Learning SOLIDWORKS 2022: A Project Based Approach, 4th Edition

Chapter 1

Introduction to SOLIDWORKS 2022

Chapter 2

Creating Axle, Disc Plate, and Rear Axle

Chapter 3

Creating Rim, Front Tire, and Rear Tire

Chapter 4

Creating Caliper Piston, Pad, and Body

Chapter 5

Creating Fork Tube, Cap, Holder, and Bodies

Chapter 6

Creating Handlebar, Handlebar Holders

Chapter 7

Creating Muffler, Swing Arm, Clamp, and Headlight Clamp

Chapter 8

Creating Shock Absorber and Engine Parts

Chapter 9

Creating Mudguards, Fuel Tank, Headlight Mask, and Seat Cover

Chapter 10

Weldment Structural Frames

Chapter 11

Creating Motor Cycle Assembly

Chapter 12

Generating Drawing Views

Learning

SOLIDWORKS 2022: 

A Project Based

Approach

(4th Edition)

CADCIM Technologies

525 St. Andrews Drive

Schererville, IN 46375, USA

(www.cadcim.com)

Contributing Author

Sham Tickoo

Professor

Department of Mechanical Engineering Technology

Purdue University Northwest

Hammond, Indiana, USA

Learning SOLIDWORKS 2022: A Project Based Approach

Sham Tickoo

CADCIM Technologies

CADCIM Technologies

525 St Andrews Drive

Schererville, Indiana 46375, USA

www.cadcim.com

Copyright ©2023 by CADCIM Technologies, USA. All rights reserved. Printed in the United States of America except as permitted under the United States Copyright Act of 1976.

No part of this publication may be reproduced or distributed in any form or by any means, or stored in the database or retrieval system without the prior permission of CADCIM Technologies.

ISBN 978-1-64057-168-6

NOTICE TO THE READER

Publisher does not warrant or guarantee any of the products described in the text or perform any independent analysis in connection with any of the product information contained in the text. Publisher does not assume, and expressly disclaims,any obligation to obtain and include information other than that provided to it by the manufacturer.

The reader is expressly warned to consider and adopt all safety precautions that might be indicated by the activities herein and to avoid all potential hazards. By following the instructions contained herein, the reader willingly assumes all risks in connection with such instructions.

The Publisher makes no representation or warranties of any kind, including but not limited to, the warranties of fitness for particular purpose or merchantability, nor are any such representations implied with respect to the material set forth herein, and the publisher takes no responsibility with respect to such material. The publisher shall not be liable for any special, consequential, or exemplary damages resulting, in whole or part, from the reader’s use of, or reliance upon, this material.

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DEDICATION

To teachers, who make it possible to disseminate knowledge

to enlighten the young and curious minds

of our future generations

To students, who are dedicated to learning new technologies

and making the world a better place to live in

THANKS

To the faculty and students of the MET Department of

Purdue University Northwest for their cooperation

To employees of CADCIM Technologies for their valuable help

Online Training Program Offered by CADCIM Technologies

CADCIM Technologies provides effective and affordable virtual online training on various software packages including Computer Aided Design, Manufacturing and Engineering (CAD/CAM/CAE), computer programming languages, animation, architecture, and GIS. The training is delivered ‘live’ via Internet at any time, any place, and at any pace to individuals as well as the students of colleges, universities, and CAD/CAM/CAE training centers. The main features of this program are:

Training for Students and Companies in a Classroom Setting

Highly experienced instructors and qualified engineers at CADCIM Technologies conduct the classes under the guidance of Prof. Sham Tickoo of Purdue University Northwest, USA. This team has authored several textbooks that are rated one of the best in their categories and are used in various colleges, universities, and training centers in North America, Europe, and in other parts of the world.

Training for Individuals

CADCIM Technologies with its cost effective and time saving initiative strives to deliver the training in the comfort of your home or work place, thereby relieving you from the hassles of traveling to training centers.

Training Offered on Software Packages

CADCIM provides basic and advanced training on the following software packages:

CAD/CAM/CAE: CATIA, Pro/ENGINEER Wildfire, Creo Parametric, Creo Direct, SolidWorks, Autodesk Inventor, Solid Edge, NX, AutoCAD, AutoCAD LT, AutoCAD Plant 3D, Customizing AutoCAD, EdgeCAM, and ANSYS

Architecture and GIS: Autodesk Revit (Architecture, Structure, MEP), AutoCAD Civil 3D, AutoCAD Map 3D, Primavera, and Bentley STAAD Pro

Animation and Styling: Autodesk 3ds Max, Autodesk Maya, Autodesk Alias, The Foundry NukeX, and MAXON CINEMA 4D

Computer Programming: C++, VB.NET, Oracle, AJAX, and Java

For more information, please visit the following link: https://www.cadcim.com

Note

If you are a faculty member, you can register by clicking on the following link to access the teaching resources: https://www.cadcim.com/Registration.aspx. The student resources are available at https://www.cadcim.com. We also provide Live Virtual Online Training on various software packages. For more information, write us at [email protected].

Preface

SOLIDWORKS 2022

SOLIDWORKS, originally developed by the SOLIDWORKS Corporation, USA, was acquired by Dassault Systemes, France, in 1997. Dassault Systemes is world’s leading developer of product life cycle management (PLM) solutions. It is one of the fastest growing solid modeling software. It is a parametric, feature-based solid modeling tool that not only unites the three-dimensional (3D) parametric features with two-dimensional (2D) tools, but also addresses every design-through-manufacturing needs. SOLIDWORKS 2022 includes a number of customer requested enhancements, substantiating that it is completely tailored to address customers needs. Based mainly on the user feedback, this solid modeling tool is remarkably user-friendly and allows you to be productive from day one.

In SOLIDWORKS, you can easily generate the 2D drawing views of the components. The drawing views that can be generated include detailed, orthographic, isometric, auxiliary, section, and other views. You can use any predefined standard drawing document to generate the drawing views. Besides displaying the model dimensions in the drawing views or adding reference dimensions and other annotations, you can also add the parametric Bill of Materials (BOM) and balloons in the drawing view. If a component in the assembly is replaced, removed, or a new component is assembled, the modification will automatically reflect in the BOM placed in the drawing document. The bidirectional associative nature of this software ensures that any modification made in the model is automatically reflected in the drawing views and any modification made in the dimensions in the drawing views automatically updates the model.

In addition to creating solid models, assembly features, and drawing views, SOLIDWORKS enables you to effectively and easily create complex sheet metal components using a number of tools. Apart from modeling and detailing, you can print your solid models directly through 3D printers. You can also define position, orientation and other parameters of the model for 3D printing in SOLIDWORKS.

Learning SolidWorks 2022: A Project Based Approach textbook has been written to help the users who are interested in learning 3D design. Real-world mechanical engineering industry examples and tutorials have been used to ensure that the users can relate the knowledge of this textbook with the actual mechanical industry designs. Some of the main features of the textbook are as follows:

• Project-based Approach

In this textbook, the author has used the project-based approach to explain the tools of SOLIDWORKS and their functioning. This approach guides users in understanding the usage of the tools as well as the procedure to design real world models.

• Coverage of Major SOLIDWORKS Modes

All major modes of SOLIDWORKS are covered in this textbook. These include the Part mode, the Assembly mode, and the Drawing mode.

• Tips and Notes

Additional information related to various topics is provided to the users in the form of tips and notes.

• Learning Objectives

The first page of every chapter summarizes the topics that are covered in the chapter.

• Self-Evaluation Test, Review Questions, and Exercises

Each chapter ends with Self-Evaluation Test that enables the users to assess their knowledge of the chapter. The answers to Self-Evaluation Test are given at the end of the chapter. Also, the Review Questions and Exercises are given at the end of the chapters and they can be used by the instructors as test questions and exercises.

Note

The author has provided additional information to the users about the topic being discussed in the form of Notes.

Tip

Special information on various techniques is provided in the form of Tips that will increase the efficiency of the users.

Formatting Conventions Used in the Textbook

Please refer to the following list for the formatting conventions used in this textbook.

Naming Conventions Used in the Textbook

Tool

If you click on an item in a toolbar and a command is invoked to create/edit an object or perform some action, then that item is termed as tool.

For example:

To Create: Line tool, Smart Dimension tool, Extruded Boss/Base tool

To Modify: Fillet tool, Draft tool, Trim Surface tool

Action: Zoom to Fit tool, Pan tool, Copy tool

If you click on an item in a toolbar and a dialog box is invoked wherein you can set the properties to create/edit an object, then that item is also termed as tool, refer to Figure 1.

For example:

To Create: Extruded Boss/Base tool, Mirror tool, Rib tool

To Modify: Flex tool, Deform tool

Flyout

A flyout is the one in which a set of tools are grouped together. You can identify a flyout with a down arrow on it. A flyout is given a name based on the types of tools grouped in it. For example, Line flyout, View Settings flyout, Fillet flyout, and so on; refer to Figure 1.

PropertyManager

The naming conventions for the components in a PropertyManager are mentioned in Figure 2.

Button

The items in a dialog box that has a 3D shape like a button is termed as Button. For example, OK button, Cancel button, and so on.

Free Companion Website

It has been our constant endeavor to provide you the best textbooks and services at affordable price. In this endeavor, we have come out with a Free Companion website that will facilitate the process of teaching and learning of SOLIDWORKS 2022. If you purchase this textbook, you will get access to the files on the Companion website.

The following resources are available for the faculty and students in this website:

Faculty Resources

• Technical Support

You can get online technical support by contacting [email protected].

• Instructor Guide

Solutions to all review questions and exercises in the textbook are provided in the instructor guide to help the faculty members test the skills of the students. Note that it is compulsory to perform exercises as they comprise some of the parts of the final model.

• Part Files

The part files used in illustrations, examples, and exercises are available for free download. Note that it is compulsory to perform exercises as they comprise some of the parts of the final model.

Student Resources

• Technical Support

You can get online technical support by contacting [email protected].

• Part Files

The part files used in illustrations and examples are available for free download.

You can get additional information at https://allaboutcadcam.blogspot.com

If you face any problem in accessing these files, please contact the publisher at [email protected] or the author at [email protected] or [email protected].

Video Courses

CADCIM offers video courses in CAD, CAE Simulation, BIM, Civil/GIS, and Animation domains on various e-Learning/Video platforms. To enroll for the video courses, please visit the CADCIM website using the link https://www.cadcim.com/video-courses.

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CHAPTER 1

Introduction to SOLIDWORKS 2022

Learning Objectives

After completing this chapter, you will be able to:

• Understand how to start SOLIDWORKS

• Understand the system requirements to run SOLIDWORKS

• Understand various modes of SOLIDWORKS

• Work with various CommandManagers of SOLIDWORKS

• Understand various important terms in SOLIDWORKS

• Save files automatically in SOLIDWORKS

• Change the color schemes in SOLIDWORKS

Introduction to SOLIDWORKS 2022

Welcome to the world of Computer Aided Design (CAD) with SOLIDWORKS. If you are a new user of this software package, you will be joining hands with thousands of users of this parametric, feature-based, and one of the most user-friendly software packages. If you are familiar with the previous releases of this software, you will be able to upgrade your designing skills with this improved release of SOLIDWORKS.

SOLIDWORKS, developed by the SOLIDWORKS Corporation, USA, is a feature-based, parametric solid-modeling mechanical design and automation software. SOLIDWORKS is the first CAD package to use the Microsoft Windows graphical user interface. The use of the drag and drop (DD) functionality of Windows makes this CAD package extremely easy to learn. The Windows graphic user interface makes it possible for the mechanical design engineers to innovate their ideas and implement them in the form of virtual prototypes or solid models, large assemblies, subassemblies, and detailing and drafting.

SOLIDWORKS is one of the products of SOLIDWORKS Corporation, which is a part of Dassault Systemes. SOLIDWORKS also works as platform software for a number of software. This implies that you can also use other compatible software within the SOLIDWORKS window. There are a number of software provided by the SOLIDWORKS Corporation, which can be used as add-ins with SOLIDWORKS. Some of the software that can be used on SOLIDWORKS’s work platform are listed below:

SOLIDWORKS Motion                                                                 SOLIDWORKS Routing                                        ScanTo3D                                 eDrawings

SOLIDWORKS Simulation                                                           SOLIDWORKS Toolbox                                         PhotoView 360                         CircuitWorks

SOLIDWORKS Plastics                                                               SOLIDWORKS Inspection                                    TolAnalyst

As mentioned earlier, SOLIDWORKS is a parametric, feature-based, and easy-to-use mechanical design automation software. It enables you to convert the basic 2D sketch into a solid model by using simple but highly effective modeling tools. It also enables you to create the virtual prototype of a sheet metal component and the flat pattern of the component. This helps you in the complete process planning for designing and creating a press tool. SOLIDWORKS helps you to extract the core and the cavity of a model that has to be molded or cast. With SOLIDWORKS, you can also create complex parametric shapes in the form of surfaces. Some of the important modes of SOLIDWORKS are discussed next.

Part Mode

The Part mode of SOLIDWORKS is a feature-based parametric environment in which you can create solid models. In this mode, you are provided with three default planes named as Front Plane, Top Plane, and Right Plane. First, you need to select a sketching plane to create a sketch for the base feature. On selecting a sketching plane, you Enter the sketching environment. The sketches for the model are drawn in the sketching environment using easy-to-use tools. After drawing the sketches, you can dimension them and apply the required relations in the same sketching environment. The design intent is captured easily by adding relations and equations and using the design table in the design. You are provided with the standard hole library known as the Hole Wizard in the Part mode. You can create simple holes, tapped holes, counterbore holes, countersink holes, and so on by using this wizard. The holes can be of any standard such as ISO, ANSI, JIS, and so on. You can also create complicated surfaces by using the surface modeling tools available in the Part mode. Annotations such as weld symbols, geometric tolerance, datum references, and surface finish symbols can be added to the model within the Part mode. The standard features that are used frequently can be saved as library features and retrieved when needed. The palette feature library of SOLIDWORKS contains a number of standard mechanical parts and features. You can also create the sheet metal components in this mode of SOLIDWORKS by using the related tools. Besides this, you can also analyze the part model for various stresses applied to it in the real physical conditions by using an easy and user-friendly tool called SimulationXpress. It helps you reduce the cost and time in physically testing your design in real testing conditions (destructive tests). You can also analyze the component during modeling in the SOLIDWORKS windows. In addition, you can work with the weld modeling within the Part mode of SOLIDWORKS by creating steel structures and adding weld beads. All standard weld types and welding conditions are available for your reference. You can extract the core and the cavity in the Part mode by using the mold design tools.

Assembly Mode

In the Assembly mode, you can assemble components of the assembly with the help of the required tools. There are two methods of assembling the components:

1. Bottom-up assembly

2. Top-down assembly

In the bottom-up assembly method, the assembly is created by assembling the components created earlier and maintaining their design intent. In the top-down method, the components are created in the assembly mode. You may begin with some ready-made parts and then create other components in the context of the assembly. You can refer to the features of some components of the assembly to drive the dimensions of other components. You can assemble all components of an assembly by using a single tool, the Mate tool. While assembling the components of an assembly, you can also animate the assembly by dragging. Besides this, you can also check the working of your assembly. Collision detection is one of the important features in this mode. Using this feature, you can rotate and move components as well as detect the interference and collision between the assembled components. You can see the realistic motion of the assembly by using physical dynamics. Physical simulation is used to simulate the assembly with the effects of motors, springs, and gravity on the assemblies.

Drawing Mode

The Drawing mode is used for the documentation of the parts or the assemblies created earlier in the form of drawing views. The procedure for creating drawing views is called drafting. There are two types of drafting done in SOLIDWORKS:

1. Generative drafting

2. Interactive drafting

Generative drafting is a process of generating drawing views of a part or an assembly created earlier. The parametric dimensions and the annotations added to the component in the Part mode can be generated in the drawing views. Generative drafting is bidirectionally associative in nature. Automatic BOMs and balloons can be added to an assembly while generating the drawing views of it.

In interactive drafting, you have to create the drawing views by sketching them using normal sketching tools and then add dimensions to them.

System Requirements

The system requirements to ensure the smooth functioning of SOLIDWORKS on your system are as follows:

• Microsoft Windows 10, Windows 8.1 or Windows 8 (64 bit only) or Windows 7 (SP1 required).

• Intel or AMD Processor with SSE2 support.

• 2 GB RAM minimum (8 GB recommended).

• Hard disk space 5 GB minimum (10 GB recommended).

• A certified graphics card and driver.

• A word processing program.

• Adobe Acrobat higher than 8.0.7 or any similar program.

• DVD drive and Mouse or any other compatible pointing device.

• Microsoft Internet Explorer version 8 or higher.

Getting Started With

S

OLID

W

ORKS

Install SOLIDWORKS 2022 on your system; on doing so, a shortcut icon of SOLIDWORKS 2022 will automatically be created on the desktop. Double-click on this icon; the system will prepare to start SOLIDWORKS and after sometime, the SOLIDWORKS window will be displayed on the screen. On opening SOLIDWORKS for the first time, the SolidWorks

License Agreement dialog box will be displayed, as shown in Figure 1-1. Choose the Accept button in this dialog box; the SOLIDWORKS 2022 window will open and the SOLIDWORKS Resources task pane will be displayed on the right. Also, the Welcome - SOLIDWORKS 2022 dialog box will be invoked simultaneously, as shown in Figure 1-2. This window can be used to open a new file or an existing file.

If the SOLIDWORKS Resources task pane is not displayed or expanded, choose the SOLIDWORKS Resources button located on the right side of the window to display it. This task pane can be used to open online tutorials and to visit the website of SOLIDWORKS partners. Choose the Part button from the Welcome - SOLIDWORKS 2022 SP1.0 dialog box or the New button from the Menu Bar to create a new document. If you start a new document using the New button from the Menu Bar then the New SOLIDWORKS Document dialog box will be displayed, as shown in Figure 1-3.

Note

If you are starting SOLIDWORKS 2022 for the first time, then on invoking the New SOLIDWORKS Document dialog box or the Welcome - SOLIDWORKS 2022 dialog box, the Units and Dimension Standard dialog box will be displayed, as shown in Figure 1-4. Using this dialog box,you can specify the default units and;dimension standards for SOLIDWORKS. In this book, the unit system used is MMGS (millimeter, gram, second) and the dimension standard used is ISO.

Choose the Part button to create a part model and then choose OK from the New SOLIDWORKS Document dialog box to Enter the Part mode of SOLIDWORKS. Hover the cursor over the SOLIDWORKS logo; the SOLIDWORKS Menus will be displayed on the right of the logo. Note that the task pane is automatically closed once you start a new file and click in the drawing area. The initial screen display on starting a new part file of SOLIDWORKS using the New button in the Menu Bar is shown in Figure 1-5.

Tip

In SOLIDWORKS, the tip of the day is displayed at the bottom of the Welcome - SOLIDWORKS 2022 dialog box. You can click on the arrows to view additional tips. These tips help you use SOLIDWORKS efficiently. It is recommended that you view at least 2 or 3 every time you start a new session of SOLIDWORKS 2022.

It is evident from the screen that SOLIDWORKS is a very user-friendly solid modeling software. Apart from the default CommandManager shown in Figure 1-5, you can also invoke other CommandManagers. To do so, move the cursor on a CommandManager tab and right-click; a shortcut menu will be displayed. Choose the required CommandManager from the shortcut menu; it will be added. Besides the existing CommandManager, you can also create a new CommandManager.

Menu Bar And SOLIDWORKS menus

In SOLIDWORKS, the display area of the screen has been increased by grouping the tools that have similar functions or purposes. The tools that are in the Standard toolbar are also available in the Menu Bar, as shown in Figure 1-6. This toolbar is available above the drawing area. When you move the cursor to the arrow on the right of the SOLIDWORKS logo, the SOLIDWORKS menus will be displayed, as shown in Figure 1-7. You can also fix them by choosing the push-pin button.

CommandManager

You can invoke a tool in SOLIDWORKS from four locations, CommandManager, SOLIDWORKS menus on top of the screen, toolbar, and shortcut menu. The CommandManagers are docked above the drawing area. While working with CommandManager, you will realize that invoking a tool from the CommandManager is the most convenient method to invoke a tool. Different types of CommandManagers are used for different design environments. These CommandManagers are discussed next.

Part Mode CommandManagers

A number of CommandManagers can be invoked in the Part mode. The CommandManagers that are extensively used during the designing process in this environment are described next.

Sketch CommandManager

This CommandManager is used to Enter and exit the 2D and 3D sketching environments. The tools available in this CommandManager are used to draw sketches for features. This CommandManager is also used to add relations and smart dimensions to the sketched entities. The Sketch CommandManager is shown in Figure 1-8.

Features CommandManager

This is one of the most important CommandManagers provided in the Part mode. Once the sketch has been drawn, you need to convert the sketch into a feature by using the modeling tools. This CommandManager contains all the modeling tools that are used for feature-based solid modeling. The Features CommandManager is shown in Figure 1-9.

MBD CommandManager

This CommandManager is used to add dimensions and tolerances to the features of a part. The MBD CommandManager is shown in Figure 1-10.

Sheet Metal CommandManager

This CommandManager provides you the tools that are used to create the sheet metal parts. In SOLIDWORKS, you can also create sheet metal parts while working in the Part mode. This is done with the help of the Sheet Metal CommandManager shown in Figure 1-11.

Mold Tools CommandManager

The tools in this CommandManager are used to design a mold and to extract its core and cavity. The Mold Tools CommandManager is shown in Figure 1-12.

Evaluate CommandManager

This CommandManager is used to measure the distance between two entities, add equations in the design, calculate the mass properties of a solid model, and so on. The Evaluate CommandManager is shown in Figure 1-13.

Surfaces CommandManager

This CommandManager is used to create complicated surface features. These surface features can be converted into solid features. The Surfaces CommandManager is shown in Figure 1-14.

Direct Editing CommandManager

This CommandManager consists of tools (Figure 1-15) that are used for editing a feature.

Data Migration CommandManager

This CommandManager consist of tools (Figure 1-16) that are used to work with the models created in other packages or in different environments.

Assembly Mode CommandManagers

The CommandManagers in the Assembly mode are used to assemble the components, create an explode line sketch, and simulate the assembly. The CommandManagers in the Assembly mode are discussed next.

Assembly CommandManager

This CommandManager is used to insert a component and apply various types of mates to the assembly. Mates are the constraints that can be applied to components to restrict their degrees of freedom. You can also move and