3D

Advanced (Inventor) – 2016 Lesson 1

3D Paths

3D sketches or geometry can be created using a number of different methods, but regardless of
how they are created they can be used to provide a 3D sketched path for other processes such as
sweep and loft.

Using Existing Geometry:

Existing geometry can be selected to define a path for an operation without creating a separate 3D
sketch entity.

Create the above sketch profile and extrude it 50mm

Place a 25mm fillet on the edge indicated

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Create a new sketch on the face shown Create the profile shown and finish the sketch

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Activate the Sweep feature. The sketch profile should be automatically selected. Pick the edges
in the order shown to define the path of the sweep using the existing geometry.

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Note that the selected path will preview. Make sure that the ‘cut’ option is selected. Click OK.

The sweep feature removes material along the 3D path using the profile created.

NOTE: When creating swept paths such as these, it is difficult for the program to have the profile
sweep around the path and then intersect itself at the start point. If this is required (a sweep along
a fully enclosed loop) then you may need to create a work plane for the profile sketch part way
along one of the path edges so that when the profile is swept it does not intersect itself at an
angle.

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Creating a 3D Sketch

We can also define a 3D sketch as a separate entity before we create the feature. This is an
additional step in some cases, but it also adds the 3D sketch to the project browser, making it an
editable and sharable part of the feature and can provide an additional level of control.

Pick ‘Start 3D Sketch’ Pick the ‘Include Geometry’ option

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2
1
5

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Pick the geometry required Click Finish Sketch

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Now you will follow the same process as before to activate the Sweep command and select the
profile and 3D path. Make sure that you select the 3D ‘sweep path’, not the individual edges which
will still be available.

Creating a ‘Freestanding’ 3D Sketch using the ‘Precise Input’ option

Using the Precise Input option requires that XYZ co-ordinate values be used to define each point
that is required, so some calculation is usually necessary. You have the option of placing points in
3D space first and then joining them using the line, arc and spline tools or you can use the precise
input option to draw these objects in the first instance.

Draw and Join 3D Points

Start a new 3D sketch Select the Draw Point tool

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Click on the Draw pallet pulldown bar and make sure that ‘Precise Input’ is selected. This will
mean that the Precise Input option will be available whenever you are defining a point in 3D
space.

Relative or Absolute values for input can be selected at any time. Make sure that you have picked
the correct option depending on the data/information you have.

You will now define the 3D location of the first point. LMB click inside the X value field.
1. Input the X value required
2. TAB
3. Input the Y value required
4. TAB
5. Input the Z value required
6. ENTER
This will place a single green 3D point on the screen. LMB click again in the X value field and
repeat this process to create all subsequent points.

1. 0,0,0
2. 25,25,0 (relative)
3. 0,0,50 (relative)
4. 50,0,0 (relative)
5. 25,-25,-25 (relative)

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 4
5
2

Now, STILL IN 3D SKETCH MODE, Draw a 3D line connecting the five points in order.

Now activate the bend tool. This is used like the fillet command in 2D sketching.

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Apply a 10mm radius bend to each corner. Note that the dimension of each bend can be edited if
needed. Finish the sketch.

Create a workplane at the starting point that is normal to the path (Normal to axis, through point)

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Sketch and dimension/constrain two circles concentric with the start point on the workplane. OD is
15mm and wall thickness is 1.2mm. Finish the sketch.

Sweep the ‘pipe wall’ profile along the 3D path and turn off the visibility of the workplane.

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Alternative method – 3D points from 2d sketches
You may also create a 3D path by creating a number of sketches on offset workplanes containing
constrained 2D points. Then use the 3D point tool to snap 3D points to the 2D points and then
draw the 3D line as above. The advantage of this technique is that the location of the points is
referenced and controlled within 2D sketches using standard dimensioning and constraint
techniques. The downside is that it can take significantly longer to do and can create a large
number of unused 2D sketches that would then need to be made invisible.

Using one of the origin planes plus three workplanes placed 50mm apart, draw the four points
shown. The first point is on the origin plane and coincident with the origin point.

Now create a new 3D sketch and snap a 3D line to each of the 2D points in turn. Make sure that
you select each point carefully.

Finish the 3D sketch and turn off visibility for the work planes and sketches used. Now the 3D
path created can be used as previously shown.

NOTE: Dimensions and some geometric constraints can be applied in 3D sketches just as they
are in 2D sketches. Keep this in mind when doing your exercises and apply this as needed. 3D
sketch geometry can be difficult to edit – hence the suggested use of 2D sketch points to control
3D locations.

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Create a 3D Sketch Coil / Helix

The 3D sketch Helix or Coil feature can be used to create solid models of coil springs and similar
items, or can be used to remove material to create specialist machine thread profiles. The feature
also allows the creation of spiral features – essentially a coil that does not have a height but
instead spirals outwards from a centre point.

Regardless of which is chosen, the first step is to provide geometry that can be used to define the
AXIS of the feature. The rest of the specifications are controlled through Helical Curve dialog box.

1. Create a sketch on the XY plane. Place and constrain a single 2D point on the origin.

2. Create a new work plane; offset 250mm from the XY plane.

3. Create a new 2D sketch on the work plane and place and constrain a single 2D point to the
origin.

4. Select 3D Sketch from the ribbon and then select the “Helical Curve” tool.

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5. The two 2D points created make up the end points of the helical curve axis – select them to
define the axis.

6. Left click to set the diameter of the helix, but then specify the diameter/ pitch/ height/
revolutions in the dialog box as well as the direction of rotation.

7. Select ‘Revolution and Height’ – note that a flattened ‘spiral’ can also be created…

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8. Set the height to 250mm and the revolutions to 1. Click OK.

9. A 3D helix is created – this can be used as a 3D path for sweep and loft features.

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Use Helix to create a screw ‘thread’ form

Specialist machine threads can be created using a 3D helix path to sweep a profile which cuts
material away from an existing cylindrical solid.

Create a cylinder 60mm in diameter and 200mm long.

Create offset work planes at each end, 50mm from the circular faces.

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Create sketches on both of the work planes and constrain a single point so that it coincides with
the centre axis of the cylinder.

Create a 3D sketch and select Helical Curve. Pick the 2 points to define the axis of the helix,
specify ‘Pitch and Height’ as type and specify a pitch of 50mm. Click OK.

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The 3D helix sketch should now appear to wrap around the surface and exist past both ends of the
cylinder. Finish the 3D sketch.

Place a workplane ‘normal to curve/through point’ at one end of the helix.

Create a new sketch on this workplane. Create a new 2D sketch using the workplane and
constrain a 20mm diameter circle to the end point of the helix. You may have to project geometry
to do this. Finish the sketch.

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Now use the sweep command to sweep the profile along the helix and cut material away, leaving
a helical groove on the surface of the cylinder.

Turn off visibility of the various work planes and 2D sketches.

Note that the location of the two offset workplanes and the profile sketch will control how the swept
profile terminates relative to the solid. In this example the sweep runs off the ends of the cylinder.

Finally, edit the sweep profile to be different shapes and note the affect.

Additional Exercise:
Use a similar process to cut a spiral path from the surface of a flat disc.

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3D Advanced (Inventor) – 2016 Lesson 2

CREATING SPLIT FEATURES

A split divides a feature into two separate pieces. A split references an existing feature and an
additional separation sketch or plane.

Inventor allows you to split a feature two different ways, depending on the purpose. One
option is to keep existing feature geometry and split feature faces. Another option is to remove
a section of an existing feature.
Create the part shown in Fig. 1.

Fig. 1.

SPLIT FACE
1. Make front face (A) current sketch face
2. Draw line and dimension
3. Finish sketch
4. Select the Split tool from the Modify pallet in the 3D Model tab.

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Splits a face. Allows you to
split one face
Splits the whole solid. only.
Inventor will prompt for
a direction to determine
which piece will remain.
Splits all faces
Splits solid but both at once.
pieces remain.

5. Leave the selections as per the dialogue box above and select the sketched line.
6. Select the face on which the line was drawn.
7. Select

You can now see by moving the mouse over the original face that it has been split into two
separate faces.

Now UNDO so that you return to the sketch prior to the split.

1. Select split
2. Select split face method
3. Select sketched line
4. Select the left button under faces to split All Faces
5. Pick the front face marked A in Fig. 1
6. Pick the opposite face
7. Select
8. The front and rear faces are now split

Note: Keep this part for the next topic.

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SPLIT PART

* Use previous part but delete the split line sketch used above.

Create two parts using spline geometry

1. Create sketch plane on face “A” from Fig.1.

2. Place four points on sketch plane.
3. Dimension the points as shown below and draw a spline (interpolation method) through
them.

Hint: To finish the spline LMB click on the ‘Tick’ icon that appears on screen…

4. Finish Sketch
5. Activate the Split tool and select the options shown to split a solid part.

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 6. Split part to remove the top of the shape

7. SAVE the file as ‘Split 1 BASE’

8. Now edit the Split feature and toggle the remove option so that the bottom of the solid is
removed.
9. Now save drawing using FILE - SAVE AS and name the new version ‘Split 1 TOP’

You have now used the Split feature to split both single and multiple faces and to create split or
segmented parts.

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 CREATING FACE DRAFT FEATURES

The face draft feature can be used to apply a taper or ‘draft’ to a selected face. It is common to
create a face for drafting using the split face tool outlined above.

Create the part shown below.

Select the Draft feature tool from the Modify pallet on the 3D Model tab.

A
B
C

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There are a number of options that are available in the Face Draft tool that will control the
exact form that is created.

A. Fixed Edge:
 This is where ONE edge of each of the faces selected will remain fixed, while the other
edges of those faces will move depending on the shape of the face and the draft angle
specified.
 The fixed edge selected is the edge on each face which is closest to the point where the
face was selected, so care must be taken in how faces are picked on screen. Note that
the fixed edge is highlighted in purple when selecting faces.
 This is the best option to use if drafting just a single face or if drafting multiple faces that
don’t all share edges with a common plane.

Fixed Edge method. Note that the top edges of the longer faces are fixed, while the bottom
edges of the shorter faces are fixed.

B. Fixed Plane:
 This is where faces are drafted with fixed axis all existing around or on a selected
common plane.
 The fixed plane does not have to be a solid face, but can be a work plane located so
that it passes through all the faces to be drafted to control the draft geometry.

Fixed Plane method. A work plane has been placed midway between the top and bottom
faces. Each selected face is then drafted so that it moves around the axis that is formed from
the intersection of it and the fixed plane. In other words, the shape retains it original
dimensions only where is passes through the fixed plane.

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C. Parting Line:
 A sketched line is placed on one face and this is used as a ‘break’ in the direction of the
draft.
 Pull direction will control the taper direction of the part of the split face which is closest to
it – the other part of the face will draft in the opposite direction.

Parting Line method. A line has been placed on a sketch to divide the face to be drafted into
two pieces. The same result could be achieved by using the face split tool and then drafting
both faces separately.

D. Pull Direction:
 Controls the direction that the selected faces are angled or taper. The direction of the
arrow denotes the direction in which the face/s will taper inwards.
 The pull direction is NORMAL (90deg) to the face that is selected to define it.
 Pull direction can be switched using the ‘flip’ button.

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3D Advanced (Inventor) – 2016 Lesson 3

EMBOSS AND ENGRAVE

Inventor will emboss (add material to) or engrave (remove material from) on an existing solid
model surface. Either text or enclosed loops/profiles can be used to define the shape that is to
be added or removed from the surface.

EMBOSS A PROFILE ON A FACE

Follow the example below to use the emboss feature.

 Create the 175x75x30 rectangular prism shown above.

 Create a new 2D sketch on the top face – marked A.

 Create the new sketch shown above using 20mm high text. Make sure that the text is
centered both horizontally and vertically and that the text box is constrained so that it
will remain centered in the sketch. (Hint: the offset command will come in handy here…)

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  Finish the sketch and activate the Emboss feature tool.

A B C D

The Emboss dialog box (above) allows you to both Emboss and Engrave.

 A – Profile selection. Only enclosed loop profiles or text can be selected.

 B – Emboss option. Will add material to the specified height to an existing face or
surface.
 C – Engrave option. Will remove material to the specified depth from an existing face or
surface.
 D – Emboss/Engrave from Plane. Will either add material or remove it to align the new
surface to the sketch plane.

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 The profile selection will allow you to pick both the enclosed region between the
sketched rectangles with the R10 and R5 fillet corners and the text itself.
 Specify the emboss option and ensure that the direction arrow on the model is pointing
upwards and coloured green. This means that material will be added in the direction of
the arrow.
 Click OK

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ENGRAVE A PROFILE ON A FACE

Now edit the Emboss feature from the previous example and modify it to engrave the same
sketch profile and text.

 Note that the direction arrow on the model should be red and face downwards, into the
surface to be engraved.
 Change the depth to 5mm.
 Click OK.

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EMBOSS / ENGRAVE A PROFILE FROM A PLANE

The ‘emboss/engrave from plane’ option allows you to both remove and add material at the
same time using a single sketch and feature. The extent of the material added or removed is
controlled by the location of the sketch plane.

 Start a new part and create and constrain the sketch profile shown above.
 Finish the sketch and EXTRUDE the profile 75mm.

 Create a new work plane that is mid-way between the two 50x75 horizontal faces.

 Create the same sketch as in the first example. This time the text is 12mm high but is
still centered within the sketch.
 Finish the sketch.

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  Start the Emboss feature command and select the same profiles as before.
 This time pick the Emboss/Engrave to Plane option and specify the ‘symmetrical both
directions’ option.
 The preview should show a blue arrow pointing both up and down perpendicular to the
sketch plane.
 Click OK.

The resulting model shows material both added and removed. Because no depth is specified
it will add/remove whatever depth is needed.

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If you edit the original profile sketch as shown above you will be able to see how this feature
operates, removing or adding material as needed to align the new surface/s to the sketch
plane.

If only one direction is specified it will either add or remove material from the sketch plane to
the surface of the solid in the direction of the blue arrow…

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EMBOSS AND ENGRAVE – WRAP TO FACE

This option allows embossing or engraving to be applied to a face that is not parallel to the
sketch plane.

 Start a new part and create and constrain the sketch profile shown above.
 Finish the sketch.
 Extrude the profile 75mm.

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 Create a work plane as shown; parallel to the base of the object and offset 70mm
upwards to ensure that is sits above the curved surface AND CLEAR OF THE
INTENDED EMBOSSED FEATURE.

 Create and constrain a new sketch on the work plane as shown above and similar to
that used in previous exercises.
 The text is 12mm high and centered in the sketch.
 Finish the sketch.

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 Activate the Emboss feature tool.
 Select the profile and text as in previous exercises.
 Specify the height / depth of the embossing or engraving required.
 Select the ‘Face’ selection option and select the curved face that the sketch is to be
wrapped on to.
 Click OK.

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SPECIAL NOTE:

It is not uncommon to have text or objects orientate themselves backwards on sketch planes
that are based on work planes, such as in the example above.

If this happens, follow this simple procedure:-

 Finish the sketch to get back to the 3D modelling mode.
 In the project browser, LMB click to select the Work Plane on which the sketch is based.
 RMB click and select ‘Flip Normal’ – existing objects in the sketch will ‘flip’.

 Edit the sketch that was created based on the Work Plane.
 Now add the text or objects selected and they should be shown in the correct
orientation.

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 RIBS AND WEBS

Ribs and webs are physical features which are often added to or made part of a component in
order to add strength or stiffness while keeping the weight of the component or the amount of
material used to a minimum. The term ‘web’ should not be confused with the same word when
it is used to describe the central piece that joins the flanges of a rolled steel section such as a
beam, column or channel.

‘Web’ ‘Rib’

CREATE A RIB OR WEB

Follow the exercise below to create both a rib and a web using the same initial sketch.

 Start a new part and create and constrain the sketch shown above.
 Finish the sketch.

 Extrude the profile 100mm.

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 Create a work plane, offset 30mm inwards from one end of the section.
 Create a new 2D sketch on the work plane.

 Create and constrain the sketch geometry as shown above. Note that everything in the
sketch except the single angled line should be made construction lines, including any
projected geometry.
 Finish the sketch.

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  Activate the Rib feature tool.

A B
C

The software should select the single line you have sketched automatically because the other
lines in the sketch are construction.
 Select ‘A’ – the parallel to sketch plane option.
 Specify ‘B’ – the thickness of the feature.
 Specify ‘C’ – the direction of the thickness relative to the sketch plan.
 Click OK.

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The Rib feature is created as shown.

Now edit the feature to create a Web.

 Select the Web option

 Specify the height of the web. This will be measured perpendicular to the sketched line.
 Click OK.

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A web feature is created.

We can also create multiple ribs/webs at the same time, but to do so we must create a single
sketch that defines them. This means that the rib/web will have to be projected perpendicular to
the sketch plane.

 Create a new work plane using the two co-planar edges as shown.
 Create a new 2D sketch on the work plane.

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 Sketch and constrain the lines as shown.
 Make sure any other lines or projected geometry are made construction lines.
 Finish the sketch.

 Activate the Rib feature tool.

 Make sure that the Normal to sketch plane option is highlighted.
 Select the two lines as the profiles to be used.
 Specify the thickness and direction.

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  Note that you can also apply the same options for webs as previously.

 Other ribs or webs can also be added with additional sketches.

The import point to remember is that to create a rib or web, the solid geometry that is used to
confine its extents must already exist… it must have a surface at which to stop.

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 RIB FEATURE OPTIONS

NOTE: The following options are only available when creating ribs or webs normal to the sketch
plane.

Draft
The draft option allows an angle or taper to be applied to rib features. This is particularly important
in the case of cast or molded parts as it allows for their release from the mold and better flow of
the material used to form the part.

Boss
A boss is a volume of additional material which is added to a rib. It is normally placed to allow
extra material for drilling holes or to provide a larger surface area for load bearing points within an
assembly.

A boss will require that a point, constrained to be coincident with a sketch line which defines the
centre of a rib or web, be included as part of the sketch.

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Rib with Boss Exercise

 Start a new part and create a 100x50x75 rectangular prism as above.

 Use the shell feature with a wall thickness of 5mm and remove one of the 100x50 faces as
shown.

 Create a sketch on the surface of the open side.

 Project the edges of the opening into the sketch.
 Place and constrain a single line between the mid points of the two short sides.
 Place and constrain two points on this line using dimensions as shown. (A function
dimension of the length of the single line divided by 4 was used in this example.)

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  Activate the Rib feature tool.
 Specify a rib thickness of 5mm.
 In the ‘Boss’ tab, ensure the centers are selected, specify Diameter = 15, Offset = 0 and
Draft angle = 5
 Click OK.

The Rib feature created will include the boss structures required. Note that a separate draft angle
can also be applied to the rib itself at the same time using the Draft tab, as already outlined.

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3D Advanced (Inventor) – 2016 Lesson 4

 
COPY FEATURES 
 
Features can be copied from the model or from within the browser, and then be placed in a different 
location or on a different face within the model. 
Note: You can use the same copy function and process to also copy the selected feature into a 
different open part file. 
 
1. Create the bracket shown in Fig. 1. 

   
Fig. 1.              Fig. 2. 
 
2. Place two work planes 30mm from and parallel to each end. See Fig. 2. 
3. Create a sketch on one work plane and create and constrain the geometry shown in Fig. 3. 
Make sure to use the co‐linear constraint as shown. 

Apply co-linear
constraint
between
sketched line
and solid edge
on both sides.

 
Fig. 3. 
 
4. Finish sketch and extrude the new profile 12mm using Mid‐plane. 

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5. Copy the new Extrude feature by… 
a) RMB click over the feature in the browser and select Copy. 
   OR 
b) Move cursor on to feature in the graphics window and select it. Then RMB click and 
select Copy. 
6. LMB click to clear selection then RMB click in the graphics window and select Paste. The 
following dialogue box will appear. 

 Independent allows you

to edit the original
feature without affecting
any of its copies.
 Dependent allows you
to edit copies of the
feature without affecting
the original but if you
edit the original it will
modify any of its copies
that are dependent.

 
a) ‘Pick Profile Plane’ by selecting the second work plane. 

     
b) Note that the preview image above is not in the correct orientation.  Change the angle 
value in the dialog box to correctly orientate it. 

2
    
c) The feature will not be accurately positioned so LMB click and hold the move symbol 
(see white cross in image above) and drag the feature into approximately the correct 
position on screen, then click Finish. 
d) Note that the new extrusion now exists in the project browser. Edit the sketch and 
apply constraints as done previously.  The new sketch will also contain any projected 
geometry from the original sketch, so this will need to be deleted. Your part should look 
like Fig.4. 

 
Fig. 4. 
 
 
   

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 MIRROR FEATURES 
 
The Mirror Feature tool mirrors features about a work plane, straight edge or planar face on the part. 
 
Create the part shown in Fig. 1. below. 

 
Fig. 1.              Fig. 2. 
Add to the front of the part a 20 X 30 long extrusion and add a M20 x 2.5 thread for 20mm of its length. 
See Fig. 2. 
 
To Create a Mirror of a Feature 
1. Create a work plane through the centre of the part as seen in Fig. 3. 
2. Select the Mirror feature from the Part Features Panel. 
 

     
3. Ensure that the ‘Mirror Feature’ option is selected on the left of the dialog box. 
4. Select the extrusion AND the thread feature.  Note that it is often easier to do this in the 
project browser than in the graphics window. 
   

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 5. Select the ‘Mirror Plane’ button and then select the work plane.  The mirror action should 
preview as shown below. 

 
6. Click OK 

 
        Fig. 3. 
   

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 SUPPRESS FEATURES 
You can suppress part features to temporarily turn off their display. Feature suppression can be used 
to simplify parts, which also increases system performance, as well as restoring geometry to be used in 
subsequent sketches. 
 
Note that suppressing a feature will also automatically suppress any sketches and features that are 
already dependent on it. 
 
1. Create the part shown in Fig. 1. 

R32

R20

 
Fig. 1.                Fig. 2. 
2. Create the R20 and R32 fillets shown in Fig. 2. using the fillet feature tool in 3D solid mode. 
3. In order to complete the part by adding the extrusion shown in Fig. 3 you must suppress at 
least the R32 fillet:‐ 
a) Move the cursor over the fillet feature in the browser which created the R32 fillet 
b) Right mouse button click. 
c) Select “Suppress Feature” 
 
 
 

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 Fig. 3  
 
4) Create sketch as shown in Fig. 3. and Extrude – Cut 
Note!  The extrusion is positioned from the  edge that would not be there if the fillet was not suppressed. 
 
To Unsuppress a Feature 
Right mouse button click over the feature in the browser and select Unsuppress Feature 

 
 
Often the use of suppressed feature geometry in sketches, such as in this case, can lead to problems or 
errors when the model is refreshed.  This may not mean that the model fails, but the system will notify 
you of the issue and highlight it in the Project Browser using an exclamation mark icon, as shown 
below. 
 

     
 
In order to maintain a stable and predictable model, it is always better to avoid these issues and fix 
them immediately should they show up.  This can sometimes be done by ‘reordering’ the existing 
features or by temporarily moving the EOP (End Of Part) marker – a process often referred to as 
‘Rollback’. 
 
Keep the exercise used above for the next section where reordering and rollback are discussed.

7
 REORDER FEATURES 
 
If we consider the example used in the previous section, we can see that the order that the work was 
carried out in could be modified to avoid the need to suppress features which then created the 
unresolved reference issue. 
 

 
 
To reorder a feature, it is simply a matter of using the LMB to select, grab and drag the feature up or 
down the Project Browser tree to place them in their new location.  Features will only move to 
locations that will not result in other issues being created. 
 

       
 
Click and drag the R32 fillet feature to move it below the last extrusion.  This will mean that the edge 
from which the 23mm dimension was taken in the sketch of the ‘T’ shaped cutout is still in place when 
that sketch is created and the fillet is only applied after the cutout is made. 
 
As shown above this removes the ‘unresolved reference’ issue that resulted from unsuppressing the 
R32 fillet. 
 
Note that it is not possible in this example to grab the cutout extrusion (Extrusion 2) and drag it up the 
browser tree to sit above the R32 fillet (Fillet 1).  This is because the cutout extrusion also relies on the 
R20 fillet (Fillet 2) to some degree.  To overcome this issue it would be necessary to delete the R20 
fillet and create it again at the end of the part / project browser tree. 
 
 
 
   

8
MOVING THE ‘END OF PART’ (EOP) or FEATURE ‘ROLLBACK’ 
 
Just like the individual features can be moved within the project browser tree as shown in the previous 
section, the End Of Part (EOP) marker can also be used.  Essentially this ‘rolls back’ the work done on 
the part so that it behaves as if this last feature in the tree before the EOP marker was the last action 
taken.  Once the EOP marker has been moved, any new features added to the part will be placed 
directly above the EOP. 
 
Start a new part and create and constrain the sketch shown below. 

   
 
Finish the sketch and extrude the profile 30mm. 
 

   
Place and constrain a new sketch on one of the faces as shown above.  Extrude – Cut the 25x25 square 
profile through the part in both directions (symmetrically) using the extents option ‘ALL’. 
 

    
Create and constrain another sketch on one face as shown above.  Extrude – Join the Ø75 circle using a 
distance of 10mm. 

9
Note that the square hole (Extrusion 2) does not also cut through the last Ø75 extrusion.  This might be 
expected, but reordering the features so that the square hole occurs AFTER the Ø75 extrusion does not 
necessarily fix this depending on the face the Ø75 sketch was placed on and the extent and direction 
options used for the Ø75 extrusion. 
 
Moving the EOP before creating the sketch for the last extrusion, however, will fix this issue. 
 
Use ‘UNDO’ to return the model to its state before starting the Ø75 sketch. 
 

   
Select and drag the EOP up the project browser tree so that it sits immediately below the first 
extrusion. 
 

     
Now create and constrain the Ø75 circle sketch, finish the sketch and extrude it 10mm. 
 

10
  
Finally, click and drag the EOP back to the bottom of the project browser tree.  This, in effect, creates a 
reordering of the features in the project browser, but does so without the risk of subsequent issues 
with unresolved geometry. 
 
Minimising file size using EOP 
 
Another advantage to relocating the EOP in a part file is that it reduces the size of the file itself.  This 
happens as the data generated to create graphical representation of any features below the EOP is not 
needed. 
 
Although this is not likely to be used within an office or design studio on a regular basis, files may be 
able to be made smaller to enable them to be sent to other users via email.  Should you receive a file 
and it not appear complete, check the location of the EOP marker in the project browser. 
 

 
Moving the EOP to the top of the project browser minimizes the file size but means that the part does 
not display.  Placing the cursor over the features in the browser highlights feature geometry in a 
dashed wireframe style as shown above. 

11
3D Advanced (Inventor) – 2016 Lesson 5

Using Parameters
Parameters enable better control of part geometry and also enable the modification of sketch 
geometry and some feature specifications using the parameters table, instead of editing individual 
sketches of features. 
 
Create the sketch below for the Flange Plate (drawing AP‐1).  Ensure that the formulas detailed 
below are used to specify dimensions as shown in the drawing. 
NOTE: Don’t use the offset command for this example as we want to be able to control the 
Edge Width and Edge Height separately. 

C  B

C 

 
 A = Length = 300 
 B = Width = 150 
 C = A / 6 
 D = B / 3 
Finish the sketch. 
 
Open the parameter file by clicking on the parameter icon at the top of the screen or in the 
Manage tab. 

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The parameters table is displayed as below.  You may see some variation from what is shown 
depending on exactly how you defined the various dimensions. 
 
Model parameters can be renamed by clicking in the Name column. 

 
 
Rename the 300mm dimension and ‘Length’ and the 150mm dimension as Width. 

 
Note that the list may re‐order itself as you rename the various parameters. 
 
Once you have done this, click DONE. 
 
   

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Extrude the Flange 10mm and click OK. 

 
 
Open the parameters table again. 
Note that two parameters have been added to the list – in this case d9 (the extrusion distance) 
and d10 (the extrusion taper angle). 

 
 
Rename the 10mm extrusion parameter as ‘Thickness’. 

 
Click DONE. 

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Now you will create a rectangular pattern of points to place hole features on using parameter 
values. 
 
Create a new sketch on the face of the flange and draw ONE centre point.  Use the rectangular 
pattern tool and the formula dimensions as shown on the drawing to layout 2 rows and 9 columns 
of points as shown. 
 

B 

A
 
 Horizontal distance = Length / 10 
 Vertical distance = Width / 4 
 
To use or access these parameters, left click on the arrow and then select ‘List Parameters’ 
 

    
 
Select the parameter required and then type in the rest of the function used to control the 
dimension value. 

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NOTE: If you remember the parameter names needed you can also simply type the names of the 
parameters into the dimension edit dialog, but note that they are case sensitive. 
 
When applying the rectangular pattern to create the rest of the points you can also use the 
parameters as shown below. 

 
 
Now finish the sketch and create a new hole feature that will select 18 points you have created 
and use parameters to define their size. 

 
 Depth = ‘Thickness’ 
 Diameter = ‘Thickness/2’ 
 
 Click OK. 

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Once the pattern is created you can edit the parameters to give each new one a name.  Note 
below all the new parameters created by the rectangular pattern and hole feature. 

 
 d11 = Horizontal Hole from Edge Offset 
 d12 = Vertical Hole from Edge Offset 
 d13 = Number of rows 
 d15 = Row spacing 
 d16 = Number of columns 
 d18 = Column spacing 
 d21 = Hole diameter 
 d26 = Hole depth 
 
 
 
 
Now that you have created a 
parametric part and customised the 
Parameters Table, try modifying the 
values of the length, width and 
thickness in the table and observe the 
changes that take place. 
   

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Other Parameter Functions: Complex Driven Constraints 
 
Parameters and parameter functions can also be used within assemblies to ‘drive’ secondary 
constraints by using the first, driven parameter as a function within (and so modify) the second.  
This means that as the first parameter changes the second one automatically changes as well and 
the assembly updates accordingly. 
 
Follow the exercise outlined below in order to explore this relationship. 
 
Create the following parts 
 
Part 1 – Threaded Pin Base 

 
 
Part 2 – Threaded Moving Plate 

 
 
 Start a new assembly file. 
 Place and ground the Threaded Pin Base part 
 Place the Moving Plate part 
 Constrain the two parts as shown below 

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 Use a Mate constraint between the 
axis of the hole in the moving plate 
and the axis of the 100mm pin. 

 
 

Use an Angular constraint between 
one edge face of the Moving Plate 
and one edge face of the Base 
Plate.

 
 

Use a Mate constraint between one 
face of the Moving Plate and the 
opposing face of the Base Plate.  
Use an Offset value of zero. 

  
Save the Assembly file    

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 Open the Parameters table by selecting the Parameter icon in the Manage tab. 

 
 

 
The parameters shown above relate to the default values applied to each of the three constraints 
applied. 
d1 = Offset of the axis to axis mate constraint 
d2 = Rotation angle of the angular constraint 
d3 = Offset distance of the face to face mate constraint 
 
Update/modify the parameter names as shown below. 
NOTE: Spaces and special characters cannot be used in parameter names 

 
 
   

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Now we will modify the value/function of the Plate_separation parameter so that it depends on 
the value of the Plate_rotation value. 
 

. 
 
Input the Equation shown above:‐ 
(Plate_rotation / 360 deg)*10 
 
This means that for every 360⁰ of rotation, the distance between the two plates will increase by 
10mm.  This is essentially describing a thread pitch and means that when the angular constraint is 
driven, the face to face offset value will change in proportion to it. 
 
Drive the Primary Constraint 
 

 
 
In the Project Browser expand the Moving Plate part and LMB click to select the Angle constraint, 
then RMB click and select ‘Drive’. 
 

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 Fill in the Drive Dialog box as shown above. 
 Click on the PLAY button. 
 Note that the settings used above will mean that the Moving Plate will rotate and move to 
the end of the pin before reversing and returning to the start position.  This process will 
repeat up to 10 times. 
 Try modifying the parameter formula to change the ‘pitch’. 
 Modify the Increment and other settings and observe the results. 
 Note that a video of the animation can also be created. 
 
Special Functions / Conditional Arguments in Parameter Formulas 
 
Following is a list of the basic Parameter functions which can also be used as part of formulas in 
the parameters table. 
Syntax  Unit  Description 
floor  Unitless  Returns next lowest whole number ‐ eg 3.33 returns 3 
ceil  Unitless  Returns next highest whole number ‐ eg 4.25 returns 5 
round  Unitless  Returns nearest whole number ‐ eg 3.65 returns 4 
abs  Any  Returns absolute value ‐ eg abs(3*‐4) returns 12 
max  Any  Returns largest of two expressions ‐ eg max(3*2;2*4) returns 8 
min  Any  Returns smallest of two expressions ‐ eg max(3*2;2*4) returns 6 
isolate  Any  Used to convert the units of an expression ‐ eg isolate(Length;mm;ul) 
where Length parameter = 100mm, returns 100ul 
 
For further information on more complex model control refer to the Inventor ‘iLogic’ programming 
feature now included with the Inventor Professional software. 

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Inventor Advanced – 2016 Lesson 6

Driving Constraints
Constraints that have been added to parts within an assembly can then be ‘driven’.  This means 
that they can be made to change across a specified range using a specified ‘step’ between each 
solution.  Graphically, this generates an animation of the actual motion of the parts within the 
assembly and this animation can then be recorded as a ‘video’ format multimedia file. 
 
Driving a constraint is essentially specifying a change to an existing offset or other constraint 
value, such as an angle. 
 
Note that a driven constraint cannot override another existing constraint, so care must be taken to 
ensure that all the constraints applied in an assembly still allow for the realistic motion of each 
component. 
 
Driving a ‘mate’ type surface constraint: 
Mate type constraints (either face‐to‐face or flush) are commonly driven to produce linear motion. 
 

 
The above assembly comprises two parts, the ‘bed’ and the ‘slide’. Note that the ‘bed’ is grounded
as we wish the slide to move relative to the bed, not the other way around. The two mate
constraints have set the slide into the bed, while the flush constraint restricts the slides movement
along the bed. It is this Flush constraint that we will ‘drive’ to produce the movement required…
 

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RMB click on the constraint to be driven in the project browser and select ‘Drive’…
 

     
A dialog box showing default values is shown… Edit the values to those required…
 

 
The expand button provides further options; including the ability to have the constraint ‘cycle’ a
specified number of times or to detect clashes between parts during motion. Note that surface
clearances can become critical if collision detection is used. When complete click on the ‘Play’
button…
   

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Driving an ‘angular’ type constraint: 
Angular constraints are commonly driven to produce rotational motion.  If one or both of the parts 
to be driven using this method does not include a flat surface that can be used to apply an angular 
constraint, it is common to add a work plane to the part to use instead. 
 

 
The base is grounded and the pin is constrained to it using an insert constraint. An angular
constraint is added between the flat faces of the two parts…
 

 
Drive the angular constraint by selecting it in the project browser with a RMB click…

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Use the repetition option to have the motion cycle back and forth a number of times…
 
Driven constraint motion can be recorded as a video file in the same way as ‘exploded’ .IPN 
animations.  Click on the Record button and set up the video file type, location and settings and 
then click play to create the video. 
 
Exercises: 
Drive appropriate constraints in your previous assembly files and create animated videos of the 
results. 
 

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Driving Complex Constraints with Parameters
Complex motion involves using the value of a driven constraint to define a second parameter 
which then varies in proportion (using a formula) to the driven constraint and controls a secondary 
constraint or offset value. 
 
For example, a driven angular constraint can be used can be used to also vary the offset of a mate 
or insert constraint… 
 

The base and the pin are constrained using the insert constraint…

Pause the cursor over the Insert constraint in the browser to see its parameter number (d0 in this
example)…

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The pin is fixed from turning using an angular constraint between it and the edge of the base…

Pause the cursor over the Angle constraint in the browser to see its parameter number (d8 in this
example)…

You can now open the parameter table and alter the value for one of these constraints to a 
formula so that it will automatically vary depending on the value of the other. 

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Change the value of the insert offset (d0) to “(d8/360 deg)*2.5mm”. Inventor will input the ‘ul’ at
the end automatically if you do not provide the correct units and this can adversely affect the
outcome. Now the value for the insert offset will equal the number of turns (angle d8 divided by
360) multiplied by the ‘pitch’ (2.5mm). Click Done and now drive the angular constrain so that it
runs in 10deg increments from 0 to 3600 degrees…

Note: In order to get the formula to work correctly you must specify all units as shown. 
 
Note: Depending on the order that the constrained objects were selected in you may find that the 
motion travels in the wrong direction – be aware of this and correct as required. 
 

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Inventor Advanced – 2016 Lesson 7a

Advanced Views for Assembly Drawings

Several more advanced view types are available which are often used within assembly drawings – 
particularly section views, detail views, break‐outs and break views. 
 
Section Views: 
A sectional or section view is created by ‘cutting’ an existing view along a specified plane and then 
viewing the resulting surfaces from normal to the cutting plane. 
 

 
Place the view that is to be sectioned on the sheet…
 

 
Activate the Section View tool…

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Select the view to be sectioned, then using snap points or tracking where possible click to create the
line along which the new view will be sectioned. Note that part section views can be created by
selecting three or more points, hence defining two or more section lines at the one time…
 

 
Once the section line is defined, RMB click and select ‘continue’…

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Now use the cursor position to place the new section view on the drawing sheet…
 

 
The view setting for the new view can be edited as per normal views…
 

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The view label can be moved by LMB click and drag and edited by double LMB clicking it. Add
text required and delete any fields not required. Note that the grey coloured ‘field’ text inserts and
updates automatically, so it always best to use these when possible…
 
Note that if an assembly is sectioned, the section display will follow the normal rules, with no shaft 
or fastener feature being sectioned. 
 
   

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Detail Views: 
A sectional or section view is created by ‘cutting’ an existing view along a specified plane and then 
viewing the resulting surfaces from normal to the cutting plane. 
 

 
With an existing view on the screen that you wish to create a detail view from, active the Detail
View tool. Now sect the view that the detail is to be created from…
 

 
A dialog box will appear allowing you to set view name, scale, etc. Note that these can also be
changed after the view is created…
 

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You will now draw the shape nominated which will define the extent of the detail view…
 

 
Now place the detail view on the drawing sheet…

 
Note that the detail extents are shown on the parent view and the text given as the view title is
shown on both the extents and the detail view itself. Detail views can be dimensioned using the
same methods as normal views…

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Break‐out Views: 
A break‐out view is used like a section view, to show hidden features within an assembly, but a 
break‐out view only cuts away a small portion of the surrounding material or part/s. 
 
To create a break‐out view you must also create a ‘sketch’ profile which is associated with the 
view that is being ‘sectioned’ by the view. 
 

 
First create a sketch of the breakout area associated with the view by first selecting the view…
 

 
Then go to the Annotate tab and select the create sketch tool…

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Use the draw tools to sketch a fully enclosed loop profile that defines the breakout area. Once
complete, click Finish Sketch…
 

 
Now return to the place views tab. Select the Break Out tool…

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You will be asked to select the view – make sure it is the one with the sketch associated with it. The
program may automatically select the profile if there is only one available. Now select a point on
the drawing which will act as the base or ‘from’ point on the view. The depth of the break out will
be measured from this point and the depth value acts as an ‘offset’ from this point. Note that you
can also select to section all parts, or just those down to the depth point specified using the
standard sectioning rules…
 

 
A Break Out view can be used to show detail within an assembly when a complete section view is
not required…

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Break Views: 
A break view is most often used to shorten an object in a view so that it ends can be shown at a 
larger scale.  The middle section of the object which is not shown is then assumed to be consistent 
in size or cross section.  Think of objects like pipes or shafts that may have specific detail at each 
end, but are uniform for much of their length. 
 
Note the object below.  In order to fit it on to the page it has been inserted at a smaller scale.  At 
this scale it would be difficult to include the dimensions needed at each of the ends.  
 

 
The above object cannot be displayed to the required scale on a single sheet due to it length…
 

 
In the Place Views tab select the Break view option and then select the view that requires the break
to be added…

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You can select the style, orientation and number of break symbols to be shown, as well as the gap
that will appear between the two ‘broken’ sections…
 

 
Click on the view near one end of the elongated section to place the first break, then click again
near the other end…

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The view is now shortened with the break symbol appearing in the middle. Note that the dimension
is still correct. You can alter the location of the break on each side simply by clicking and dragging
it with the cursor…
 

 
You can now alter the scale of the view so that it will display more clearly on the selected sheet size.
Note that you could also set the scale as desired first, then break the view to make it fit the sheet…

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Inventor Advanced – 2016 Lesson 7b

Exploded Views
Exploded views allow the operator to create views and animations which show details on how 
components might be assembled.  To create an exploded view in Inventor the operator will create 
and manipulate ‘tweaks’ and ‘trails’ which are applied within an Inventor presentation file, called 
an ‘.IPN’ file. 
 
.IPN Files: 
An .IPN file (Inventor Presentation file) is created from an existing Assembly.  It will show a 3D 
model of the assembly but will allow for the movement of different parts within the assembly 
(tweaks) without affecting the original assembly file itself or needing to break the existing 
assembly constraints.  Each tweak or movement of a part within the file creates a ‘trail’, which 
traces the movement of the part in 3D space.  This process can then be animated and recorded to 
create a video file that might be used to assist in product development, maintenance or sales. 
 

 
The above assembly has been created and now needs to be placed into an ‘.IPN’ file to create an
exploded model and subsequent animation…
 

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Start a new presentation file by selecting the ‘Standard (mm).IPN metric template…

 
Select ‘Create View’ to bring an existing assembly into the Presentation environment…

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The software will automatically select an assembly if there is only one open, or you may chose from
the list of open assemblies or click the browse button to access saved assembly files…

 
The assembly will appear on the screen. Now create ‘tweaks’ by selecting the ‘Tweak Component’
tool. Each tweak created will move one part by a defined distance in one direction…

Note: Tweak directions are relative to the XYZ axis which is associated with the part being moved, 
not the XYZ axis shown in the bottom right hand corner of the presentation screen which comes 
from the assembly.  If you find that a part moves in a direction that is not consistent with the rest 
of the model, you may need to add a constraint to the assembly file to correct the problem.  This is 
common for cylindrical parts that use the ‘insert’ constraint as there is often no control or 
constraint to prevent them from being rotated around their axis. 
 

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Select the part to be moved by LMB clicking and dragging it in the direction desired. Note that an
XYZ axis appears within the part in red and that movement is relative to this axis…

 
The direction and distance the part was moved will be inputted into the dialog box on screen and
the distance can then be manually edited to an appropriate number…

 
Now click on the next ‘transformation’ (movement) to be applied. Select X, Y or Z to apply positive
or negative movement along that axis or the rotational transformation to make an object spin
around the selected axis. All transformations can be edited and reordered later if required…

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Creating a trail such as the one shown below with 3 tweaks will mean inputting
direction/distance/rotational data and then clicking the green tick icon 3 times…
 

 
 
Below is the same process – this time shown step by step…
 

 
Select then click and drag part in first direction…

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Update distance to an appropriate number then click the green check mark button…
 

 
Select the next direction relative to the axis displayed in red, input a distance and click the green
check mark button…
 

 
Repeat to apply the last of the three directional transformations…
 

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Use a rotational transformation to spin the part, click the green check mark button, then close.
Each transformation has now been saved as part of the presentation…
 

 
Now open the animation list by selecting the ‘animate’ option…
 

 
Each trail created is shown in the sequence list. The first one created is at the bottom of the list…

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To edit a trail, go back to the main screen and double LMB click on the trail (the actual line on the
screen to be edited…
 

 
The Tweak dialog box appears, make the required changes here and click the green check mark
button and then close…
 

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Once satisfied that the trails are as required return to the animation dialog box…
 

 
 The ‘interval’ setting controls the speed and smoothness of each transformation – the higher
the number the smoother but slower the movement will occur.
 The ‘repetitions’ setting controls how many times the animation will run through each time
it is activated.
 The ‘motion control’ buttons work to start, stop, pause and rewind the animation, while the
red ‘record’ button starts the video file creation process. It is normally best to also
minimise the dialog box during recording…

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Transformations can be selected in the sequence list and moved up or down as required to change
their order…
 

     
Transformations can be selected together (using the control button to select them) and then
grouped, so that they will occur at the same time, otherwise the sequence will run one
transformation at a time from one end to the other…
 

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Selecting an individual transformation which is grouped with others allows for it to be
‘ungrouped’…
 
Now play the created animation to see how it works.  Make further changes to both trails and 
animation features to access their effect and operation. 

Recording Animations: 
Once tweaks and trails are created and the animation sequence is set and tested, it is time to 
record the animation.  This process creates a video file which can then be used and viewed by 
others that may not have the Inventor software.  As previously mentioned such videos are 
particularly good for training, maintenance, demonstrations, displays and sales.  They can also be 
used to demonstrate an assembly process to others involved in the same, similar or related 
projects. 
 

 
Click on the record button…

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Select the video file type, name and location and then click SAVE…

Select file compression technique if required and configure to suit needs…

.WMV video files will require appropriate network speed and image size settings to be selected.
Note that videos should always be kept to a minimum size depending on their intended use…

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With the red record button turned on, click on the play button to start recording. When complete
the screen will return to its previous appearance…
 
 

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Inventor Advanced – 2016 Lesson 8

Creating Derived Components

New parts can be derived from existing ones, so that the new solid is dependent on the
existing one and will update if the original is changed. The differences between this
process and that used to create ‘Adaptive’ components are that we do not require an
assembly file and that the entire solid body of the existing part can be used at the same
time – not just selected geometry.

Exercise 1:
1. Copy the Part File ‘Derived Part Casting.ipt’ into your own folder.

2. Open a new .ipt file, but instead of creating your own geometry using sketches etc
you will bring the geometry of an existing part into the model. Select the Derive tool
from the Create panel of the 3D Model tab or from the Manage tab.

3. Select the Derived Part Casting file from your folder. Click OPEN.

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 4. The Derived Part Dialog will appear. Select the ‘Body as Work Surface’ option at
the top of the dialog. Note that at this point you can also change the scale of the
part and/or mirror the part about a plane. Click OK.

5. The part will now appear in the model as a translucent orange surface.

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 6. Create a new sketch by selecting the flat face of the surface part. The objective is
to now create a solid body that will be used to part the solid leaving only the
‘negative’ mould shape behind.

7. Draw a rectangle around the object face and dimension it so as to provide sufficient
material around the surface object.

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 8. Finish the sketch and extrude it in the direction of the surface object so that the
surface is fully contained within the solid.

9. Select the Split tool from the modify panel. The solid to be selected is the extrusion
just created, while the Split Tool is the surface object itself. Note that you may need
to edit the split once done so that the direction of the split (hence the part that is
retained) is as needed.

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 10. This should leave the extruded block with the derived surface removed from it.

11. Since the derived surface is still visible and will be in the way if you are trying to
select other surfaces, it is best to turn off its visibility.

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Exercise 2:
1. Copy the ‘Derived Part Back Plate.ipt’ file to your own folder.

2. Open a new .ipt file and then bring in ‘Derived Part Back Plate.ipt’ as a surface.

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 3. Create a sketch on one face as shown.

4. Extrude the sketch 10mm

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 5. Create a new rectangular sketch on the back of the 10mm extrusion which covers
the area that does not sit on the derived surface.

6. Extrude this sketch TO the other side of the derived surface object.

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 7. Create a new sketch on the newly extruded solid.

8. Create a rectangular sketch region that covers part of the derived surface object
below it.

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 9. Extrude the sketch another 10mm.

10. Turn off the visibility of the derived surface object.

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 11. Now edit both the sketch and the extrusion of the original Back Plate model. Then
save the file.

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 12. Use the Update tool in the manage tab OR the icon in the shortcut toolbar to update
the derived features in the new part.

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Inventor Advanced – 2016 Lesson 9

Using the Frame Generator

The frame generator is a way of quickly creating steel frame structures in the 3D
environment. The frames are created within an assembly based on the geometry of a
placed 3D Part, 2D or 3D sketch.

Open a new .ipt file and create a 2D sketch of a 1200x600 rectangle. Make sure that it is
fully constrained.

With only the sketch completed, save the .ipt file as ‘Frame.ipt’.

Open a new metric assembly (.iam) file.

Place the .ipt file that was saved as ‘Frame.ipt’ into the assembly.

Save the assembly file as ‘Frame.iam’.

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Go to the Design Tab and select the Insert Frame tool.

The ‘frame generator’ dialog box will appear –

 Select ‘AS’ from the standards list
 Select AS3679-1990 Universal Beam from the family list
 Pick 150 UB – 14 from the size list
 Material = Steel, Mild
 Appearance = As material
 Select the centre most of the nine positional icons to determine orientation
 Offset values can be specified
 Pick a rotation angle as required to position the frame member correctly in the
preview
 Select the first placement option to pick an existing sketch line (or part model edge).
It is also possible to use start and end points (the second icon/button) to define the
member.
 With the select arrow highlighted pick/define each member of the frame (in this case
the four lines of the sketched rectangle)

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Once the preview looks correct click Apply.

Click OK twice to save the part files generated to create the frame. Double check to make
sure the new parts are being saved into the correct folder.

Click Cancel to get out of the frame generator. The frame has been created as below.

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Edit the original skeleton frame sketch in the .ipt file to add 3 equally spaced 600mm long
lines within the rectangle.

Save the ‘Frame.ipt’ file and return to the assembly – the sketch should have updated.

Reactivate the Insert Frame tool. Specify 100mm PFC, Select the three new sketch lines
Rotate the new members if necessary. Specify a vertical offset of 25mm to align the tops
of the members with the top surface. Click Apply

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Click OK.
Click OK to save new parts.

Use the Frame Editing tools to create intersections as required…

Use Mitre to create 45deg mitres on front corners. Note that you can also specify a gap
between the members which is often required when pieces are to be welded together.

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Use ‘Trim to Frame’ tool to extend rear member to align with outer faces of left and right
end members.

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Note that these relationships can be edited by expanding the part in the project browser
and double clicking on the relationship that needs to be modified.

Use the ‘Notch’ tool to notch each end of the 3 PFC members to fit into the beam profiles.

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Note that this removes the overlapping volumes between the members.

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Using the ‘Create Part’ Option for a Top Down Frame Assembly

Just like in standard assemblies, new parts can be created from within Frame assemblies
which means you will now be working in ‘Top Down’ mode.

Go to the Assembly tab, select Create tool.

Name the new part that will be created. MAKE SURE TO SPECIFY THE CORRECT
METRIC TEMPLATE FILE LOCATION.

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Click on the rear face of the rear member to base the new part on. This will create a new
part which can then be used to base further frame members on.

Create a new 2D sketch and pick the rear face of the web of the rear UB member as the
new sketch plane.

Project the geometry of the two side UB members so that a second frame can be sketched
that is 800mm high and constrained to the centre lines of the side UB members.

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Finish the sketch then click on the ‘Return’ button.

Place 50x50x4mm RHS on sketch lines.

Use ‘Trim to Frame’ to finish top corners.

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The frame should now look as below.

Create another new part named ‘Top Horizontal Frame.ipt’ (METRIC TEMPLATE!)
Use the top surface of the top 50x50x4RHS to base the part and sketch plane on.
Project geometry from the edge of the top 50x50x4 RHS and add the three lines as shown.

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Finish the sketch and ‘Return’.

Add a frame of 30x30x2 RHS steel orientated ‘inside and below’ the 3 sketch lines as
shown.

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Click OK and mitre the front corners of the 30x30x2 RHS top horizontal frame.

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Inventor Advanced – 2016 Lesson 10a

A Little Bit of Background about Welding

 
Welding in its most primitive forms has been used by man for thousands of years, but what we 
understand as welding today has only been developed since the industrial revolution and 
following the widespread availability of pressurised gases and/or electricity. 
 
There are four main types of metal welding that are commonly used in industry today and the 
technique selected for any particular job may vary depending on:‐ 
 Availability of the necessary equipment and the personnel that are able to use it 
 Availability of the resources needed (such as electricity) 
 The materials to be welded and the physical properties (eg strength) required from the 
resulting item 
 The conditions where the welding is to be carried out (eg indoors, outdoors, dry, wet, 
windy, difficult access) 
 Speed of the process selected 
 Overall cost of the process selected 
 
The four types of welding in common use are:‐ 
 Thermal welding – also called ‘oxy‐acetyene’ welding or just ‘oxy’ or ‘gas’ welding 
 Manual Metal Arc Welding (MMAW) – also commonly called ‘stick’ welding 
 Gas Metal Arc Welding (GMAW) – often called MIG welding 
 Gas Tungsten Arc Welding (GTAW) – also called TIG welding 
 
In very crude terms, each of these methods work as outlined below. 
 
Thermal Welding uses a flammable gas or mix of gases and a torch to create a hot flame that can 
be directed onto the weld area.  This flame is used to either: 
a) Heat a metal filler rod that has a lower melting temperature than the metal being joined.  
The weld metal flows into the joint and ‘sticks’ to the parent material fusing them 
together. 
b) Heat the parent material (either with or without a filler rod being added) so that it melts 
and fuses together at the ‘molecular’ (microscopic) level. 

 
Source: http://www.dixonsgas.co.uk/gases/industrial‐gases/welding/welding‐gas/ 

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Thermal equipment can also be used to cut or ‘gouge’ metal. 
 
Manual Metal Arc Welding uses a flux covered electrode (also called a rod or stick) and an electric 
current.  An electric arc is struck between the end of the electrode and parent material.  The heat 
of the arc melts the electrode which forms a molten pool of material in the surface of the material 
being joined.  The parent metal also melts and so fuses together.  The flux covering on the 
electrode helps direct the arc, can add elements to the material within the weld, removes 
impurities from the weld pool and also forms a hard flux or ‘slag’ layer over the weld as it cools to 
protect it from oxygen and nitrogen in the air, which can affect the quality and strength of the 
weld. 

 
Source: https://en.wikipedia.org/wiki/Shielded_metal_arc_welding 

 
Source: http://www.northerntool.com/shop/tools/category_welding+arc‐stick‐welding+arc‐stick‐welders 
   

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Gas Metal Arc Welding is similar to MMAW in that an electrode is consumed by the process and 
added to the weld material.  Instead of using a flux covered electrode, GMAW uses a continuous 
roll of bare wire which is mechanically feed into the weld pool through a hand piece.  Instead of 
flux, this process uses a shield of inert gas (normally argon or an argon/carbon dioxide mix) which 
comes out of the handpiece around the wire electrode to keep atmospheric gases away from the 
molten weld metal. 

    
Above Left ‐ Source: http://www.cutterweldermaestro.com/best‐mig‐welder‐reviews/ 
Above Right ‐ Source: https://www.millerwelds.com/resources/article‐library/mig‐welding‐for‐street‐rods 

 
Source: http://www.engineerstudent.co.uk/mig_welding.php 
 
   

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Gas Tungsten Arc Welding also uses an electrical arc to create an intense, high temperature weld 
pool and a gas shield to protect it from impurities, but any additional weld material is added using 
a hand held filler rod.  The tungsten electrode within the handpiece is not consumed by the 
process. 
 

 
Source: http://www.welderbros.com/best‐tig‐welder‐reviews 
 
 

 
Source: https://www.quora.com/What‐is‐the‐difference‐between‐TIG‐MIG‐welding 
 
   

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Each of these techniques have their own advantages and disadvantages and the method selected 
will depend on the conditions and needs of the particular job in question. 
 
Process  Materials  Advantages  Disadvantages 
Commonly Welded 
Thermal  Mild steel, alloy  Mobile, doesn’t need  Welds generally not as strong; 
Welding  steels, copper,  electricity; safer in damp  highly flammable gases create 
brass, (aluminium)  conditions; lower temps have  hazards; can’t be easily used on 
less effect on parent material  thicker materials (>2mm) 
properties 
MMAW  Mild Steel, alloy  Portable if power available  Flux/slag creates more clean up 
steel, stainless  (mains or generator); creates  after weld; flux electrodes react 
steel  strong weld; better for  badly to moisture; slower than 
thicker materials (2‐12mm);  GMAW; increased skill level of 
works well on site and in  operator needed for quality 
windy conditions  welds; high heat input will 
create distortion 
GMAW  Mild Steel, alloy  Fast, cheap and relatively  Size of equipment means not 
steel, aluminium  easy to use once set up;  easily portable; windy 
lower skill level required by  conditions affect gas shield 
operator; can be more easily 
adapted to automated / 
robotic welding; works well 
on a large range of material 
thicknesses (1.5‐20mm); less 
clean‐up than MMAW 
GTAW  Mild steel, alloy  Can produce neat, fine, high  Slower than GMAW; higher skill 
steels, stainless  quality welds; moderate skill  level required by operator for 
steel, aluminium,  level required; used on large  quality welds; windy conditions 
non‐ferrous metals  range of materials and  affect gas shield 
thicknesses; less clean‐up 
than MMAW; equipment 
more portable than GMAW 
 

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Types of Welds 
 
The most common types of weld are the Fillet Weld (where the parent material being joined 
meets at an angle) and Butt Weld (where the parent material meets edge to edge).  These types of 
welds are also described depending on their orientation when the weld is made, such as 
Horizontal, Vertical, Angled, Flat or Overhead. 
 

 
 

 
Above: Examples of types of welds. 

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There are also some common variations of Fillet Welds which depend on the orientation of the 
parent metal pieces.  This includes the Lap, Tee and Corner Fillet. 
 

 
 
 
 
Also, the size and surface shape required for the weld can vary.  The size and shape of a weld can 
have a critical impact on its strength, while welds that are larger than required are likely to cause 
distortion and changes to the physical properties of the parent material because of the heat 
generated. 
 

 
 

 
   

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Edge Preparation 
 
The edges of the parent material are normally prepared to allow for a better, cleaner or quicker 
weld to be made.  The Edge Preparation specified will usually depend on the material type and 
thickness being welded as well as the type of weld required.  Edge Preparation is an important 
part of the welding process and must be specified correctly. 
 
 
 
 

 
 
 
 
 

 
   

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Above and Previous: Typical edge preparation types.  Note that the measurements shown will vary 
depending on the thickness of the parent material being welded. 
 
 
   

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Naming and Measuring Parts of a Weld 
 
Standard names and measurements are used to describe the parts and size of a weld and edge 
preparations.  To be able to correctly specify welds you must be familiar with the terms used. 

 
Above: Common terms used to describe different parts of a metal weld. 

 
Above: Throat thickness and leg length are two of the most common dimensions used to specify 
fillet weld dimensions. 
   

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Weld Symbols 
 
To simplify the process of displaying weld types a systems of symbols are used. 

 
Source: http://www.draftsperson.net/images/6/63/Weld_Symbols.png 

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Inventor Advanced – 2016 Lesson 10b

Weldment Assemblies
Welding is both a common and critically important process which is used in the fabrication and 
manufacture of a huge range of goods.  Although mild steels are the most common materials to be 
welded, alloy steels, stainless steels, aluminium alloys as well as various other ferrous and non‐
ferrous metals can be welded.  A number of plastics can also be welded, but in this course we will 
refer chiefly to metals. 
 
Because the method and technique that is used to weld materials can contribute substantially to 
the strength and performance of the end item, welds are commonly specified by the engineer or 
designer and so become an important part of the specifications which are then relayed to the 
fabricator in the drawings they receive. 
 
As the name implies, weldments are assemblies made from different pieces of material that are 
then welded together to form a single fabricated item.  In Inventor a weldment essentially remains 
an assembly, but includes special features which represent the welds that join the various parts as 
well as the edge preparations that can be specified and are carried out before welding begins. 
 
1.  Create Part 1 using the profile below and extrude 100mm. 

        
 
2.  Create Part 2 using the profile below and extrude 100mm. 

        

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3.  Start and save a new weldment assembly – use the “Weldment (ANSI – mm).iqw” template.  We use the 
American ANSI standard as it is the closest to our own Australian Standard. 
 
4.  Change to the Assemble tab and use the standard tools to place components Part 1 and Part 2 then 
constrain them as shown below.  This should only require two mate and one flush constraint… 

 
 
5.  Now select the weld tab to activate the weldment features ribbon as shown below. 
 

 
 
6.  Start the Preparation tools by selecting the Icon under the Weld tab or by double LMB clicking on the 
‘Preparations’ icon in the Project Browser. 
 

       
 
   

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7.  Now use the Preparation and Machining Tools to apply a single 2mm chamfer (a single bevel with a 1mm 
root face) 
 

 
 

 
 
8.  Once you have finished the weld preparation select the ‘Return’ icon and then click on the ‘Welds’ 
process icon in the ribbon…  
 

        
 
OR … double click on the Welds icon in the browser to activate the weldment features ribbon. 
 

 
 
   

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 Apply a Fillet Weld 
Fillet welds connect two and are normally used when no edge preparation has been carried out in the 
model.  The two faces to be selected are shown below.  Note that you can select multiple face for the two 
‘sets’, so you will need click on the #2 select button after picking the first face. 
 

 
 
Set dialogue box as shown below 
  Selects the  Weld 
  faces to be  surface  Sizes for 
  welded  contour  stitch welds 

Select Extent 
Size of  options to 
weld  control start 
and end of 
Determines  weld bead 
application of 
above size 

 
  If ticked will create a 
  weld symbol on the  Apply or OK to 
assembly  create weld 

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Apply a Groove Weld 
 
Groove welds are used for Butt Welds and where edge preparation has created a face of restricted size.  
Again, multiple faces can be selected for the two ‘sets’, so you will need click on the #2 select button after 
picking the first face.  
 

 
 
  Selects the  Fill Direction controls uses existing 
faces to be  faces to control the direction of the 
 
welded  surface of the resulting weld. 
 

 
  If ticked will create a  The radial fill option will use 
weld symbol on the    the selected faces to 
  assembly 
          Apply or OK to 
determine the location and 
create weld 
  direction of the weld surface 

Note that the resultant weld 
fills the groove created but 
the chamfer edge preparation 

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A Note about Weld Symbols… 
 
As you have seen in the dialog boxes above, a weld symbol can be created and added to the assembly so 
that it displays in 3D model mode.  Here it can have its visibility turned off and later be retrieved in the 2D 
drawing mode, but it is just as easy to use the same dialogue box in Annotate in the 2D drawing to create 
the appropriate weld symbols there. 
 
Cosmetic welds do not show the weld in 3D, just a line and the weld symbol.  A Fillet or groove weld (as 
shown in the above examples) will show the weld in 3D and the weld symbol if it is selected. 
 

 
 

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Inventor Advanced – 2016 Lesson 11

Using the Sheet Metal Punch Tool

The punch tool can be used to punch irregular shaped holes in sheet metal.  A number of 
‘standard’ type punch tools are commercially available for use within industry and customised 
tools can also be made. 
 
Exercise 1: 
 
Create a new sheet metal part using 1.6mm thick Aluminium 6061 and create a 200x200 square 
face.  Create a new sketch on the top surface of this face and place a single point 30mm from two 
edges and finish the sketch. 

 
 
Activate the Punch Tool 

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From the Punch Tool Directory, select ‘D‐sub connector’ and click OPEN. 

 
 
Note that the shape to be punched appears in preview. 

 
 
   

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Pick the Geometry tab to select/unselect points and use the angle setting to rotate the shape as 
required. 

 
 
Use the Size tab to enter alternate dimensions.  Note that many of the standard punch tools will 
be in imperial measurements.  You will need to take care when changing them to ensure that the 
units used are clearly defined as they will default to those used in you model, not necessarily what 
is shown in the punch tool details.  

 
 
Click FINISH and the punch tool shape is used to cut the sheet metal face. 

 
 
Also note that the punch tool can also be used to ‘emboss’ a sheet metal part by adding a shaped 
‘dimple’ to it. 
 

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Select either the round or square emboss tool. 

     
 
Define centres, angle and dimensions to be used. 

     
 
Select FINISH and the emboss feature with the updated dimensions is added to the model.  Note 
that the preview may not update before applying the tool. 

     
 
Double click on the ‘iFeature’ in the project browser to modify any of the feature settings including 
dimensions. 
 
Also note that these features can be added ‘across bend’ so that the model places the feature as if 
it was placed into the flat pattern before the bend was made. 
   

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Sheet Metal Contour Rolls
Contour rolling (or roll forming) is a process used to create elongated ‘contour flange’ type 
products.  Metal roofing and guttering are good examples of these. 
 
 

       
From: http://en.wikipedia.org/wiki/Roll_forming#mediaviewer/... 
 
 
 
The process can also include placing a bend or ‘roll’ into the piece. 

 
 
   

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Exercise 1: 
 
Create a new sheet metal part using 2.0mm thick Steel, High Strength, Low Alloy and create a 
contour flange feature 200mm long of the profile shown below.  

 
Now create a new sketch on the very top 2mm wide face (A) 

 
 
On this sketch plane, project the geometry of the outside edge of the 2mm wide face and draw a 
single line offset 100mm from the edge of the profile as shown below.  This line will be the centre 
line of the radius through which the channel will bend. 

             

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Finish the sketch and select the Contour Roll feature tool from the Sheet Metal ribbon. 

 
 
Pick the Profile and then the axis from the sketch and set the angle to 45deg.  The preview should 
appear as below.  Click OK. 

 
 
   

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Now repeat this process on the new angled face that has been created using the profile and axis as 
shown below. 

 
 
Finally, create a new sketch on the top 2mm wide end face and project the outer edge geometry.  
Now use the Contour Flange tool to add another 200mm section which is parallel to the first one. 

 
 

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You may now create a flat pattern.  This would not be possible had other solid modelling tools 
been used to create this solid. 

       
 

Adding Features to a Rolled Section

 
Additional features can now be added to the folded model.  Common features such as cut outs 
and perforations are normally added to the feature as if it were straight as they are preferably cut 
into the flat raw sheet before the rolling process begins.  In order to do this we must use the 
‘unfold’ and ‘refold’ tools as features added to a model in flat pattern mode do not update to the 
folded model. 
 
Select the Unfold tool from the Modify panel or the Sheet Metal tab. 

 
 

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Select the lower of the two planes displayed as the stationary reference plane.  This controls from 
where the part unfolds. 

 
 
Now select the curved face shown to unfold that particular bend.  The preview will the result of 
the unfold face selected. 

     
 
Now select the higher face show, which is part of the second bend.  Again the preview shows the 
result of unfolding the faces selected 

     
 
 
 
 

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Click OK to accept the ‘unfold’ process as previewed. 

 
 
We can continue the unfold process, although it is not necessary to completely unfold the model. 
Active the unfold tool again and select the face show to remain stationary. 

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Now select the two vertical bends either side of the stationary face so the preview is as shown and 
then click OK 

 
 
The model now displays as shown.  New features can now be added to the model before the 
refold tool is used. 

 
 

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Start a new sketch on the face shown. 

 
 
Place a single point in the centre of the face aligned with the centre point of the bottom edge and 
50mm above it. 

 
 
 
 

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Finish the sketch and place a 15mm dia hole on the point in the sketch. Click OK. 

 
 
Use the Rectangular Pattern tool to create a total of 14 holes spaced at 40mm centres and aligned 
vertically.  Click OK. 

 
 

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The model now shows our unfolded object with a series of holes along its length.  We will now 
refold the model so that these holes will exist in the locations they would if they were to be placed 
into the material before folding took place. 

 
 
Go to the project browser and select the most recent unfold feature.  Unfold features must have 
the refold applied in the reverse order in which they were applied.  RMB click on the unfold and 
select Refold Feature from the context menu. 

     
 

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Again RMB click on the remaining unfold feature and select Refold Feature. 

     
 
The primary benefit of this process is that features can be added with reference to less 
complicated ‘pre fold’ geometry and the software is able to calculate their new location when the 
refold is performed.  Also these types of features are most often created before the folding 
process, so any measuring to locate them will be done on a flat piece of material, not on the 
folded component. 

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Lofted Flange
A lofted flange is similar to a lofted solid but utilises two open profiles and the sheet metal rules to 
produce a sheet metal form.  These forms can become extremely complicated so care should be 
taken to keep the profiles used as simple as possible. 
 
Start a new Sheet Metal part and set the material to 1.5mm mild steel and use R6 bend radius. 
 
Create the sketch outline below. 

 
 
Create a new work plane, offset 200mm from the origin pane used for the first sketch. 

 
 
   

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Create a new sketch on the work plane as below. 

 
 
Activate the Lofted Flange feature tool. 

 
 
   

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Select the two sketches and observe the preview shown. 

 
 
The sheet metal form is produced.  To ensure it is correct make sure that a flat pattern can be 
produced. 

     

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Inventor Advanced – 2016 Lesson 12

The Autodesk Content Centre

The Autodesk Content Centre is a library of standard components that is available from Autodesk 
via an internet connection.  The Content Centre allows you to add various parts and sub‐
assemblies to an assembly using various national and industry standards.  These include 
 bolted connections and pins 
 bearings 
 shafts 
 gears 
 pulley, belt and chain driven systems 
 keyways 
 cams 
 splines 
 o‐rings 
 springs 
 
In order to use any of these features you need to be connected to the internet and any assemblies 
that reference Content Centre files will only be functional when this internet connection is 
maintained.  In order to be able to save and transfer assemblies that use Content Centre features 
we need to utilise the ‘Pack and Go’ feature.  This copies content centre information that is used in 
an assembly into a new folder and then saves all the files and data required so that the entire 
project can be picked up and moved to another location without needing internet access or access 
to part files that might have been stored in different locations (such as on a different network 
drive). 

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‘Pack and Go’
 
To use the Pack and Go facility, first make sure that you have created a project (which should 
always be done at the start of the project, not later) and that all the part files used are correctly 
linked to the assembly and display as expected. 
 
Under the Inventor Quick access icon (the ‘big I’), expand the Save As command to access the Pack 
and Go option. 

 
 
The Pack and Go dialog box will appear. 

 
 Make sure the Source file name and location is as expected. 
 Click the browse button to set the destination folder.  This is the folder that you will be 
able to transfer so it could be on a flash/USB drive or other location. 

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 Create and then select a new folder if required. 
 Click OK. 
 

 
 Under Options you can choose to move all the files into the one folder OR retain the 
existing file and folder structures. 
 You should Include linked files – this will copy any content centre of other part files that 
are related to the assembly. 
 Make sure that the Project file referenced is correct.  If it is not, browse for the correct .ipj 
file. 
 Under ‘Find Referenced Files’ click on the ‘Search Now’ button.  This will list all the files 
that are attached to or referenced within the project. 

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 Under ‘Search for referencing files’ click the ‘Search Now’ button.  This will locate any files 
that reference back to the project.  You can choose to also add these to the Pack and Go 
suite of files to be created. 
 

 
 
   

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Finally, review the total number of files and the disk space required. 
To create the Pack and Go folder and save all the files click on the ‘Start’ button. 

 
 
You will now have a new set of files inside the destination folder.  These files should be 
independent of the original project and all parts and assemblies (including Content Centre files) 
and their relationships will be included and fully functional.  Opening these files in another 
location or on another computer will not affect the original files. 
 
NOTE:  Using the Pack and Go facility means that you can create numerous copies of the same 
files which could then be modified separately.  This can create issues within projects so always 
be certain that the procedure used is in accordance with workplace practices. 

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Inventor Advanced – 2016 Lesson 13

The Autodesk Content Centre

The Autodesk Content Centre is a library of standard components that is available from Autodesk 
via an internet connection.  The Content Centre allows you to add various parts and sub‐
assemblies to an assembly using various national and industry standards.  These include:‐ 
 bolted connections and pins 
 bearings 
 shafts 
 gears 
 pulley, belt and chain driven systems 
 keyways 
 cams 
 splines 
 o‐rings 
 springs 
 
To activate these features you will be using the ‘Design’ tab. 
 
In order to use any of these features you need to be connected to the internet and any assemblies 
that reference Content Centre files will only be functional when this internet connection is 
maintained. 

Pack and Go
In order to be able to save and transfer assemblies that use Content Centre features we need to 
utilise the ‘Pack and Go’ feature.  This copies content centre information that is used in an 
assembly into the associated Project Folder and then saves all the files and data required so that 
the entire project can be picked up and moved to another location without needing internet 
access or access to part files that might have been stored in different locations (such as on a 
network drive).  See separate notes on utilising the Pack and Go feature. 
 
 
 

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Bolted Connections
Bolted Connections are added to existing assemblies in Inventor and include all of the different 
parts that make up the fastener ‘set’ (such as the selected bolt, washers and nut). 
 
Start a new part file and sketch and extrude the 10mm plate shown below. 

 
 
In a new sketch place and constrain 4 points to be used as hole centres. 

 
 
   

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Place a clearance holes for an M10 Hex Head Bolt on each point. 

 
 
Save the file as ‘Bolted Base 1.ipt’. 
 
Start a new part file and sketch and extrude the 12mm plate shown below.

 
 
   

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In a new sketch place and constrain 2 points to be used as hole centres. 

 
 
Place a clearance holes for an M10 Hex Head Bolt on each point. 

 
 
Save the file as ‘Bolted Top 1.ipt’. 
 
   

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Start a new Assembly file. Place and ground one occurrence of ‘Bolted Base 1.ipt’ and then add 
two occurrences of ‘Bolted Top 1.ipt’. 

 
 
Constrain these face to face and with holes axis to axis as shown below. 

 
Note: The green, red and grey colours shown here have been added here only for clarity.  They are 
not required in the exercise. 
 
Go to the Design tab and select the Bolted Connection icon. 

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The Bolted Connection Generator dialog box will appear. 

 
 
Select the appropriate placement option – in this case we will use the ‘By Hole’ option. 

 
 
   

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Select the top most edge of one of the holes ON ONE OF THE SMALLER PLATES.  The termination 
plane will be the other side of the larger plate.  Note that the first face/plane selected will control 
what Inventor recognises as the ‘start’ of the bolted connection. 

 
By selecting the ‘Follow Pattern’ option the software will automatically place the same fastener in 
any other hole of the same size on the same face. 
 
Select ‘Click to add fastener’ in the items list shown on the right hand side.  This is the point where 
you will specify the size and type of fastener to be applied.  You will normally place the ‘bolt’ or 
largest part that make the connection through the existing parts/material first.  Additional 
components such as nuts and washers will be added after. 

 
 

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Filter the list of possible fasteners by selecting the appropriate National or Industrial standard 
from the drop down list.  Australian Standards are abbreviated as ‘AS’.  Then select the category 
required for the first component of the connection.  Then double LMB click on the item required. 

 
 
The initial component should now preview with the model. 
DO NOT CLICK OK.  You will now add the other components needed to form a full bolted 
connection. 
 
Note that in the items list on the right that the bolt appears at the top of the list and the ‘Selected 
Hole’ in the middle with ‘Click to add a fastener’ on either side of it.  This is important. 
 
To add a new component between the bolt head and the surface of the plate, click on the line that 
is immediately below the bolt description. 

 
 
   

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Select the washer type required.  Note that the selection has defaulted to washers only, as no 
other type of component is likely to be required in this location. 

 
 
Now click on the other ‘add a fastener’ line to place a new component on the other side of the 
plates. 

 
 
   

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You will need to select between washers or nuts here because either might be used.  Then pick the 
washer required. 

 
 
Finally select the bottom ‘add a fastener’ option again. 

 
 
   

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Pick the nut category and place a nut as shown below 

 
 
Note now the components list in the dialog box and how each component displays in the preview 
(green wireline) in the model.  Click OK. 

 
 
   

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You will need to confirm the connection file name and the location where it will be saved.  This 
should be controlled by your project settings. 

 
 
Click OK and the bolted connections become part of your assembly and are now also shown in the 
project browser. 

       
 
   

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To edit or add to an existing bolted connection, select it in the project browser and then RMB click 
and pick ‘Edit using design accelerator’. 
 

 
 
Select the ‘Click to add fastener’ line at the bottom of the list and we will add an additional locking 
washer to the assembly. 

 
 
Under the washer category pick the AS1698 spring washer. 

 
 
   

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You will see that the spring washer has been placed on the list and in the preview, but is BELOW 
the nut, which is not correct.  To change its location, LMB click and hold in the item and drag it up 
the list into the correct position. 

 
 
It now displays in the correct location.  Click OK and the model will update.  At the next save you 
may be asked to confirm the new component. 

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To delete a particular component of a bolted connection, edit the connection using the Design 
Accelerator and then LMB click on the small, red cross adjacent to the item in the components list. 
 
To edit or alter a particular component of a bolted connection (such as the length of a bolt), LMB 
click on the small ‘3 dot’ button adjacent to the item. 
 

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Inventor Advanced – 2016 Lesson 14

The Shaft Generator

The shaft generator is one of the design centre tools available in Inventor.  The software 
essentially creates an assembly of ‘parts’ (for lack of a better word) the represents each specific 
section or feature that is required as part of the shaft being designed. 
 
The shaft generator is only available within the assembly environment. 
 
The shaft generator also includes various mechanical and performance analysis tools, but these 
will not be covered within this course. 
 
To Start: 
Create a new project folder and project file. 
Open a new assembly file using the standard metric template. 
Save the assembly file. 
Go to the Design tab and select the Shaft tool from the Power Transmission panel. 
 

 
 

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The Shaft Generator dialog will open and a default shaft will appear on the screen, ghosting the 
cursor.  LMB click once in the model area to place the shaft in 3D space. 
 

 
 
You can now edit, add or delete sections of the shaft as required.  Note that keyways and splines 
can be added to shafts later using their own separate Design Centre tools. 
 
At any time the section being edited is highlighted in blue. 
 
   

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First Edge Features – include fillets, chamfers, threads and keyways that are located at the starting 
end of the section.  The length they require is included in the length of the section. 

 
 
Chamfers and fillets require basic information to define 

 
 
Threads and keyways require significantly more information and the size of the section can also be 
edited at the same time if needed. 

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Features such as threads and keyways will size themselves depending on the selected standard 
and the nominal size of the shaft section being edited. 
 
ALWAYS CHECK AUTOMATICALLY CREATED SECTIONS AND FEATURES AGAINST AUSTRALIAN 
STANDARDS OR THOSE REQUIRED BY THE APPLICATION, AS THESE OFTEN DIFFER FROM THE 
DEFAULT STANDARDS USED IN INVENTOR. 
 
Section Type ‐ The section type can be selected as a parallel sided cylinder, a cone or taper or a 
polygon such as a hexagonal section. 

 
 
Second Edge Features – The second or 
end edge of the section can also be 
defined.  Again this feature will take up 
part of the length of the section and 
often controls how the section 
transitions to the next one.  Where the 
diameter increases for the next section 
it is common to use a fillet feature to 
distribute stresses and make 
mechanical failure less likely.  Reliefs 
are used so that surface machining 
process and the cutting tools used to 
create them have a space off the 
machined face to stop and start each 
pass.  This also reduces the chance of 
surface damage to adjacent faces 
caused by the machining tools. 
 
 

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Second Features – Include keyways, wrench flats, grooves reliefs and holes that can be applied to 
the section.  Again some of these require additional input and automatically assigned dimensions 
are based on default standards and these should be double checked against those required. 

 
 
The dimensional settings for each section can be edited using the 3dot button at the RH end of the 
section row.  A section can be deleted using the red cross icon. 

 
 
   

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These icons are also be used to edit and delete individual features once they have been added to 
the shaft. 

 
 
Tools that can be used to insert a cylinder, cone or polygon section or split an existing section into 
two are available near the top of the dialog box. 
 

 
 
   

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To add a tapered or parallel sided hole to either end of the shaft, select either the ‘bore on left’ or 
‘bore on right’ options from the drop down list. 

 
 
   

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Exercise: 
Using the details shown below and the supplied drawing, recreate the specified shaft. 

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Insert Bearings from the Content Centre
The Content Centre contains a library of standard bearing sizes and types that can be inserted into 
an assembly.  Like the Bolted Connections feature, the geometry that is selected in the existing 
assembly file to place a Bearing will go some way to control the size and orientation of the item. 
 
An existing part that is within an assembly (such as the bearing housing shown below) is used to 
specify and place the required bearing.  Bearings come in a large range of standard types and sizes 
so the operator should already have information on the specific bearing to be used before starting 
the process. 

 
 
In the assembly environment go to the Design tab and select the Bearing icon. 

 
 
   

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The Bearing Generator dialog box will appear.  LMB click the bearing type drop down list at the top 
of the dialog box. 

 
 
The bearing list will download from the content centre, at which point you can select the Standard 
(eg AS for Australian Standard) and Category (or type of bearing eg deep groove ball) from the 
drop down lists which filter the options displayed in the section below them. 

 
Pick the specific bearing type and/or manufacturer required. 
   

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Now you will select the cylindrical face that will help size the bearing.  If you select an internal 
surface this will control the OD of the bearing, while if you select an external surface (such as that 
on a shaft or similar) it will control the ID of the bearing. 
 
Next you will pick a ‘start plane’ which will be the face or surface that one side of the bearing will 
sit flush against or flush with.  What plane you select will depend on what face you want one side 
of the bearing to align itself to.  Note that you can ‘toggle’ the orientation of the bearing to be 
either side of the selected plane, so check the preview and make sure that the bearing is sitting in 
the correct location. 
 
The ‘flip over’ icon/option allows you to select which side or face of the bearing sits in which 
direction.  Some bearings (such as tapered roller bearings) have specific orientations they must sit 
in so that they can be installed and function correctly.  Other bearings might have special seals or 
covers on only one side so the orientation in which the bearing is installed could be critical. 
 

 
Above: Note that the OD value of the bearing is greyed out – this is because the value (in this case 52mm) 
needs to coincide with the diameter of the cylindrical face that was selected.  If an options for different 
bearings exist they will appear in the designation list shown and can be selected from that list. 
 
Click OK. 
 
On creating the bearing in the assembly you will need to specify/verify the file name and location 
of the new ‘part’ (in this case actually a sub‐assembly) that will be created. 

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The assembly will now contain a new part/sub‐assembly that is fully constrained and fully 
functional. 
 

 
 
 
 
 
 
 

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Inventor Advanced – 2016 Lesson 15

The Keyway Generator

Keys and keyways are used to connect shaft objects to hub objects or bushings so they are locked 
(constrained) together and forced to rotate as one unit.  As we have already seen, keyways can be 
added when creating shafts using the shaft generator.  Keys and keyways can also be added to 
shafts or hubs or to assemblies that already contain a shaft and hub together using the Key 
Generator. 
 

Source: 
http://www.linearmotiontips.com/transmi
   
  tting‐torque‐with‐keyed‐shafts/  Source: 
  http://machinedesign.com/motion‐
  control/making‐right‐shaft‐connections
 
 
There are also different types of keys which are used under different conditions or standards.  
Generally we will use square or rectangular keys which are generally the most common of the 
various types in light to medium duty industrial and automotive applications. 
 

Source: 
http://machinedesign.com/archi
ve/shaft‐keys‐reduce‐
manufacturing‐costs‐and‐
machine‐downtime 

 
The Key Generator is able to create the shaft keyway (the groove cut into the outer surface of the 
shaft piece), the key itself and the hub keyway (the groove cut into the inside of the hub piece) or 
any combination of these, depending on what is required. 
 
We will look at two examples – cutting only a keyway in a shaft or hub and cutting keyways and 
adding a key to create a full shaft/hub assembly. 
 

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Cutting a Simple Keyway: 
Consider the example shown below, which is created by revolving the profile shown around its 
central axis. 

       
 
Start a new assembly file and place the shaft component into the assembly. 
 
In the Design tab, select the ‘Key’ icon/option. 
 

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The Key Generator dialog box will appear. 
 

 
 
Select the standard key required from the dropdown list.  The British Standard BS4235 is one that 
is commonly used in Australia, but no Australian Standard exists within the Content Centre at time 
of writing. 
 
Note the section in the bottom right corner ‘Select Objects to Generate’.  This allows you to pick 
only the objects needed.  For this example we will pick only Shaft Groove option and unselect the 
others.  Note that the selected button is blue. 

 
 
Pick the first reference.  This will be the cylindrical face that the keyway will be cut into. 

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Now pick the second reference.  This will be the plane that the keyway starts from or is measured 
from. 

 
 
The screen shows a preview of the keyway to be cut in red wireframe and also shows the key itself 
in green wireframe.  All the dimensions are dependent on the key that is specified, so even though 
the key itself is not needed in the model it is still shown here. 

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The orientation of the keyway can be controlled by selecting an origin or work plane that passes 
through the centre of the shaft and is perpendicular to the bottom face of the keyway. 

 
 
Dimensional options for the keyway are also available in dropdown lists that are shown in the 
dialog box preview.   

 
 
You can also select how many keyways are to be placed on the shaft and their angle of separation. 

 
 
As we are not, in this example, applying a hub keyway or key, click OK. 

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You will be prompted for a file name.  Note that the default folder and location are controlled by 
the current project settings. 

 
 
Click OK. 
 

 
Two BS4235 square keyways added to the existing shaft. 
 
   

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Creating a Keyed Connection: 
Create a new part – this time a ‘wheel’ that will fit onto the other end of the shaft we have created 
with an ID of 25mm, an OD of 125mm and a thickness of 30mm. 

       
 
Save the part and then place it into the existing assembly. Constrain the wheel to the end of the 
shaft with a 5mm offset as shown.  Note that the yellow colour has been added only for clarity. 

     
 
If we ‘ground’ the shaft temporarily and look at the degrees of freedom for the wheel we can see 
that the wheel is still free to spin on the end of the shaft.  Applying a Key and Keyways to the 
assembly will fix this.

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Start the Key Generator facility again. 

 
 
Specify to create both keyways and the key object at the same time. 
Specify the shaft keyway by picking the outer face and the end face as done previously.  

 
 
For the hub keyway select the end face or the hub object as Reference 1. 

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Select the internal diameter edge of the hub object as Reference 2. 

 
 
Click OK. 
 
Ensure that the name and location of the new file/s to be created is as required. (Note that your 
Project folder location should control this.) 

 
 
Click OK. 
 

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The Spline Generator
In a similar way to the Keys and Keyways described above, the Inventor Design facility allows for 
the addition of Spline connections between objects in an assembly. 
 
Splines are essentially ridges or ‘teeth’ formed on the outside of a shaft object that mesh with 
grooves cut in a hub object which can slide over the shaft.  Splines are commonly used in power 
transmission applications as they are able to take high torque loads and are easy to assemble by 
simply sliding the pieces together.  They can also help ensure proper alignment between 
components as they essentially ‘self‐align’ with each other and can allow for longitudinal (along 
the axis of the spline) movement.  For this reason they are selected for one of their most common 
applications – that of drive shafts that connect a motor or drive unit to a flexible drive train or 
suspension system such as those used in cars, trucks and other heavy wheeled equipment. 

 
Source: http://www.speedwaymotors.com/Pin‐Style‐Quick‐Release‐Aluminum‐Steering‐Wheel‐Hub‐5‐8In‐Steel‐Shaft,29001.html 
 
Use ‘File – Save As’ or create again the same shaft as used in the previous Keyway example.  We 
cannot use the same shaft.ipt file as in the previous example because it now has keyways cut on 
both ends. 

       
Start a new assembly file and place the shaft component into the assembly. 

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Go to the Design tab and select a spline… 

 
 
A Parallel spline ‐ where the sides of the grooves which are evenly spaced around the axis of the 
shaft/hub are parallel in both directions, both radially and axially. 
 
An Involute spline ‐ where the sides of the grooves which are evenly spaced around the axis of the 
shaft/hub are involute, as with an involute gear (see example below), but not as tall. The curves 
increase the strength of the connection by decreasing stress concentrations but are also more 
costly to manufacture. 

The ‘Involute’ 
form or shape 
as seen in an 
involute gear.

 
Source: https://en.wikipedia.org/wiki/Involute_gear 
 

       
 
NOTE: The process for creating both parallel and involute splines is exactly the same, the only 
difference being the standards that are available with each.  The examples that follow may use 
either type. 
 
   

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Cutting a Simple Spline: 
The process is almost exactly the same as for the creation of keys and keyways.  In the bottom 
right corner of the dialog box you can select to create either shaft or hub splines (or both at the 
same time). 
Select only the shaft spline option. 

 
 
Select Reference 1 – this is the outside surface of the shaft. 

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Select Reference 2 – this is the end face of the shaft or a face used to control the ‘start point’ of 
the spline. 

 
 
Use the Standards Filter and the drop down list to select the standard to be applied. 

 
 
   

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Select the required spine specifications which might be used for the selected shaft diameter. 

 
 
Specify the length of the spline to be cut on the shaft. 

 
 
Click OK. 
 

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Ensure that the name and location of the new file/s to be created is as required. (Note that your 
Project folder location should control this.) 
 
Click OK. 
 

 
The new involute spline form/feature is created. 
 
   

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Creating a Spline Connection: 
Just as with Keys and Keyways, you can also connect two existing parts (one a shaft and the other 
a hub) and ‘lock’ them together using a Spline Connection. 
 
Use File – Save As or recreate from scratch the same Wheel object from the previous exercise – 
BUT THIS TIME WITH AN I.D. OF 15mm. This is done so that the spline connection has material to 
remove from the hub to create the smaller inside diameter that will mesh with the grooves cut 
into the shaft. 
 
If using Save As you will also have to remove the Keyway feature from the newly duplicated 
object.  Name the file Wheel 2.ipt 

       
 
Constrain the two parts together.  There will be an overlap or ‘interference’ between the shaft and 
smaller hole diameter.  Note that there is no need to constrain the wheel from spinning on the 
shaft, as the spine connection will do this for us. 

 
   

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Start the Parallel Spline creation tool. 

 
 
Make sure that both SHAFT and HUB spline objects are selected for creation. 

 
 
Select the appropriate standard. 

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Select the outer surface of the shaft. 

 
 
Select the end face of the shaft – this will act as a start point for the spline feature. 

 
 
   

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Specify the correct spline length.  Note that the radius or ramp cut on the end of the spline 
grooves (which reduces the concentration of internal stresses within the shaft hence reducing the 
chance of failure) is additional to the stated groove length. 

 
 
Select the starting plane / face of the hub object.  Note that if the hub object is a more 
complicated shape (eg is stepped) you may also need to specify an End Reference plane. 

 
 
   

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Select the ID of the hub to create a reference centre point.  Note that you may also need to flip 
the direction that the spline is applied using ‘Reference 2 Flip’ button. 

 
 
Click OK. 
 
Ensure that the name and location of the new file/s to be created is as required. (Note that your 
Project folder location should control this.) 

 
 
Click OK. 
 
   

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The new parallel spline form/feature is created and the shaft and hub are now constrained or 
‘locked’ together. 

 
 

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Inventor Advanced – 2016 Lesson 16

The Gear / Gear Set Generator

Gears are used in many mechanical applications as a means of transferring rotational motion.  
They can also be used to change the direction of rotation and also to apply a gear ‘ratio’ which 
allows for speed and torque to be varied in proportion to the number of teeth on each gear. 
 
There are numerous types, styles and applications of gears and gear sets.  The ones available in 
the Inventor software include Spur Gears, Worm Gears and Bevel Gears.  These different gears can 
be defined by the relationship between the axes of the shafts on which they sit. 
 
Spur gears have axes which are parallel to each other… 

Source: 
http://www.hercus.com.au/spur‐gears/ 

       
 
Worm Gears have axes which sit at 90deg to each other and that are in different planes… 

Source: 
http://gear.sormor.com/Product/
Other%20Gears/worm2.html 

       
 
   

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Bevel gears have axes which are at 90deg to each and that sit in the same plane… 

        
 
  Source: http://machinedesign.com/whats‐difference‐between/what‐
s‐difference‐between‐spur‐helical‐bevel‐and‐worm‐gears 
   
 
As with all Design and Content Centre elements, gears and gear sets are created within an 
assembly file and the resulting new ‘parts’ are created and saved within the current project folder. 
 
Create a Spur Gear Set 
In a new part file, sketch and constrain a 150x50 rectangle. 

 
 
Finish the sketch and extrude the profile 10mm. 

 
 

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Create a new sketch on the 150x50 face and place and constrain two 20mm diameter circles at 
100mm centres. 

 
 
Finish the sketch and extrude these circles 40mm. 

 
 
Save the part created as “Base 1.ipt”. 
 
Start a new assembly and place and then ground “Base 1.ipt” within it. 

 
 

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 In the Design tab, select the Spur Gear feature. 

 
 
If you have not yet saved the assembly you will be prompted to do so.  Click OK and name the file 
“Spur Gear 1.iam” 

Gear Tooth Nomenclature

 
Pitch circle diameter For two meshing
  these are the diameters of the discs
gears
  would transmit the same velocity ratio
that  
by friction (if there was no slipping) as the
gears.
Module, m this indicates the tooth size and
is the number of mm of pitch circle
diameter (p.c.d.) per tooth. For gears to
mesh, their modules must be equal.
Gear ISO standards and design methods are
now normally based on the module.
EG a gear of module 3 has 16 teeth, its
pitch circle diameter is: 3 x 16 = 48 mm.
Diametral pitch,P is the number of teeth
per m or mm of gear pitch circle diameter. The diagram shows the tooth geometry
P = 1/m for the ISO basic rack in terms of
Circular pitch, p is the distance from one module 1 size teeth; PI means 3.14159
point on the pitch circle of one tooth to the
corresponding point on the adjacent tooth,
measured around the pitch circle. pP=PI
Source: 
http://www.tech.plym.ac.uk/sme/desnotes/gears/nomen1.htm 

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The Spur Gear Generator dialog box will appear.  We will create a simple pair of spur gears based 
on the centre distance of the ‘shafts’ (the cylindrical pins) from ‘Base 1.ipt’ and the desired gear 
ratio. 

 
 
Make sure that the ‘Module and Number of Teeth’ option is selected. 

 
 

TAFE NSW – Western Sydney Institute Lesson 16 - Content Centre 4 - Gears and Pulleys.docx
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Specify a Gear Ratio of 2.4 and a centre distance of 100mm – the same as that used to locate the 
pins in the ‘Base 1’ part file. 

 
 
For Gear 1, click on the ‘Cylindrical Face’ button and then select the cylindrical face of the first pin. 

 
 
   

TAFE NSW – Western Sydney Institute Lesson 16 - Content Centre 4 - Gears and Pulleys.docx
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Now pick the ‘Start Plane’ button for Gear 1 and then select the end face of the first pin. 

 
 
Repeat the above process, this time for the Gear 2 and selecting faces on the second pin.  You may 
need change the ‘start plane’ direction for one or both gears to make sure that the preview shows 
them sitting on the correct side of the start plane. Then click on the Calculate button which will 
finalise the preview.   

 
 
Before clicking OK we will change the specified gear ratio to see the effect this has on the preview.  
Change the gear ration to 1.8 and again click on the Calculate button. 

 
Note that the previewed gears change in size to allow for the required ratio. 

TAFE NSW – Western Sydney Institute Lesson 16 - Content Centre 4 - Gears and Pulleys.docx
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Click OK 
 
Check the file names and locations that will be created in the project folder location. 

 
 
Click OK. 
 
The new spur gears are generated and added to the assembly.  Note that the new parts won’t be 
fully saved until you save the assembly and confirm the new part files along with it. 
 

 
   

TAFE NSW – Western Sydney Institute Lesson 16 - Content Centre 4 - Gears and Pulleys.docx
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