Introduction to Sheet Metal Toothbrush Holder

Toothbrush Holder Exercise 1.

Prerequisite Knowledge

Previous knowledge of the following commands is required to complete this lesson; Sketch (Line, Centerline, Circle, Add Relations, Smart Dimension,), Extrude Boss/Base, and Edit Materials. A basic knowledge of the drawing environment is also required

Focus of the Lesson This lesson focuses on designing a sheet metal part from the flattened state. In this case, you create a sheet metal part and then insert bend lines on which to fold the part. Commands Used This lesson includes Sketch (Line/Centerline, Circle, Mirror Entities, Add Relations, and Smart Dimension), Base Flange, Extruded Cut, Sketched Bend and Edit Material. A drawing of the sheet metal part will also be created. New File Save File Create a new part file. Save the file as Toothbrush Holder to a folder called Holder exercise (Continue to save periodically throughout the exercise)

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Introduction to Sheet Metal Toothbrush Holder

Getting Started

In order to begin working with Sheet Metal you must first activate the sheet metal tab on the command manager. To activate this tab, right click on the command manager. Choose Sheet Metal from the drop-down list.

The Sheet Metal tab is now active on the command manager.

Note:

The Sheet Metal commands are also available from the drop down menu by selecting Insert and Sheet Metal

Creating a sketch:

How do we start to model the toothbrush holder as a sheet metal part? We begin by creating a sketch to generate the rectangular piece of acrylic required to manufacture the artefact. What plane will this sketch be created on? Because the material sits on the horizontal plane while we carry out the work, we will create a sketch on the Top Plane. Create a rectangular sketch on the Top Plane. Left click On the Top plane and click on the sketch icon

From the Sketch toolbar, select the Corner Rectangle.

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Introduction to Sheet Metal Toothbrush Holder

Left click on the Origin, move the cursor diagonally and left click on the opposite vertex to create the rectangle. (Press Esc to exit the Corner Rectangle command) Note the automatic relations that are added to the sketch. If these are not shown, go View/Sketch Relations on the dropdown menu.

Select Smart Dimension from the Sketch toolbar and dimension the rectangle as shown.

Remember always to dimension from the shortest to the longest distances.

The sketch lines turn black when fully defined.

Exit the sketch

Sheet Metal Feature:

To create a sheet metal feature, click the Sheet Metal tab on the Command Manager and choose Base Flange Enter a value of 3mm for thickness in the Base Flange options dialog box

Click Ok

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Introduction to Sheet Metal Toothbrush Holder

About Base Flange A base flange is the first feature in a new sheet metal part. When you add a base flange feature to a SolidWorks part, the part is marked as a sheet metal part. Bends are added wherever appropriate, and sheet metal specific features are added to the FeatureManager design tree. The Base-Flange feature is created from a sketch. The sketch can be a single open, single closed or multiple-enclosed profiles. There can be only one base flange feature in a SolidWorks part. The thickness and bend radius of the Base-Flange feature become the default values for the other sheet metal features. When a base flange feature is created a number of items are added to the feature manager design tree. Sheet-Metal1: is automatically added above the Base flange feature. It holds the default sheet metal settings such as sheet metal thickness, radius etc. Sheet-Metal1 will remain at the top of the feature manager design tree (under Origin) Sheet-Metal 1 Right click on Sheet-Metal 1 and choose Edit Feature

The sheet metal settings may be changed here. Set the bend radius to 1mm in the Bend Parameters Choose OK Flat-Pattern Feature This is added below the base flange feature. It has a couple of special properties that are not found with other features. Unlike other features, flat-pattern will remain at the bottom of the tree. Other sheet metal features, when added, will appear overhead even though they are added after its creation. Secondly, the feature is suppressed when added to the design tree. We will look further at this feature as we work through this exercise.

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Introduction to Sheet Metal Toothbrush Holder

Creating the Rectangular holes

A sketch needs to be created on the top face of the Base Flange so that the rectangular holes can be formed. Right click on the top face and select the sketch icon

Select Normal To from the Heads-Up toolbar

` Select the Centerline command from the Sketch Toolbar (use the down arrow beside Line command)

Hover over the edge of the base flange and the midpoint will appear

Sketch the vertical centerline

Using the Line Command, sketch the lines shown opposite

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Introduction to Sheet Metal Toothbrush Holder

Select the two vertical lines by holding down the Ctrl key. Add a Collinear and Equal relation between the two lines.

Select Mirror Entities from the sketch toolbar

Select the 6 lines at the Entities to mirror

Click on the Mirror about dialogue box and select the centerline to mirror the sketch entities and select OK.

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Introduction to Sheet Metal Toothbrush Holder

Dimension the sketch as shown below. Note that the sketch is fully defined.

Exit the sketch.

Extruded Cut

Select Extruded Cut from the Sheet Metal toolbar

Select the sketch containing the rectangles and select Through All as the end condition. Select

Rename Feature

Double click on the Extrude 1 feature and rename as Rectangular holes

Circular Holes

Create a sketch on the top face of the base flange. Draw a vertical centerline as described earlier. Select the Circle command from the sketch toolbar

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Introduction to Sheet Metal Toothbrush Holder

Create two circles, one of which is coincident with the centerline

Use Mirror Entities to create a circle on the right of the centerline

Smart dimension as shown opposite

Exit the sketch

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Introduction to Sheet Metal Toothbrush Holder

Extruded Cut

Select Extruded Cut from the Sheet Metal toolbar. Select the previous sketch in the graphics area and choose Through All as the end condition.

Rename feature

Rename this feature as Circular holes

Shaping

Create a sketch on the top face of the base flange. Using the Line command, create the sketch shown opposite

Select the line segment and arc by holding down the CTRL key and apply a Tangent relation

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Introduction to Sheet Metal Toothbrush Holder

Apply a Tangent relation between the arc and edge of base flange

Apply a Horizontal relation between the endpoints of the line segments and the points of tangency in turn.

Dimension the sketch as shown opposite.

Exit the sketch.

Extruded Cut

Select Extruded Cut from the Sheet Metal toolbar. Select the previous sketch in the graphics area and choose Through All as the end condition. Rename as Shaping

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Introduction to Sheet Metal Toothbrush Holder

Filets

Select the Break-Corner/Corner-Trim from the Sheet Metal toolbar

Choose the settings in the property manager as indicated below

Sketched Bend

Create a sketch on the top face of the base flange. Using the line command, sketch a line coincident with the endpoints of the shaping. This line will be used as the bending line.

Select Sketched Bend from the Sheet Metal Toolbar.

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Select the bending line

Select the face that you wish to remain horizontal after the bending process

Select Material Inside as the Bend Position

Select 90 as the bending angle

Choose the default radius as the bending radius

Edit Material

Right click on Materials <not specified> in the Design Tree and select Edit Material

Scroll down to the Plastics folder and select Acrylic (Medium-high impact and choose Apply and Close

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Introduction to Sheet Metal Toothbrush Holder

Apply Colour

Right click on any face of the toothbrush holder

Select the Appearance icon and select the Toothbrush part

Select a colour from the swatch In the Appearances Property Manager

Improve Image Quality

Go to Tools/Options on the standard toolbar

Select Document Properties

Select Image Quality and move the slider to the right.

Select Ok.

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Introduction to Sheet Metal Toothbrush Holder

Flat-pattern

It is added to the bottom of the feature manager design tree when we create a sheet metal part. As sheet metal features are added to the part it remains at the bottom. You will also notice that it is greyed out or suppressed.

Unsuppress Flat-pattern

Right click on the feature and choose Unsuppress from the pop-up toolbar Or Select Flatten from the sheet metal toolbar

The sheet metal model flattens out into the surface development used to create it.

The bend line is also displayed.

Suppress

Left click on Flat-Pattern1 and choose Suppress to return to the unflattened state Or Click on Flatten in the sheet metal toolbar

Save

Save the Toothbrush Holder part file.

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Introduction to Sheet Metal Toothbrush Holder

Creating a drawing of the Toothbrush Holder

Drawing Templates These templates are used when creating presentation drawings. Parameters include sheet size, orientation etc.. The template may include a border, title block projection symbol, and text. When a presentation drawing is to be created using a part model, the template is the starting point. You should refer to the Creating Drawings CAD notes for further information on creating, saving and editing templates Creating Drawing Make Drawing from Part/Assembly takes the current part and steps through the creation of a drawing file and initial drawing views using this part. Select Make Drawing from Part/Assembly on the Standard Toolbar or choose File, Make Drawing from Part/Assembly. With the Toothbrush Holder part file open, Select Make Drawing from Part/Assembly.

Where to find it?

Getting Started

Select Drawing and then click Advanced

Choosing a Drawing Choose the drawing template you wish Template to use from the list displayed DCGA4L Choose OK

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Introduction to Sheet Metal Toothbrush Holder The DCG Templates will only be displayed here if they have been saved following the instructions outlined in the Creating Drawings CAD resource exercise Drawing Template This template creates an A4 landscape drawing. The sheet format includes a title block, projection symbol, T4 Logo and text. Note: For detailed instructions on editing the sheet format refer to Customising drawing templates in the appendix to Creating Drawings document

View Palette

The view palette is displayed in the task pane. If this is not shown, click on the icon on the task pane

The file which we are creating the drawing from, Toothbrush Holder, is displayed on top. Ensure Auto-start projected view is selected. This will project other views automatically from the parent view. The standard views are displayed in the view palette as well as any saved views from the part file. Because this is a sheet metal part, you will notice that a Flat pattern view of the model is also given.

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Introduction to Sheet Metal Toothbrush Holder Select and drag the Front view from the view palette into the drawing area. Position in the top left hand corner, as shown. This view is known as the Parent View. The other orthographic views will be projected from this view.

Projected Views

Drag the cursor to the right to project an end view; left click to position the view. Repeat the procedure to project a plan view.

Projecting an Isometric View

A number of isometric views may be projected from this view also. To project an isometric view, drag the cursor to any of the 4 corners of the front view. A different isometric view of the model will be displayed in each position. Press Esc to quit projected view

Positioning the View

When the cursor is dragged to position the isometric view on the sheet the projected view changes. This may be overcome by holding down the ctrl key while dragging, thus allowing the current view to be positioned correctly. Drag the view to a position overhead the title block, left click to position. Choose OK in the PropertyManager.

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Introduction to Sheet Metal Toothbrush Holder

Insert Flat Pattern View

Select and drag the Flat pattern view from the view palette into the drawing area

Repositioning Views

The orthographic views may be moved around the sheet but will maintain alignment. To reposition a view, move the cursor over the view. A red dotted line will surround the view. Position the cursor on the red dotted line, hold down the left mouse button and drag.

Reposition the views on the sheet

Display Style

Individual views may be displayed in a number of ways; Wireframe Displays all edges. Hidden lines visible Displays all edges, hidden lines are visible Hidden lines removed Displays edges that are visible at the chosen angle; obscured lines are removed. Shaded with edges Displays items in shaded mode with hidden lines removed. Shaded Displays items in shaded mode.

Edit display style

Highlight the isometric view by left clicking on the view. All of the properties of that view appear in the PropertyManager.

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Choose Shaded with Edges from Display Style and accept The appearance that is on the part file now is visible on the drawing view

Adding Centre Marks

Centre Marks may need to be placed on circles or arcs in drawings. These may then be used as a reference for dimensioning. Centre Marks must be added to all the circles in the various views Choose Center Mark Toolbar. from the Annotation

Deselect Use document defaults Input a Mark Size of 2mm Select the circles representing the two holes in the various views

A centre mark will be added as shown

Adding Dimensions

While dimensions can be added to all the views, they will only be added to the flat pattern view in this case Select the flat pattern view (a green box appears around it) Select Model Items from the Annotation toolbar

Choose the Entire model as the source from which to import the dimensions. Choose Marked for drawing dimensions from the model. Choose OK

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Introduction to Sheet Metal Toothbrush Holder The position of the dimensions may need to be edited

Editing Dimensions Deleting dimensions To delete a dimension highlight it and press delete on the keyboard. Move dimensions Hold down the left hand mouse button on the dimension and drag. Inference lines will appear to ease alignment of dimensions. Edit the dimensions by either moving or deleting them, to match the drawing.

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Manual Dimensioning

All of the necessary dimensions may not be present on the model. When this occurs the dimension must be inserted manually using Smart Dimension. This type of dimension is called a driven dimension because its value is driven by the model. Driven dimensions are shown in a different colour. Select Smart Dimension from the Annotation toolbar.

Smart Dimension

Using the same technique as in dimensioning sketches, select the two edges defining the distance to be dimensioned. Drag and place the dimension. Ensure that the zoom features are used to make placement and alignment of dimensions easier.

Detail View

A Detail View may be created in a drawing to show a portion of a view, usually at an enlarged scale. This detail may be taken from an Orthographic View, an Isometric View, a Section View or another Detail View. The detail view is determined by the contents of a closed sketch. The default used is a circle

Where to find it

Select Detail View from the View Layout toolbar. or Choose Insert, Drawing View, Detail. Click Detail View, the following prompt will appear.

Create a Detail View

Move the cursor to the approximate position of the centre of the viewing circle. Click and drag the radius. Note The position and radius of the viewing circle may be altered afterwards.

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Positioning the View

When the viewing circle has been defined the detail view will appear. Drag the view to position, click to drop it.

Full Outline

Selecting Full Outline will display the viewing circle in the detail view. Select OK.

Edit the scale

Select the detail view and apply a 2:1 scale

Editing the centre position

To edit the centre position, click on the circle. A blue dot with crosshairs appears at the centre. Hold and drag this to reposition the centre.

Editing the radius

Hold and drag the circumference to increase the radius. Using these two techniques, whilst displaying the detail view, will establish the detail view to show the required information.

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Introduction to Sheet Metal Toothbrush Holder Editing the title block

Right click on a clear area of the drawing sheet Select Edit Sheet Format the drawing views will disappear as the sheet background is being viewed

Double click on Design and Communication Graphics

While the text is highlighted, type in Leaving Certificate Technology. You can also edit the font type, size and colour while text is highlighted. Press Esc when you have edited the text. You can reposition the text box by left clicking on the text and dragging it into the required position

When finished, right click on the drawing sheet and select Edit Sheet the drawing views reappear

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