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—------ Introduction to
Solid Modeling
Using SOLIDWORKS® 2022
Introduction to
Solid Modeling
Using SOLIDWORKS 2022
William E. Howard
East Carolina University

Joseph C. Musto
Milwaukee School of Engineering

Me
Graw
Hill
Me
Graw
Hill
INTRODUCTION TO SOLID MODELING USING SOLIDWORKS® 2022

Published by McGraw Hill LLC. 1325 Avenue of the Americas. New York. NY 10019 Copyright
©2023 by McGraw Hill LLC All rights reserved. Printed in the United States of America Previous
editions ©2022, 2021, and 2020 No part ol this publication may be reproduced or distributed in any
form or by any means, or stored in a database or retrieval system, without the prior written consent
ol McGraw 11111 LLC, including, bin not limited to, in any network or other electronic storage or
transmission, or broadcast for distance learning

Some ancillaries, including electronic and print components, may not be available to customers outside
the United States

1 his book is printed on acid-free paper

12 3 4 5 6 7 8 9 LKV 27 26 25 24 23 22

ISBN 978-1-264-16309-0 (bound edition)

MHID 1-264-16309-6 (bound edition)
ISBN 978-1-264-44655-1 (loose-leaf edition)
MHID 1-264-44655-1 (loose-leaf edition)

Portfolio Manager Beth Bettchcr

Product Developer. Heather Ervohno
Marketing Manager: Lisa Granger
Content Project Managers: Jem McAtee, Rachael Hillebrand
Buyer Rachel Hirschtield
Designer. David W Hash
Content Licensing Specialist Lorraine Buc/ek
Cover Image Joseph C Musto
Compositor Fleck's Communications, Ine-

All credits appearing on page or at the end ol the book arc considered to be an extension of the copy -
right page

Library ol Congress Cataloging in-Publication Data

All Figures within, unless olherw ice noted, are from SOLID33 ORKS- Software

The Internet addresses listed in the test were accurate at the time of publication The inclusion of a
website docs not indicate an endorsement by the authors or McGraw Hill LLC . and McGraw Hill LLC
does not guarantee the accuracy ol the information presented at these sites

nih cd ucacion co ni/high c re d

About the Authors
Ed Howard is an Associate Professor in the Department of Engineering
at East Carolina University, where he teaches classes in solid modeling,
engineering computations, solid mechanics, and composite materials.
Prior to joining ECU, Ed taught at Milwaukee School of Engineering.
He holds a B.S. in Civil Engineering and an M.S. in Engineering
Mechanics from Virginia Tech, and a Ph.D. in Mechanical Engineering
from Marquette University.

Ed worked in design, analysis, and project engineering for 14 years

before beginning his academic career. He worked for Thiokol
Corporation in Brigham City, UT; Spaulding Composites Company in
Smyrna, TN; and Sta-Rite Industries in Delavan, WI. He is a registered
Professional Engineer in Wisconsin.

Joe Musto is a Professor in the Mechanical Engineering Department

at Milwaukee School of Engineering, where he teaches in the areas of
machine design, solid modeling, and numerical methods. He holds a B.S.
degree from Clarkson University, and both an M.Eng. and Ph.D. from
Rensselaer Polytechnic Institute, all in mechanical engineering. He is a
registered Professional Engineer in Wisconsin.

Prior to joining the faculty at Milwaukee School of Engineering, he

held industrial positions with Brady Corporation (Milwaukee, WI) and
Eastman Kodak Company (Rochester, NY). He has been using and
teaching solid modeling using SOLIDWORKS since 1998.

Joe and Ed, together with Rick Williams of Auburn University, are the
authors of Engineering Computation: An Introduction Using MATLAB®
and Excel®.

iii
 --T3
Special Features vii
Preface ix
4 Advanced Part Modeling 119
4.1 A Lofted and Shelled Part 119
4.2 Parts Created with Swept
PART ONE Geometry 129

Learning SOLIDWORKS" 1 4.3 A Part Created with a 3-D Sketch as the

Sweep Path 133
1 Basic Part Modeling Techniques 3 Problems 140
1.1 Engineering Design and Solid Modeling 4
1.2 Part Modeling Tutorial: Flange 5 O Parametric Modeling Techniques 149
1.3 Modifying the Flange 25 5.1 Modeling Tutorial: Molded Flange 150
1.4 Using Dimensions and Sketch Relations 30 5.2 Creation of Parametric Equations 163
1.5 A Part Created with Revolved Geometry 35 5.3 Modeling Tutorial: Cap Screw with
Problems 49 Design Table 167
5.4 Incorporating a Design Table in a
2 Engineering Drawings 55 Drawing 174
2.1 Drawing Tutorial 55 Problems 181
2.2 Creating a Drawing Sheet Format 70
2.3 Creating an eDrawing 76
6 Creation of Assembly Models 191
Problems 80 6.1 Creating the Part Models 192
6.2 Creating an Assembly of Parts 197
3 Additional Part Modeling 6.3 Adding Features at the Assembly Level 206
Techniques 83
6.4 Adding Fasteners to the Assembly 209
3 .1 Part Modeling Tutorial: Wide Flange Beam 6.5 Creating an Exploded View 213
Section 84
Problems 219
32 Part Modeling Tutorial: Bracket 92
33 Sharing and Displaying the Solid
Model 106
I Problems 111

v
vi Contents

11. 4 Creating Simulations and Animation with

/ Advanced Assembly Operations 229 a Motion Study 306

7.1 Creating the Part Models 229 11. 5 Investigating Mechanism Design 310

72 Creating a Complex Assembly of Problems 315

Subassemblies and Parts 230

7.3 Detecting Interferences and Collisions 236 12 Design of Molds and Sheet Metal
Problems 238 Parts 327
121 A Simple Two Part Mold 327
O
0 Assembly Drawings 241 1 2.2 A Core and Cavity Mold 332
81 Creating an Assembly Drawing 241
12 3 A Sheet Metal Part 340
82 Adding an Exploded View 243
Problems 348
83 Creating a Bill of Materials 246

Problems 250 13 The Use of SOLIDWORKS111' to

111
Accelerate the Product Development
Cycle 353
PART TWO 131 3 D Printing 354

Applications of SOLIDWORKS' 253 132 Finite Element Analysis 362

13.3 Product Data Management 364

9 Generation of 2-D Layouts 255 13.4 Some Final Thoughts 366

9.1 A Simple Floor Plan Layout 255

92 Finding the Properties of 2-D Shapes 268

Problems 273 APPENDIX

10 Solution of Vector Problems 277 A Recommended Settings 367
101 Vector Addition 277 A1 System Settings 367

10.2 Vector Addition with SOLIDWORKS 278 A2 Part Settings 369

10.3 Modifying the Vector Addition A3 Drawing Settings 374

Drawing 280 A4 Assembly Settings 376
10.4 Further Solution of Vector Equations 283 A5 Backing Up and Transferring Settings 377
10.5 Kinematic Sketch of a Simple A6 Summary of Recommended Settings 381
Mechanism 286

Problems 293 B The SOLIDWORKS Interface:

Use and Customization 383
11 Analysis of Mechanisms 297
111 Approaching Mechanism Design with Index 399

SOLIDWORKS Assemblies 298

112 Development of Part Models of Links 299

11.3 Development of the Assembly Model of the

Four-Bar Linkage 302
 1

SPECIAL
FEATURES
DESIGN INTENT FUTURE STUDY
Planning the Model 19 Dynamics (Kinetics) 47

Selecting a Modeling Technique 24 Manufacturing Processes, Geometric Dimensioning

and Tolerancing, and Metrology 67
Planning for Other Uses of the Model 40
Industrial Design 128
Choosing the Initial Sketch Plane 42
Industrial Engineering 267
Keeping It Simple 46
Mechanics of Materials 271
Exploiting Associativity 62
Machine Dynamics and Machine Design 311
Symmetry in Modeling 104
Materials and Processes 339
Planning an Assembly Model 199

Part-Level and Assembly-Level Features 209

VIDEOS
Manufacturing Considerations 215
Example 1 6
Assembly-Level Dimensions 244
Example 2 56

Example 3 105

Example 4 120

Example 5 192

Example 6 362

Example 7 368

vii
PREFACE
As design engineers and engineering professors, the authors have witnessed
incredible changes in the way that products are designed and manufactured. One of
the biggest changes over the past 35 years has been the development and widespread
usage of solid modeling software. When we first saw solid modeling, it was used
only by large companies. The cost of the software and the powerful computer
workstations required to run it, along with the complexity of using the software,
limited its use. As the cost of computing hardware dropped, solid modeling software
was developed for personal computers. In 1995, the SOLIDWORKS® Corporation
released the initial version of SOLIDWORKS® software, the first solid modeling
program written for the Microsoft Windows operating system. Since then, the use
of solid modeling has become an indispensable tool for almost any company, large
or small, that designs a product.

Motivation for This Text

When we saw a demonstration of the SOLIDWORKS software in 1998. we were both
instantly hooked. Not only was the utility of the software obvious, but the program
was easy to learn and fun to use. Since then, we have shared our enthusiasm for the
program with hundreds of students in classes at Milwaukee School of Engineering
and East Carolina University, in summer programs with high school students, and in
informal training sessions. Most of the material in this book began as tutorials that
we developed for these purposes. We continue to be amazed at how quickly students
at all levels can learn the basics of the program, and by the sophisticated projects
that many students develop after only a short time using the software.

While anyone desiring to learn the SOLIDWORKS program can use this book,
we have added specific elements for beginning engineering students. With these
elements, we have attempted to introduce students to the design process and to
relate solid modeling to subjects that most engineering students will study later. We
hope that the combination ol the tutorial style approach to teaching the functionality
of the software, together with the integration of the material into the overall study of
engineering, will motivate student interest not only in the SOLIDWORKS software
but in the profession of engineering.

SOLIDWORKS is a registered trademark of Dassault Systémes SolidWorks Corporation.

eDrawings is a trademark of Dassault Systémes SolidWorks Corporation.

ix
X Preface

Philosophy of This Text

The development of powerful and integrated solid modeling software has
continued the evolution of computer-aided design packages from drafting/graphical
communication tools to full-fledged engineering design and analysis tools. A solid
model is more than simply a drawing of an engineering component; it is a true
virtual representation of the part, which can be manipulated, combined with other
parts into complex assemblies, used directly for analysis, and used to drive the
manufacturing equipment that will be used to produce the part.

This text was developed to exploit this emerging role of solid modeling as an
integral part of the engineering design process; while proficiency in the software
will be achieved through the exercises provided in the text, the traditional “training"
exercises will be augmented with information on the integration of solid modeling
into the engineering design process. These topics include:

• The exploitation of the parametric features of a solid model, to not only provide
an accurate graphical representation of a part but also to effectively capture an
engineer’s design intent.
• The use of solid models as an analysis tool, useful for determining properties of
components as well as for virtual prototyping of mechanisms and systems,
• The integration of solid modeling with component manufacturing, including
the generation of molds, sheet metal patterns, and rapid prototyping files from
component models.

Through the introduction of these topics, students will be shown not only the
powerful modeling features of the SOLIDWORKS program, but also the role of the
software as a full-fledged integrated engineering design tool.

The Use of This Text

This text primarily consists of chapter-long tutorials, which introduce both basic
concepts in solid modeling (such as part modeling, drawing creation, and assembly
modeling) and more advanced applications of solid modeling in engineering analysis
and design (such as mechanism modeling, mold creation, sheet metal bending, and
rapid prototyping). Each tutorial is organized as "keystroke-lever' instructions,
designed to teach the use of the softw are.

While these tutorials offer a level of detail appropriate for new professional users,
this text was developed to be used as part of an introductory engineering course,
taught around the use of solid modeling as an integrated engineering design and
analysis tool. Since the intended audience is undergraduate students new’ to the field
of engineering, the text contains features that help to integrate the concepts learned
in solid modeling into the overall study of engineering. These features include:
Video Examples: Short video tutorials accompany multiple chapters.
These videos introduce students to the concepts of solid modeling and the
SOLIDWORKS commands that they will use in the chapter following the step-
by-step tutorials. These videos cox er:
— Getting started with modeling (Chapter 1 ):
— Making 2-D drawings (Chapter 2):
 Preface xi

— Using symmetry when creating parts (Chapter 3);

— Creating parts with lofts and sweeps (Chapter 4);
— Making assemblies from part files (Chapter 6);
— Making parts with 3-D printing (Chapter 13);
— Setting up the SOLIDWORKS interface (Appendix A).
• Design Intent Boxes: These are intended to augment the “keystroke-level"
tutorials to include the rationale behind the sequence of operations chosen to
create a model.
• Future Study Boxes: These link the material contained in the chapters to
topics that will be seen later in the academic and professional careers of new
engineering students. They are intended to motivate interest in advanced study
in engineering, and to place the material seen in the tutorials within the context
of the profession.
While these features are intended to provide additional motivation and context for
beginning engineering students, they are self-contained, and may be omitted by
professionals who wish to use this text purely for the software tutorials.

New in This Edition

Connect has been added for this latest release, which will include curated question
banks that are assignable as high stakes assessment or unlimited practice problems.
These algorithmic, auto-graded banks save faculty time while providing instant
feedback to students. Instructors can edit these questions and/or add their own
questions to these banks.

This new edition has been fully updated for the release of the SOLLDWORKS 2022
software package. All tutorials and figures have been modified for the new version
of the software. Additionally, all videos have been updated to reflect the latest
software.

The Organization of This Text

The organization of the chapters of the book reflects the authors’ preferences in
teaching the material, but allows for several different options. We have found that
covering drawings early in the course is helpful in that we can have students turn
in drawings rather than parts as homework assignments. The eDrawings® feature,
which is covered in Chapter 2, is especially useful in that eDrawings files are small
(easy to e-mail), self-contained (not linked to the part file), and can be easily marked
up with the editing tools contained in the eDrawings program.

The following flowchart illustrates the relations between chapters, and can be used
to map alternative plans for coverage of the material. For example, if it is desired to
cover assemblies as soon as possible (as might be desired in a course that includes
a project) then the chapters can be covered in the order 1-3-4-6-7-2-8, with the
remaining chapters covered in any order desired. An instructor who prefers to cover
parts, assemblies, and drawings in that order may cover the chapters in the order
1-3-4-5-6-7-2-8 (skipping section 5.4 until after Chapter 2 is covered), again with
the remaining chapters covered in any order.
xii Preface

Chapters 9 and 10 may be omitted in a standard solid modeling course; however,

they can be valuable in an introductory engineering course. Engineering students
will almost certainly find use at some point for the 2-D layout and vector mechanics
applications introduced in these chapters. Chapter 13 is intended to wrap up the
course with a discussion of how solid modeling is used as a tool in the product
development cycle. Appendix A summarizes the recommended settings to the
SOLIDWORKS program that are used throughout the book, while Appendix B
shows options for customizing the SOLIDWORKS interface.

Resources for Instructors

Additional resources are available through Connect. Included are tutorials for three
popular SOLIDWORKS Add-Ins: SOLIDWORKS Simulation'-, SOLIDWORKS
Motion™, and PhotoView 360 . and the book figures in PowerPoint format.
Instructors can also access PowerPoint files for each chapter and model files for
all tutorials and end-of-chapter problems as well as a teaching guide (password-
protected; contact your McGraw-Hill representathe for access).
 Preface xiii

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Educators know that the more students can see, hear, and experience class resources,
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xiv Preface

Writing Assignment
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McGraw Hill believes in unlocking the potential of every learner at every stage of
life. To accomplish that, we are dedicated to creating products that reflect, and are
accessible to, all the diverse, global customers we serve. Within McGraw Hill, we
foster a culture of belonging, and we work with partners who share our commitment
to equity, inclusion, and diversity in all forms. In McGraw Hill Higher Education,
this includes, but is not limited to. the following:
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including generalizations and stereotypes, gender, abilities/disabilities, race/
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that reflect our student populations.
 Preface xv

Including more diverse voices in the development and review of our content.
Strengthening art guidelines to improve accessibility by ensuring meaningful
text and images are distinguishable and perceivable by users with limited color
vision and moderately low vision.

The authors wish to thank those that offered their feedback to be considered for the
current revision: Irma Berner (Valencia College); Roberto Champney (Louisiana
State University); Bill Cohen (Ohio State University); Raj Desai (Midwestern
State University, Texas); Forrest Grady Kidd III (Guilford Technical Community
College); Scott Hansen (Southern Utah University); Jody Kliska (Colorado Mesa
University); Thomas Looker (Edison State); Elias Perez (Utah State University
Eastern); Jorge Rodriguez (Western Michigan University); Jeff Roessler (University
of Wisconsin—Madison); Arun Saha (Albany State University); Anand Vyas
(Milwaukee School of Engineering); and Hank Wade (Lawson State Community
College).

We are grateful to our friends at McGraw Hill, especially Beth Bettcher and Heather
Ervolino, for their support and encouragement during this project. In particular, we
offer special thanks to Karen Fleckenstein of Fleck's Communications, Inc. who
did the page layouts. Also, thanks to Tim Manina, who encouraged us to initiate
this project.

At SOLIDWORKS Corporation, Marie Planchard has provided continuous support

for the project. The authors are also appreciative of the support of our SOLIDWORKS
resellers, Computer Aided Technology, Inc. and TriMech Solutions.

We also want to thank the reviewers whose comments have undoubtedly made the
book better.

Many of our students and colleagues used early versions of the manuscript and
materials that eventually became this text. We thank them for their patience and
helpful feedback along the way.

Ed Howard
Joe Musto
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