SolidWorks 2010- P6 ppt

Press S on the keyboard, and select the Offset Entities button on the shortcut bar.. The Offset Entities command allows you to create sketch entities that are offset by a specified dis

F i g u r e 3 4 8 Defining the bottom wall thickness of the cutout

3 Do the same on the two vertical rectangle segments that are closest

to the part edges

4 Now all that is left is to define the height of the cutout Select one of

the two segments on the side of the rectangle, and place the

dimen-sion Set the height of the rectangle to be 2 inches in the Modify

win-dow, as shown in Figure 3.49

F i g u r e 3 4 9 Fully defined sketch of the cutout

5 Exit the sketch by clicking the Exit Sketch button in the

confirma-tion corner

Cut Out the Cavity

Since you started the process by clicking the Cut-Extrude button prior to

cre-ating the sketch of the cutout, when the sketch was exited, the Extruded Cut

command automatically initiated This approach reduces the number of mouse

clicks and in the long run will save you time while you are modeling, which is

always a good thing

1 Press Ctrl+7 on your keyboard, or select the isometric view in the

Heads-up View toolbar

2 In the Extrude PropertyManager, set the depth of the extrusion to

be 1.00 inch deep, and click the green check mark to complete the action, as shown in Figure 3.50

F i g u r e 3 5 0 Setting the depth of extrusion in the Extrude PropertyManager

3 Press Ctrl+S on your keyboard or press the Save button on the menu

bar to save the changes you have made to the model Figure 3.51 shows an isometric view of the model so far

F i g u r e 3 5 1 Part model showing a rectangular-shaped cavity cut out

from the bottom

Add Cutout for electronics Cover

When the lamp is manufactured and in use, the electronics and wiring will be housed in the cavity and cannot be allowed to just fall out This could be a huge

cutout that a small plastic cover will sit in The cutout has to be recessed since

this is the side of the base that will ultimately be placed on a desktop, and if it is

above the surface of the base, the base will tilt to one side and be very unstable

To add the cutout, do the following:

1 Press Ctrl+6 or select the bottom view in the Heads-up View toolbar.

2 Press S on the keyboard, and select Cut-Extrude in the shortcut bar.

3 Select the bottom face of the lamp base model to insert a blank sketch.

4 Since the cutout for the cover will follow the outline of the cavity cutout,

you’ll offset the edge rather than create a new rectangle Press S on the

keyboard, and select the Offset Entities button on the shortcut bar

The Offset Entities command allows you to create sketch entities

that are offset by a specified distance from existing sketch entities, model edges, or model faces Using the Offset Entities tool, you’ll off-set the edges of the cavity you created earlier to ensure that the geom-etry for the cover cutout will be updated as dimensions are changed

5 In the Offset Distance field in the PropertyManager, enter the value 1

This is the distance a line will be created from the edge of the cavity

6 Ensure that the Add Dimensions option is selected in the

PropertyManager Without this option selected, the newly created sketch entities will not be defined Also, make sure that the other selected options shown in the previous image are selected

7 In the graphics area, select the bottom face of the cavity to offset the

four edges by the specified dimension

8 Click the green check mark to exit the command and create the

off-set, shown in Figure 3.52

F i g u r e 3 5 2 Creating an offset entity

The lines that are created by the Offset Entities command take

on the Offset Entities relation, eliminating the need for additional relations such as Horizontal or Vertical since these relations should have been applied to the original edges Also, by selecting the Add Dimensions option in the PropertyManager, you’re able to create a fully defined sketch without the need to add more dimensions With the sketch fully defined, all that is left to do is to create the extruded cut

9 By clicking the Extruded Cut command prior to creating the sketch,

you eliminated a couple of extra steps Once the sketch is complete, click the Exit Sketch icon in the confirmation corner to initiate the Extruded Cut command

10 In the Depth field in the PropertyManager, enter the value of 1, and

make sure that the Blind end condition is selected Since these are the only options you need for this feature, click the green check mark to make the cut Figure 3.53 shows the part model with the offset entity

Add Holes for Wiring

In the previous couple of sections, you created a cavity that will eventually be

used to house the wiring and electronics for the lamp But you may have noticed

that there is nowhere for the wiring to go Well, you do, in fact, need to remedy

that, and you are going to do it by creating a hole in the boss from earlier in the

chapter to pass the wires up to the bulb subassembly You’ll also create a hole in

the back of the lamp base that will be used for the AC plug cord First is the hole

for running the wires up to the bulb assembly and the counterbore that will be

necessary for the shaft nut

Sketch a Circle with a Defined Diameter

Here are the steps for adding a hole for the counterbore:

1 If you changed the display style of the part back to Shaded With Edges,

you will need to return to the Hidden Lines Visible view in order to ate the next couple of features In the Display Style pull-down on the Heads-up View toolbar, select the Hidden Lines Visible option

cre-2 Press S on your keyboard, and select Extruded Cut from the shortcut bar.

3 Rotate the part to show the bottom, and select the face on the bottom

of the wiring cavity to insert a sketch for the extruded cut, as shown

in Figure 3.54

F i g u r e 3 5 4 Selecting a face for an extruded cut sketch

The following step is another example of how design intent affects how a sketch is created In the next step, you can easily decide to offset the edge of the round boss to specify the wall thickness, if that was indeed what your design intent required Since the hole going through the boss and counterbore require that the shaft and shaft nut have enough room, you must instead specify the hole diameter

The easiest way to do this is to create a circle and specify the circle diameter in the sketch.

4 Press S on your keyboard, and select the Circle button in the shortcut

bar Press Ctrl+8, or select Normal To in the Heads-up View toolbar

5 To ensure that the circle drawing in the sketch is concentric with the

boss, you will specify that the center of the circle shares the same ter point of the boss Without clicking the mouse button, hover over the edge of the boss with the mouse pointer until the four quadrants

cen-of the circle are shown with small yellow diamonds and the center is displayed with a small circle with a cross, as shown in Figure 3.55

F i g u r e 3 5 5 Drawing a circle concentric with the boss

6 Move the mouse pointer over the center mark for the boss, and press

and release the left mouse button

7 Drag the mouse slowly from the center point to create the circle

When the radius value displayed next to the mouse pointer shows the R value to be somewhere close to 0.500, click and release the left mouse button, as shown in Figure 3.56

8 Press the S key, and click the Smart Dimension button in the

shortcut bar

9 Select the circumference of the circle with the mouse pointer, and

click and release the left mouse button Place the dimension on the

outside of the circle, and enter 1 in the field of the Modify window If

you properly selected the center of the circle, the circle will be shown

as black after applying the dimension, since the location and size of the circle will be fully defined, as shown in Figure 3.57

F i g u r e 3 5 6 Drawing the circle, continued

F i g u r e 3 5 7 Fully defined concentric circle

The sketch with the 1.00≤ circle is what will become the counterbore that

makes room for the shaft nut When the lamp is assembled, the threaded end of

the shaft will be held into place securely fastened to the lamp base with a nut

execute an extruded Cut for the Counterbore

Now it is time to create the actual extruded cut feature that will become the

counterbore Here’s how:

1 Click the Close Sketch icon in the confirmation corner in the

upper-right corner of the graphics area Once the sketch is exited, the Extruded Cut command will automatically be initiated To make the next couple of steps easier, press Ctrl+7 on your keyboard to switch to

an isometric view

2 In yet another example of design intent dictating the modeling of

fea-tures, instead of creating a blind extrusion, you will create the feature

to ensure that a specified wall thickness is met To do this, you will need to select another end condition in the PropertyManager for the Extruded Cut command Click the End Condition field to display the available ways to terminate the feature.

3 To ensure that the wall thickness is properly specified, select the

Offset From Surface option in the End Condition field

4 Although you should not have to select it, you should at least be aware

that the Face/Plane field in the PropertyManager is highlighted and expecting the selection from the graphics area, as shown in Figure 3.58

F i g u r e 3 5 8 Face/Plane field in PropertyManager

The Face/Plane field, when using the Offset From Surface end dition, is the one that will be used to create the theoretically offset terminating plane for the feature created Select the top face of the boss at the top of the lamp base, as in Figure 3.59

con-5 The Offset Distance setting must now be specified in the

PropertyManager As with the Face/Plane field, you should not have to select the field in order to input the value since it should automatically gain focus after specifying the face of the boss In the

Offset Distance field, enter the value 125 to represent the thickness

of material that will be spared after creating the cut, as shown in Figure 3.60 After entering the value, click the green check mark to create the extruded cut.

F i g u r e 3 5 9 Specifying the face for the Extruded Cut offset

F i g u r e 3 6 0 Offset Distance field in PropertyManager

The last feature was the counterbore that will be used for the shaft nut Now

you need to create the hole that allows the shaft to mount to the lamp base

Create the Through Hole for the Lamp Shaft

This feature, like the counterbore, will be defined with another sketch of a circle

with the diameter specified in order to ensure that the shaft will fit properly in

place At this point, you can also switch the view display back to Shaded With

Edges since it will no longer be necessary to see the hidden lines of the model

1 Once again, press S on your keyboard, and click the Extruded Cut

command in the shortcut bar This time, select the top face of the boss to insert a sketch for the extruded cut, as shown in Figure 3.61

F i g u r e 3 6 1 Selecting a face on which to draw the sketch

2 While in the sketch, open the shortcut bar, and click the Circle

command

3 Display the center mark for the edge of the boss by hovering over

the edge with the mouse pointer Specify that the center point of the circle will share the center point with the boss, as in Figure 3.62

F i g u r e 3 6 2 Creating the concentric circle for the thru hole

4 Create the circle, and specify the diameter to be 7, as in Figure 3.63

Exit the sketch to initiate the Extruded Cut command

F i g u r e 3 6 3 Setting the diameter of the circle

5 In the Extruded Cut PropertyManager, change the end condition of

the feature to be Up To Next This will terminate the hole on the next face it encounters, which in the case would be the terminating face of the counterbore

6 Click the green check mark to create the hole The boss with a hole

for the lamp shaft is shown in Figure 3.64

F i g u r e 3 6 4 Boss with a hole big enough for a lamp shaft

Last but not least is the hole for the AC power cord in the back of the lamp base

Create a Through Hole for the AC Power Cord

Even though you will not be going as far as creating the power cord or even the grommet that is snapped into the hole to protect the cord, you should still make sure that the features on this lamp base are as accurate as possible At a later date when you become more comfortable with modeling parts in SolidWorks,

it would be great practice to design these components to finish your assembly

Here’s how to make that hole:

1 Click the Extruded Cut command in the shortcut bar, and select the

back face of the lamp base to insert a sketch for the hole

2 Press Ctrl+8 on your keyboard to change the view to be normal to

the viewing plane

3 With the sketch mode active, select the Circle tool in the shortcut bar.

4 Create a small circle in the lower-left area of the face, and apply a

dimension to the circle by selecting the Smart Dimension tool in the shortcut bar, as shown in Figure 3.65 Make the Diameter of the

circle 400 by entering the value in the Modify window.

F i g u r e 3 6 5 Drawing a circle on the back face of the model

In the future revisions, it may be necessary to specify a new eter for the hole created for the power cord Since you want to ensure that the distance between the bottom edge of the part and the edge

of the hole will always remain the same regardless of the hole eter, you will specify the gap between the edges rather than to the center of the circle

diam-5 From the shortcut bar, select the Smart Dimension.

6 Instead of just selecting the circle to dimension to the center, press

and hold the Shift button on the keyboard while selecting the bottom quadrant of the circle This will specify that you are actually dimen-sioning the edge of the circle, as shown in Figure 3.66

F i g u r e 3 6 6 Selecting a circle while holding Shift to dimension to its tangent

7 While still holding the Shift key, select the bottom edge of the part,

and place the dimension Specify the distance to be 300 in the

Modify window

8 While the Smart Dimension tool is still active, select the circle once

again, and select the sketch origin

9 Place the dimension and specify that the center of the circle will be

2.00 inches from the sketch origin, as shown in Figure 3.67

F i g u r e 3 6 7 Circle with defined diameter, distance from sketch origin,

and distance from bottom edge

10 Once the sketch is fully defined, click the Exit Sketch icon in the

con-firmation corner

11 In the Extruded Cut PropertyManager, change the End Condition

field to Up To Next, and click the green check mark Figure 3.68 shows the lamp base with the newly created holes

F i g u r e 3 6 8 Solid part with holes added

Add Fillets and Chamfers

The main modeling of the lamp base is now complete, but the part is not yet ready to be manufactured Even though the shape and size meet the require-ments of the assembly, all the edges are considered sharp and not very appealing

to the consumer To finish the model, you need to add some chamfers and fillets

to the many sharp edges to soften up the final look and in some cases make the part easier to manufacture

In many designs, a fillet is used to add an overall softer appearance to a part,

and it is rare that a part not utilize a fillet in one way or another A fillet is often

an edge of a part that is rounded to a specified radius Depending on whether the fillet is on the outside or inside corner, the manufacturing process will dif-

fer, but the process in SolidWorks is the same A chamfer is is used a lot less

often in consumer products because it is not as “soft” as a fillet, but removing the edge is the same A chamfer is used to break a sharp edge with an angled edge, often 45° at a specified distance

In the lamp base, you will be using both fillets and chamfers, but how you choose which type to use will mostly depend on the function For example, you can use fil-lets to soften the look of a part or make it easier to machine inside corners, but you can also use chamfers to create lead-in chamfers Especially when it is necessary to insert a part into another part, lead-in chamfers make it easier for the person doing the assembly to quickly find the hole

Add Fillets using FilletXpert

You’ll start by adding fillets to the four corner edges of the lamp base Even though you can individually select each of the four edges separately, you will use the little used FilletXpert to help in edge selection to save time To use FilletXpert, do the following:

1 Press S on the keyboard, and select the Fillet tool in the shortcut bar.

2 In the PropertyManager, instead of selecting each edge in the Items To

Fillet section, click the FilletXpert button located near the top

N O t e The FilletXpert has a number of features that aid in the creation

of fillets The reason for using the FilletXpert in this case is to quickly ate multiple fillets This, in my opinion, is one of the best reasons for using the FilletXpert—it is an amazing time-saver, especially in larger parts

cre-3 With the Edges, Faces, Features, And Loops selection box in the

PropertyManager selected, click one of the four outside edges of the lamp base in the graphics area

4 After selecting the edge, a context toolbar will pop up next to the

mouse pointer allowing you to specify which edge combination the fillets will be applied Hovering the mouse pointer over each button

on the toolbar will highlight the potentially selected edges on the part and will also display a tooltip explaining the selection set For this particular fillet, the outside four edges need to be filleted Click the Connected To End Loop button on the toolbar that shows these edges highlighted, as in Figure 3.69 The four selected edges will be displayed in the PropertyManager

F i g u r e 3 6 9 Selecting the edges to be filleted

5 In the Radius field in the Items To Fillet section of the

PropertyManager, enter the value 250, and click Apply button.