The book’s primary market is four-year
colleges and two-year community colleges. Freshman Engineering Design
courses should find this book useful, refreshing, and interesting. Other
important markets include high schools, professionals, and training
courses. We have written the book with the target audience in mind. Page iii
highlights some of the book’s features.
The book includes relevant math in Chapter 8 (Curves), Chapter 9
(Surfaces), and Chapter 13 (Analysis Tools). The math is concentrated in
one or two sections in each of these three chapters. We include the math for
two reasons. First, it shows students who are curious how CAD/CAM
systems work “under the hood.” Second, it broadens the book’s appeal to
many students, professors, and readers. This math may be ignored without
affecting the continuity of the coverage of the material in any of these three
chapters.
The philosophy behind the book is original, unique, and effective. We
cover and present SolidWorks as a design system rather than a software
program. Thus, instead of focusing on describing SolidWorks menus and
syntax, we describe design approaches, methodologies, and techniques to
help CAD designers/engineers and draftspersons achieve engineering tasks
in the fastest, easiest, and most effective way.
Based on this philosophy, the book focuses on design, modeling, and
drafting concepts instead of menus and commands. Thus, we present
command sequences to achieve CAD and modeling tasks. Of course, we
provide SolidWorks syntax and details, but do so in accordance with the
proposed philosophy of the book. We start with a CAD task to accomplish
(what to do) and then go about accomplishing it (showing how to use
SolidWorks to do it). This philosophy is more motivating to student learning
than simply going through layers of menus and commands.
The book approach is designed to showcase SolidWorks as a powerful
modeling and design system instead of only a software program. We include
challenging modeling and design examples and problems in the book. As
part of the book’s unique approach, we cover the theoretical concepts
behind the various functions of SolidWorks. This should provide
information to curious minds about why things work the way they do, as
well as explain their limitations and use.
The book provides abundant illustrations, step-by-step instructions,
and rich and challenging end-of-chapter problems. The book is suitable for
use at various levels, from freshman to senior to graduate courses.
Instructors can choose the chapters and topics that suit their teaching
needs and courses. They can also choose the level of depth. The book
includes both examples and tutorials. An example covers one concept
whereas a tutorial is more comprehensive by covering a full design task.
Most examples and tutorials have a hands-on exercise at the end that
serves two purposes. First, it ensures that the student has completed the
example or tutorial, because it builds on it. Second, it both challenges and
extends the student’s understanding.

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 The book is organized into parts and chapters. Instructors may cover
the chapters in any order to fit their course and student needs. However,
we recommend covering Chapters 1 and 2 first to build a sound foundation
in 3D CAD/CAM modeling concepts. Chapter 1 is designed to provide a
quick grasp of basic functionalities: create parts, create assemblies, and
create drawings. These three functionalities correspond to the three modes
of SolidWorks: part, assembly, and drawing. Therefore, students can start
designing basic and simple products after using only one chapter of the
book; they do not have to wait until later chapters to learn how to design
and document simple parts and assemblies. Later chapters provide further
details. Thus, Chapter 1 provides breadth and the remainder of the book
provides depth. Chapter 2 covers essential concepts required for a sound
understanding of 3D modeling and efficient use of today’s parametric
features-based solid modeling CAD/CAM systems such as SolidWorks.

Acknowledgments from Second Edition

I would like to thank many people who contributed to this book including
my students, the book reviewers, the Pearson team, the editorial team, and
my family. Many of my students have shaped how I should present and
teach concepts to help them understand better. They have also contributed
directly and indirectly to the book. This book is the outcome of their
influence.
I would also like to thank Boston Gear for granting permission to
download and use some of their gears in the book tutorials. I thank Jake
Hustad for providing the Universal Joint assembly. I also thank Ivette
Rodriguez of ASME for granting permission to use ASME Y14.5M-1994
(R2004) material.
Many thanks are due DS SolidWorks Corporation for its technical support
throughout the writing process and using SolidWorks. My sincere thanks go
to my friends Marie Planchard, Christian Blanc, and Christine Morse.
I owe thanks to the many reviewers who helped to shape this book (first
edition). They are:
Charles Coleman, Argosy University
Paige Davis, Louisiana State University
Joe Fitzpatrick, VIC Inc., Boston, Massachusetts
Max P. Gassman, Iowa State University
Julia Jones, University of Washington
Dean Kerste, Monroe County Community College
Julie Korfhage, formerly of Clackamas Community College
Paul Lienard, Northeastern University College of Professional Studies
Payam H. Matin, University of Maryland Eastern Shore
Jianbiao (John) Pan, California Polytechnic State University
Lisa Richter, Macomb Community College
Nishit Shah, NyproMold Inc., Massachusetts
David W. Ward, Clackamas Community College

Preface   vii

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 Last, but not least, my family and friends deserve many thanks for
their support, and apologies to them for hiding out to finish this book
project. Their love and unconditional support is priceless.

—Abe Zeid

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 Contents at a Glance

Prefacevi

Part I  Computer Aided Design (CAD) Basics1

Chapter 1 Getting Started 3

Chapter 2 Modeling Management 37

Chapter 3 Design Intent 81

Part II  Basic Part Modeling97

Chapter 4 Features and Macros 99

Chapter 5 Drawings 135

Chapter 6 Assemblies 157

Chapter 7 Rendering and Animation 195

Part III  Advanced Part Modeling215

Chapter 8 Curves 217

Chapter 9 Surfaces 249

Chapter 10 Sheet Metal and Weldments 289

Chapter 11 Sustainable Design 319

Part IV  Part Development and Analysis337

Chapter 12 Tolerances 339

Chapter 13 Analysis Tools 377

Part V  Part Manufacturing409

Chapter 14 Rapid Prototyping 411

Chapter 15 Numerical Control Machining 427

Chapter 16 Injection Molding 463

Appendix A  ANSI and ISO Tolerance Tables 491

Appendix B  SolidWorks Certification 505

Index 517

   ix

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 Contents

Part I Computer-Aided Design (CAD) 2.18 Grids 54

Basics1 2.19 Patterns 54
Chapter 1  Getting Started 3 2.20 Selecting, Editing, and Measuring Entities 58
1.1 Introduction 3 2.21 Boolean Operations 59
1.2 Engineering Design Process 4 2.22 Templates 61
1.3 CAD Process 4 2.23 Viewing 61
1.4 Manufacturing Process 5 2.24 Model Communication 62
1.5 CAM Process 6 2.25 Tutorials 63
Tutorial 2–1 Create a Coil Spring 63
1.6 SolidWorks Installation and Resources 6
Tutorial 2–2 Create a Mount Plate 65
1.7 SolidWorks Overview 8 Tutorial 2–3 Create a Bracket 66
1.8 Customize SolidWorks 11 Tutorial 2–4 Create a Wheel 67
1.9 Modeling Plan 12 Tutorial 2–5 Create a Tire and a Pin 69
Tutorial 2–6 Create a Caster Assembly 70
1.10 Part Creation 14
Problems 73
1.11 Examples 15
1.12 Tutorials 22 Chapter 3  Design Intent 81
Tutorial 1–1 Create a Flap 22
3.1 Introduction 81
Tutorial 1–2 Create a Pin and Bushing Bearing 24
Tutorial 1–3 Create a Pillow Block 25 3.2 Capturing Design Intent 82
Tutorial 1–4 Create Drawings 28 3.3 Documenting Design Intent 83
Tutorial 1–5 Create an Assembly 29 3.4 Comments 83
Problems 32 3.5 Design Binder 84
3.6 Equations 85
Chapter 2  Modeling Management 37
3.7 Design Tables and Configurations 85
2.1 Overview 37
3.8 Dimension Names 85
2.2 Types of CAD Models 37
3.9 Feature Names 85
2.3 Planning Part Creation 39
3.10 Folders 86
2.4 Part Topology 40
3.11 Tutorials 86
2.5 Parametric Modeling 40
Tutorial 3–1 Design Intent via Two Modeling Plans 86
2.6 Customizing SolidWorks 42 Tutorial 3–2 Design Intent via Three Modeling Plans 89
2.7 Productivity Tools 43 Tutorial 3–3 Design Intent via Design Specifications 91
2.8 Coordinate Systems 43 Tutorial 3–4 Design Intent via Mating Conditions 93
2.9 Sketch Planes 44 Problems 95
2.10 Sketch Status 46
Part II  Basic Part Modeling97
2.11 Part Feature Tree 47
2.12 Construction Geometry 48 Chapter 4  Features and Macros 99
2.13 Reference Geometry 48 4.1 Introduction 99
2.14 Sketch Entities 50 4.2 Features 100
2.15 Sketch Relations 51 4.3 Spur Gears 103
2.16 Equations and Link Values 51 4.4 Design Library and Library Features 109
2.17 Geometric Modifiers 53 4.5 Configurations and Design Tables 110

x  

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 4.6 Macros 111 6.7 Assembly Exploded Views and Animations 164
4.7 Tutorials 114 6.8 Assembly Motion Study 165
Tutorial 4–1 Create Sweep Features 114 6.9 Interference and Collision Detections 166
Tutorial 4–2 Create Loft Features 116
6.10 Assembly Design Tables 166
Tutorial 4–3 Use the Hole Wizard 118
Tutorial 4–4 Create Compression Spring 119 6.11 Tutorials 166
Tutorial 4–5 Create Spiral 120 Tutorial 6–1 Create a Cam and a Follower
Tutorial 4–6 Create Features 121 Assembly 167
Tutorial 4–7 Use the Smart Fasteners Wizard 122 Tutorial 6–2 Create a Working Hinge Assembly 168
Tutorial 4–8 Create a Bolt 123 Tutorial 6–3 Mate Two Gears with a Gear Mate 169
Tutorial 6–4 Create a Functional Rack and Pinion 171
Problems 126
Tutorial 6–5 Create a Functional Ball Screw 173
Tutorial 6–6 Study Universal Joint Motion 174
Chapter 5  Drawings 135
Tutorial 6–7 Create a Motion Study 176
5.1 Introduction 135 Tutorial 6–8 Detect Collision and Interference 178
5.2 Engineering Drafting and Graphics Tutorial 6–9 Create a Design Table 179
Communication 136 Tutorial 6–10 Create a Part in the Context of
5.3 ASME Abbreviation Rules 137 an Assembly 180
5.4 ASME Drafting Rules 138 Problems 183
5.5 ASME Dimensioning Rules 139
Chapter 7  Rendering and Animation 195
5.6 Dimensions 142
7.1 Introduction 195
5.7 Drawing Content and Layout 144
7.2 Scenes and Lighting 196
5.8 Angles of Projection 145
7.3 Rendering Models 197
5.9 Views 146
7.4 Decals 198
5.10 Sheets 148
7.5 Textures 199
5.11 Title Blocks 149
7.6 Materials 199
5.12 Drafting Control 150
7.7 Appearance and Transparency 201
5.13 Tolerances 150
7.8 Background and Scenes 201
5.14 Bills of Materials 151
7.9 Cameras and Camera Sleds 201
5.15 Model and Drawing Associativity 151
7.10 Animation 201
5.16 Design Checker 151
7.11 Tutorials 202
5.17 Tutorials 152 Tutorial 7–1 Apply Colors to Objects 202
Tutorial 5–1 Create Drawing Views 152 Tutorial 7–2 Apply a Background and a Scene 203
Tutorial 5–2 Insert Annotations 153 Tutorial 7–3 Apply Lights to a Scene 204
Tutorial 5–3 Fill Title Block 153 Tutorial 7–4 Add Material and Transparency 205
Tutorial 5–4 Create Assembly Drawing with Tutorial 7–5 Add a Camera to a Scene 206
Bill of Materials 154 Tutorial 7–6 Create a Motion Study 207
Tutorial 5–5 Use Model-Drawing Associativity 155 Tutorial 7–7 Create a Camera-Sled Based
Problems 156 Animation 210
Problems 213
Chapter 6  Assemblies 157
6.1 Introduction 157 Part III  Advanced Part Modeling215
6.2 Assembly Mates 158
Chapter 8  Curves 217
6.3 Bottom-Up Assembly Modeling 159
8.1 Introduction 217
6.4 Top-Down Assembly Modeling 159
8.2 Curve Representation 218
6.5 The Assembly Tree 164
8.3 Line Parametric Equation 219
6.6 Assembly Drawings 164

Contents   xi

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 8.4 Circle Parametric Equation 220 Chapter 10  Sheet Metal and Weldments 289
8.5 Spline Parametric Equation 221 10.1 Introduction 289
8.6 Two-Dimensional Curves 222 10.2 Sheet Metal 289
8.7 Three-Dimensional Curves 223 10.3 Sheet Metal Features 291
8.8 Curve Management 224 10.4 Sheet Metal FeatureManager Design Tree 296
8.9 Tutorials 224 10.5 Sheet Metal Methods 297
Tutorial 8–1 Create a 2D Curve by Using 10.6 Weldments 299
an Explicit Equation 224
10.7 Weldment Features 301
Tutorial 8–2 Create a 2D Curve by Using
a Parametric Equation 225 10.8 Weld Symbols 305
Tutorial 8–3 Create a 3D Curve by Using 10.9 Tutorials 306
a Parametric Equation 225 Tutorial 10–1 Create Sheet Metal 306
Tutorial 8–4 Create a 3D Curve by Using Tutorial 10–2 Create a Sheet Metal Drawing 308
3D Points 227 Tutorial 10–3 Create a Sheet Metal Part from
Tutorial 8–5 Create a 3D Curve by Using a Solid Body 309
3D Sketching 228 Tutorial 10–4 Create a Sheet Metal Part from
Tutorial 8–6 Create a 3D Curve by Using a Flattened State 310
Composite Curves 229 Tutorial 10–5 Create a Weldment 311
Tutorial 8–7 Create a 3D Curve by Projecting Tutorial 10–6 Create a Weldment Drawing 313
a Sketch onto a Curved Face 231 Problems 316
Tutorial 8–8 Create a 3D Curve Using
Projected Curves 232 Chapter 11  Sustainable Design 319
Tutorial 8–9 Create a Stethoscope Model 241 11.1 Introduction 319
Problems 244 11.2 Design and Society 321
11.3 Guidelines and Principles 321
Chapter 9  Surfaces 249
11.4 Life Cycle Assessment 323
9.1 Introduction 249
11.5 Impact Metric 325
9.2 Surfaces 249
11.6 Implementation 327
9.3 Using Surfaces in Solid Modeling 252
11.7 Design Activities 327
9.4 Surface Representation 254
11.8 Sustainable Design Tools 328
9.5 Plane Parametric Equation 255
11.9 SolidWorks Sustainability 329
9.6 Ruled Surface Parametric Equation 257
11.10 Tutorials 332
9.7 Surface Visualization 260
Tutorial 11–1 Redesign a Steel Washer 332
9.8 Surface Management 260
Problems 335
9.9 Tutorials 261
Tutorial 9–1 Create Basic Surfaces: Extrude, Part IV  Part Development and Analysis337
Revolve, Loft, Sweep, Knit, and Radiate 261
Tutorial 9–2 Create Basic Surfaces: Planar, Chapter 12  Tolerances 339
Filled, Boundary, and Offset 263 12.1 Introduction 339
Tutorial 9–3 Visualize Surfaces 264
12.2 Tolerance Types 340
Tutorial 9–4 Create an Artistic Bowl 265
Tutorial 9–5 Use Surface Intersections 268 12.3 Tolerance Concepts 340
Tutorial 9–6 Create a Tablespoon 269 12.4 ASME Tolerance Rules 343
Tutorial 9–7 Create a Computer Mouse 271 12.5 Tolerancing Tapers 347
Tutorial 9–8 Create a Baseball Hat 273
12.6 Limits of Dimensions 348
Tutorial 9–9 Create a Hair Dryer 277
Tutorial 9–10 Create an Oil Container 279 12.7 Tolerance Accumulation 353
Problems 282 12.8 Statistical Tolerancing 354

xii  Contents

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 12.9 True Position 356 14.5 SolidWorks Triangulation 417
12.10 Geometric Tolerances 357 14.6 RP Steps 418
12.11 Datum Target Symbols 359 14.7 RP Building Techniques 419
12.12 Tolerance Interpretation 360 14.8 Bottle Prototype 420
12.13 Tolerance Analysis 362 14.9 Tutorials 421
12.14 SolidWorks Tolerance Analysis 364 Tutorial 14–1 Generate Part Prototype File 421
Tutorial 14–2 Generate Assembly Prototype File 422
12.15 Tutorials 367
Tutorial 14–3 Read Back an STL File 423
Tutorial 12–1 Create Conventional Tolerances 367
Tutorial 12–2 Create Geometric Tolerances 369 Problems 425
Tutorial 12–3 Define Datum Targets 370
Chapter 15  Numerical Control Machining 427
Tutorial 12–4 Tolerance a Taper 371
Tutorial 12–5 Perform Tolerance Stack-up 15.1 Introduction 427
Analysis 372 15.2 Basics of Machine Tools 428
Problems 374 15.3 Basics of Machining 430
15.4 Turning 438
Chapter 13  Analysis Tools 377
15.5 Drilling 438
13.1 Introduction 377
15.6 Milling 439
13.2 Data Exchange 378
15.7 Electrical Discharge Machining 439
13.3 Mass Properties 381
15.8 Manufacturing of Design 441
13.4 Animation and Motion Analysis 385
15.9 SolidWorks DFMXpress 442
13.5 Flow Simulation 386
15.10 Basics of NC Machining 445
13.6 Finite Element Method 386
15.11 G-Code and M-Code Programming 447
13.7 Finite Element Analysis 389
15.12 CAM Add-In Software 449
13.8 SolidWorks Simulation 391
15.13 Tutorials 449
13.9 Von Mises Stress 391
Tutorial 15–1 Drill Holes 450
13.10 Tutorials 396 Tutorial 15–2 Mill Faces 452
Tutorial 13–1 Export Native SolidWorks Files 396 Tutorial 15–3 Mill Pockets 455
Tutorial 13–2 Import IGES and STEP Files Tutorial 15–4 Mill Slots 457
into SolidWorks 396
Problems 460
Tutorial 13–3 Calculate Mass Properties
of a Solid 397 Chapter 16  Injection Molding 463
Tutorial 13–4 Perform Motion Analysis
16.1 Introduction 463
Using a Motor 398
Tutorial 13–5 Perform Static Linear FEA 16.2 Basics of Injection Molding Machines 464
on a Part 403 16.3 Basics of Injection Molding 465
Tutorial 13–6 Perform Thermal FEA on a Part 405 16.4 Basics of Mold Design 467
Tutorial 13–7 Perform Flow Analysis on a Hose 406
16.5 Basics of Part Design 470
Problems 408
16.6 Phases of Mold Design 471
Part V  Part Manufacturing409 16.7 SolidWorks Mold Design 472
16.8 Tutorials 473
Chapter 14  Rapid Prototyping 411 Tutorial 16–1 Create a Block Mold 473
14.1 Introduction 411 Tutorial 16–2 Create a Sandbox Mold 477
14.2 RP Applications 412 Tutorial 16–3 Create a Hemisphere Mold 481
Tutorial 16–4 Create an Easter Egg Mold 484
14.3 RP Overview 414
Tutorial 16–5 Generate a Mold Drawing 487
14.4 RP Concepts 414
Problems 488

Contents   xiii

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 Appendix A  ANSI and ISO Tolerance Tables 491 B.6 CSWP–Simulation507
B.7 CSWP–Mold Making508
Appendix B  SolidWorks Certification 505
B.8 Testing Resources508
B.1 Certified SolidWorks Associate (CSWA)505
B.9 Sample Test Questions 509
B.2 Certified SolidWorks Professional (CSWP)506
B.3 CSWP–Surfacing506 Index517
B.4 CSWP–Sheet Metal507
B.5 CSWP–Weldments507

xiv  Contents

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 Figure Credits

Chapter Figure Credit

Cover Philipp Tur/Shutterstock
SolidWorks screenshots © 2002–2020 Dassault Systèmes SolidWorks
Corporation
2 FIG02–33 Courtesy of VIC
2 FIG02–34 Courtesy of VIC
6 FIG06–07_Step-02   Screenshot © 2020 Altra Industrial Motion Corp
6 FIG06–08_Step-01 Screenshot © 2020 Altra Industrial Motion Corp

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This page intentionally left blank
 Part II
Basic Part Modeling

The primary goal of this part is to explore and cover the details of
­engineering drawings, assemblies, and rendering. We have covered these
topics briefly in Part I. Each topic has its own chapter in Part II to under-
stand it in depth. Part II also covers the full set of features that can be used
in CAD modeling. In Part I, we purposely limited our models to the basic
features of extrusions and revolves.
Chapter 4, “Features and Macros,” is all about when and how to use
the full set of features available to design advanced parts with complex
geometry. Chapter 5, “Drawings,” covers the details of drawings, including
the creation and control of the title block. Chapter 6, “Assemblies,” covers
assembly details, including the bottom-up and top-down approaches.
Chapter 7, “Rendering and Animation,” closes Part II by showing how to
create realistic renderings of parts and assemblies that show material and
texture. CAD visualization is important to convey and present designs
­efficiently.

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This page intentionally left blank
 4 chapterfour
Features and
Macros

4.1 Introduction
We have been using a limited set of features thus far in the book. We have
used extrusions and revolves. We have used the SolidWorks features
Extruded Boss/Base and Revolved Boss/Base and their subtracting
counterparts, Extruded Cut and Revolved Cut. These four features create
one class of parts: those with constant cross sections. We use the extruded
boss or cut to create uniform thickness parts. We use the revolved boss or
cut to create axisymmetric parts. Amazingly, these four features can create
80% or more of the mechanical parts you are likely to need.
These four features cannot create some classes of parts: They cannot
create parts whose cross sections are variable or parts that have nonplanar
faces or other geometric shapes. The features that allow us to create these
types of parts are Lofted Boss/Base, Swept Boss/Base, Lofted Cut,
Swept Cut, Hole Wizard, Rib, Draft, Shell, and Dome, as shown in
Figure 4.1. We cover all these features in this chapter. You can also access
more features by clicking this sequence: Insert (menu) > Features.

Figure 4.1
Available
features

A feature is defined as a solid that, when combined with other features

(solids), creates parts. A CAD part consists of a set of features created in a
certain sequence stored in its feature tree. Some features, such as bosses
and cuts, originate as sketches, while others, such as shells and fillets,
modify other features. Features are always listed in the feature tree (which
SolidWorks calls the FeatureManager Design Tree) of the part.

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 Today’s modeling is referred to as feature-based modeling, and the
resulting models are known as feature-based models. The first feature you
create in a part is known as the base feature. You use the base feature as
the basis to create other features. A base feature obviously cannot be nega-
tive (i.e., a cut), and SolidWorks does not allow it. When you begin creating
a feature, Extruded Boss/Base and Revolved Boss/Base are the only
selectable feature types. You might also expect Swept Boss/Base and
Lofted Boss/Base to be selectable when you begin creating a feature, but
they are not. Lofted Boss/Base becomes selectable only after you create a
sketch (profile), and Swept Boss/Base becomes selectable after you create
a cross section and a path (sweep direction).

4.2 Features
To master feature-based modeling, you should be able to answer three
­fundamental questions:
1 What are the available features that a CAD/CAM system offers for
modeling parts?
2 What is the input required to create each feature?
3 Which feature should you use for a given modeling problem?
Section 4.1 and Figure 4.1 provide the answer to the first question.
Table 4.1 answers the other two questions. It shows a simple basic example
of each feature. Keep in mind that the third question may have multiple
answers; one of them is always the best answer. For example, you may use
a loft or a sweep. However, if a part has a constant cross section along a
curve, sweep is better to use because it requires fewer steps to create the
part. If the part has a variable cross section, a loft is better to use. The
tutorials in this chapter provide some modeling examples.

Table 4.1
Available Features

No. Feature Input (sketch) Resulting Feature When to Use in Modeling?

1 Extrusion Cross section and a thickness • Use for parts with constant
cross section (CS) and
uniform thickness (UT).
• If needed, break part
into subparts, each with a
constant CS and UT.

2 Revolve Cross section, an axis of • Use for parts that are

revolution, and an angle of axisymmetric.
revolution
• If needed, break part into
subparts, each of which is
axisymmetric.

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 No. Feature Input (sketch) Resulting Feature When to Use in Modeling?

Chapter 4
3 Sweep Linear sweep: cross section and a • Use for parts with constant
line as a path cross section (CS) along
a linear direction (path)
that may or may not be
perpendicular to the cross
section.
• If the path is perpendicular
to the cross section, the
linear sweep becomes an
extrusion.
Path

Profile

Nonlinear sweep: cross section • Use for parts with constant

and a curve as a path cross section (CS) along a
nonlinear direction that may
or may not be perpendicular
to the cross section.

Path
Profile

4 Loft Linear loft: at least two cross • Use for parts with variable
sections (profiles) cross section along a given
direction.
• The cross sections are
blended linearly from one
section to the other.

Nonlinear loft: at least two cross • Use for parts with variable
sections (profiles), and a curve as cross section along a given
a guide curve direction.
• The cross sections are
blended nonlinearly from
Guide Curve one section to the other,
along the guide curve.

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 No. Feature Input (sketch) Resulting Feature When to Use in Modeling?
5 Rib Rib profile (e.g., line or stepwise • Use when a stiffener
line) between angled walls
(faces) of a part is required
to increase part structural
strength.
Profile

6 Shell Shell face and shell wall thickness • Use when you need to
remove material from an
Shell face existing part.
• The material removal
(shelling) occurs in a
direction perpendicular to
the selected shelling face.
• While you can achieve the
same result using an extrude
cut for simple shells, a shell
operation is faster to use.

7 Draft Direction of pull, parting lines, • Use when you need to draft
and a draft angle. The direction faces at an angle; usually
of pull must be perpendicular to used for injection molding
the parting lines. to allow pulling the molded
part from the mold cavity.

The other features shown in Figure 4.1 and not covered in Table 4.1
are covered in the tutorials in this chapter.

Example 4.1  Create the free-form torus shown in Figure 4.2.

Solution  The torus shown in Figure 4.2 is a variation of the torus

(donut shape) feature (No. 2) shown in Table 4.1. While that feature of
Table 4.1 is a revolve, the free-form torus shown in Figure 4.2 can only
be created as a sweep. The key modeling concept here is to use pierce
relations to force the torus cross section (small circle) to conform to
the sweep path (large circle) and the guide curve (closed spline), as
shown in Figure 4.2. You pierce the small circle to the spline and pierce
the center of the small circle to the large circle. These two pierce
conditions force the small circle to become “elastic”; that is, it
expands and shrinks, as it must always touch the spline and the big
circle. Pierce condition is only available to pierce a point to a curve.
You cannot pierce two curves. SolidWorks enables the pierce condition
in the right context. Figure 4.2
Free-form torus

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 Step 1: Create Sketch1-Path (sweep Step 4: Create

Chapter 4
path): File > New > Part > OK > Top pierce relations:
Plane > Sketch tab > Circle on Sketch While Sketch3-
tab > click origin to sketch and dimension as Profile is still
shown > exit sketch > File > Save As > open from Step 3,
example4.1 > Save. click small circle
center + Ctrl + select large circle > Pierce relation > ✓ > select point
created on circle + Ctrl + spline > Pierce relation > ✓ > exit sketch.

Step 5: Create Sweep-Torus feature: Features tab > Swept

Step 2: Create Sketch2-Guide (sweep Boss/Base > select Sketch3-Profile as Profile > select Sketch1-Path
guide curve): Top Plane > Sketch tab > as Path > select Sketch2-Guide as Guide Curve > ✓.
Spline on Sketch tab > sketch free spline
as shown > exit sketch.

Note: Sketch1-Path and Sketch2-Guide are

two separate sketches, and they both use
Top Plane.

Step 3: Create
Sketch3-Profile (sweep
profile): Front Plane >
Sketch tab > Circle on
Sketch tab > sketch a
circle anywhere > Point
on Sketch tab > click
circle anywhere.

Note: Do not dimension the circle as doing so over-constrains it when

you apply the pierce relation.

HANDS-ON FOR EXAMPLE 4.1

Re-create the free-form torus by replacing the spline by a circle that is not centric with
the large circle.

4.3  Spur Gears

Gears are an important and essential mechanical element in mechanical
design. A wide range of products and applications use gears. There are vari-
ous types of gears: spur, helical, bevel, spiral, worm, planetary, and rack
and pinion, to name a few. A spur gear is the simplest type of gear and the
type we cover here. Typical mechanical design courses in colleges cover the
principles and design of gears. In this section, we cover spur gears from a
CAD point of view (i.e., how we construct a gear once it is designed). While
gears are standard elements that can be purchased off the shelf (they can
also be inserted from the SolidWorks Toolbox into a part or assembly file), it
is important to learn how to create a gear feature in a CAD/CAM system.
A gear tooth is the intricate part of a gear. Figure 4.3 shows two mesh-
ing gears. Figure 4.4A shows the conjugate line and pressure angle. Figure
4.4B shows the involute profile. Gearing and gear meshing ensure that two
disks (the two gears) in contact roll against one another without slipping.

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 Base Circle

Root Circle

Pitch Circle
+

Pinion Addendum Circle

Dedendum Circle
Tooth Involute Profile

Gear

Figure 4.3
Meshing gears

Moreover, the gear teeth should not interfere with the uniform rotation that
one gear would induce in the other—a requirement known as the conjugate
action. The conjugate action also ensures that the perpendicular line to a
tooth profile at its point of contact with a tooth from the other gear always
passes through a fixed point on the centerline connecting the centers of the
two meshing gears. Figure 4.4A shows the conjugate line. The conjugate
line is also known as the line of force because the driving force from the
driving gear (driver) is transmitted in the direction of this line to the other
gear (driven). The angle between the perpendicular radius to the conjugate
line and the centerline is always constant for two meshing gears. This angle
is known as the pressure angle and is shown as the angle Ø in Figure 4.4A.
The key to successful functional gears is the conjugate action. While
various profiles can produce conjugate action, the involute profile is the
best because it allows for imperfections in gear manufacturing and yet
maintains the conjugate action. The imperfection may produce a slightly
different distance between the two shafts of the gears from the designed
value. Figure 4.4B shows how the shape of the involute profile is generated.
An involute is defined as the path of the endpoint of a cord when it is
pulled straight (held taut) and unwrapped from a circular disk, as shown in
Figure 4.4B. The involute geometry ensures that a constant rotational
speed of the driving gear produces a constant rotational speed in the driven
gear. For spur gears, the teeth are cut perpendicular to the plane of the
gear, where the involute profile resides.
The creation of a gear CAD model requires two basic concepts: knowl-
edge of the gear geometry and the involute equation. The geometry is shown
in Figure 4.3. The base circle is the circle where the involute profile begins.
The pitch circle defines the contact (pitch) point between the two gears (see
Figure 4.4A). The dedendum circle is usually the same as the base circle,
as can be concluded from Figure 4.4A (dedendum d = rp − rb). The
­addendum circle is the circle that defines the top of the tooth as shown in
Figure 4.4C (addendum a = ra − rp, where ra is the addendum circle radius).
Typically, the addendum and the dedendum are equal. In such case, the
pitch and base circle sizes determine the values for both. The root circle is

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 Chapter 4
Base Circle
+
Pitch Circle
Involute
Line of Force Point of Contact Cord
(conjugate line) of Gear Teeth
rp
Pressure Angle rb
+
+ Base Circle

(A) Conjugate action (B) Involute profile

Pa
P (x, y)

a
Circular Pitch pc  Pb
d
pc
2 Addendum
Circle
Pitch Circle
rb
Base Circle
rb

Y
rp  2
X
+
(D) Involute coordinate system
(C) Tooth angle

Figure 4.4
Details of a gear tooth

smaller than the base circle to allow cutting the tooth during manufactur-
ing. The tooth profile between the base and root circles is not an involute. It
could be any geometry, such as line.
The creation of a gear CAD model requires two steps: Calculate the
tooth angle α and the tooth involute profile. While many books on mechani-
cal engineering design offer extensive in-depth coverage of gear analysis, we
offer a simplified but accurate version that enables us to create a CAD
model of the gear. We begin with the definition of circular pitch. As shown
in Figure 4.4C, the circular pitch, pc, is defined as the distance along the
pitch circle between corresponding points on adjacent teeth. As shown in
Figure 4.4C, we use pc as the circular pitch of the gear, rp as the pitch circle
radius, and α as the tooth angle. Using these variables, we can write:
πdp
pc =
N (4.1)

where dp = 2rp is the pitch circle diameter and N is the number of gear teeth.
From the tooth geometry shown in Figure 4.4C, we can write:

pc
= rp α (4.2)
2
Substituting pc from Eq. (4.2) into Eq. (4.1) and reducing gives:

π 180
α= radius or α = degrees (4.3)
N N

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 The derivation of the involute equation is more complex and is not cov-
ered here. We align the involute of one tooth with the XY coordinate system
as shown in Figure 4.4D, where the lowest point Pb on the involute lies on
the Y axis. This orientation does not represent a limitation but rather sim-
plifies the form of the involute equation, which is therefore given by:
x = −rb (sin θ − θ cos θ ) θ ≤ θ ≤ θ max
(4.4)
y = rb (cos θ + θ sin θ )

where rb (the base circle radius) is given by (see Figure 4.4A):

rb = rp cos φ (4.5)

and (x, y) are the coordinates of any point P on the involute at an angle θ,
as shown in Figure 4.4D. The lowest point Pb on the involute corresponds
to the value of θ = 0 and lies on the base circle. Point Pa lies on the adden-
dum circle and does not necessarily correspond to the value of θ = θ max. We
can arbitrarily select a large enough value for θ max so that the involute
crosses the addendum circle and then trim it to that circle. Therefore, we
create the involute profile by generating points on it using Eq. (4.4) and
connecting them with a spline curve, or we input Eq. (4.4) into a CAD/CAM
system.
The root circle is always less than the base circle. For simplicity, we
have the root circle radius, rr, be 0.98 of the base circle radius. (There are
other formulas that do not give consistent results.) Thus, we write:

rr = 0.98rb (4.6)

The following steps summarize the calculations we need to create a

gear CAD model:
1 The input parameters we need are the pitch circle radius rp, the
­pressure angle ∅, and the gear number of teeth N.
2 Calculate rb using Eq. (4.5).
3 Calculate rr using Eq. (4.6).
4 Calculate the gear dedendum d = rp − rb.
5 Assuming that the addendum and dedendum are equal, calculate the
addendum circle radius as ra = rp + a = rp + d (see Figures 4.4C and 4.4D).
6 Use Eq. (4.3) to calculate the tooth angle α.
7 Enter the involute parametric equation given by Eq. (4.4) into a
CAD/CAM system to sketch the involute curve as a spline.
8 Create one gear tooth and use a sketch circular pattern to pattern it to
create all gear teeth.

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 Example 4.2  Create the CAD model of a spur gear with rp = 60 mm, ∅ = 20°, and N = 20.

Chapter 4
Solution  Using the above calculation steps, you get rb = 56.382 mm, d = a = 3.618 mm, ra = 63.618 mm, rr = 55.254 mm, and
α = 9°. There are two methods to create the tooth involute curve. 
In the first method, you use Eq. (4.4) with Δθ = 5°. You generate 11 points on the involute, for θ max = 50°. You generate the points on
the involute curve. You then use Insert > Curve > Curve Through XYZ Points. A better method is to input Eq. (4.4) into
SolidWorks and let SolidWorks generate the curve. You need to use radians for the angle θ. You use 1 radian for θ max. This value is
arbitrary to ensure that the involute curve intersects and crosses the addendum circle to be able to trim it to the intersection point.
Also, SolidWorks uses the parameter t, requiring us to replace θ with t when you input the equation. Figure 4.5 shows the spur gear.
You create half a tooth, mirror it to create a full tooth, and use a circular pattern for the full tooth to create all teeth of the gear. Here
are the detailed steps.

Figure 4.5
Spur gear

Step 1: Create Sketch1 circles and axes: File > New > Part > OK > Step 2: Create Sketch1 tooth involute: Front Plane > Sketch tab
Front Plane > Circle on Sketch tab > sketch four circles and > Spline dropdown on Sketch tab > Equation Driven Curve
dimension as shown > Centerline on Sketch tab > sketch vertical > Parametric > enter x and y equations and limits as shown > ✓.
line > File > Save As > example4.2 > Save.

Note: Set the part units to mm before you start. The vertical centerline
serves as a validation that the involute bottom endpoint passes through
it when you create it in Step 2. Also, you will not close the sketch until
you finish Step 5.

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 Step 3: Create Sketch1 tooth Step 4: Create Sketch1 tooth
bottom: Line on Sketch tab other half: Trim Entities on
> sketch a line passing through Small line Sketch tab > Trim to
segment
bottom end of involute curve closest > select involute top
and crossing the root circle part > Centerline on Sketch
> Esc on keyboard > select the tab > sketch a line passing
line + Ctrl on keyboard + through origin and to left of
involute curve > Tangent from involute > Smart Dimension
Add Relations options on left on Sketch tab > select the
pane > ✓ > Point on Sketch centerline just created and the
tab > create a point at other centerline to the right of it > enter 4.5 > ✓
intersection of involute and pitch circle (turn relations on: View > > Mirror Entities on Sketch tab > select involute + Ctrl key + line
Sketch Relations to see all) > Centerline on Sketch tab > sketch segment connected to involute + fillet created in Step 3 > click Mirror
a line passing through origin and crossing involute at any point > Esc about box on left of screen > select the far left centerline > ✓ > Trim
key > select centerline just created + Ctrl + point > Coincident from Entities on Sketch tab > Trim to closest > click addendum circle
Add Relations options on left pane > ✓ > Trim Entities on Sketch outside tooth > click root circle inside tooth twice to delete its two
tab > Trim to closest > select line below root circle and select root segments inside the tooth > ✓.
circle between two centerlines > ✓ > Fillet on Sketch tab > enter 1
mm for radius > select line and root circle > Yes to continue > ✓ >
select base circle > Delete key on keyboard.
Step 5: Create Sketch1 Step 6: Create Gear feature: Select Sketch1 > Features tab >
all gear teeth: Linear Extruded Boss/Base > Enter 25 for D1
Sketch Pattern > reverse extrusion direction > ✓.
dropdown on Sketch tab
> Circular Sketch
Pattern > click first box
under Parameters on left
pane > select origin to
define axis of pattern >
click Entities to Pattern
box > select the tooth
profile 7 entities
> enter 20 for the number of instances to create > ✓ > the sketch
becomes over defined when you pattern the tooth because of the profile
mirror of first tooth. Click this sequence to resolve it: Over Defined
(shown red in status bar) > Diagnose > Accept > Trim Entities
> Trim to closest > trim all excess from root circle (segments inside
teeth) > ✓ > exit sketch.

Step 7: Create Sketch2 and Cut- Step 8: Create Sketch3 and Cut-Extrude2-Chamfer: Repeat Step 7 but
Extrude1-Chamfer: Select Gear front use the back face of Gear.
face > Features tab > Extruded
Cut > Circle on Sketch tab > click
origin and draw circle > select root
circle and sketched circle and add
Coradial relationship > exit sketch
> enter 10 for D1 > check Flip side
cut > click Draft icon > enter 60 for
Draft Angle > ✓.

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 HANDS-ON FOR EXAMPLE 4.2

Chapter 4
Add a hole and a keyway to the gear blank. Use a diameter of 50 mm for the hole and
10 × 10 mm keyway.

4.4  Design Library and Library Features

Design reuse and using off-the-shelf standard components are important
concepts that speed up design and thus make it less expensive. The field of
mechanical design has many standard parts that designers use every day
in their designs (e.g., fasteners [nuts and bolts], gears, bearings). While
these parts are universally standard, a company may have some parts that
are unique and reusable only in that company’s designs. SolidWorks pro-
vides the concepts of design library and library features to enable designers
to reuse off-the-shelf components.
A library feature is a part that you create once and save in a library
for reuse in the future. This library is known as the design library. You
may save a library feature with the .sldprt or .sldlfp extension. Most of the
time library features are inserted into assemblies as components or
inserted into new empty (blank) parts. Commonly used library features
include holes and slots. Using several library features to construct a single
part saves time and also ensures consistency in your CAD models.
Using library features is easy: You drag a library feature from the
design library and drop it onto the open part or assembly. SolidWorks
asks you if you want to insert a copy or instance (derived part) of the
part, as shown in Figure 4.6. If you select Yes, it inserts the copy in
the open part. If you select No, it opens a blank part and inserts it
there.
Figure 4.6 You save library features in a design library, which you can organ-
Using a library feature ize into folders. The path to the SolidWorks design library folder is
C:\Program Data\SolidWorks\SolidWorks version\design library. (Make
sure that hidden files are visible in Windows to see the Program Data
folder.) Click the Design Library tab in the SolidWorks Task Pane (on the
right of the screen), as shown in Figure 4.7A, to open the design library.

Investigate these
icons to learn
more about the
Design Library

Expand this node

to learn more
about the Toolbox

(A) Open Design Library (B) Design Library folders

Figure 4.7
SolidWorks Design Library

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 The library is organized into folders, and you can add new custom folders to
the library. You should save your library features into the SolidWorks
design library to have them accessible. If you do not, you have to navigate
to the folder where you saved the features. The most commonly used
SolidWorks library is Toolbox, shown in Figure 4.7B. Expand the Toolbox
node and investigate its contents.

4.5  Configurations and Design Tables

A family of parts is a natural outcome from the concept of parametric solid
modeling. Defining a solid (part) in a sketch by parameters (dimensions are
values for the parameters) enables us to modify the dimensions and create
a similar but different-size replica of the part with a click of a button. We
refer to these replicas as a family of parts. SolidWorks calls them configura-
tions. You can also create configurations of assemblies. The configurations
are created by changing the dimensions of some key parameters of the part
or assembly. The configurations have the same topology as the original but
different geometry. For example, consider a two-feature part: a base block
and a shaft boss. You configure the part into a square block and a skinny
long boss or a rectangle block and short fat boss.
You use design tables to help create and control configurations in three
ways: change sizes, change configurations of components, and/or sup-
press/unsuppress features. SolidWorks uses a Microsoft Excel sheet as
its design table. You can insert a design table into an open part or
assembly by clicking this sequence: Insert (menu) > Tables > Design
Table. This opens the Design Table under the PropertyManager tab on
the left pane, as shown in Figure 4.8. You can specify one of the three
sources shown to create the design table. When you click the green
checkmark to finish, SolidWorks acts accordingly. For example, if you
select the Auto-create (default) option, SolidWorks displays a list of the
open part dimensions and asks you to select some to include in the
design table. The table is created with the current values of the part
dimensions as the default configuration. The configuration appears as a
row in the table. You can add other rows with different values for dimen-
Figure 4.8 sions. Each row is a different configuration. The Design Table is saved
Design table under the ConfigurationManager tab.

Example 4.3  Create design tables.

Solution  This example builds on Example 2.4. It shows how to create a design table where you change the value of parameter
(dimension name) D2 to create four configurations of the sketch. The steps are as follows.

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 Step 1: Open example2.4 part: File > Open > locate and select the Step 2: Create design table with Default config: Insert > Tables >

Chapter 4
file > Open. Design Table > ✓ > click D1 (shown here) + Shift key on keyboard +
D5 (shown here) to select all dimensions > OK.

Step 3: Create three other configurations: Step 2 opens the Excel Step 4: Review the design configurations: Step 3 creates a tree with
sheet shown > copy the Default config row and paste three times > edit four nodes, as shown, under the ConfigurationManager tab >
the name cell and change configuration names as shown > edit the D2 double-click any configuration to display the corresponding sketch > the
column and change as shown > click anywhere on screen away from current configuration is displayed in dark black in the tree.
Excel sheet to make it disappear > OK to accept the popup window
indicating that new configurations were created.

Step 5: Investigate effect of design table on sketch parameters:

Click feature tree > select Sketch1 > observe that dimensions are
displayed in a pink color and each time you click or move one, you get
a window (shown to the right) warning you.

HANDS-ON FOR EXAMPLE 4.3

Edit the sketch and change the value of D2 to 6. What happens to the design table?
Explain the result.

4.6 Macros
Design automation offers two benefits. First, it enhances productivity.
Second, it helps with repetitive tasks that are mundane. For example, if you
follow the same design process over and over, automating it would be the
logical thing to do.
Macros aid in design automation. Macros are also viewed as a way to
customize your CAD/CAM system. A macro is a short computer program

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 that is used to repeat commonly performed operations. That computer pro-
gram is generated automatically by a CAD/CAM system in the background
during use of the system, from the time you turn on the macro until you
turn it off. You can use the macro after creation over and over, with differ-
ent input values (e.g., new dimensions). After you create a macro, you can
use it for recording, edit it, run it, pause it, stop it, and assign it to a short-
cut key (hotkey) or to a menu item. When you assign a macro to a shortcut
key or to a menu item, you can specify which method (function) of the
macro to run. Click Tools > Macro to access the macro menu. SolidWorks
saves the macro file in the same part folder and uses .swp as the file exten-
sion, with the default names Macro1.swp, Macro2.swp, and so on, unless
you change them.
A higher level of automation than using macros is to use Visual Basic
(VB) or another programming language to perform full automation and have
better control of the automation. As a matter of fact, VB is the program-
ming engine behind macros. Instead of writing the macro VB code, the
SolidWorks macro interface enables us to generate the code automatically
while you perform the design tasks as usual. It is this VB code that you
save in a file when you save the macro. You can use the VB editor to edit
and tweak the VB code.
Macro VB code uses the SolidWorks API (application programming
interface). The code makes calls to API functions. Think of the API as a
gateway between the application you want to write and SolidWorks code
that has been already written. In other words, the API provides access to
the SolidWorks geometric engine.
You can learn VB programming by creating multiple macros, studying
their generated VB code, and expanding on it. VB is an object-oriented pro-
gramming (OOP) language that requires knowledge and understanding of
object-oriented design and how objects are defined and implemented.
The programming approach could be useful for creating an entire
assembly from a few parameters. You can write a program to define some
variables and store them in a row in a design table. Each row represents a
new version of the assembly. You delete all rows from the table and keep
the last row, which is the new assembly.

Example 4.4  Develop a macro to create an extrusion.

Solution  This example illustrates the creation and use of macros. It shows how to create a block extrusion and record the steps of
creating it in a macro.

Step 1: Turn on macro and create Sketch1 and Boss-Extrude1 feature:

File > New > Part > OK > Tools > Macro > Record > Front
Plane > Extruded Boss/Base on Features tab > Sketch tab >
Center Rectangle on Sketch tab > sketch a rectangle and
dimension as shown > exit sketch > enter 2 for D1 > reverse extrusion
direction > ✓ > File > Save As > example4.4 > Save.

Note: Macro > Record opens the Macro recording window shown.
Hover over its buttons to read them.

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 Step 2: Stop and save macro: Tools > Macro > Stop (or click black Step 3: View the macro VB code: Tools > Macro > Edit > select

Chapter 4
square on Macro window shown in Step 1) > type BlockShaft for macro BlockShaft.swp > Open. The editor displays all the lines of code
name in the Save As window that opens > Save. associated with the macro. Figure 4.9 shows the first lines of the macro
VB code. Explore the code and try to understand which sections pertain
Note: The full macro file name is BlockShaft.swp. The default folder for
to which steps performed in SolidWorks.
the file is the part file folder from Step 1.

Step 4: Run the macro: Open a new part or delete the feature from the current part > Tools > Macro > Run > select BlockShaft.swp >
Open > enter 8 for rectangle width when dimension box appears > ✓ > enter 6 for rectangle height when dimension box appears > ✓.

HANDS-ON FOR EXAMPLE 4.4

Modify the part as shown to the right and re-create the
macro. Rerun the macro twice to investigate locating the
shaft to the left or to the right side from the center. This
simulates the idea of using a macro to investigate “what
if” design scenarios such as sizes or feature locations.

Figure 4.9
VB editor window

Chapter 4  |  Features and Macros 113

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 Example 4.5  Create a hotkey for a macro.

Solution  This example assigns the macro from Example 4.4 to the Shift+X hotkey on the keyboard. When the user presses this
combination on the keyboard, the macro runs.

Step 1: Create macro hotkey: File > Open > locate example4.4 > Step 2: Locate macro file: Tools > Customize > Keyboard tab >
Open. scroll to bottom and locate Macros row > click ellipsis button (…) in
this row to open window shown > click the browse button (…) > locate
Step 3: Create hotkey: Click Shortcut(s) column in Macros row as
macro file (.swp extension) > Open > OK.
shown > Shift+X to add shortcut as shown below > OK.

Step 4: Use hotkey to run macro: Press

Shift+X in an open part.

4.7 Tutorials

Tutorial 4–1  Create Sweep Features

A sweep feature requires, at minimum, a profile (cross section) to sweep
and a path (curve) to sweep along. You can use a guide curve to control the
sweep further. If you do not use a guide curve, the sweep cross section
stays constant.
Sweep operations may fail for different reasons. Figure 4.10 shows
three error messages. As a general rule, the sweep path and guide must
intersect the cross-section plane, and the cross section must not intersect
itself as it traverses the path and/or the guide curve.

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 Chapter 4
(A) Path does not intersect cross-section (B) Guide curve does not intersect
plane cross-section plane (C) Cross section intersects itself

Figure 4.10
Some possible sweep operation errors

Create the sweep features shown in Figure 4.11. All dimensions are in
inches.

(A) No guide curve (B) With guide curve

Figure 4.11
Sweep features

No-guide-curve sweep (Figure 4.11A) modeling steps:

Step 1: Create Sketch1-Profile: Step 2: Create Sketch2-Path:
File > New > Part > OK > Front Right Plane > Spline on
Plane > Circle on Sketch tab > Sketch tab > sketch spline as
click origin and sketch circle and shown (press Esc after last point
dimension as shown > exit sketch > is clicked to exit Spline); make
File > Save As > tutorial4.1A > sure spline snaps to origin > exit
Save. sketch.

Step 3: Create Sweep1 feature: Sweep Boss/Base on Features tab > select circle
sketch as Profile, as shown to the right > select spline sketch as Path, as shown to the
right > ✓.

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 With-guide-curve sweep (Figure 4.11B) modeling steps:
Step 1: Create Sketch1-Profile: Step 2: Create Sketch2-Path: Top Plane > Line on
File > New > Part > OK > Front Sketch tab > sketch line as shown (to the right) from
Plane > Circle on Sketch tab > origin > exit sketch.
click origin and sketch circle as
shown > exit sketch > File > Save Step 4: Create Sweep feature: Sweep Boss/Base
As > tutorial4.1B > Save. on Features tab > select circle sketch as Profile, as
shown > select Step 2 spline sketch as Path > select
Step 3 spline sketch as Guide > ✓.

Step 3: Create Sketch3-Guide:

Right Plane > Spline on
Sketch tab > sketch spline as
shown (press Esc after last point
is clicked to exit Spline); select
spline endpoint near circle sketch > Ctrl + select circle sketch > Make
Pierce > exit sketch.

HANDS-ON FOR TUTORIAL 4–1

Change the cross sections of both sweeps to a 2 × 2-inch square. What happens? Resolve
the error(s) and explain your solution.

Tutorial 4–2  Create Loft Features

Create the wine glass shown in Figure 4.12. All dimensions are in inches.
We introduce the concept of Convert Entities on the Sketch tab in this
tutorial. You copy one circle in one sketch to another sketch. This concept
enables you to copy entities from one sketch to another. While you could
easily create a new circle and dimension it, using the Convert Entities
method is faster (as there is no need to sketch a circle and dimension it).
SolidWorks creates an On Edge relation between the two circles and shows
a small green cube on the copied entity to indicate the relation. When you
click the copied circle while editing the sketch, SolidWorks displays the On
Edge relation in the relations pane to the left of the screen.

Figure 4.12
Loft feature

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 Step 1: Create Plane1–Plane3: File > New > Part > OK > Step 2: Create Sketch1–

Chapter 4
Reference Geometry on Features tab > Plane > expand feature Sketch4: Top Plane > Circle
tree and select Top Plane > enter 1.0 for Offset Distance > ✓ > on Sketch tab > click origin
repeat for Plane2 and Plane3 but select the previously created plane > and drag to sketch and
File > Save As > tutorial4.2 > Save. dimension a 2.0-inch diameter
circle > exit sketch > select
Plane1 as sketch plane and
create a 0.5-inch diameter
circle > exit sketch > select
Plane2 as sketch plane >
Sketch on Sketch tab >
Convert Entities on
Sketch tab > click circle on
Plane1 > ✓ > ✓ > exit sketch
> select Plane3 as sketch
plane > Sketch on Sketch tab > Convert Entities on Sketch tab
> click circle on Top Plane > ✓ > ✓> exit sketch.

Step 3: Create Loft- Step 4: Create Plane4–Plane6:

Base feature: Lofted Reference Geometry on
Boss/Base on Features tab > Plane > expand
Features tab > select feature tree and select Plane3 >
Sketch1–Sketch4 > ✓. enter 1.0 for distance > ✓ > repeat
for Plane5 and Plane6 but select the
previously created plane.

Step 5: Create
Sketch5–Sketch7: Select
Plane4 as Sketch
Plane > Circle on
Sketch tab > click
origin and drag to
sketch and dimension a
3.0-inch diameter circle
> exit sketch > select
Step 6: Create
Plane5 as Sketch
Loft-Thin1-Top
Plane > Sketch on
feature: Lofted
Sketch tab >
Boss/Base on
Convert Entities on
Features tab >
Sketch tab > click
select the circle of
Sketch5 (just created)
Sketch4 and then
> ✓ > ✓> exit sketch >
select Sketch5–
select Plane6 as sketch
Sketch7 > check
plane > Sketch on
Thin Feature box
Sketch tab >
> enter 0.1 for
Convert Entities on Sketch tab > click circle on Plane3 > ✓ > ✓>
thickness (T1) > if
exit sketch.
needed, click direction box to toggle direction of thickness to the
inside > ✓.

Note: Make sure you select the circle and sketches in a way so that the
interpolation points (green circles shown here) line up; otherwise, you
twist the loft.

Note: The thickness of the thin feature has a direction: inside or outside
the profile. Reverse the direction of the double arrows shown to toggle.

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 HANDS-ON FOR TUTORIAL 4–2
Create a loft using three squares of different sizes as cross sections separated
by 1 inch. The square sizes are 2 × 2, 1 × 1, and 2 × 2, respectively. Create the
loft connecting the three sections such that the loft is twisted as shown.

Tutorial 4–3  Use the Hole Wizard

The hole wizard provides two advantages. First, it helps create standard
hole sizes and types so that off-the-shelf bolts will fit perfectly in the holes.
Second, it greatly speeds up the process of creating these holes. This tuto-
rial shows how to create sample holes: counterbore, countersink, and
tapped holes. Figure 4.13 shows these holes. You create an extrusion and
add holes to it. You also create Sketch2 on the top face of the Block feature
with a center rectangle (construction rectangle) that you use to place holes
at its corners.

Figure 4.13
Wizard holes

Step 1: Create Sketch1 and Step 3: Create two

Block feature: File > New > diagonal countersink
Part > OK > Top Plane > hole features (CSK…
Extruded Boss/Base on node in feature tree):
Features tab > Center Hole Wizard on
Rectangle on Sketch tab > Features tab >
click origin and sketch and dimension rectangle as shown > exit sketch select Countersink
> enter 1 for D1 > reverse extrusion direction > File > Save As > under Hole Type
tutorial4.3 > Save. (hover over types
until you read it) >
Step 2: Create Sketch2: Top face of Block > Center Rectangle on
select #8 for Size under Hole Specifications > Positions tab >
Sketch tab > click origin and sketch a 3.0 × 1.5 rectangle, as shown in
click top face of Block and then click two corners of construction
Figure 4.13 > click For Construction box > exit sketch.
rectangles as shown > ✓.

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 Step 4: Create two diagonal counterbore hole features (CBORE… Step 5: Create Tapped Hole1 feature: Hole Wizard on Features

Chapter 4
node in feature tree): Hole Wizard on Features tab > select tab > select Tapered Tap (hover over types until you read it) > select
Counterbore under Hole Type (hover over types until you read it) > 1/4 for Size under Hole Specifications > Positions tab > click top
select #10 for Size under Hole Specifications > Positions tab > face of Block and then click rectangle center as shown > ✓.
click top face of Block and then click two other corners of construction
rectangles as shown > ✓.

HANDS-ON FOR TUTORIAL 4–3

Create a 1/16 tapered pipe tap through all holes, located 0.5 from the top edge and 1.5
from the left edge of the block.

Tutorial 4–4  Create Compression Spring

Figure 4.14 shows the constant length compression spring you create in
this tutorial.

Figure 4.14
Compression spring

Step 1: Create Sketch1 and Helix/Spiral1 curve: File > New > Part > OK > Top
Plane > Circle on Sketch tab > click origin and sketch and dimension circle with
1.0-inch diameter > exit sketch > Insert (menu) > Curve > Helix/Spiral > select the
circle just sketched > Height and Revolution from Defined By dropdown shown >
Constant Pitch > enter 2.0 for Height, 20 for Revolutions, and 90 for Start
Angle, as shown > ✓ > File > Save As > tutorial4.4 > Save.

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 Step 2: Create Sketch2: Front Plane > Circle on Sketch tab > Step 3: Create
sketch and dimension circle as shown (align center with X-axis as Sweep1 feature
shown) > exit sketch. (spring): Swept
Boss/Base on
Features tab >
select Sketch2 as
Profile > select
Helix/Spiral1 as
Path > ✓.

HANDS-ON FOR TUTORIAL 4–4

Edit the spring helix to have a variable pitch. Use a pitch of 0.2 at midheight point.

Tutorial 4–5  Create Spiral

Figure 4.15 shows the spiral spring you create in this tutorial.

Figure 4.15
Spiral spring

Step 1: Create Sketch1 and Helix/Spiral curve: File > New > Part > OK >
Top Plane > Circle on Sketch tab > click origin and sketch and dimension
circle with 1.0-inch diameter > exit sketch > Insert (menu) > Curve > Helix/
Spiral > select the circle just created > Spiral from Defined By dropdown
shown > enter 0.5 for Pitch and 5 for Revolutions, as shown > Start Angle
of 90 and select Counterclockwise > ✓ > File > Save As > tutorial4.5 >
Save.

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 Step 2: Create Sketch2: Front Plane > Center Rectangle on Step 3: Create Sweep feature (spiral): Swept Boss/Base on

Chapter 4
Sketch tab > sketch and dimension rectangle as shown (align center Features tab > select Sketch2 as Profile > select Helix/Spiral as Path
with X-axis as shown) > exit sketch. > select Show Preview under Options > ✓.

HANDS-ON FOR TUTORIAL 4–5

Change the spiral cross section to a circle with 2.0-inch diameter. Can you generate the
spiral? Why or why not? Explain.

Tutorial 4–6  Create Features

This tutorial covers the creation of these features: chamfer, fillet, slot, shell,
draft, and rib. All dimensions are in inches. Consider these useful
­observations:
1 Make sure to pay attention to the visual clues shown in the left pane
while creating these features.
2 For example, the box symbol under Chamfer parameters indicates
that you can chamfer a face, an edge, or a vertex (corner point). As you
would expect, chamfering a face chamfers all its edges. Chamfering a
corner chamfers the three edges that meet there.
3 A rib requires a profile sketch (e.g., a line or stepwise line) and a
­thickness.

Step 1: Create Sketch1 and Step 2: Chamfer an edge of

Block feature: File > New > Block feature: Fillet dropdown
Part > OK > Top Plane > on Features tab > Chamfer >
Extruded Boss/Base on select Angle Distance chamfer
Features tab > Center > select Block edge shown > use
Rectangle on Sketch tab > 0.1 for Distance and 45 degrees
click origin and sketch and dimension as shown > exit sketch > reverse for Angle > ✓.
extrusion direction > enter 0.5 for D1 > ✓ > File > Save As >
Step 4: Create a straight slot in
tutorial4.6 > Save.
Block feature: Select Block top
Step 3: Fillet an edge of Block face as a sketch plane >
feature: Fillet on Features tab Extruded Cut on Features
> select Constant Size Fillet tab > Straight Slot on Sketch
> select Block edge shown > use tab > sketch and dimension slot
0.1 for Radius > ✓. as shown > make origin and slot
midpoint Coincident > exit
sketch > Through All > ✓.

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 Step 5: Shell Block feature: Step 6: Draft Block feature:
Shell on Features tab > select Suppress the chamfer, fillet, and
top face of Block > enter 0.1 for shell features > Draft on
D1 > ✓. Features tab > enter 10 degrees
for Draft Angle > select top
face of Block as Neutral Plane
> select Block four side faces to
draft > ✓.

Step 7: Create a rib feature: Suppress the slot and draft features > select front face of Block > Extruded Boss/Base on Features tab >
Rectangle on Sketch tab > sketch and dimension rectangle as shown below > exit sketch > reverse extrusion direction > enter 3.0 for D1 > ✓
> Front Plane > Rib on Features tab > Line on Sketch tab > sketch a line using the midpoints of the two edges as shown below > exit sketch
> enter 0.5 for rib thickness (T1) > select Second Side for Thickness > Parallel to Sketch for Extrusion Direction > ✓.

HANDS-ON FOR TUTORIAL 4–6

Create the following features:
• Distance-distance chamfer
• Vertex chamfer
• Variable-size fillet
• Face fillet
• Full round fillet
• 3-point arc slot
• Three-stepped rib using three-stepped line as the rib profile

Tutorial 4–7  Use the Smart Fasteners Wizard

You use the Smart Fasteners wizard to insert the correct fastener based on
the hole you select. It is a form of automation using off-the-shelf compo-
nents. SolidWorks has its own standard library of fasteners. You can only
use the wizard at the assembly level. You need to activate the wizard in
order for the Smart Fasteners icon on the Assembly tab to work. If you
click the icon before activation, you get this error: Smart Fasteners
requires SolidWorks Toolbox, which is not present.
In this tutorial, you create an assembly of a block and plate. You create
a counterbore hole in the plate and a blind hole in the block, assemble
them, and fasten them together with a smart fastener. Figure 4.16 shows
the assembly and its tree. All dimensions are in inches.

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 Step 2: Create Block feature: File > New > Part > OK > Front

Chapter 4
Plane > Extruded Boss/Base on Features tab > Center
Rectangle on Sketch tab > click origin and sketch and dimension
rectangle as shown > exit sketch > enter 2 for D1 > reverse extrusion
direction > ✓ > front face of Block > Extruded Cut on Features tab >
Circle on Sketch tab > click origin and sketch and dimension as shown
> exit sketch > enter 1 for D1 > ✓ > File > Save As > Block > Save.

Figure 4.16
Assembly using smart fastener

Step 1: Create Plate feature: File > New > Part > OK > Front Step 3: Create assembly: File > New > Assembly > OK >
Plane > Extruded Boss/Base on Features tab > Center Browse > locate Block and Plate parts > select Block + Ctrl + Plate
Rectangle on Sketch tab > click origin and sketch and dimension > Open > click ✓ to place Block instance in assembly origin > click
rectangle as shown > exit sketch > enter 1 for D1 > reverse anywhere in graphics pane to place Plate instance > Mate on
extrusion direction > ✓ > Hole Wizard on Features tab > select Assembly tab > Coincident > select the corresponding top edges of
Counterbore under Hole Type (hover over each hole type until Block and Plate > ✓ > select the corresponding right edges of Block and
you read the correct type) > ANSI inch for Standard > binding head Plate > ✓ > ✓.
screw for Type > select #5 for Size under Hole Specifications >
Positions tab > click front face of Plate and then click origin > ✓ > Step 4: Activate Smart Fasteners wizard: Tools > Add-Ins >
File > Save As > Plate > Save. SolidWorks Toolbox Library > OK. This adds the Toolbox menu
to the menu bar to the right of the Tools menu. You may deactivate the
Note: The diameter of the counterbore hole shown below corresponds Toolbox by using the same sequence but unchecking the Toolbox
to #5 size. You need it to create the corresponding hole in the block in Browser from the Add-Ins window.
Step 2.
Step 5: Add a
fastener: Smart
Fasteners on
Assembly tab
> OK (to accept
that it may take
extra time) >
expand feature
tree > expand
Plate instance
tree node > select CBORE for #5 node > Add > ✓ > File > Save As >
Tutorial4.7 > Save.

HANDS-ON FOR TUTORIAL 4–7

Modify Block and Plate parts to create four corner countersink holes. Re-create the
assembly and use four smart fasteners.

Tutorial 4–8  Create a Bolt

Bolts, like gears, are important and essential mechanical elements. While
bolts are standard off-the-shelf components, this tutorial shows how to cre-
ate the CAD model of one due to its learning value. Figure 4.17 shows the
bolt and its feature tree. All dimensions are in inches.

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 Figure 4.17
A bolt

Step 1: Create Sketch1 and Shaft Step 4: Create

feature: File > New > Part > OK > BottomChamfer
Top Plane > Extruded Boss/Base feature: Fillet
on Features tab > Circle on Sketch dropdown on
tab > click origin and sketch and Features tab >
dimension as shown > exit sketch > Chamfer > select
enter 4 for D1 > reverse extrusion bottom edge of Shaft
direction > ✓ > File > Save As > feature > enter 0.1
Bolt > Save. for D > enter 45 for
A > ✓.

Step 2: Create Sketch2 and Head

feature: Select top face of Shaft feature
> Extruded Boss/Base on
Features tab > Polygon (hexagon Step 5: Create
icon) on Sketch tab > click origin and Plane1: Reference
sketch and dimension as shown > Geometry on
apply vertical relation to one edge > Features tab >
exit sketch > enter 0.9 for D1 > ✓. Plane > expand
feature tree > select
Top Plane > enter
3.9 for D1 > click
Step 3: Create Sketch3
Flip offset
and Head-TopTaper
checkbox > ✓.
feature: Select top face
of Head feature > Note: You use a distance of 3.9 for Plane1, not 4.0, because the chamfer
Extruded Cut > is 0.1 high.
Circle on Sketch tab >
click origin and sketch
(make circle tangent to
hexagon sides) > exit
sketch > enter 0.5 for
D1 > click checkbox as
shown > enter 60 for draft angle > ✓ > repeat to create Head-
BottomTaper to chamfer the bottom of the head.

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 Step 6: Create Step 9: Create

Chapter 4
Sketch5 and Helix/ Plane3: Reference
Spiral1: Select Plane1 Geometry on
> select Sketch on Features tab >
Sketch tab > Plane > expand
Convert Entities feature tree > select
on Sketch tab > Top Plane > select
expand feature tree > Parallel > click
select Sketch1 > ✓ > Second Reference
exit Sketch > select box > select top endpoint of Helix/Spiral1 > ✓.
Sketch5 > Insert > Curve > Helix/Spiral > select Height and
Step 10: Create
Pitch > enter 3.5 for Height, 0.25 for Pitch, and 225 for Start
Sketch7 and Helix/
angle > ✓.
Spiral2: Select Plane3
Note: The helix 3.5 height is arbitrary. That leaves 0.4 (out of 3.9). You > select Sketch on
use 0.25 for the other end thread helix and 0.15 underneath the bottom Sketch tab
of bolt head as a length with no threads. Convert Entities
on Sketch tab >
Step 7: Create
expand feature tree >
Plane2: Reference
select Sketch1 > ✓ >
Geometry on
exit sketch > select
Features tab >
Sketch7 > Insert >
Plane > expand
Curve > Helix/Spiral > select Height and Pitch > enter 0.25
feature tree >
for Height > click Taper Helix checkbox > enter 30 for taper angle
select Right Plane
(A) > click Taper outward checkbox > ✓.
> select Parallel >
click Second Step 11: Create Cut-Sweep2-EndThread feature: Swept Cut on
Reference box > Features tab > select Sketch6 as Profile > select Helix/Spiral2 as
select top endpoint of Path > ✓.
Helix/Spiral1 > ✓.

Step 8: Create
Sketch6 and Cut-
Sweep1-Thread feature:
Select Plane2 > select
Sketch Swept Cut
on Features tab >
Polygon (hexagon
icon) on Sketch tab >
3 for Number of
Sides > click near end
of helix and sketch and
dimension as shown
with right side vertical
and Helix/Spiral1 endpoint and right triangle edge midpoint coincident >
exit sketch > Swept Cut on Features tab > select Sketch6 as Profile
> select Helix/Spiral1 as Path > ✓.

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 4 chapterfour Problems
1

2
What is a feature? Give two examples of features.
Why can an extruded cut or a revolved cut not be a base feature?
3 What is the required input needed to create a sweep? What is the
optional input?
4 What is the required input needed to create a loft? What is the optional
input?
5 Table 4.1 shows a rib feature. Which is the better way to create it: by
using a rib or by using an extrusion? Explain your answer.
6 Table 4.1 shows a block that is shelled. Which is the better way to create
it: by using shelling or by using extrusion cut? Explain your answer.
7 A spur gear has a pitch circle radius of 3 inches, a pressure angle of
14.5 degrees, and 20 teeth. Calculate all the parameters required to
create the gear CAD model. Create the CAD model.
8 Same as Problem 7, but for a pitch circle radius of 100 mm, pressure
angle of 14.5 degrees, and 30 teeth.
9 Create a macro to automate the creation of a donut revolve.
10 Create the brace drill handle shown in Figure 4.18. All dimensions are
in millimeters.

All vertical dimensions are measured from the

bottom end of the drill handle. The top curve is a
spline connecting three points.

Figure 4.18
Brace drill handle

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 Chapter 4
Drill handle cross section Cross section of middle handle

Figure 4.18
(continued)

11 Create the loft feature shown in Figure 4.19. Assume dimensions.

Hint #1: This loft shows you the local and global influence of the guide
curve. Hint #2: Use Guide curves influence types under the Guide
Curves section shown on the left pane of the screen.

Two profiles and guide curve

Local influence of guide curve Global influence of guide curve

Figure 4.19
Influence of guide curve

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 12 Create the CAD model of the helical spring shown in Figure 4.20. All
dimensions are in centimeters.

Figure 4.20
Helical spring

13 Create the CAD model of the 3D probe shown in Figure 4.21. All
dimensions are in millimeters.

x y z
0 2.4 0
0 –50 0
A-A
0 –60 150
15 –65 160
150 –65 160

The probe uses a 3D

curve to define its
profile. The probe is
hollow. The outer
diameter is 20 mm and
thickness is 2 mm

Figure 4.21
3D probe

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 Chapter 4
Figure 4.21
(continued)

14 Create the CAD model of the football goal post shown in Figure 4.22.
All dimensions are in inches. Hint: The dimensions of the post are per
NFL specs: The post is 10 feet (120 in.) high, the crossbar is 18.5 feet
(222 in.) wide from the inner edges of the uprights, and the uprights
are 20 feet (240 in.) high. The diameter of the post tubes is arbitrary,
so use 8 in. here.

Note:
upright diameter = post diameter

Uprights

Crossbar

Post
Post dimensions Dimensions of crossbar and uprights

Figure 4.22
Football goal post

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 15 Create the CAD models shown in Figure 4.23. All dimensions are in
inches.

(A) Banana (B) Water bottle

Figure 4.23
CAD models

16 Create the CAD models shown in Figure 4.24. All dimensions are in
inches.

Figure 4.24
CAD models (A) Coffee mug (B) Hand drill

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 17 Create the CAD models shown in Figure 4.25. All dimensions are in

Chapter 4
inches.

(A) Goblet (B) Baseball bat

Figure 4.25
CAD models

18 Create the CAD models shown in Figure 4.26.

(B) Torpedo
(dimensions in
(A) Funnel (dimensions in mm) inches)

Figure 4.26
CAD models

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 19 Create the CAD models shown in Figure 4.27. All dimensions are in
inches.

(A) Fiber optic wire (B) Desk lamp

Figure 4.27
CAD models

20 Create the CAD models shown in Figure 4.28. All dimensions are in
inches.

(A) Fruit basket (B) Bowl

Figure 4.28
CAD models

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 21 Create the CAD models shown in Figure 4.29.

Chapter 4
(A) Candle and holder
(dimensions in inches) (B) Pitcher (dimensions in millimeters)

Figure 4.29
CAD models

22 Create the CAD models shown in Figure 4.30.

(A) A flex (B) Steel cone

Figure 4.30
CAD models

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 23 Create the CAD models shown in Figure 4.31.

(A) Computer mouse (B) Auger drill

Figure 4.31
CAD models

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 Index

NUMBERS types of, 377–378

Von Mises stress, 391–396
2D curves, 222 analytic curves, 217, 218
tutorials analytic surfaces, 249
explicit equations, 224 angle dimension tolerances, 346
parametric equations, 225 angle tolerance (STL files), 418
stethoscope model creation, 241–243 angles of projection, 145–146
3D curves, 223 angular dimensions, 139
tutorials animations
3D points, 227–228 analysis tools for, 385–386
3D sketches, 228–229 of assembly models, 164–165
composite curves, 229–230 tutorials, 210–212
parametric equations, 225–226 types of, 201–202
projected curves, 232–241 annotations, inserting, 153
projected sketches on curved faces, ANSI (American National Standards
231–232 Institute), 137, 491
stethoscope model creation, 241–243 ANSI fits, 348–349
3D points, 227–228 ANSI weld symbols, 305–306
3D printing, 419. See also rapid anti-aliasing, 195
prototyping (RP) API (application programming interface),
3D Sketch feature, 303 112
3D sketches, 228–229 appearance
.3dxml file format, 379 of models, 201
tutorials, 205–206
A applications of rapid prototyping, 412–413
arithmetic tolerancing, 355
abbreviation rules (ASME), 137–138 artistic bowl creation tutorial, 265–267
abort symbol, 9 ASME (American Society of Mechanical
actual size, 340–341 Engineers), 137
addendum circle (gears), 104 abbreviation rules, 137–138
additive manufacturing, 412 dimensioning rules, 139–144
additive modeling plan in drain plug drafting rules, 138
tutorial, 90 tolerance rules, 343–346
.ai file format, 380 assemblies. See assembly models
air acidification, 326 assembly drawings, 164
aliasing, 195 creating with bill of materials, 154–155
ambient light, 196 Assembly mode (SolidWorks), 8
analysis tools. See also tolerance analysis assembly models, 157–158
animation and motion analysis, 385–386 applying colors, 202–203
finite element analysis, 389–390 configurations, 165
finite element method, 386–389 creating
flow simulation, 386 bottom-up modeling, 159
mass properties calculations, 381–385 example, 20–22
purpose of, 377–378 top-down modeling, 159–163
SolidWorks Simulation/SimulationXpress, tutorial, 29–31
391 defined, 157
tutorials design tables, 166
flow simulation, 406–407 exploded views and animations, 164–165
mass properties calculations, 397–398 interference and collision detection, 166
motion analysis, 398–403 mates, 158
static linear analysis, 403–404 motion study, 165–166, 385–386
thermal analysis, 405

517


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 parts versus, 157 bosses, 471
planning, 157 bottle prototype, 420–421
saving as images, 62 bottom-up assembly modeling, 159
tutorials boundaries as surfaces, 251, 263–264
ball screw creation, 173–174 bracket creation tutorial, 66–67
cam and follower creation, 167–168 broken views, 147
design table creation, 179–180 broken-out sections, 147
gear mates, 169–171 Brundtland Report, 320
interference and collision detection, 178 B-splines. See splines
motion analysis, 398–403 bubbles, 466
motion study creation, 176–177 build orientation, 415
part creation in context, 180–182 burn marks, 467
rack and pinion creation, 171–173 burrs, 436
universal joint motion, 174–176 bushing bearing creation tutorial, 24
working hinge creation, 168–169
viewing, 62
assembly prototype file creation tutorial, C
422–423 CAD (computer-aided design) process, 4–5
assembly trees, 157, 164 CAD models. See parts
associativity of parts and engineering CAD/CAM systems
drawings, 151, 155 analysis tools
attachments in design binders, 85 animation and motion analysis, 385–386
auxiliary views, 146 finite element analysis, 389–390
finite element method, 386–389
flow simulation, 386
B mass properties calculations, 381–385
BA (bend allowance), 290–291 purpose of, 377–378
background SolidWorks Simulation/SimulationXpress,
of models, 201 391
tutorials, 203–204 tutorials, 396–407
ball screw assembly creation tutorial, types of, 377–378
173–174 Von Mises stress, 391–396
base circle (gears), 104 data exchange, 378–381
base features, 99 SolidWorks supported file formats,
base flanges, 292 379–380
base plate creation example, 17–18 standard/de facto file formats, 378
base support structure for rapid validating file translation, 380–381
prototyping, 416–417 CAM (computer-aided manufacturing)
baseball hat creation tutorial, 273–277 process, 6. See also manufacturing
baseline dimensions, 139, 354 process
basic size, 340–341 CAM add-in software, 449–450
BD (bend deduction), 291 cam and follower assembly creation
bend allowance (BA), 290–291 tutorial, 167–168
bending sheet metal, 290–291, 298–299, camera sleds, 201, 202, 210–212
310–311 camera-based animation, 202, 210–212
bends, 292, 293 cameras, 201, 206–207
bicycle handlebar model tutorial, 228–229 canned cycles, 447
bilateral tolerances, 342 capturing design intent, 82–83
bill of materials (BOM), 144, 151 carbon footprint, 321–322, 325
assembly drawings with, 154–155 Cartesian dimensions, 139
Bill of Rights for the Planet, 322–323 caster assembly creation tutorial, 70–72
block mold creation tutorial, 473–477 caustic effects, 198
blocks in top-down assembly cavity (of molds), 468
modeling, 160 center modifiers, 53–54
bolt creation example, 123–125 center planes for features, 38
Boolean operations, 59–61 .cgr file format, 380
BootCamp, 6 chain dimensioning, 354

518 Index

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 Chamfer feature, 304 curves
chamfers, creating, 121–122 2D curves, 222
changing font size of dimensions, 9 3D curves, 223
circle parametric equation, 220–221 analytic curves, 217, 218
circular patterns, 54–55 equations
circular pitch, 105 circle parametric equation, 220–221
CL (cutter location) data, 447 line parametric equation, 219–220
coil spring creation tutorial, 63–65 parametric versus explicit, 218–219
collision detection in assembly models, spline parametric equation, 221–222
166, 178 in sketches, 217
colors, applying to objects, 202–203 splitting, 224
comments, 83–84 surfaces and, 249
communication synthetic curves, 218
guidelines for, 137 tutorials
abbreviation rules, 137–138 2D curve creation with explicit equation,
dimensioning rules, 139–144 224
drafting rules, 138 2D curve creation with parametric
SolidWorks tools for, 62 equation, 225
components. See parts 3D curve creation with 3D points,
composite curves, 229–230 227–228
composites 3D curve creation with 3D sketches,
defined, 37 228–229
images of, 38 3D curve creation with composite curves,
in part creation, 38 229–230
compression spring creation example, 3D curve creation with parametric
119–120 equation, 225–226
computer mouse creation tutorial, 3D curve creation with projected curves,
271–273 232–241
concurrent engineering, 442 3D curve creation with projected sketches
configurations on curved faces, 231–232
in assembly models, 165 stethoscope model creation, 241–243
in design intent, 85 customizing SolidWorks, 11–13, 42
design tables and, 112–114 cutter location (CL) data, 447
conical tapers, 347 cutting solids with surfaces, 253
conics. See analytic curves cutting tools, 431–433
conjugate action (gears), 103–104
construction geometry, 48
continuous machining, 437–438
D
contours (loops), 217 data exchange between CAD/CAM
conventional tolerances, 340, 367–368 systems, 378–381
converting SolidWorks supported file formats, 379–380
shelled solids to sheet metal, 298 standard/de facto file formats, 378
solids into sheet metal, 297, 309–310 tutorials
surfaces into solids, 253 exporting SolidWorks files, 396
cooling time, 468 importing IGES and STEP files, 396–397
coordinate systems, 43–44, 437–438 validating file translation, 380–381
copying datum targets, 343, 359–360, 370–371
entities, 58, 116–118 datums, 343, 359
features, 58–59 de facto file formats, 378
cores (of molds), 468 decals, 198–199
corners, 292, 294 Declaration of Interdependence for
crop views, 147 a Sustainable Future, 323
cross-section modeling approach, dedendum circle (gears), 104
12–14 defects
in drain plug tutorial, 90 in injection molding, 466–467
in slider block tutorial, 87 in weldments, 300
curve-driven patterns, 54–55 degrees of freedom (DOF), 158, 431

Index 519

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 deleting radius/diameter display, 10
entities, 9, 349 in SolidWorks, 142–144
features, 9 types of, 139, 155
depth of cut, 433–436 DimXpert module, 364–365
derived parts, 109 direct dimensioning, 354
design, sustainable. See sustainable design directional light, 196
design binders, 84–85 disabling snap to endpoint/midpoint,
design checkers, 151–152 9, 54
design for anything (DFX), 442 documenting design intent, 83
design for assembly (DFA), 442 comments, 83–84
design for manufacturing (DFM), 442–445 design binders, 84–85
design intent design tables and configurations, 85
capturing, 82–83 dimension names, 85
defined, 81 equations, 85
documenting, 83 feature names, 85–86
comments, 83–84 folders in feature tree, 86
design binders, 84–85 drafting rules (ASME), 138
design tables and configurations, 85 drafts, 102, 470
dimension names, 85 creating, 121–122
equations, 85 drain plug tutorial
feature names, 85–86 additive modeling plan, 90
folders in feature tree, 86 cross-section modeling approach, 90
geometric modeling versus, 81 subtractive modeling plan, 91
manufacturing process and, 441–442 Drawing mode (SolidWorks), 8
tutorials drawing templates, 148
design specifications, 91–93 drawings. See engineering drawings
mating conditions, 93–94 drilling, 438–439, 442–443
three modeling plans, 89–91 drilling holes tutorial, 450–452
two modeling plans, 86–89 drills, 431
design intent systems, 81 driving tools in NC machining, 446
design library, 110–112 dry machining, 430
design specifications in design intent, ductile material, 391–392
91–93 .dwg file format, 380
design tables .dxf file format, 380
in assembly models, 166, 179–180
configurations and, 112–114
in design intent, 85
E
examples, 110–114 Easter egg mold creation tutorial, 484–486
designated points in part creation, 38 edge flanges, 293
detail views, 146–147 edges, 40
deviation tolerance (STL files), 418 editing
DFA (design for assembly), 442 entities, 58–59
DFM (design for manufacturing), 442–445 sketch planes, 45–46
DFMXpress, 442–445 templates, 12–13
DFX (design for anything), 442 EDM (electrical discharge machining),
diameter/radius display, toggling, 10 439–441
dimensioning engineering drawings, EDP (engineering design process),
135–136 4. See also sustainable design
dimensioning rules (ASME), 139–144 eDrawings, 7, 62
dimensions. See also tolerances ejection, 468
changing font size, 9 ejector marks, 467
in configurations, 112–114 enabling snap to endpoint/midpoint, 9, 54
defined, 40–41 enclosure, sheet metal as, 290
in engineering drawings, examples, End Cap feature, 302–303, 304
143–144 end modifiers, 53–54
limits of, 348–353 energy
naming, 85 measuring consumption, 326

520 Index

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 minimizing consumption, 321 .eprt file format, 379
renewable versus nonrenewable, 320 equations
engineering design process (EDP), 4. See for curves
also sustainable design 2D curve creation with explicit equation
engineering drawings tutorial, 224
assembly drawings, 164 2D curve creation with parametric
associativity with parts, 151, 155 equation tutorial, 225
communication guidelines for, 137 3D curve creation with parametric
abbreviation rules, 137–138 equation tutorial, 225–226
dimensioning rules, 139–144 circle parametric equation, 220–221
drafting rules, 138 line parametric equation, 219–220
content and layout, 144–145 parametric versus explicit, 218–219
angles of projection, 145–146 spline parametric equation, 221–222
bill of materials (BOM), 151 in design intent, 85
control options in SolidWorks, 150 in part creation, 38, 51–53
sheets, 148–149 for surfaces
title blocks, 149 parametric equations, 254–255
tolerances, 150, 343–346 plane parametric equation, 255–256
view types, 146–148 ruled surface parametric equation,
creating, 148 257–260
example, 18–20 event-based motion studies, 385–386
tutorial, 28–29 examples
design checkers, 151–152 assembly model creation, 20–22
dimensioning, 135–136 base plate creation, 17–18
examples, dimensions in engineering Boolean operations, 59–61
drawings, 143–144 circle parametric equation, 221
purpose of, 135 decal creation, 198–199
saving as images, 62 design table creation, 110–114
tutorials dimensions in engineering drawings,
annotation insertion, 153 143–144
assembly drawing creation with bill of engineering drawings creation, 18–20
materials, 154–155 equations and link values, 51–53
model-drawing associativity, 155 feature-based pattern creation, 56–57
mold drawing creation, 487 fit limits and tolerance zone calculations,
sheet metal drawing creation, 308–309 352–353
title block filling, 153–154 free-form torus creation, 102–103
view creation, 152–153 Gauss quadrature, 384
weldment drawing creation, 313–315 line parametric equation, 220
viewing, 62 macro creation, 113–115
engraving parts tutorial, 231–232 macro hotkey creation, 114
entities mass properties calculations, 384–385
copying, 116–118 material and texture additions, 200
deleting, 9, 349 modeling plan approaches, 39–45
editing, 58–59 parametric modeling, 41–42
enabling/disabling snap to part creation, 49–50
endpoint/midpoint, 9 pin creation, 16–17
geometric modifiers, 53–54 plane parametric equation, 256
measuring, 59 plate creation, 15–16
offsetting, 58 ruled surface parametric equation, 257–258
in part creation, 50 sketch-based pattern creation, 55–56
patterns, 54–57 SolidWorks DFMXpress, 445
selecting multiple, 9, 58 SolidWorks TolAnalyst, 365–367
transforming, 58 spline parametric equation, 222
trimming, 58 spur gear CAD model creation, 107–109
viewing/hiding, 9 stress testing, 393–396
environmental sustainability. See surface-to-surface intersection curve
sustainable design creation, 258–260

Index 521

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 tolerance analysis, 364 patterns, 54–57
top-down assembly modeling, 161–163 reference geometry, 48–49
exiting current mode, 9 sheet metal, 291–296
explicit equations for curves, 218–219, transforming, 58–59
224 types of, 99, 100–102
exploded views of assembly models, weldments, 301–304
164–165 features modeling approach, 12–14
exporting SolidWorks files, 396 base features, 99
extension lines, 140 questions in, 100
extrusions, 15, 100 in slider block tutorial, 88–89
creating with macro, 113–115 feedrate, 433–436
defined, 37 FEM/FEA (finite element modeling/finite
images of, 38 element analysis), 386–390, 393–396
in part creation, 38 file data exchange between CAD/CAM
as surfaces, 250, 261–263 systems, 378–381
SolidWorks supported file formats,
379–380
F standard/de facto file formats, 378
fabrication with rapid prototyping, 413 tutorials
faces exporting SolidWorks files, 396
milling tutorial, 452–455 importing IGES and STEP files, 396–397
part topology, 40 validating file translation, 380–381
facets (STL files), 418 file formats
FDM (fused deposition modeling), 419 SolidWorks supported, 379–380
FEA (finite element analysis), 389–390 standard/de facto, 378
static linear analysis tutorial, 403–404 filled surfaces, 252, 263–264
thermal analysis tutorial, 405 fillets, creating, 121–122
feature tree, 9 filling title blocks, 153–154
assembly trees versus, 164 finite element analysis (FEA), 389–390
folders in, 86 static linear analysis tutorial, 403–404
in part creation, 14, 47–48 thermal analysis tutorial, 405
for sheet metal, 296–297 finite element method, 386–389,
for weldments, 301–302 393–396
feature-based pattern creation example, fits, types of, 348–353
56–57 flanges, 291–293
FeatureManager Design Tree. See feature flap creation tutorial, 22–23
tree flashing, 467
features, 15. See also parts; names of flat tapers, 347
specific features flattening sheet metal, 292, 296
base features, 99 flow marks, 467
Boolean operations, 59–61 flow simulation, 386, 406–407
center planes, 38 FloXpress, 406–407
creating, 15, 121–122 flutes, 431
defined, 100 fog light, 196
deleting, 9 folders in feature tree, 86
design intent. See design intent folding sheet metal, 295
examples font size of dimensions, changing, 9
bolt creation, 123–125 free forms
feature creation, 121–122 defined, 37
free-form torus creation, 102–103 images of, 38
hole wizard usage, 118–119 in part creation, 38
loft feature creation, 116–118 surfaces as, 249
Smart Fasteners wizard usage, 122–123 free-form torus creation example,
sweep feature creation, 114–116 102–103
library features, 110–112 fully defined sketches, 46
measuring, 59 fused deposition modeling (FDM), 419
naming, 85–86

522 Index

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 G creation tutorial, 369–370
symbols, 357
GaBi, 328 true position, 356–357
gate and runner system, 469–470 green design. See sustainable design
gauges of sheet metal, 290 grids, 54
Gauss quadrature, 382–385 Gusset feature, 302–303, 304
G-code programming, 447–449
GD&T (geometric dimensioning and
tolerancing). See tolerances H
gear teeth, 103 hair dryer creation tutorial, 277–279
gears Hannover Principles, 322–323
conjugate action, 103–104 .hcg file format, 380
examples, 107–109 healthy buildings, 322
geometry of, 104–105 Help menu (SolidWorks), 11–12
modeling, 105–106 hemisphere mold creation tutorial,
spur gears, 103–109 481–484
tutorials hems, 292, 294
gear mates, 169–171 hiding
rack and pinion creation, 171–173 sketch relations, 38
types of, 103 sketches, 9
genera (genus), 40 Task Pane (SolidWorks), 9
geometric arrays. See patterns hinge assembly tutorial, 168–169
geometric dimensioning and tolerancing hole wizard, 118–119
(GD&T). See tolerances hole-based systems, 341
geometric modeling holes
capturing design intent, 82 drilling tutorial, 450–452
curves tolerances, 341
2D curves, 222 home position, 436
3D curves, 223 hose flow analysis tutorial, 406–407
analytic curves, 217, 218 hotkeys, 43, 114
circle parametric equation, 220–221 housing (of molds), 468
line parametric equation, 219–220 .hsf file format, 380
parametric versus explicit equations,
218–219
in sketches, 217 I
spline parametric equation, 221–222 IGES files, importing, 396–397
splitting, 224 .igs file format, 379
synthetic curves, 218 images, saving as, 62
tutorials, 224–243 impact metric of sustainable design,
design intent versus, 81 325–326
surfaces importing IGES and STEP files, 396–397
curves and, 249 inch tolerances, 345–346
as free forms, 249 in-context assembly modeling,
manipulation, 260 159–163
parametric equations, 254–255 injection molding
plane parametric equation, 255–256 benefits and drawbacks, 464
purpose of, 249–250 defects in, 466–467
ruled surface parametric equation, machines for, 464–465
257–260 materials, 464
in solid modeling, 252–253 mold design
tutorials, 261–281 overview, 467–470
types of, 250–252 phases of, 471–472
visualization, 260 in SolidWorks, 472–473
geometric modifiers, 53–54 part design, 470–471
geometric relation symbols, 10 purpose of, 463–464
geometric tolerances, 340 steps in, 464, 465–466
assigning and interpreting, 357–359 tutorials

Index 523

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 block mold creation, 473–477 LMC (least material condition), 342–343
Easter egg mold creation, 484–486 lofted bends, 292, 295
hemisphere mold creation, 481–484 lofts, 101
mold drawing creation, 487 creating, 116–118
sandbox mold creation, 477–480 as surfaces, 251, 252, 261–263
inserting annotations, 153 LOM (laminated object manufacturing),
inserts, 470 419
inspecting loops, 40, 217
parts, 340
weld joints, 300
instances, 158 M
interference detection in assembly machine tools, 428–430
models, 166, 178 machining
interpolations, 447 cutting tools, 431–433
interpreting tolerances, 360–362 drilling, 438–439
intersection (Boolean operation), 59 EDM (electrical discharge machining),
intersection modifiers, 53–54 439–441
intersections (surfaces) tutorial, 268–269 home position, 436
involute profile, 104 machine tools, 428–430
ISO (International Organization for machining parameters, 433–436
Standardization), 137, 327, 491 machining quality, 436
ISO fits, 348–349 milling, 439
ISO weld symbols, 305 motion axes, 431
NC machining
G-code and M-code programming,
J 447–449
job shop production, 428 programming concepts, 445–447
jogs, 292, 294 process types, 428
.jpg file format, 380 rapid positioning, 438
SolidWorks DFMXpress, 442–445
squaring stock, 436
K stock, 433
K-Factor, 290 toolpaths, 436–438
knit surfaces, 252, 261–263 turning, 438
tutorials
drilling holes, 450–452
L face milling, 452–455
laminated object manufacturing (LOM), pocket milling, 455–457
419 slot milling, 457–459
lathes, 428–430, 438 machining parameters, 433–436
layering (slicing), 415–416 machining quality, 436
layout sketches, 159–160 MacOS, SolidWorks on, 6
LCA (life cycle assessment), 322, 323–327 macros, 111–114
leaders, 140 defined, 111
least material condition (LMC), 342–343 examples
library features, 110–112 extrusion creation, 113–115
life cycle assessment (LCA), 322, 323–327 hotkey creation, 114
lighting manufacturing engineers, 5
in rendering, 196–198 manufacturing process, 5
tutorials, 204–205 CAM add-in software, 449–450
types of, 196 design and, 441–442
limit dimensions, 341, 343 dimensioning for, 136
limits of dimensions, 348–353 injection molding
line parametric equation, 219–220 benefits and drawbacks, 464
linear patterns. See rectangular patterns defects in, 466–467
link values, 51–53 machines for, 464–465
linking parameters, 51 materials, 464

524 Index

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 mold design overview, 467–470 pocket milling, 455–457
mold design phases, 471–472 slot milling, 457–459
part design, 470–471 types of, 427–428
purpose of, 463–464 mass customization, 428
SolidWorks mold design, 472–473 mass production, 428
steps in, 464, 465–466 mass properties calculations, 381–385,
tutorials, 473–487 397–398
machining master parts. See templates
cutting tools, 431–433 material conditions, 342–343
drilling, 438–439 materials
EDM (electrical discharge machining), in injection molding, 464
439–441 properties, 392
home position, 436 rendering, 199–200
machine tools, 428–430 sheet metal, 289–290
machining parameters, 433–436 in sustainable design, 325–326
machining quality, 436 transparency, 205–206
milling, 439 Von Mises stress, 391–396
motion axes, 431 mates, 20
process types, 428 applying, 158
rapid positioning, 438 defined, 157
SolidWorks DFMXpress, 442–445 tutorials
squaring stock, 436 ball screw creation, 173–174
stock, 433 gear mates, 169–171
toolpaths, 436–438 rack and pinion creation, 171–173
turning, 438 mating conditions in design intent,
NC machining 93–94
G-code and M-code programming, maximum material condition (MMC),
447–449 342–343
programming concepts, 445–447 M-code programming, 447–449
prototyping MCS (model coordinate system), 43–44,
purpose of, 411 437–438
visualization with, 412–413 measuring entities/features, 59
rapid prototyping (RP) meshing gears, 103–104
applications, 412–413 millimeter tolerances, 344–345
benefits of, 411–412 milling, 439, 443
bottle prototype, 420–421 faces, 452–455
build orientation, 415 pockets, 455–457
layering (slicing), 415–416 slots, 457–459
steps in, 414, 418–419 milling machines, 428–430
STL files, 417–418 mills, 431
support structure, 416–417 mirroring
techniques, 419 entities, 58
triangulation (tessellation), 414–415 features, 59
tutorials, 421–424 miter flanges, 293
tolerances MMC (maximum material condition),
datum targets, 359–360 342–343
geometric tolerances, 357–359 model coordinate system (MCS), 43–44,
interpreting, 360–362 437–438
purpose of, 339–340 model items (dimensions), 155
standardizing, 348–353 modeling plan approaches
statistical tolerancing, 354–355 design intent tutorials
terminology, 340–343 three modeling plans, 89–91
true position, 356–357 two modeling plans, 86–89
types of, 340 example, 39–45
tutorials explained, 12–14
drilling holes, 450–452 models. See parts
face milling, 452–455 modes (SolidWorks)

Index 525

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 exiting, 9 P
list of, 8
mold base, 469 panning parts, 10
mold design parameters, 40–41
overview, 467–470 in configurations, 112–114
phases of, 471–472 in equations, 51
in SolidWorks, 472–473 linking, 51
molds. See injection molding parametric equations
motion axes, 431 for circles, 220–221
motion study for curves, 218–219
of assembly models, 165–166, 176–177 2D curve creation tutorial, 225
tutorials, 207–210, 398–403 3D curve creation tutorial, 225–226
types of, 385–386 for lines, 219–220
mount plate creation tutorial, 65–66 for planes, 255–256
mouse button usage, 9 for ruled surfaces, 257–260
mouse wheel usage, 9 for splines, 221–222
moving for surfaces, 254–255
entities, 58 parametric modeling, 40–42
features, 58–59 part history tree. See feature tree
Task Pane (SolidWorks), 10 Part mode (SolidWorks), 8
multiaxial loading, 393 part prototype file creation tutorial,
multiple entities, selecting, 9, 58 421–422
multiple open windows, 9 partial filling (short shot), 466
multiple parts, viewing, 10 parting axes, 469
parting lines, 468
parting surfaces, 469
N parts. See also features
NA (neutral axis), 290 applying colors, 202–203
named (orthographic) views, 146 assembly models versus, 157
naming associativity with engineering drawings,
dimensions, 85 151, 155
features, 85–86 configurations. See configurations
NC (numerical control) machining creating, 14–15. See also sketches
G-code and M-code programming, 447–449 in assembly context, 180–182
programming concepts, 445–447 Boolean operations, 59–61
neutral axis (NA), 290 coordinate systems, 43–44
nominal size, 340–341 equations and link values, 51–53
nonrenewable energy, 320 example, 49–50
normal vectors, 255 feature tree, 47–48
numerical control machining. See NC grids, 54
(numerical control) machining modeling plan approaches, 12–14
parametric modeling, 40–42
patterns, 54–57
O planning, 38–39
offsetting sketch entities, 50
entities, 58 sketch planes, 43–46
surfaces, 263–264 templates, 61
oil container creation tutorial, 279–281 curves. See curves
opening data exchange between CAD/CAM systems,
parts, 8 378–381
STL files, 423–424 derived parts, 109
optimization with rapid prototyping, 413 design intent. See design intent
ordinate dimensions, 139 designing for injection molding, 470–471
orthographic (named) views, 146 engraving tutorial, 231–232
Our Common Future (Oxford University examples
Press), 320 assembly model creation, 20–22
over defined sketches, 46 base plate creation, 17–18

526 Index

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 engineering drawings creation, 18–20 .prt file format, 380
part creation, 49–50 .prtdot file format, 379
pin creation, 16–17 .psd file format, 379
plate creation, 15–16 PTP (point-to-point) machining, 437–438
inspecting, 340
model communication tools in
SolidWorks, 62
R
opening, 8 rack and pinion assembly creation
reusing, 110–112 tutorial, 171–173
saving as images, 62 radial dimensions, 139
sheet metal. See sheet metal radiate surfaces, 261–263
surfaces. See surfaces radius/diameter display, toggling, 10
tolerancing, 136, 150. See also tolerances rapid positioning, 438
topology, 40 rapid prototyping (RP)
types of, 37–38 applications, 412–413
viewing, 10, 61, 62 benefits of, 411–412
viewing multiple, 10 bottle prototype, 420–421
visualization. See visualization build orientation, 415
welded. See weldments layering (slicing), 415–416
zooming/panning/rotating, 10 steps in, 414, 418–419
patterns, 38, 54–57 STL files, 417–418
.pdf file format, 379 support structure, 416–417
PDM (product data management), 442 techniques, 419
picture frame model tutorial, 229–230 triangulation (tessellation), 414–415
pillow block creation tutorial, 25–27 tutorials
pin and bushing bearing creation assembly prototype file creation, 422–423
tutorial, 24 opening STL files, 423–424
pin creation example, 16–17 part prototype file creation, 421–422
pitch circle (gears), 104 real-time animation, 201
placing toolbars, 10 rectangular patterns, 54–55
planar surfaces, 252, 263–264 recycling, 320, 322
plane parametric equation, 255–256 reference dimensions, 155
planning reference geometry, 48–49
assembly models, 157 reflection in rendering, 197–198
part creation, 38–39 regardless of feature size material
plate creation example, 15–16 condition (RFS), 342–343
playback animation, 201–202 relations, 51
PLM (product life cycle management), 442 relative-to-model views, 148
plus and minus tolerancing, 343 rendering
pocket milling tutorial, 455–457 appearance and transparency, 201
point light, 196 background, 201
point-to-point (PTP) machining, 437–438 cameras, 201
pressure angle, 103 complexity of, 195–196
process planners, 5 decals, 198–199
product data management (PDM), 442 lighting, 196–198
product life cycle management (PLM), 442 materials, 199–200
productivity tools, 43 models, 197–198
programmable mice, 43 purpose of, 195
programming. See NC (numerical control) resolution, 195
machining scenes, 196
projected curves, 232–241 textures, 199
projected views, 146 renewable energy, 320
projection, angles of, 145–146 resolution
prototyping. See also rapid in rendering, 195
prototyping (RP) of STL files, 417–418
purpose of, 411 resources for SolidWorks, 11–12
visualization with, 412–413 reusing parts, 110–112

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 revolves, 15, 100 sheet metal creation, 306–307
defined, 37 sheet metal creation from solid body,
images of, 38 309–310
in part creation, 38 sheet metal drawing creation, 308–309
as surfaces, 250, 261–263 types of, 289
RFS (regardless of feature size material sheets in engineering drawings, 148–149
condition), 342–343 shelled solids, converting to sheet
ribs, 102, 471 metal, 298
creating, 121–122 shells, 102, 121–122
rips, 292, 294 short shot (partial filling), 466
root circle (gears), 104 shots, 468
rotating shrinkage, 468
entities, 58 shut-off surfaces, 472
features, 58–59 simple tensile tests, 392–393
parts, 10 Simulation, 391
rotation speed, 433–436 SimulationXpress, 391
ruled surface parametric equation, single limits in tolerances, 346
257–260 sink marks, 466
runners, 469–470 sinker EDM, 439–441
sizes, types of, 340–341
sketch entities. See entities
S sketch planes, 15, 43–46
sandbox mold creation tutorial, 477–480 sketch relations, viewing/hiding, 38
.sat file format, 379 sketch symbols, 9
save symbol, 9 sketch-based pattern creation example,
saving 55–56
as images, 62 sketches
STL files, 417–418 construction geometry, 48
scaling creating features, 15
entities, 58 curves in, 217
features, 59 entities, copying, 116–118
scenes parametric modeling, 40–42
accessing library, 201 relations, 51
cameras in, 201, 206–207 status, 46–47
in rendering, 196 tutorials
tutorials 3D curve creation with 3D sketches,
applying, 203–204 228–229
lighting, 204–205 3D curve creation with projected sketches
screen capture, 9, 62 on curved faces, 231–232
section views, 146 viewing/hiding, 9
selecting multiple entities, 9, 58 SLA (stereolithography apparatus), 419
selective laser sintering (SLS), 419 .sldftp file format, 379
SGC (solid ground curing), 419 .sldlfp file format, 379
shaft-based systems, 341 .sldprt file format, 379
shafts, 341 slicing (layering), 415–416
sheet metal slider block tutorial
bending, 290–291, 298–299 cross-section modeling approach, 87
creating, 297–299 features modeling approach, 88–89
as enclosure, 290 slots
feature tree, 296–297 creating, 121–122
features, 291–296 milling, 457–459
gauges, 290 SLS (selective laser sintering), 419
materials, 289–290 Smart Fasteners wizard, 122–123
purpose of, 289 snap to endpoint/midpoint, enabling/
rules in DFMXpress, 443 disabling, 9, 54
tutorials society, design and, 321
part creation via bending, 310–311 solid ground curing (SGC), 419

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 solid models, 40 stethoscope model creation tutorial,
converting to sheet metal, 297, 309–310 241–243
mass properties calculation tutorial, .stl file format, 379
397–398 STL files
surfaces in, 252–253 opening, 423–424
SolidWorks saving, 417–418
API (application programming interface), tutorials
112 assembly prototype file creation, 422–423
CAM add-in software, 449–450 part prototype file creation, 421–422
certification, 505–516 stock
communication tools, 62 defined, 433
customizing, 11–13, 42 squaring, 436
dimensions in, 142–144 stress testing, 391–396
drafting control options, 150 stress-strain curve, 391–392
exporting files, 396 stretching entities, 58
FEM/FEA modules, 391 Structural Member feature, 302, 303
FloXpress, 406–407 subtraction (Boolean operation), 59
importing IGES and STEP files, 396–397 subtractive manufacturing, 412
machining, 442–445 subtractive modeling plan in drain plug
on MacOS, 6 tutorial, 91
modes support structure for rapid prototyping,
exiting, 9 416–417
list of, 8 surface finish, 199
mold design, 472–473 surface intersections tutorial, 268–269
operational overview, 8–12 surfaces
productivity tools, 43 curves and, 249
resources, 11–12 equations
starting, 8 parametric equations, 254–255
STL files, 417–418 plane parametric equation, 255–256
sustainable design tools, 328–332 ruled surface parametric equation,
system requirements, 6 257–260
tolerance analysis, 364–367, 372–373 as free forms, 249
viewer version, 62 manipulation, 260
Sphera, 328 purpose of, 249–250
spindle speed, 433–436 in solid modeling, 252–253
spiral spring creation example, 120–121 tutorials
spline parametric equation, 221–222 artistic bowl creation, 265–267
splines, 50 baseball hat creation, 273–277
splitting curves, 224 basic surface creation, 261–264
spot light, 196 computer mouse creation, 271–273
springs hair dryer creation, 277–279
compression spring creation example, oil container creation, 279–281
119–120 surface intersections, 268–269
spiral spring creation example, 120–121 tablespoon creation, 269–271
spur gears, 103–109 visualization, 264–265
squaring stock, 436 types of, 250–252
standard file formats, 378 visualization, 260
standardizing tolerances, 348–353 surface-to-surface intersection curve
start parts. See templates creation example, 258–260
starting SolidWorks, 8 Sustainability, 328–332
static linear analysis, 389, 403–404 SustainabilityXpress, 328
statistical tolerance analysis, 363–364 sustainable design
statistical tolerancing, 354–355 Declaration of Interdependence for a
steel washer redesign tutorial, 332–334 Sustainable Future, 323
.step file format, 379 defined, 320
STEP files, importing, 396–397 guidelines for, 321–322
stereolithography apparatus (SLA), 419 Hannover Principles, 322–323

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 impact metric, 325–326 purpose of, 362
LCA (life cycle assessment), 323–327 in SolidWorks, 364–367
manufacturing process and, 441–442 tutorial, 372–373
purpose of, 319–320 tolerance notes, 343
society and, 321 tolerance synthesis, 362
SolidWorks Sustainability, 328–332 tolerance zone, 341
steel washer redesign tutorial, 332–334 tolerances. See also dimensions
steps in, 327–328 ASME tolerance rules, 343–346
tools, 328 datum targets, 359–360
sustainable manufacturing, 319–320 geometric tolerances, 357–359
sustainable waste, 319–320 interpreting, 360–362
sweeps, 101 purpose of, 339–340
creating, 114–116 standardizing, 348–353
as surfaces, 251, 261–263 statistical tolerancing, 354–355
symmetric tolerances, 342 of STL files, 418
symmetry of parts, 38 terminology, 340–343
synthetic curves, 218 true position, 356–357
synthetic surfaces, 249 tutorials
system requirements for SolidWorks, 6 conventional tolerance creation, 367–368
datum target definition, 370–371
geometric tolerance creation, 369–370
T taper tolerances, 371–372
tablespoon creation tutorial, 269–271 tolerance analysis, 372–373
tabs, 292, 293 types of, 340
tangent vectors, 219, 254 tolerancing
tapers, tolerancing, 347–348, 371–372 parts, 136, 150
tapping tools, 431 tapers, 347–348, 371–372
targets in Boolean subtraction, 59 tool offset, 447
Task Pane (SolidWorks) tool splitting, 468
moving, 10 toolbars, placing, 10
viewing/hiding, 9 tooling, 468
templates tooling cost, 470
creating, 61 tooling split, 472
drawing templates, 148 toolpaths, 436–438, 449–450
editing, 12–13 tools
tessellation (triangulation) in Boolean subtraction, 59
defined, 414–415 driving in NC machining, 446
STL files, 417–418 injection molding machines, 464–465
testing with rapid prototyping, 413 machine tools, 428–430
textures, 199, 200 for sustainable design, 328
thermal analysis tutorial, 405 top-down assembly modeling, 159–163
thickening surfaces, 253 topology of parts, 40
thread types, 431 torus creation example, 102–103
threads, 471 transforming
.tif file format, 380 entities, 58
time-based motion studies, 385 features, 58–59
tire and pin creation tutorial, 69–70 translating
title blocks entities, 58
in engineering drawings, 149 features, 58–59
filling, 153–154 files, 380–381
tolerances in, 343 transparency
toggling radius/diameter display, 10 of models, 201
TolAnalyst module, 364–367, 372–373 tutorials, 205–206
tolerance accumulation, 353–354 triangulation (tessellation)
tolerance analysis, 362–367 defined, 414–415
example, 364 STL files, 417–418
methods of, 362 Trim/Extend feature, 302–303

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 trimming entities, 58 two modeling plans, 86–89
true length dimensions, 139 engineering drawings
true position, 356–357 annotation insertion, 153
turning, 438, 442 assembly drawing creation with bill of
tutorials materials, 154–155
for analysis tools creating, 28–29
flow simulation, 406–407 model-drawing associativity, 155
mass properties calculations, 397–398 title block filling, 153–154
motion analysis, 398–403 view creation, 152–153
static linear analysis, 403–404 feature creation, 121–122
thermal analysis, 405 flap creation, 22–23
assembly models hole wizard usage, 118–119
ball screw creation, 173–174 for injection molding
cam and follower creation, 167–168 block mold creation, 473–477
creating, 29–31 Easter egg mold creation, 484–486
design table creation, 179–180 hemisphere mold creation, 481–484
gear mates, 169–171 mold drawing creation, 487
interference and collision detection, 178 sandbox mold creation, 477–480
motion study creation, 176–177 lighting in scenes, 204–205
part creation in context, 180–182 loft feature creation, 116–118
rack and pinion creation, 171–173 for machining
universal joint motion, 174–176 drilling holes, 450–452
working hinge creation, 168–169 face milling, 452–455
background and scene application, pocket milling, 455–457
203–204 slot milling, 457–459
bolt creation, 123–125 materials and transparency, 205–206
bracket creation, 66–67 motion study creation, 207–210
camera-based animation creation, 210–212 mount plate creation, 65–66
cameras in scenes, 206–207 object color application, 202–203
caster assembly creation, 70–72 pillow block creation, 25–27
coil spring creation, 63–65 pin and bushing bearing creation, 24
compression spring creation, 119–120 for rapid prototyping (RP)
for curves assembly prototype file creation, 422–423
2D curve creation with explicit opening STL files, 423–424
equation, 224 part prototype file creation, 421–422
2D curve creation with parametric for sheet metal
equation, 225 part creation via bending, 310–311
3D curve creation with 3D points, sheet metal creation, 306–307
227–228 sheet metal creation from solid body,
3D curve creation with 3D sketches, 309–310
228–229 sheet metal drawing creation, 308–309
3D curve creation with composite curves, Smart Fasteners wizard usage,
229–230 122–123
3D curve creation with parametric spiral spring creation, 120–121
equation, 225–226 steel washer redesign, 332–334
3D curve creation with projected curves, for surfaces
232–241 artistic bowl creation, 265–267
3D curve creation with projected sketches baseball hat creation, 273–277
on curved faces, 231–232 basic surface creation, 261–264
stethoscope model creation, 241–243 computer mouse creation, 271–273
data exchange hair dryer creation, 277–279
exporting SolidWorks files, 396 oil container creation, 279–281
importing IGES and STEP files, 396–397 surface intersections, 268–269
design intent tablespoon creation, 269–271
design specifications, 91–93 visualization, 264–265
mating conditions, 93–94 sweep feature creation, 114–116
three modeling plans, 89–91 tire and pin creation, 69–70

Index 531

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 for tolerances materials, 199–200
conventional tolerance creation, 367–368 models, 197–198
datum target definition, 370–371 purpose of, 195
geometric tolerance creation, 369–370 resolution, 195
taper tolerances, 371–372 scenes, 196
tolerance analysis, 372–373 textures, 199
for weldments of surfaces, 260, 264–265
weldment creation, 311–313 voids, 467
weldment drawing creation, 313–315 Von Mises stress, 391–396
wheel creation, 67–68
twist vectors, 254
W
warpage, 467
U water eutrophication, 326
under defined sketches, 46 water footprint, 326
undercuts, 470, 471 WCS (working coordinate system), 43–44
undo symbol, 9 Weld Bead feature, 302–303, 304
unfolding sheet metal, 295 weld joints
uniaxial stress tests, 392–393 inspecting, 300
unilateral tolerances, 341–342 types of, 301
union (Boolean operation), 59 weld lines, 467
universal joint motion assembly tutorial, weld symbols, 305–306
174–176 welding
equipment, 300
processes, 299–300
V purpose of, 299
validating file translation, 380–381 weldments
VB (Visual Basic), 112 creating, 299–301
.vda file format, 379 defects in, 300
venting, 470 feature tree, 301–302
verification with rapid prototyping, 413 features, 301–304
vertices (vertex), 40 tutorials
viewing weldment creation, 311–313
multiple parts, 10 weldment drawing creation, 313–315
parts, 10, 61 weld symbols, 305–306
sketch relations, 38 wet machining, 430
sketches, 9 wheel creation tutorial, 67–68
Task Pane (SolidWorks), 9 wire EDM, 439–441
without SolidWorks software, 62 working coordinate system (WCS), 43–44
views working hinge assembly creation tutorial,
creating, 152–153 168–169
exploded, 164–165 worst-case tolerance analysis, 362–363
types of, 146–148 .wrl file format, 379
virtualization software on MacOS, 6
Visual Basic (VB), 112
visualization X
animations, types of, 201–202 .x_b file format, 379
with prototyping, 412–413 .x_t file format, 379
purpose of, 195 .xaml file format, 380
rendering
appearance and transparency, 201
background, 201 Z
cameras, 201 zero-radius programming, 446
complexity of, 195–196 zooming parts, 10
decals, 198–199
lighting, 196–198

532 Index

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