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1. INTRODUCTION
Solid Works is a 3D mechanical CAD program that runs on Microsoft Windows which was
developed by Solid Works Corporation, headquartered in USA, a subsidiary of Dassault
systemes. SolidWorks provides engineers, designers and other creative professionals with the
tools they need to design the worlds greatest products.
SolidWorks provides a full range of integrated modeling, simulation, visualization;
communication and validation tools that product designers need to develop better products faster
and at lower cost. In addition, its unique capabilities enable the mechanical designer to
concentrate on the product design.
SolidWorks enable the design engineer to:

Precisely turn creative concepts into 3D design.

Create the most ergonomic designs possible.
Produce design iterations in less time.
Reduce prototyping time and cost.
Work with customer data.
Manage product information more effectively.
Render highly detailed 3D design.

1.1 Modules in SolidWorks

SolidWorks extends design applications through full integration with best in class solutions. The
following modules are mainly used.

Part Modeling
Assembly Modeling
Surface Modling
Sheet Metal Design
Drawing

1.2 Features of Solidworks

SolidWorks is software developed for mechanical design engineers and contains many features
that facilitate the engineers to easily create and manage designs. Some of the important features
of solidworks are as follows:

Feature-based
Parametric
Solid modeling
Constraints

1.2.1 Feature-based
Just as an assembly is composed of a number of individual piece parts, a solidWorks model also
consists of individual constituent elements. These elements are called features. When you create
a model using the solidworks software, you work with intelligent, easy to understand geometric
features such as bosses, cuts, holes, ribs, fillets, chamfers and draft. The features are applied
directly to the work piece as soon as they are created.

1.2.2 Parametric
The dimensions and relations used to create a features are captured and stored in the model. This
enables not only to capture your design intent, but also to quickly and easily make changes to the
model. In the revolved body, hole size is reduced parametrically since all the circles are driven
by relation and dimension. A change in one hole reflects the others.

1.2.3 Solid Modeling

A solid model is the most complete type of geometry model used in CAD systems. It contains all
the wire frame and surface geometry necessary, to fully describe the edges and the faces of the
model.

1.2.4 Constraints
Geometric relations such as parallel, perpendicular, horizontal, vertical, concentric and
coincident are some of the constraints supported by solidworks.

2. Graphic User Interface of SolidWorks and Control

The format of the SolidWorks window reflects that of windows itself. The same is true for any
SolidWorks document. Once opened a document appears split into two panels. The right is the
graphics window, where your model or drawing appears. You can create and manipulate the
document in the graphics window. The Main elements of the SolidWorks user interface are as
follows:

FeatureManager design tree: Similar to the windows explorer tree it lists the structure of
the part, assembly or drawing.

PropertyManager: Appears in the left panel when you select many of the SolidWorks
commands such as sketches, fillet features and so on. The PropertyManager displays selection
icons to enter relevant command options and boxes/fields to enable the user to enter relevant
design and data parameters.

ConfigurationManager: Appears in place of the FeatureManager design tree. Helps create,

select and view multiple configurations (variations of parts and assemblies in a single document).

Main Menu: A set of drop down menus (File, Edit, View, and so on) across the top of the user
interface. The menu bar contents are task dependent based on the active document type.
SolidWorks toolbars display these functions whereas the menu bar contains the complete set.

Standard toolbar: Found just beneath the main menu this toolbar is consists of a set of the
most commonly used command buttons.

View toolbar: Features a series of commonly used command buttons that allow you to zoom,
rotate and view the part in different orientations.

Command Manager: A dynamic toolbar that lists the command buttons for the type of
document you are working on.

Graphics area: Displays the part assembly or drawing.

Quick tips help: Indicates with a question mark button whether Quick Tips is on or off. Click
the icon to toggle

Design Library: Click to open the design library. Inside you see the Design Library, Toolbox
and 3D Content Central each which contain many standard design elements you can drag and
drop into your design.

File Explorer: Duplicates Windows Explorer in your computer. Lists recently opened
documents and currently opened documents. You can drag documents from here into the
graphics area.

Triad: A traid appears in part and assembly documents to help you orient when viewing
models. The Triads is for reference only. You can not select it.

2.2 View and Orientation

A set of predefined views can be selected through the Standard view toolbar, a flyout (similar to
a drop down Menu) tool bar that is embedded in the View toolbar. If you click the Standard View
button in the View toolbar, you get a pull-down menu of several commands that represent
standard engineering views. This enables the user to select views such as Side, Front, Top, Right
and Bottom as well as perspectives: Isometric, Trimetric and Dimetric which vary in viewing.

2.2.1 Orientation
The orientation section of the View toolbar offers several tools to enable the user to manually
manipulate the orientation of a model. These manipulation tools include the following:
Zoom to Fit: Zooms in or out so the entire model is visible.
Zoom to Area: Zooms in on a portion of the view that you select by dragging a bounding box.
The centre of the box is marked with plus (+) sign.
Zoom In/Out: Zooms in as you press and hold the left mouse button and drag the mouse up.
Zooms out as you drag the mouse down.
Zoom to Selection: Zooms to the size of a selected entity.
Rotate View: Rotates the view as you press and hold the left mouse button and drag the mouse
around the screen.
Pan View: Scrolls the view so the model moves as you drag the mouse.

2.2.2 Display Modes

The third section of the View toolbar offers the following display modes for model and drawing
view in drawing documents. These tools include the following:
Shaded
Shaded with Edges

Hidden Lines Removed

Hidden Lines Visible
Wireframe (Displays all edges of the model)
Section View

Fig : Section View and PropertyManager

Control
Mouse buttons
SolidWorks uses three mouse buttons to access features, select objects and perform tasks:
Left: Selects menu items, entities in the graphics area, and objects in the
design tree.

FeatureManager

To select an entity click on the entity in the graphics window or in the feature manager design
tree. Selected objects become highlighted in both the graphics area and FeatureManager design
tree. To select multiple entities hold down the Ctrl button while continuing to click on the
objects to be selected. To select a group of objects hold down the mouse button and drag a
window around the objects. To deselect all objects click anywhere in the document window
outside the part or assembly.
Right: Displays context sensitive options and shortcut menus.
Middle:
Rotate: Hold down button and move mouse. To rotate about a vertex edge or axis (other than the
origin) click the middle mouse button on the geometry then hold and move the mouse.
Pan: Hold Ctrl button while holding down button and move the mouse
Zoom: Position cursor over the chosen position in the graphics window and hold shift and mouse
button or if available spin roller button toward you to zoom out and reverse to zoom in

Keyboard Shortcuts
Listed below are the predefined keyboard shortcuts options:
Arrow Keys . . . . . . . . . . . . . . . . Rotate the view
Shift+Arrow Keys . . . . . . . . . . . Rotate the view in 90 increments
Alt+Left or Right Arrow Keys .Rotate about normal to the screen
Ctrl+Arrow Keys . . . . . . . . . . . Move the view
Shift+z . . . . . . . . . . . . . . . . . . . . Zoom In
z. . . . . . . . . . . . . . . . . . . . . . . . . . Zoom Out
f . . . . . . . . . . . . . . . . . . . . . . . . . . Zoom to Fit

Ctrl+1 . . . . . . . . . . . . . . . . . . . . . Front Orientation

Ctrl+2 . . . . . . . . . . . . . . . . . . . . . Back Orientation
Ctrl+3 . . . . . . . . . . . . . . . . . . . . . Left Orientation
Ctrl+4 . . . . . . . . . . . . . . . . . . . . . Right Orientation
Ctrl+5 . . . . . . . . . . . . . . . . . . . . . Top Orientation
Ctrl+6 . . . . . . . . . . . . . . . . . . . . . Bottom Orientation
Ctrl+7 . . . . . . . . . . . . . . . . . . . . . Isometric Orientation
Ctrl+8 . . . . . . . . . . . . . . . . . . . . . View Normal To
Spacebar . . . . . . . . . . . . . . . . . . View Orientation dialog
Ctrl . . . . . . . . . . . . . . . . . . . . . . . Hold and select multiple items with mouse button
Ctrl+c . . . . . . . . . . . . . . . . . . . . . Copy selected entity/item
Ctrl+z . . . . . . . . . . . . . . . . . . . . . Undo
Ctrl+y . . . . . . . . . . . . . . . . . . . . . Redo
Ctrl+Tab . . . . . . . . . . . . . . . . . . .Switch between documents
Alt+drag . . . . . . . . . . . . . . . . . . . Select anywhere in a drawing view
Shift+drag . . . . . . . . . . . . . . . . . Maintains distance between drawing views while dragging
Ctrl+R . . . . . . . . . . . . . . . . . . . . .Redraw
Ctrl+B . . . . . . . . . . . . . . . . . . . . .Rebuild

Customizing the SolidWorks window

System options
The options grouped under the heading System Options are saved on your system and affect
every document you open in your SolidWorks session. System settings allow you to control and
customize your work environment. For example, you might like working with a coloured

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graphics window background. Since this is a system setting, parts or assemblies opened on your
system would have a coloured graphics window.

Fig: Located on the tools menu the options dialogue box allows you to customize the
SolidWorks software.

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3. CREATE A PART (PART MODELING)

3.1 Create Your Part

Stages in the Process

Create a New part document

New parts can be created in inch, millimetre or other units. Parts are used to create and hold
the solid model.

Sketch the profile

Sketches are collections of 2D geometry that are used to create solid features. These include
lines, circles and rectangles.

Applying Sketch relations and dimensions

Geometric relationships such as horizontal and vertical are applied to the sketch geometry.
Dimension size the geometry while the relations restrict the movement of the entities.

Extruding the sketch

Extruding uses the 2D sketch to create a 3D solid feature.

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3.2 Procedure
The process in this includes sketching and extrusions. To begin with, a new part file is
created.

3.2.1 Create a New part document

1. New part

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2. Filing a part.
Using the Save option from the File menu or selecting the Save button on the Standard
toolbar; file the part under the name Candle Holder. The extension, *.sldprt, is added
automatically. Click Save.

3. Select the Plane we want to Sketch on.

It is important to choose the correct plane to sketch on this is done by selecting the best profile to
sketch of the part. The best profile to sketch is the profile when selected extruded generated the
majority or most complexities of the part.
The direction we look at to part to get the get the best profile whether it be the plan, elevation or
end view will determine sketching on the Top, Front or Right Plane.
By giving careful thought to which plane is used to sketch the profile, the proper views are easily
generated on the detail drawing.

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Fig: Sketching Planes

Sketch toolbar

4. What is Design Intent:

Design Intent is our plan as to how our model should behave when changes are made. How Do
we Imbed Design intent?

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We can imbed design intent following the steps below:

4.

Choose the Best Profile

Choose the Plane
Sketch
Rough Sketch
Automatic (sketch) Relations
Added Relations
Dimensions
Equations
Link Values
Extrusion
Type of extrusion used
End Condition
Blind
Mid Plane

Create our sketch by selecting the Top Plane and then the Sketch Icon

Rule of Thumb When Sketching

Rough Sketch
Add Relations
Add Dimensions

Relations such as parallel, horizontal, vertical and tangent and so on, can be automatically
added to the sketch while sketching.

Link Values / Equations

5. We know we are actively in a sketch by the following screen

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6. Select the Line Command on the sketch toolbar and draw a rectangle on the screen.
The positioning of the sketch in relation to the origin is important. ( your sketch must be attached
to the origin in some form in order to fully define the sketch)
Tip: By positioning the origin in the centre of the square by using a construction line the origin is
positioned in the centre. This enables you to place the circle in the centre of the cube later on.

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7. Dimension the Sketch using the dimension icon.

8. Conditions of a Sketch.
Under Defined
There is inadequate definition of the sketch, but the sketch can still be used to create features.
This is good because many times in the early stages of the design process, there isnt
sufficient information to fully define the sketch. When more information becomes available,
the remaining definition can be added at a later time. Under defined sketch geometry is blue
(by default).

Fully Defined
The sketch has complete information. Fully defined geometry is Black (by default). As a
general rule, when a model is completed, the sketches within it should be fully defined.

Over Defined
The sketch has duplicate dimensions or conflicting relations and it should not be used until
repaired. Unnecessary dimensions and relations should be deleted. Over defined geometry is
red (by default).

9. Select the Features Icon on the Command Manager.

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10. Select the extrude command and extrude the 2d Profile.

Design Intent at extrusion stage.

Examples of design intent in respect of features

Base Extrude
Revolve
Cut Extrudes
Shell
Fillets
Chamfer
Examples of design intent in respect to End Conditions of features
Blind
Through all
Mid-plane
Up to Next
Up to Surface

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Fig. Extruded 2D sketch

11. Select Top Face of the Cube and create a sketch by selecting the Sketch icon

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12.

Select a circle command start the center of the circle at the origin.

13. Select the Cut Extrude command form the Feature Tool Bar.

14. Cut Extrude Blind into the cube or as required.

15. Create a Sketch on the Front Face of the Cube.

16. Using the Centre Line command sketch a centre line across the diagonal

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17. Using the Polygon Command, sketch a polygon starting on the midpoint of the centre
line.
18. Select the top line of the polygon and add the relationship of horizontal in the Property
Manager
19. Dimension the top line of the polygon.

20. Cut Extrude the Sketch.

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21. Add a chamfer to the Polygon.

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Fig. Chamfer options and Projected view of chamfered part.

22. Select all 6 edges of the Polygon.

23. Apply the same chamfer to the edge of the circle.
24. Add Fillet to all 8 edges as can be seen in Picture.
25. Select Fillet command from the Features Tool Bar.
26. Select the options like dimension and angle of fillet.

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Projected view of Fillet

27. Apply a material to the part. In the Feature Manager right click on add material and
select any material(say brass) and say ok.

29. Save the Part File as *.SLDPRT format.

4. REFERENCE GEOMETRY

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Reference geometry assist in creating the CAD models. Reference geometry includes planes,
axes, points and coordinate systems. These reference geometries act as a reference for drawing
the sketches in sketched features, defining the sketch planes and assembling the components.
They also serve as a interface for various placed and sketched features and so on.

Fig. Reference geometry option in toolbar.

4.1 Types of Reference Geometry

4.1.1 Reference Planes
This feature allows the user to create additional planes to sketch on other than the given right,
front, and top plane. To create a reference plane left click on plane
and select the desired option in the property manager for creating
the plane. These options include:
1. Through lines/points: creates a plane through a point an
edge, sketch line, three points, or axis.
2. Parallel plane at point: creates a plane through a point
parallel to a plane or face.
3. At angle: create a plane through an axis, edge or sketch line at
a specified angle from a face or plane.
4. Offset distance: create a plane parallel to an existing plane
and specifying the desired distance.
5. Normal to curve: Create a plane through a specified point
and makes it perpendicular to a desired curve or edge.
6. On surface: creates a plane on a non-planer face or angled
surface.

4.1.2 Reference Axes

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Allows the user to insert an axis in the part document. Axes

are particularly useful in creating part features. To create a
reference axis left click on axis and select the desired option
in the property manager for creating the axis. These options
include:
1. On edge: places an axis on a desired edge or sketch line of
the part.
2. Two planes: create an axis at the intersection of two
planes or planar faces.
3. Two points/vertices: create an axis through two selected
points, vertices, or midpoints on a line, edge, or part corner.
4. Cylindrical/conical faces: places an axis through the
center of a circular, cylindrical, or conical face. This axis can
also be seen by right clicking on view and then selecting
temporary axes.
5. Point and a face: creates an axis perpendicular to a selected face or plane and through a
selected point, midpoint, or vertex.

4.1.3 Reference Coordinate Systems

Create an additional coordinate system on the part
by specifying the x, y, and z directions with the
parts geometry. This can be helpful when
integrating a part into an assembly as a reference
for directional part interactions as well as setting up
a zero point for machining and manufacturing the
part.

4.1.4 Reference Point

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Add a singular location on a part document that references geometries found on the modeled
part. These can be placed at the center of an arc, the center of a face, an intersection, along a
curve, or projected onto another entity. These can be helpful in making point clouds to help
define and place three or two dimensional sketches. Most commonly used in complicated parts
such as vehicle frames.

5. ASSEMBLY MODELING

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Assembly is a combination of two or more components using parametric relationship. In solid

works, these relations are called Mates. These mates enable you to constrain degrees of freedom
of the components at their respective work positions. Components can be part or sub assembly.

5.1 Types of Assembly Design Approach

There are two approaches for making an assembly.

Bottom-up Design
Top-down Design

Bottom-up Design
It is the traditional method. In bottom-up design, you can create parts, insert them into an
assembly, and constraint them as required by your design. Bottom-up design is the preferred
technique when you are using previously constructed, off-the-shelf parts. An advantage of
bottom up design is that, because components are designed independently, their relationships and
regeneration behavior are simpler than in top-down design.

Top-Down Design
In top down design you can start your work in the assembly and built parts to fit in the assembly.
You can use the geometry and built parts to fit in the assembly. You can use the geometry of one
part to help define the other parts or to create machined features that are added only after the
parts are assembled. You can start with a skeleton model/layout sketch that defines fixed part
locations, planes and so on. Then design the parts referencing these definations.

5.2

ASSEMBLY MATES

Mates create geometric relationships between assembly components. As you add mates, you
define the allowable directions of linear or rotational motion of the components. You can
move a component within its degrees of freedom, visualizing the assembly's behavior. Mates
are solved together as a system. The order in which you add mates does not matter; all mates
are solved at the same time. You can suppress mates just as you can suppress features. These
include:

Standard mate
Advanced mate
Mechanical mate

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Smart mate
Mate reference

5.2.1

Standard mate

Mates create geometric relationships, such as coincident,

perpendicular, tangent, and so on. Each mate is valid for specific
combinations of geometry. The following tables list the valid
mates for all geometry types.

Coincident - The Coincident mate is applied to make two

planar faces coplanar. However, you can apply the
Coincident mate to other entities as well.
Concentric - The Concentric mate is used to align the
central axis of one component with that of the other. You
need to select the circular faces or circular edges to apply
the Concentric mate. You can also apply the Concentric
mate between a point and a circular face or a circular
edge.
Distance - The Distance button is chosen to apply the
Distance mate between two components. To apply this
mate, invoke the Mate Property Manager and select the
entities from both components. Choose the Distance
button from the Mate pop-up toolbar; the Distance
spinner will be displayed in the Mate pop-up toolbar.
Angle - The Angle button is used to apply the Angle mate
between two components. This mate is used to specify
the angular position between the selected plane, planar face, or edges of the two
components. To apply this mate, invoke the Mate Property Manager and select the
entities from the two components.
Parallel - The Parallel button in the Mate pop-up toolbar is used to apply the Parallel
mate between two components. To apply the Parallel mate, invoke the Mate Property
Manager and select two entities from two components.

Perpendicular - The Perpendicular button in the Standard Mate rollout is used to

apply the Perpendicular mate between the two components. Invoke the Mate Property
Manager and select two entities from two components.

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Tangent - The Tangent button available in the Mate pop-up toolbar is used to apply
the Tangent mate between two components. To apply the Tangent mate between two
components, invoke the Mate Property Manager and select two components.

5.2.2

Smart Mate

Smart Mates is the most attractive feature of the assembly

design environment in Solid Works. The Smart Mates
technology speeds up the design process in the assembly
environment of Solid Works. To add smart mates to the
components, choose the Move Component button from the
Assemble Command Manager ;the Move Component
Property Manager will be displayed .Now, choose the Smart
Mates button available in the Move rollout; the Move
Component Property Manager will be replaced by the Smart
Mates Property Manager.

5.2.3

Mate Reference

In Solid Works, you can define the mate reference for the part
in the Part mode or in the Assembly mode. The mate
references allow you to define the mating references such as
planar surfaces, axes, edges, and so on before assembling the
component. To define the mate references, choose Reference
Geometry > Mate Reference from the Assemble Command
Manager; the Mate Reference Property Manager will be
displayed.

5.2.4

Advanced Mates

Advanced mates include limit, linear/linear coupler, path, symmetry, and width mates.

Symmetric

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A symmetric mate forces two similar entities to e symmetric about a plane or planar
face of a component or a plane of the assembly. The following entities are allowed in
symmetry mates:
Points such as vertices or sketch points
Lines such as edges, axes or sketch lines
Planes or planar faces
Spheres of equal radii
Cylinder of equal radii

Width
A width mate centers a tab within the width of a groove . groove width references can
include:
Two parallel planar faces
Two non-planar faces

Path
A path mate constrains a selected point on a component, to a path. You can define the
path by selecting one or more entities in the assembly. You can define pitch, yaw and
roll of the component as it travels along the path.

Linear/linear Coupler
A linear/linear coupler mate established a relationship between the translation of one
component and the translation of another component.

Linear
Limit mates allows components to move within the range of values for distance or
angle as well as a maximum and minimum value.

5.2.5

Mechanical Mates

Mechanical mates include cam-follower, gear, hinge, rack and pinion, screw, and universal
joint mates.

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Cam
A type of tangent or coincident mate. Asks the user to
select all of the cam face to which the follower will lie
on and the face of the follower that will touch the
cam.

Hinge
Constrain two components rotational degrees of
freedom. Asks user to input two concentric sections,
coincident faces, and the angle limit (how far the
components can move from each other identical to
angle mate).

Gear
Mates two gears or cylindrical faces so that the two
components rotate relative to one another about an
axis.
Note: Select the inside bore hole of the gear or the
axis, do not select the face of the gear.

Rack Pinion
Similar to the gear mate except that the revolution of one component corresponds to
the linear movement of the mating component. This mate does not require gear teeth.

Screw
Constrains two components with a concentric mate and defines a pitch relationship
between the rotation of one component and the translation of another.

Universal Joint
The rotation of a component about its axis is controlled by the rotation of the mating
component about its axis.

5.3

ROTATING INDIVIDUAL COMPONENTS

In SolidWorks, you can rotate an individual unconstrained component in the assembly
document without affecting the position and location of the other components. The
Rotate Component tool is used to rotate the component.

5.3.1

Rotating Individual Components by Dragging

You can rotate the component placed in the assembly without invoking any tool. To
rotate an individual component, select the component, press and hold the right mouse

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button and then drag the cursor to rotate the component. Release the right mouse
button after attaining the desired orientation of the individual component.
5.3.2

Rotating Individual Components Using the Rotate Component Tool

You can also rotate an individual component using the Rotate Component tool. To
rotate an individual component using this tool, choose Move Component > Rotate
Component from the Assemble Command Manager; the Rotate Component
Property Manager will be invoked. You will notice that the Free Drag option is
selected from the Rotate drop-down list in the Rotate rollout. Therefore, you will be
prompted to select a component and drag it to rotate. The select cursor will be
replaced by the rotate cursor. Select the component and drag the cursor to rotate the
component.

6. DRAWING VIEWS
Drawings are essentially a mean to communicate the design to the manufacturing entity of
any organization. Mechanical drawings are important because they allow those who are
technically trained to reconstruct your 3D geometry from 2D drawings. Fortunately,
SolidWorks makes it very easy for us to create drawings from a part or assembly file. In fact,
if built properly, SolidWorks will also dimension the entire part and assembly for us,
something that saves a lot of time.

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More important than the ability to create a complex lofted surface is the fact that once you
have modeled your design, multiview drawings are just a few mouse clicks away. BOMs can
be created automatically from the assembly structure, and alternate position views are
generated with a simple drag of the mouse.

6.1 Steps Involved In Creating Drawing Views

1. Click New in the standard toolbar, or click file>> new from the menu bar.
2. In the new solid works document dialog box that is displayed, as shown, select the
drawing option and click ok.

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3. Select the desired sheet format in sheet format/size dialog box as shown in earlier topic
and then click ok. Click cancel, if you do not want to use any sheet format. You can also
create
custom
sheet
size
selecting
custom
sheet
size.

4. In model view property manager, select a model from open documents as shown or
browse to part or assembly file.

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5. Specify options in the Model View Property Manager, and

then place the view in the graphics area.
6. Position the Front Elevation on the drawing sheet and Left
click.
7. Move Mouse to the Left of the Front Elevation to Create
the Side Elevation (left click to position view).
8. Move Mouse Under the Front Elevation to Create the Plan
View / Top View (left Click to position View).
9. Move Mouse up too the Left Diagonal of the Front View
to Create the isometric view. Hold down the Ctrl key and
position the view under the Side Elevation.
10. Hold Down the Ctrl Key and Select all Drawing Views.
11. Select the Hidden Lines icon from the views toolbar to
show hidden lines in all views.
12. Drawing Views Should Look like below.
13. Smart dimensions can be used to apply any missing
dimensions manually.
14. For saving the file, click save in the standard toolbar or
click file>>save. The file will be saved with .slddrw.

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7.

SHEET METAL
Sheet metal is simply metal formed into thin and flat pieces. It is one of the fundamental
forms used in metalworking, and can be cut and bent into a variety of different shapes. The
main feature of sheet metal is its ability to be formed and shaped by a number of processes.
Each process does alter the metal, finally giving it a different shape or size.
Sheet metal is generally sheets less than 6 mm. Sheet metal is formed by reducing the
thickness of a long metal work piece by compressive forces applied through a set of rolls. It
is characterized by its thickness or gauge of the metal and ranges from 30 gauge to about 8
gauge. The higher the gauge, the thinner is the metal.
There are many different metals that can be made into sheet metal. Aluminum, brass, copper,
cold rolled steel, mild steel, tin, nickel and titanium are just a few examples of metals that
can be made into sheet metal. Sheet metal has applications in car bodies, airplane wings, etc.

7.1 Sheet Metal Tools

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When you create a sheet metal operation in SolidWorks, new feature namely, sheet-metal ,
base-flange and flat-pattern, are automatically created. Sheet-metal contains the bend
parameters such as bend radius, bend allowance, bend deduction, etc. Base-flange is the first
solid feature of sheet metal part. Flat-Pattern flattens the sheet metal part. It is suppressed by
default, as the part is in its bent state. Unsuppress the feature to flatten the sheet metal part.
There are various tools within the part module that SolidWorks provides to build the sheet
metal parts.

7.2 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.

7.3 Edge Flange

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Edge Flange is used to add flanges to one or more edges. You can also select multiple linear
edges, which are contiguous or non- contiguous. With contiguous edges, the software
automatically trims to 45 degrees.

7.4 Miter Flange

A miter flange feature adds a series of flanges to one or more edges of a sheet metal part.
Some items to note about a miter flange feature are:
1. The sketch for a miter flange must adhere to the following requirements:
The sketch can contain lines or arcs.
The miter flange profile can contain more than one continuous line. For example,
it can be an L-shaped profile.

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The sketch plane must be normal to the first edge where the miter flange is
created.
2. The thickness is automatically linked to the thickness of the sheet metal part.
3. You can create a miter flange feature on a series of tangent or non-tangent edges.
4. Instead of creating a miter flange across the entire edge of a sheet metal part, you can
specify an offset of the flange.

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7.5 Hem
The Hem tool adds a hem to your sheet metal part at a selected edge. The following points
are to be noted for Hem feature.
1. The selected edge must be linear.
2. Mitered corners are automatically added to intersecting hems.
3. If you select multiple edges to add a hem, the edges I must lie on the same face.

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7.6 Jog
The jog tool adds material to a sheet metal part by creating two bends from a sketched line.
Some additional items to note about the Jog tool are:
1. The sketch must contain only one line. The line does not need to be horizontal or vertical.
2. The bend line does not have to be the exact length of the faces you are bending.

7.7 Break Corner/Corner Trim

The Break Corner tool cuts away material from a sheet metal part on an edge or a face. The
Corner Trim tool cuts material away from a flattened sheet metal SB on an edge or a face.

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7.8 Closed Corners

You can add closed corners between sheet metal flanges. The
Closed Comer feature adds material between sheet metal
features. The following are the capabilities of Closed Comer:
1. Close multiple corners simultaneously by selecting the
faces for all the comers that you want to close.
2. Close non-perpendicular corners.
3. Apply a closed corner to flanges with bends other than
90.
4. Adjust the Gap distance, the distance between the two
sections of material where area is added by the Closed
Comer feature.
5. Adjust the Overlap/Underlap ratio. The ratio between the
material that overlaps and the material that underlaps. The
value 1 indicates that the overlap and the underlap are
equal.
6. Close or open the bend region.
Closed corner

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7.9 Rip
A Rip feature is a cut that is used to "saw" a part along a specified line or edge. SolidWorks
creates a rip feature, along selected internal or external model edges, from linear sketch
entities or by combining model edges and single linear sketch entities. A rip feature is
commonly used to create sheet metal parts. You can add a rip feature to any part.

7.10

Sketch Bend

You can add bend lines to the sheet metal part, while; the part is in its folded state with a
sketched bend feature. This allows you to dimension the bend line to other folded-up
geometry. Some items to note about a sketched bend feature are:
1. Only lines are allowed in the sketch. You can add more than one line per sketch.
2. The bend line does not have to be the exact length of the faces you are bending.

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7.11 Unfold/Fold
With the Unfold and Fold tools, you can
flatten and bend one, more than one or
all the bends in a sheet metal part. This
combination is useful while adding a cut across a bend. First, add an Unfold feature to flatten
the bend. Next, add your cut. Finally, add a Fold feature to return the bend to its folded state.

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7.12

Forming Tools

forming tools act as dies that bend, stretch, or otherwise form sheet metal to create form
features such as louvers, lances, flanges and ribs. The SolidWorks software includes some
sample forming tools to get you started. They are stored in < mstai/_dir >\data\design library\
forming tools. You can insert forming tools only from the Design Library and you can apply
them only to sheet metal parts. A sheet metal part has the Sheet-Metal I feature in the
FeatureManager design tree. You can create your own forming tools using many of the same
steps you use to create any SolidWorks part.
Creating a Forming Tool
You can create forming tools and add them to sheet metal parts. When you create a forming
tool:
1. The locating sketch is added to position the forming tool on the sheet metal part.
2. The colors are applied to distinguish the stopping face from the faces to remove.

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7.13

Cross Break

In HVAC (Heating, Ventilating and Air Conditioning) or

duct work design, cross breaks are used to stiffen sheet i
metal. The Cross Break command allows you to insert [ a
graphical representation of a cross break in a sheet metal
part. Cross break characteristics:
1. You can flatten a sheet metal part with a cross break.
2. You can add edge or miter flanges to the edge of a face
that contains a cross break.
3. The dimensions of a part with a cross break are not
changed.
4. You can edit the cross break sketch to move comers
and change relationships.
5. When you create a part with a cross break, the flattened view is labeled with the bend
direction, bend radius and bend angle.

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7.14

Welded Corner

The Welded Comer PropertyManager allows you to add a weld bead to the corners of a
folded sheet metal part, including miter flanges, edge flanges and closed comers.

7.15

Lofted Bends

Lofted bends in sheet metal parts use two open-profile sketches that are connected by a loft.
The Base-Flange feature is not used with the Lofted Bend feature The SolidWorks software
contains several pre-made sheet metal parts created with lofted bends, locate! in:
<install_dir>\Documents and Settings\AIl Users! Application Data\SolidWorks\SolidWorks
2010\desig* library\ Parts\sheet metal\lofted bends.
Characteristics of Lofted Bends:
1. K-Factor or Bend Allowance to calculate bends.
2. Cannot be mirrored.
3. Requires two sketches that include:
Open profiles without sharp edges.
Aligned profile openings to ensure flat pattern accuracy.

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8. WORKBOOK
8.1
Part Modeling

Fig. Pivot

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Fig. Body of Vice

Fig. Spring

Fig. Screw Rod

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8.2

Surface Modeling

Fig. Water Container

Fig. Oil Can

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Fig. Helmet

8.3

Sheet Metal

Fig. CPU cover

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Fig. Amplifier Cover

8.4

Assembly

Fig. Safety Valve

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Fig. Machine Vice