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SolidWorks 2005 Advanced Assembly Modeling SolidWorks Corporation 300 Baker Avenue Concord, Massachusetts 01742 USA © 1995-2004, SolidWorks Corporation 300 Baker Avenue Concord, Massachusetts 01742 USA All Rights Reserved U.S. Patents 5,815,154; 6,219,049; 6,219,055; 6,603,486; and 6,611,725; and certain other foreign patents, including EP 1,116,190 and JP 3,517,643. U.S. and foreign patents pending. SolidWorks Corporation is a Dassault Systemes S.A. (Nasdaq:DASTY) company. The information and the software discussed in this document are subject to change without notice and should not be considered commitments by SolidWorks Corporation. No material may be reproduced or transmitted in any form or by any means, electronic or mechanical, for any purpose without the express written permission of SolidWorks Corporation. The software discussed in this document is furnished under a license and may be used or copied only in accordance with the terms of this license. All warranties given by SolidWorks Corporation as to the software and documentation are set forth in the SolidWorks Corporation License and Subscription Service Agreement, and nothing stated in, or implied by, this document or its contents shall be considered or deemed a modification or amendment of such warranties. SolidWorks, PDMWorks, and 3D PartStream.NET, and the eDrawings logo are registered trademarks of SolidWorks Corporation. SolidWorks 2005 is a product name of SolidWorks Corporation. COSMOSXpress, DWGEditor, eDrawings, Feature Palette, PhotoWorks, and XchangeWorks are trademarks, 3D ContentCentral is a service mark, and FeatureManager is a jointly owned registered trademark of SolidWorks Corporation. COSMOS, COSMOSWorks, COSMOSMotion, and COSMOSFloWorks are trademarks of Structural Research and Analysis Corporation. FeatureWorks is a registered trademark of Geometric Software Solutions Co. Limited. ACIS is a registered trademark of Spatial Corporation. GLOBEtrotter and FLEXlm are registered trademarks of Globetrotter Software, Inc. Other brand or product names are trademarks or registered trademarks of their respective holders. Document Number: PMT0043-ENG COMMERCIAL COMPUTER SOFTWARE - PROPRIETARY U.S. Government Restricted Rights. Use, duplication, or disclosure by the government is subject to restrictions as set forth in FAR 52.227-19 (Commercial Computer Software - Restricted Rights), DFARS 227.7202 (Commercial Computer Software and Commercial Computer Software Documentation), and in the license agreement, as applicable. Contractor/Manufacturer: SolidWorks Corporation, 300 Baker Avenue, Concord, Massachusetts 01742 USA Portions of this software are copyrighted by and are the property of Electronic Data Systems Corporation or its subsidiaries Portions of this software © 1988, 2000 Aladdin Enterprises. Portions of this software © 1996, 2001 Artifex Software, Inc. Portions of this software © 2001 artofcode LLC. 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Portions of this software © 1994-2004, Visual Kinematics, Inc. This software is based in part on the work of the Independent JPEG group. All Rights Reserved SolidWorks 2005 Training Manual Table of Contents Introduction About This Course . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Course Design Philosophy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Using this Book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 About the CD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Windows® XP and Windows® 2000. . . . . . . . . . . . . . . . . . . . . . . 4 Conventions Used in this Book . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Lesson 1: Top-Down Assembly Modeling Top-Down Assembly Modeling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Stages in the Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 In-context Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Edit Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Appearance of Components While Editing . . . . . . . . . . . . . . . . . 12 How Transparency Affects Selecting Geometry . . . . . . . . . . . . . 13 Propagating Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 A Note of Caution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Building In-context Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Adding a New Part into an Assembly. . . . . . . . . . . . . . . . . . . . . . 19 Results of Insert, Component, New Part. . . . . . . . . . . . . . . . . . . . 19 Building Parts in an Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Using Offsets from Assembly Parts . . . . . . . . . . . . . . . . . . . . . . . 21 Assembly Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Hole Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Smart Fasteners. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Fastener Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 i SolidWorks 2005 Training Manual Fasteners List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Changes to Smart Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Fastener Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Fastener Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Out of Context . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Putting a Part Back Into Context . . . . . . . . . . . . . . . . . . . . . . . . . 37 Breaking External References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Breaking and Locking External References . . . . . . . . . . . . . . . . . 39 External Reference Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Removing External References . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Editing the Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Exercise 1: Top-Down Assembly Modeling . . . . . . . . . . . . . . . . . . . 49 Exercise 2: In-context Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Exercise 3: Level Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Exercise 4: 3D Sketches in a Top-Down Assembly . . . . . . . . . . . . . . 53 Exercise 5: The Hole Wizard and Smart Fasteners . . . . . . . . . . . . . . 57 Lesson 2: Working with Assemblies Working with Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Key Topics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Mating Shortcuts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 SmartMates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Mate References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 SmartMates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 From an Open Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 SmartMates from Within the Assembly . . . . . . . . . . . . . . . . . . . . 66 Adding Mate References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Primary, Secondary, and Tertiary References . . . . . . . . . . . . . . . 69 Special Case of Mate Reference . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Design Library Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Capture Mate References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Limitations of SmartMates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Advanced Mate Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Summary: Inserting and Mating Components . . . . . . . . . . . . . . . . . . 79 Inserting the First Component . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Inserting Additional Components . . . . . . . . . . . . . . . . . . . . . . . . . 80 Inserting and Mating Simultaneously . . . . . . . . . . . . . . . . . . . . . . 81 Mating Existing Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Configurations of Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Terminology Review . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Adding a New Assembly Configuration. . . . . . . . . . . . . . . . . . . . 82 Suppressing Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Design Library Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Using Move Component with Configurations . . . . . . . . . . . . . . . 90 Assembly Design Tables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 What They Can Do . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 ii SolidWorks 2005 Training Manual Specifying Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Controlling Part Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Controlling Assembly Features and Mates . . . . . . . . . . . . . . . . . . 93 Comments and Other Headers . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Creating and Inserting Design Tables. . . . . . . . . . . . . . . . . . . . . . 94 Building the New Design Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Component Headers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Mate Headers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Extra Columns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Editing the Design Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Configuration Properties. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Changing Component Mates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Completed Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Component Sub-assemblies in an Assembly . . . . . . . . . . . . . . . 103 Adding Sub-assembly Configurations . . . . . . . . . . . . . . . . . . . . 104 Other Ways of Creating Configurations . . . . . . . . . . . . . . . . . . . 106 Assembly Patterning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Exercise 6: Mating and Assembly Motion . . . . . . . . . . . . . . . . . . . . 111 Exercise 7: Using Smart Mates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 Exercise 8: Gear Mates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Exercise 9: Configurations of an Assembly . . . . . . . . . . . . . . . . . . . 122 Exercise 10: Assembly Design Tables . . . . . . . . . . . . . . . . . . . . . . . 125 Exercise 11: Component Patterning . . . . . . . . . . . . . . . . . . . . . . . . . 127 Lesson 3: Assembly Editing Assembly Editing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 Key Topics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 Editing Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 Finding and Repairing Problems . . . . . . . . . . . . . . . . . . . . . . . . 133 Information from an Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . 134 Design Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 Converting Parts and Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 Parts into Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 Assemblies into Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 Parts into Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 Replacing Parts with Assemblies . . . . . . . . . . . . . . . . . . . . . . . . 135 Replacing and Modifying Components . . . . . . . . . . . . . . . . . . . . . . 139 Working in a Multi-user Environment . . . . . . . . . . . . . . . . . . . . 139 Replacing a Single Instance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 Mates Folder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 Troubleshooting an Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 Mate Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 Viewing Mates Using the PropertyManager . . . . . . . . . . . . . . . 146 Visual Display of a Mate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 Replace Mate Entities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 Over Defined Mates and Components . . . . . . . . . . . . . . . . . . . . 149 iii SolidWorks 2005 Training Manual Mate Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 Replacing Components Using Save As . . . . . . . . . . . . . . . . . . . . . . 152 Time-Dependent Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 Parent/Child Relationships . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 Reorder and Rollback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 Controlling Dimensions in an Assembly . . . . . . . . . . . . . . . . . . . . . 154 Link Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 Assembly Equations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 Dimension Names in an Assembly . . . . . . . . . . . . . . . . . . . . . . . 155 Adding Equations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 Mirroring Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 Mirroring or Copying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161 Exercise 12: Assembly Errors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167 Exercise 13: Assembly Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169 Exercise 14: Assembly Equations. . . . . . . . . . . . . . . . . . . . . . . . . . . 170 Exercise 15: Mirror Component . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172 Lesson 4: Large Assemblies Large Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177 Key Topics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177 Efficient Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178 Errors When Opening an Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 180 Designing with Sub-assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181 Modifying the Structure of an Assembly . . . . . . . . . . . . . . . . . . . . . 182 Dissolving a Sub-assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182 Promoting and Demoting Components. . . . . . . . . . . . . . . . . . . . 183 Creating a New Sub-assembly with Components. . . . . . . . . . . . 184 Opening a Sub-assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188 Information from an Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . 189 Large Assembly Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190 Lightweight Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190 Creating Lightweight Components . . . . . . . . . . . . . . . . . . . . . . . 191 After the Assembly is Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191 Best Practice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192 Comparison of Component States . . . . . . . . . . . . . . . . . . . . . . . 192 Indicators of Lightweight Status. . . . . . . . . . . . . . . . . . . . . . . . . 194 Taking Advantage of Configurations . . . . . . . . . . . . . . . . . . . . . . . . 195 Detail Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195 Comparative Savings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196 Mate Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197 Sub-assembly Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . 198 Drawing Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199 Using Component Patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 Sub-assembly Solving. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201 iv SolidWorks 2005 Training Manual Editing a Sub-assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203 Advanced Selection Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204 Advanced Show/Hide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204 Advanced Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204 Use with Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205 Property Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205 Custom Properties. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205 Saving the Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206 Envelopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206 Using Envelopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206 Layout Sketches in the Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 209 Sketch Appearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210 SolidWorks Explorer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211 Window Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212 Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213 File Management Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214 Using SolidWorks Explorer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214 Renaming Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215 Where Used. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217 Exercise 16: Using SolidWorks Explorer . . . . . . . . . . . . . . . . . . . . . 219 Exercise 17: Flexible Sub-assemblies. . . . . . . . . . . . . . . . . . . . . . . . 223 Exercise 18: Working with Sub-assemblies . . . . . . . . . . . . . . . . . . . 226 Exercise 19: Simplified Configurations . . . . . . . . . . . . . . . . . . . . . . 229 v SolidWorks 2005 Training Manual vi no Pr t c e-R op e y o lea r d se ist rib ut e SolidWorks 2005 Training Manual Do Introduction 1 SolidWorks 2005 Training Manual Do no Pr t c e-R op e y o lea r d se ist rib ut e Introduction 2