SolidWorks Advanced Surfaces

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S o l i d W o r k s 2009 T r a i n i n g M a n u a l
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Table of Contents
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The information and the software discussed in this Product Lifecycle Management Software III (GB) Ltd.
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Reserved.
About This Course 3
warranties given by DS SolidWorks as to the software
and documentation are set forth in the SolidWorks Prerequisites 3
Portions of this software incorporate P h y s X ™ by
Corporation License and Subscription Service N V I D I A 2006 - 2008. Course Design Philosophy 3
Agreement, and nothing stated in, or implied by, this
document or its contents shall be considered or deemed Portions of this software are copyrighted by and arc the Using this Book 3
a modification or amendment of such warranties. property of U G S Corp. © 2008. Laboratory Exercises 3
SolidWorks, 3D PartStream.NET, 3D ContentCentral, Portions of this software O 2001 - 2008 Luxology, Inc. A Note About Dimensions 4
AH Rights Reserved, Patents Pending.
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FeatureManager is ajointly owned registered licensors. A l l rights reserved.
Conventions Used in this Book 4
trademark of DS SolidWorks.
Protected by U.S. Patents 5,929,866; 5,943,063;
Windows® XP 4
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names of DS SolidWorks. Pending.

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Lesson 1:
Other brand or product names are trademarks or Other portions of SolidWorks 2009 are licensed from
DS SolidWorks licensors. Understanding Surfaces
registered trademarks of their respective holders.
A l l Rights Reserved. Solids and Surfaces 9
What is a Solid? Ю
Edges, not Holes Ю
Behind the Scenes 40
Introducing: Extruded Surface 11
Introducing: Planar Surface 12
Introducing: Trim Surface 12
Introducing: Untrim Surface 14
Working with Surface Bodies 14
Introducing: Knit Surface 15
Checking for a Closed Surface 16
Document Number: P M T 0 9 0 4 - E N G
Introducing: Offset Surface 70

Introducing: Thicken 16
Problem Statement 70
Decomposing a Solid into Surfaces 17
Exercise 5: Finial Wrap 73
Introducing: Delete Face 17
Lesson 4:
Parameterization 18
Repairing and Editing Imported Geometry

Introducing: Face Curves 18
Importing Data 81
Surface Types ' 9
What to Import? 81
Why Use Surfaces? 21
Why Do Imports Fail? 81

When Not to Use Surfaces 22
Resulting Problems 82
Hybrid Modeling 22
Repairing Models 82
Continuity Explained 22
Workflow 83
Workflow with Surfaces 24
Stages in the Process 83

Working with Images 24
Feature Works® 84
Layout Sketch 24
Repairing and Editing Imported Geometry 84

Identify Symmetry and Edges 26
Introducing: Import Diagnostics 85

Identify Functional Faces 27
Options for Deleting Faces 86

Check your Models Frequently 27
Patching Holes 86
Introducing: Verification on Rebuild 27
Introducing: Filled Surface 87

Introducing: Check Entity 28
Consistency Notification 87
Folders in the FeatureManager 28
Editing Imported Parts 88

Clean-up 2 8
Introducing: Delete Hole 90

Exercise 1: Trimming Surfaces 29
Exercise 6: Import Diagnosis 91

Exercise 2: Trimming and Knitting 32
Exercise 7: Using Import Surface and Replace Face 95

L e s s o n 2: Exercise 8: Using Surfaces to Create Solids 98
Introduction to Surfacing Lesson 5:
Similarities Between Solid and Surface Modeling 35
A d v a n c e d Surface Modeling
Basic Surfacing ^5
Introducing: Revolved Surface 36
Using Sketch Picture to Capture Design Intent 106
Introducing: Swept Surface 38
Ruled Surfaces Ill
Filleting Surfaces 40
Introducing: Ruled Surface Ill

Cutting the Bottom 42
Lofting Surfaces 113

Introducing: Radiate Surface 42
Modeling the Lower Half 117

Introducing: Cut with Surface 43
Introducing: Partial Ellipse 119

Exercise 3: Basic Surface Modeling 45
Preparation for Using Filled Surface 120

Introducing: Extend Surface 46
Consistency Notification 121

Exercise 4: Halyard Guide 49
Deviation Analysis 121

Lesson 3: Conclusion 123
Solid-Surface Hybrid Modeling
Introducing: Curve Through Reference Points 124
Hybrid Modeling 57
Design Changes 126
Using Surfaces to Modify Solids 58
Dynamic Feature Editing 127
Display 5 9
Introducing: Instant3D 127

Introducing: Replace Face 60
Replacing a Face 128
Interchanging Between Solids and Surfaces 61
Exercise 9: Mouse Model 133
Performance Implications 63
Exercise 10: Bar of Soap 142
Surfaces as Construction Geometry 64
Exercise 11: Finial Scroll 148
Exercise 12: Handle 154
Making Copies of Faces 70
iii
ii
Introducing: Draft Analysis 245

L e s s o n 6:
Introducing: Draft 245
Blends and Patches
Complex Blends 165 Snap Hook and Groove 246
Stages in the Process 166 Saving the Bodies and Creating an Assembly 249
Splitting Trim Boundaries 169 SolidWorks Explorer 251
Hide/Show Bodies 172 Rule#l 251
Introducing: Hide/Show Bodies 172 Exercise 16: Solid Master Model 255
Trimming the Bottom Bracket 174
Wrap Feature 174
Introducing: Isolate 174
Smoothing Patches 176
Three Alternative Approaches 176
Introducing: Boundary Surface 180
Curvature Combs 181
Freeform Feature 183
Introducing: Freeform 184
Mesh Orientation 185
Using the Triad 187
Moving Control Points 188
Undoing Changes 189
Boundary Conditions 190
Comer Blends 193
Alternative Approach 196
Spline on Surface 197
Introducing: Spline on Surface 197
Exercise 13: Bicycle Frame 201
Exercise 14: Patches 207
Exercise 15: Corner Blend 214
L e s s o n 7:
Master Model Techniques
Introduction to Master Models 219
Transmitting Curve Data 220
Push and Pull type Operations 220
Naming Bodies 221
Split Feature 222
Summary of Recommendations 222
Surface Master Model Technique 223
Propagating Changes 224
Working with a Solid Master Model 230
Splitting the Part 230
Modeling the Keypad 232
Finishing Touches 237
Mounting Boss 238
Introducing: Fastening Features 238
Reveal 241
iv v
Introduction
About This The goal of this course is to teach you how to use surface features to
Course build parts using SolidWorks software. Most of the case studies and
exercises in this course are taken from consumer product design
applications, and the lessons center around the combined use of solids
and surfaces, with the goal always being to create a good solid.
During this course we will learn industry standard surfacing
terminology necessary to understand a ground-up surface modeling
approach, as well as answer some of the "when" and "why" questions
which are inevitable with the solids to surfaces paradigm shift. If your
modeling experience to date has been completely in the solids realm,
you may find that working in surfaces requires a different approach.
This course has several examples showing functions that do not
ultimately create the intended geometry, necessitating an alternative
approach. This is not to highlight shortcomings of the software, but
rather to help you identify situations in which you need to try more than
one method. Working with more complex models and shapes means
you will run into more situations when you need to have at your
disposal alternate methods for achieving particular shapes.
Prerequisites Students attending this course are expected to have the following:
• Completed the course Advanced Part Modeling.
Course Design This course is designed around a process-based (or task-based)
Philosophy approach to training. Rather than focus on individual features and
functions, a process-based training course emphasizes the processes
and procedures you follow to complete a particular task. By utilizing
case studies to illustrate these processes, you learn the necessary
commands, options and menus in the context of completing a design
task.
Course Length The recommended minimum length of this course is two days.
Using this Book This training manual is intended to be used in a classroom environment
under the guidance of an experienced SolidWorks instructor. It is not
intended to be a self-paced tutorial. The examples and case studies are
designed to be demonstrated "live" by the instructor.
Laboratory Laboratory exercises give you the opportunity to apply and practice the
Exercises material covered during the lecture/demonstration portion of the
course. They are designed to represent typical design and modeling
situations while being modest enough to be completed during class
time. You should note that many students work at different paces.
Therefore, we have included more lab exercises than you can
reasonably expect to complete during the course. This ensures that even
the fastest student will not run out of exercises.
About This Course 3

S o l i d W o r k s 2009 T r a i n i n g M a n u a l S o l i d W o r k s 2009 T r a i n i n g M a n u a l
A Note About The drawings and dimensions given in the lab exercises are not Use Of Color The SolidWorks 2009 user
Dimensions intended to reflect any particular drafting standard. In fact, sometimes interface makes extensive use
dimensions are given in a fashion that would never be considered of color to highlight selected
acceptable in industry. The reason for this is the labs are designed to geometry and to provide you
encourage you to apply the information covered in class and to employ with visual feedback. This
and reinforce certain techniques in modeling. As a result, the drawings greatly increases the
and dimensions in the exercises are done in a way that compliments intuitiveness and ease of use of
this objective. SolidWorks 2009. To take
maximum advantage of this,
A b o u t the A complete set of the various files used throughout this course can be
the training manuals are printed in full color.
Training Files downloaded from the SolidWorks website, www.solidworks.com.
Click on the link for Training & Support, then Training, then Training Also, in many cases, we have used additional color in the illustrations
Files, then SolidWorks Training Files. Select the link for the desired to communicate concepts, identify features, and otherwise convey
file set. There may be more than one version of each file set available. important information. For example, we might show the result of an
operation in a different color, even though by default, the SolidWorks
Direct URL:
software would not display the results in that way.
www.solidworks.com/tralnln^filessoltdworks
Graphics and SolidWorks sets a new standard with best-in-class graphics. The
The files are supplied in signed, self-extracting executable packages. Graphics Cards combination of a highly reflective material and the realism of
The files are organized by lesson number. The Case Study folder RealView Graphics is an effective tool for evaluating the quality of
within each lesson contains the files your instructor uses while advanced part models and surfaces.
presenting the lessons. The Exercises folder contains any files that are RealView Graphics is hardware (graphics card) support of advanced
required for doing the laboratory exercises. shading in real time. For example, if you rotate a part, it retains its
Conventions Used This manual uses the following typographic conventions: rendered appearance throughout the rotation.
in this Book
Convention Meaning
Bold Sans Serif SolidWorks commands and options appear in

this style. For example, Insert, Boss means
choose the Boss option from the Insert menu.
Typewriter Feature names and file names appear in this
style. For example, Sketch 1.
Double lines precede and follow sections of
17 Do this step the procedures. This provides separation
between the steps of the procedure and large
blocks of explanatory text. The steps
themselves are numbered in sans serif bold.
Windows® XP The screen shots in this manual were made using SolidWorks 2009
running on Windows® XR
4 Windows® XP Use of Color 5

S o l i d W o r k s 2009 Training M a n u a l
Color Schemes Out of the box, SolidWorks 2009 provides several predefined color
schemes that control, among other things, the colors used for
highlighted items, selected items, sketch relation symbols, and shaded
previews of features.
We have not used the same color scheme for every case study and
exercise because some colors are more visible and clear than others
when used with different colored parts.
In addition, we have changed the viewport background to plain white
so that the illustrations reproduce better on white paper.
As a result, because the color settings on your computer may be Lesson 1
different than the ones used by the authors of this book, the images you
see on your screen may not exactly match those in the book. Understanding Surfaces
Toolbars The icons for a number of the commands covered in this course do not
appear their respective toolbars by default. For example, The Thicken
icon Ш is not on the Features toolbar by default. If you want to access
these commands from the toolbars, you will need to add them using
Tools, Customize.
Hide/ShOW Tree Certain items in the top of the FeatureManager design tree are
Items automatically hidden if they are not used. For this course it is helpful to
have several of these folders always shown. Upon successful completion of this lesson, you will be able to:
Click Tools, Options, System Options, FeatureManager. Under • Understand the differences and similarities between solid bodies
Hide/Show Tree Items, set the following to Show: and surface bodies.
• Lights, Cameras and Scene folder • Create extruded and planar surfaces.
• Solid. Bodies folder
• Trim and untrim surfaces.
• Surface Bodies folder
• Knit surfaces.
• Create solid bodies from surfaces.
• Delete faces of surface or solid bodies.
• Understand the properties of NURBS surfaces and iso-parameter
(U-V) curves.
• Be familiar with common surface types.
• Understand typical surface modeling workflow scenarios.
7
Toolbars
Lesson 1 S o l i d W o r k s 2009 T r a i n i n g M a n u a l S o l i d W o r k s 2009 T r a i n i n g M a n u a l Lesson 1
Understanding Surfaces Understanding Surfaces
Solids and In SolidWorks, solid bodies and surface bodies are very nearly the
Surfaces same. This is one of the reasons it is so easy to use them together in
advanced modeling. To understand their differences, and their
similarities, it helps to know what exactly it is that constitutes a surface
or solid body.
Solid and surface bodies are made up of two types of information, or
for want of a better word, entities:
• Geometry
Geometry describes shape. Something can be flat or warped, straight or
curved. A point is a specific, unique location in space.
• Topology
Topology describes relationships. For example:
• The inside versus the outside of a solid. This is defined by the face
normal.
• Which edges meet at which vertices.
• Which edges form the boundaries of which face.
• Which edge is the common boundary between two adjacent faces.
The table below shows the correspondence between the two types of
information:
Topology Geometry
Face Plane or surface

Edge Curve, i.e. a line, arc, or spline
Vertex Endpoint of a curve
Consider the two solids pictured below:
Both are composed of 6 faces, 12 edges, and 8 vertices. Topologically,

they are identical. However, it is clear that geometrically they are quite
different. The solid on the left has faces that are all planar and edges
that are all straight. That is not the case with the solid on the right.
8 Solids and Surfaces 9

S o l i d W o r k s 2009 T r a i n i n g M a n u a l S o l i d W o r k s 2009 T r a i n i n g M a n u a l Lesson 1
Lesson 1
What is a Solid? One way to differentiate between a solid body and a surface body is by 1 Extrude a solid cylinder.
this rule: In а solid body, every edge is the boundary between exactly Open a new part using the P a r i _ M M
two faces. template.
That means that in a surface body, we can On the Top reference plane, sketch a circle
have edges that bound only one face. The with a 25 mm diameter centered on the origin
surface shown at the right has five edges, and extrude it 25 mm.
each the boundary of a single face. Three faces have been created, two planar end
faces and the cylindrical face that connects
them.
That also is why in SolidWorks,
Save this part naming it Solid.
you cannot create geometry shown
in the illustration at the right as a
single solid body. The red edge Introducing: Extruded Surface works exactly like its solid counterpart except that
would be a boundary between four Extruded Surface it produces a surface instead of a solid, it does not cap the ends, and it
faces. does not require a closed loop sketch.
Edges, not Holes What we perceive as holes in faces are really boundaries defined by Where to Find It • Click Extruded Surface |g on the Surfaces toolbar
edges. When cut features are added to a solid model, new edges are ш Or, click Insert, Surface, Extrude.
created that define boundaries in the faces. When these edges are
removed, the underlying surfaces are restored. This is key to the 2 Extrude a surface.
interoperability of solids and surfaces. Open another new part with the P a r t J N
template.
On the Top reference plane, sketch a circle
with a 25 mm diameter centered on the origin
and extrude it 25 mm.
Click Window, Tile Vertically to display the
window with the solid and the window with
the surface side by side.
Save this part naming it Surface.
Behind the Scenes When SolidWorks builds solid models it is really automating a lot of
surface modeling tasks by creating surface bodies and assembling them
to form a closed volume. One way to get a better grasp of what is going
on is to see what it takes to do the same tasks manually.
We can use a simple cylinder as an example.
Mid I М Ь Ь А Г - Г
10 Solids and Surfaces Solids and Surfaces 11

S o l i d W o r k s 2009 T r a i n i n g M a n u a l Lesson 1
Lesson 1 S o l i d W o r k s 2009 T r a i n i n g M a n u a l
Understanding Surfaces
Trim the surfaces.

Click Trim Surface \#j on the Surfaces toolbar.
Introducing: Planar A Planar Surface is created from a non-intersecting closed-loop
Surface sketch, a set of closed edges, multiple co-planar parting lines, or a pair Under Trim Type, click Standard.
of planar entities such as curves or edges. Note Since we are going through a somewhat contrived
Where to Find It • Click Planar Surface g| on the Surfaces toolbar. example to create manually what a solid feature
• Or, click Insert, Surface, Planar. creates automatically, we will use the Standard Surfawfxlrudel
trim type.
0вкрмкс*тя
3 Create a planar surface. For the Trim tool, select the cylindrical surface. O BP"*** Mtaceon*
Working in the Surface part, open a sketch on the Top reference plane.
Click Keep selections.
Sketch a square centered on the origin and whose sides are tangent to
the cylindrical surface. Tip Rotate the view so you can easily see the bottom
of the cylinder.
Tip Use the Polygon tool I©) to sketch the square. Make the construction
circle Coradial with the edge of the cylinder. As the cursor moves over the surfaces to be trimmed, the system
highlights various solutions.
Click Planar Surface @. The current, active sketch is automatically
selected. Select the circular area of the planar surface and click OK.
Click OK. Portion of surface you want to keep
Note In some models you may find it easier to click Remove selections and
select the portions you want to discard.
Introducing: Trim The Trim Surface command enables you to cut back a surface using Second planar surface.
Surface either another surface, a plane or a sketch. Under Trim Type there are
Change to a Trlmetric view.
two choices:
Click Planar Surface Q.
• Standard
A surface, plane, or sketch is used as the trimming tool. Select the circular edge at the top of the cylinder.
• Mutual Click OK.
Multiple surfaces trim one another.
Mutual trim also knits the resulting surfaces together while Standard 6 Results.
trim leaves them as separate surface bodies. The resulting planar surface looks identical to the
X
Where to Find It • Click Trim Surface @ on the Surfaces toolbar. results of step 4. However this was accomplished in
• Or, click Insert, Surface, Trim. one operation instead of two.
Furthermore, what we have now looks very much like
the solid cylinder we made in step 1. However, it is
not a solid body. It is only a collection of three
surface bodies.
Solids and Surfaces 13

12 Solids and Surfaces
S o l i d W o r k s 2009 Training M a n u a l S o l i d W o r k s 2009 T r a i n i n g M a n u a l Lesson 1
Lesson 1
Managing visibility of surface bodies ^ [ r f f l g i y i «йДЕДе®

can at times be a challenge. The jcjr
Introducing: Untrim With Untrim Surface you can restore a surface to its natural Hide/Show state of the body can be
Surface boundaries. If you remove internal edges you are, in effect, patching affected by rollback state and I тШ"*а,стттмлт
holes in the surface. The result of the operation can be a new surface configurations. Using the Display j a
n
body or one that replaces the original. Pane with the Surface Bodies фм»»™.. g
Where to Find It • Click Untrim Surface Й on the Surfaces toolbar. folder expanded may be helpful. != >«»u «.i««d««f>
• Or, click Insert, Surface, Untrim. Although you cannot show or hide
bodies from the Display Pane, you can easily see which bodies are
7 Untrim Surface. shown.
Click Untrim Surface ® on the Surfaces Click » at the top of the FeatureManager pane (to the right of the tabs)
toolbar. to expand the Display Pane. Click « to collapse the Display Pane.
Select the planar surface created in step 5. Introducing: Knit Knit Surface joins together separate surface bodies into a single
The preview verifies that the system actually Surface surface body. There are several rules for knitting:
created a rectangular surface which was • Surface bodies must touch edge to edge.
automatically trimmed to the circular edge. • Surface bodies must not intersect, touch either body at a point or
Click Cancel to quit the command without any place that is not an edge (in the middle of a face for example).
untrimming the surface. • Disjoint bodies cannot be knit.
Where to Find It • Click Knit Surface ifflj on the Surfaces toolbar.
• Or, click Insert, Surface, Knit.
Working W i t h Working with surface bodies is in many respects similar to working
Surface Bodies with solid bodies, but there are significant differences as well. Surface
8 Knit Surface.
bodies are listed in the Surface Bodies folder at the top of the
Click Knit Surface ( I on the Surfaces toolbar.
FeatureManager just like solid bodies are listed in the Solid Bodies
folder, and can be hidden or deleted from there. Select the three surface bodies either from the graphics window or from
the FeatureManager.
One of the major differences is that boolean type operations do not
work on surfaces in the same way that they do on solids. With solids, if
you want to add a boss to a body, you simply sketch it and extrude it. » Ч Й lights. Cameras and Scene
SolidWorks automatically trims the faces and merges the new feature MSsufaceBoctas<3)
h*
into the existing solid body. "Ф
Surbcr&cfcudtl
l
*
1
!Н Material <ret45erihed>
^ Front Plane
^St Top Plane
Right Plane
S- U Origin
ф-ф Surface-Extrudel
Qlry toformioM t> 0 Surface-Plane.
I ф Surface-Trlml
': 0 Surface-Piane2
Note The Knit Surface command has an option, Try to form solid, that will
create a solid body when the knit surfaces form a closed volume.
However, since we are intentionally doing every step manually, we will
not use this option.
With surface bodies the intersecting faces have to be trimmed and knit
Click OK.
manually.
The Surface Bodies folder now only contains one ~i ф surfaceeoctesm
surface body. *$> ***«»**.
14 W o r k i n g with S u r f a c e B o d i e s W o r k i n g with S u r f a c e B o d i e s 15
10 Compare the two parts.

Click Window, Tile Vertically to display the two parts side by side.
Checking for a There are three ways to check a surface body to see if it is closed.
Closed Surface
• Try to thicken the surface. The Create solid from enclosed
volume option is only available when you have a volume that is
fully enclosed by surfaces.
• The command Check Entity will highlight open edges of a surface.
(Check Entity is discussed in more detail on page 28.)
• In any display mode that displays model edges, look to see if any
edges are shown in the color specified in Tools, Options, System
Options, Colors, Surfaces, Open Edges.
Note Tools, Options, System Options, Display/Selection, Show
open edges of surfaces in different color must also be selected.
Introducing: The Thicken feature has two functions. One is to add thickness to an
Thicken open surface by offsetting the faces and connecting their edges. The
second is to solidify an enclosed volume made of surfaces.
Where to Find It • Click Thicken gj on the Features toolbar.
• Or, click Insert, Boss/Base, Thicken. Check the volume for each part. You should get 12271.846 cubic
millimeters.
Note The icons for a number of the commands covered in this course do not
appear on their respective toolbars by default. For example, The The parts look identical. And geometrically, they are in fact identical
Thicken icon ft) is not on the Features toolbar by default. If you want although their feature trees are quite different.
to access these commands from the toolbars, you will need to add them Conclusion Creating a solid feature is an automated way of surface modeling. The
using Tools, Customize. solid feature automates creating the faces, trimming them if necessary,
knitting them together, and converting them into a solid.
Make the surface into a solid.
Click Insert, Boss/Base, Thicken or click
Thicken |Щ| on the Features toolbar. Decomposing a There is no command that is the reverse of Knit Surface. So there is no
Solid into Surfaces convenient way to reduce a solid down to a collection of surfaces.
Select the surface body. However, there are a number of techniques that are useful:
/ / /
The Create solid from enclosed volume option • Deleting a face of a solid reduces the solid to a surface body.
is only available when you have a volume that is • You can make copies of the faces of a solid, modify them, and then
fully enclosed by surfaces. use them to replace the original faces of the solid.
Click OK. Introducing: Delete The Delete Face tool removes one or more faces from the model,
The Surface Bodies folder has been removed and the Face allowing it to be replaced by extending the boundaries of adjacent faces
Solid Bodies folder appears containing one solid body. IQrhJctenl or by filling in the gap with a completely new surface. Delete Face can
also turn a solid body into a surface body by simply removing the face
and not replacing it with anything.
Where to Find It • Click on Delete Face g) on the Surfaces toolbar.

• Or, click Insert, Face, Delete.
16 W o r k i n g with S u r f a c e B o d i e s 17
W o r k i n g with S u r f a c e B o d i e s
Lesson 1 Lesson 1
11 Delete all but one end of the cylinder. r

D£l£leI.Mje Where to Find It • Click Face Curves ф on the Sketch toolbar.
Make sure you are working on the part named «/ M • Or, click Tools, Sketch Tools, Face Curves.
Solid. w*BUM* Я
Ф Surface Types There are several classes of surface geometry. Although there are
Click Delete Face ® on the Surfaces toolbar. others beyond those listed here, the major types are:
Select the cylindrical face and the circular face on • Algebraic surfaces can be
the top end of the cylinder. см * described with simple algebraic
Ом» expressions. These include
Under Options, select Delete and click OK.
..... surfaces that are flat, spherical,
cylindrical, conical, toroidal, and so on. U-V curves on algebraic
surfaces are straight lines, arcs or circles.
• Ruled surfaces are
surfaces where every
point on the surface has
a straight line that
passes through it and
lies on the surface.
The Solid Bodies folder is removed and replaced with & surface шиш B
the Surface Bodies folder. * D"***** 1

• Developable surfaces
are a subset of ruled surfaces,
and can be flattened without
Parameterization A l l surfaces in SolidWorks u,v. stretching the surface. These
can be described by a include planar, cylindrical and
parameterized mesh of conical surfaces. This surface
curves. These are called type is important because SolidWorks sheet metal functions can
iso-parameter or U-V only flatten these shapes. Besides sheet metal, developable surfaces
curves. The curves along U v 0 are widely applied in shipbuilding (for easily formed flat plates or
one side of a four-sided sheets of fiberglass) and label application (labels will stretch or
surface are the U curves. pucker on non-developable surfaces) among many others.
Those in the perpendicular • NURBS (non-uniform rational b-
direction are the V curves. The parameter is the number representing spline) is a surfacing technology
the position along the length of the edge, between 0 and 1. widely used by C A D and computer
Think of the U - V curves as being a kind of coordinate system for the graphics software. NURBS surfaces
surface. U V would be the parametric center of the surface.
5 5
are defined by parameterized U-V
curves where the curves are splines,
You can see the U - V mesh by using the Face Curves commands. and the surface is interpolated
Certain features such as Dome, Shape, Fill Surface, Boundary between the splines.
Surface, Freeform, and Loft also have previews with mesh. The mesh
is helpful in troubleshooting unexpected results. We will examine this Algebraic, ruled, and developable surfaces are sometimes referred to as
in more detail in later lessons. analytical surfaces. NURBS surfaces are often called algorithmic
surfaces.
Introducing: Face The Face Curves command creates a series of 3D sketches forming a
Curves mesh on the selected face. This mesh represents the underlying U-V NURBS One of the implications of having a mesh of perpendicular curves is
curves of the face. The mesh density can be changed or you can limit that the surfaces tend to be four-sided. Obviously, SolidWorks models
the lines to one in each direction located at a point of your choosing. can have surfaces that are not four-sided. There are two ways for this to
When you click OK, each curve becomes its own 3D sketch. happen:
Tip Place the 3D sketches in a folder for easier management.
18 W o r k i n g with S u r f a c e Bo d i e s W o r k i n g with S u r f a c e Bo d i e s 19
One or more of the sides is of zero • Using surface modeling, it takes much more time to model the same
length, and the curves in that geometry compared with using solids. However, not everything can
direction intersect at a single point be modeled in solids, so surfacing is a necessary and important tool.
called a singularity. These • CAD-neutral surfacing terminology and concepts are essentially the
surfaces are called degenerate same for all solid modelers; Applying these concepts will help you
surfaces and often, but not always, understand how surfaces and solids, imported and native geometry
cause problems in filleting, can be manipulated.
shelling or offsetting. Why Use Now that you know what surface bodies are, we can build the case for
An initially four-sided surface is Surfaces? why they are used. There are several reasons:
trimmed to the required shape.
These typically will not cause • Some shapes cannot be
problems shelling because the created with solids.
system offsets the underlying four- Solid features like lofts and
sided surface and then retrims it. sweeps tend to result in shapes
that have one or more flat sides.
Surfaces are frequently used to
cap off flat ends, or to create
12 Apply face curves. geometry which has no flat ends.
Still working on the part named The part shown to the right is an
Solid, select the remaining example of this use of surface
circular face and click Tools, modeling.
Sketch Tools, Face Curves.
• Surfaces build a shape face by
The preview of the face curves O&Mtton
face rather than all at once.
gives the appearance of a surface Solid features build several sides
0iFI
that was rectangular, and then of a shape at once, and the entire
trimmed to be circular. feature flows in a single direction,
0 C o r e t w i B > model
which sometimes makes it
Click Cancel to quit the
difficult or impossible to get all of
command without creating the
the sides correct. Surface features
face curves.
build shapes one face at a time, so
13 Untrim the face. different techniques and different
The preview shows that this face, even though it directions can be used for different faces.
was created when we extruded a circle, is also a
rectangular surface, just as we saw when we Surfaces can be used as reference geometry.
used the Untrim Surface command in step 7. Surfaces are not limited to complex geometry, they also include
extruded and revolved shapes. Any type of surface feature can be used
14 Close the parts without saving them. as reference geometry to assist construction of or to modify solids.
Surface features are sometimes more efficient than solid
features.
Why did you come to an advanced surface modeling class to learn to Solid features build a viable, stand-alone solid body for every feature
create simple cylinders? There are a couple of reasons: before it is merged with the rest of the solid. This often requires
• Solids are just surfaces which follow special rules. To make a solid, building a lot of extra geometry and knitting. From the point of view of
SolidWorks is going through the same steps behind the scenes rebuild time, surfaces are often more efficient, enabling you to only
which we went through manually to build the surface model. build the faces that are necessary.
Understanding what is happening behind the scenes helps you
troubleshoot and avoid problems better.
Why Use Surfaces? 21

20 W o r k i n g with S u r f a c e B o d i e s
Lesson 1
Lesson 1 S o l i d W o r k s 2009 T r a i n i n g M a n u a l S o l i d W o r k s 2009 T r a i n i n g M a n u a l Understanding Surfaces
The concept of continuity can be explained using a series of spirals. In

When Not to Use Modeling with surfaces is almost always more work than modeling
each case we are looking at how the gray surface patch is related to the
Surfaces with solids. If you have the option and the results will be equivalent,
you should model with solids. Here are some situations when you colored spiral. Remember: continuity applies equally to curves and
should avoid surface features: surfaces. We are only using surfaces here because the illustrations are
clearer.
• Use solids when the end result can be achieved more easily and
more efficiently than with surfaces. Sometimes rebuild time is not
the driving factor, and is overridden by actual modeling time.
• It is generally best practice to avoid leaving a model as an open
surface. Surfaces are usually an intermediate step to a solid. There
may be some valid reasons for leaving models as open surfaces, but
these will be the exception rather than the rule. In Lesson 7: Master
Model Techniques, we will leave a model as a surface model, but it
is being used as reference geometry to create a solid later in the
workflow.
Note: There are certain types of master model functions which are
not available for surface features, but only for solids. More detailed
information on this topic is presented in Lesson 7: Master Model
Techniques,
Hybrid Modeling SolidWorks enables you to combine the best advantages of solids with
the best advantages of surfaces. Solid-surface hybrid modeling is often
the best approach. This generally entails using surfaces to modify
solids or converting a solid model into a surface model to make
changes, and then converting it back to a solid. Techniques that fall into
this category include: In the first case the gray surface isn't even touching
• Using a surface body to replace one or more faces of a solid. the spiral. This represents no continuity at all. This
• Using surfaces as construction geometry such as with the Up To condition is referred to as discontinuous.
Surface end condition.
• Using a surface body to cut or sculpt the solid.
• Using a surface body to split a solid body into two or more solid
bodies.
Hybrid modeling is mentioned here by way of a general introduction.
The topic will be covered in more detail in Lesson 3: Solid-Surface
Hybrid Modeling.
In the second case, the gray surface is touching the
Continuity The concept of continuity applies equally to curves and surfaces
colored spiral They share a common edge but that
Explained (faces). For practical purposes, there are three types of continuity that is all. This represents contact, or CO continuity.
we are concerned about in C A D systems. They are:
• Contact, or CO continuity,
• Tangent, or CI continuity, and
a Curvature, or C2 continuity.
While there are orders of continuity higher than C2, they are not used in
the SolidWorks software and therefore will not be addressed here.
23
22 Continuity Explained Continuity Explained
Lesson 1
S o l i d W o r k s 2009 T r a i n i n g M a n u a l Understanding Surfaces
In the third case, the gray surface is not only Sketch picture sketches do not need to have
touching the colored spiral, it is tangent to it. This any sketch geometry in them. Also, more than
represents tangent, or CI continuity. While CI one sketch picture can be used in separate
continuity technically provides a smooth sketches on orthogonal planes or where ever
transition between the two surfaces, it is not very sketch references may be needed. This is
pleasing esthetically. This is because of the useful, for example, if you want to have sketch
sudden change in the radius of the two adjoining pictures to show front, top and side views.
faces. At the common edge, the spiral has a
radius of about 65 mm. The gray surface is flat; its radius is infinite. In
a finished product, this abrupt change can be both seen and felt.
Note Tangent continuity is acceptable for most applications with the
exception of Class A surfacing.
Tips for Taking Perspective can make it difficult to accurately get measurements from
In the final case, the gray surface is touching the Digital Pictures objects in a digital image. Reduce perspective by moving the camera
colored spiral (CO continuity), is tangent (CI further away from the object. Flatbed document scanners can also help
continuity), and it has the same curvature as the reduce perspective, but are only usable on parts that do not have much
spiral. This represents curvature, or C2 continuity. depth to them.
It is important to note that to have C2 continuity,
Sharp comers are another issue to watch out for. You are modeling the
you also have to have CO and C1.
sharp edges, but most real parts have rounded edges, so you may have
When two adjacent faces have C2 continuity, we to extrapolate past the rounded edges to the virtual sharp.
often say they are curvature continuous.
Place a ruler in the photograph with the part to allow you to scale the
Workflow with When working with surfaces, especially when starting a complex image. Draw a line or circle in the sketch and dimension it to the largest
Surfaces model as a surface model, there are some general workflow guidelines visible dimension on the ruler, and then match the image size to the
that may be useful. sketch.
Working with By the time you start modeling a part with SolidWorks, you probably Avoid strong, directional lighting that casts shadows which tend to
Images have some idea of what the part will look like. This idea may come obscure edges.
from hand sketches, digital photos of an existing product or a
Use images with very high contrast and good focus. The best example
handmade model, or 3D scan data from a physical model.
is a very sharp black and white image. If the image bleeds or fades from
Digital images can be used in one color to another, it becomes difficult to distinguish edges with
SolidWorks as Sketch accuracy.
Pictures, which in turn can
be used to trace over or as a
visual reference. Sketch
pictures should be used early
in the modeling process and
the sketch they are connected
to should be named to
indicate the presence of a
picture.
Layout Sketch Layout sketches are often helpful when embarking on a complex part.
L o w contrast: e d g e s m a y H i g h contrast: s h a r p , c l e a r
You may want to sketch items such as key features or locations, an
b e difficult t o distinguish i m a g e but s h a d o w s m a y
overall size, driving contours, or a size reference for a sketch picture. c a u s e confusion.
24 W o r k f l o w with S u r f a c e s 25
W o r k f l o w with S u r f a c e s
Lesson 1 S o l i d W o r k s 2009 T r a i n i n g M a n u a l Understanding Surfaces
Identify Functional If the model you are working on has any functional faces, these are
Identify Symmetry Getting started on a complex shape with no flat faces to use as a datum Faces generally easy to identify and use for a starting location. Functional
and Edges or reference can be tricky. With prismatic parts, it is generally easy to faces are items like a bottle neck, which must be circular, or a base
visualize how to create the shape. But parts that do not sit flat on a table which must be flat or have feet, or a face which mates to another part
are a different matter. with a defined shape, or a face where a label will sit, which must be
Symmetry One of the first and easiest things to look for is symmetry. Position any developable.
sketch pictures to center the part around the origin. The symmetry may In the part shown below, the functional surface is the round area which
not be complete, but take as much advantage of it as possible. This fits onto a door latch mechanism. The first sketch in the part acts as a
makes not only modeling easier, but also mating the part into an layout sketch and defines the size of the outer face as well as the inner
assembly later. diameter which is not yet cut.
Projected Curves Identifying and creating hard edges on the part can help you get a start
on a tough model. Edges are relatively easy to create as projected
curves. An edge is traced from two orthogonal sketch pictures, and a
projected curve is created from the two sketches.
Check your Because surface models are built face by face, they are not subjected to
Models Frequently the rigorous, checking and verification that solid features are. They
may have defects which are not plainly visible. If you build important
geometry with errors, the rest of the model may be compromised.
Therefore, it is important to make sure after every important step to
check the model for errors.
The two tools used to check models are Check Entity and Verification
on Rebuild.
Introducing: By default, each time you add or modify a feature, the feature is
Verification on checked against any adjacent faces and edges. To increase the level of
3D Splines 3D edges can also be created as 3D Rebuild error checking, turn on the Verification on rebuild option in Tools,
splines. Editing splines in 3D space Options, System Options, Performance. When this option is turned
requires some practice, but can be on, the software checks every new or changed feature against all
done effectively. One technique for existing faces and edges, not just adjacent faces and edges. Features
editing 3D splines is to split the that cause invalid geometry fail when this option is turned on.
graphics window using the Four This option has a negative effect on performance. Rebuilding the model
View [aj tool on the Standard Views is considerably slower and more CPU-intensive. This option applies to
toolbar. Dragging 3D items in space all documents, not just the active document. Use this option only when
always moves the item in a plane needed, then be sure to turn it off when you are done.
parallel to the screen unless there are
other constraints on the item. When you press Ctrl+Q, it causes a complete rebuild of all the features
in the model. The Edit, Rebuild Д) operation (Ctrl+B) only rebuilds
Silhouette Edges Curves on the plane of symmetry can also be useful for establishing a new or changed features and their children.
starting point for a model. Even though these curves do not represent a
hard edge, they represent a silhouette edge, which is also useful. Where to Find It • Click Tools, Options, System Options, Performance,
Verification on Rebuild.
W o r k f l o w with S u r f a c e s 27
26 W o r k f l o w with S u r f a c e s
Introducing: Check Check Entity is a checking utility that identifies geometry problems. Exercise 1: Create this part by following the steps as
Entity Sometimes features will fail for seemingly no apparent reason, and a Trimming shown.
check will reveal that somewhere earlier in the feature history bad Surfaces This lab reinforces the following skills:
geometry was created. Check Entity also will help you find open
surface edges that prevent a surface from knitting into a solid, and short • Move/Copy Bodies which was covered
edges and minimum radius points that prevent a part from shelling. in the Advanced Part Modeling course.
• Trim Surface on page 12.
Where to Find It • Click Check Щ on the Tools toolbar. • Knit Surface on page 15.
• Or, click Tools, Check.
Units: millimeters
Note It is a recommended best practice to work with the Verification on
rebuild option cleared, but to turn it on, check the model every several Procedure Open an existing part named TTim_Exerolse.
features, and then turn it off again. At a minimum, all models, 1 Create an axis.
particularly complex ones, should be checked with Verification on Create a reference axis from the two corners of the
rebuild before completing the model. surface nearest the Top reference plane.
Folders in the Working with surface models will often produce feature Make sure it is named A x i s l .
FeatureManager trees with hundreds of features. Because you are gM-) layout
Ш ejeRevoKwl
building parts one face at a time and there are so many Qimmryface
Ш sjaRevdveZ
steps, there can be many, many features. At times there
will be many features related to a particular area of the ffi О*"»
S Qweaw
part. It is good practice to put long lists of related
features into a single folder for clearer organization and Ш Q Leaves
to assist other people who might have to edit the part after you are done 2 Rotate the surface body.
with it. Often creating and naming a single folder eliminates the need to Use the Move/Copy Body Ш command to
rename several individual features. It also makes the FeatureManager rotate (no copy) the body 35° about A x i s l as
more navigable. shown.
Clean-up Many modeling "housekeeping" practices fall into the category of Tip Depending on the order in which you selected
personal preference rather than best practice. Clean-up is one of those. the vertices to define the axis, you may need
to enter the rotation angle as a negative value
At the end of a surface modeling project, you may find that you have
many left over surface or solid bodies. Some SolidWorks users choose to get the surface to rotate in the correct
to delete all but the final target solid from the bodies folders using the direction.
Delete Bodies command. This creates a Body-Delete feature in the 3 Create another axis.
FeatureManager and that can be suppressed, edited or deleted later if Create another reference axis using the intersection of the
access to some of the affected bodies is required. the Right reference planes.
This should be named Axis2.
4 Copy surface bodies.
Use the Move/Copy Body feature to
rotate and copy the surface body about
A x i s 2 , making two copies each at an
angle of 120°.
28 W o r k f l o w with S u r f a c e s Exercise 1: Trimming Surfaces

9 Thicken into a solid.

5 Create a new sketch. - Front P l a n e
The Create solid from enclosed volume option
Change to a Right view. will only be available if you have successfully
On the Right reference plane, created an enclosed volume.
open a sketch and insert a sketch
point.
Dimension the point to the Front
and Top reference planes as
r
shown.
Exit the sketch. Top P l a n e
T 10 Save and close the part.
6 Create another axis.

Create another reference axis using the sketch point and the Right
reference plane.
This should be named A x i s 3 .
7 Copy the surface body.
Rotate and copy the original surface
body 136° about A x i s 3 .
8 Trim the surfaces.

Click Trim Surface ® on the Surfaces toolbar.
For Trim Type, select Mutual.
Click Keep selections and select the faces to yield the results shown
below.
Note The trimming operation automatically knits the surfaces into a single
surface body.
Exercise 1: Trimming Surfaces

30 Exercise 1: Trimming Surfaces
Exercise 2: Starting with a surface model,

Trimming and create the solid model as shown.
Knitting This lab reinforces the following
skills:
• Planar Surface on page 12.
• Knit Surface on page 15.
Units: millimeters
Procedure Open an existing part named SurfaceJModel.
Lesson 2
Introduction to Surfacing
•J Top
dh
Upon successful completion of this lesson, you will be able to:
• Create revolved surfaces.
• Create swept surfaces.
• Fillet surfaces.
1 Dlghl
• Create radiated surfaces.
Using Trim Surface, Planar

Surface, and Knit Surface,
create a solid model.
Add 2.5 mm radius fillets and
shell it with a thickness of
1.5 mm.
32 E x e r c i s e 2: T r i m m i n g a n d Knitting 33
Introduction to Surfacing Introduction to Surfacing
Similarities While surface modeling has many unique and specialized commands, a
Between Solid number of surface commands are identical to their solid modeling
and Surface counterparts. For example:
Modeling • Insert, Boss, Extrude = Insert, Surface, Extrude
• Insert, Boss, Revolve = Insert, Surface, Revolve
• Insert, Boss, Sweep = Insert, Surface, Sweep
• Insert, Boss, Loft = Insert, Surface, Loft
Basic Surfacing The primary рифове of this

lesson is to introduce and
demonstrate some of the basic
surfacing commands. Some
steps in the procedure may be
somewhat contrived so that
certain commands will be
utilized.
We will not build the entire part
as shown because after a point
the surface modeling is complete and it becomes an exercise in solid
modeling.
Procedure Open the existing part Bezel.
1 First sketch.
Open the sketch named Sketch for Extruded Surface.
104-
I!
-25-
>—15.75
3.00°
2 Extruded surface.
Click Extruded Surface [g| on the
Surfaces toolbar.
Using the end condition Mid Plane,
extrude a surface to a depth of
90 mm.
34 Similarities Between Solid a n d S u r f a c e Modeling 35

Lesson 2
Lesson 2 S o l i d W o r k s 2009 T r a i n i n g M a n u a l S o l i d W o r k s 2009 T r a i n i n g M a n u a l
3 Second sketch. 6 Offset plane.

Open the sketch named Sketch for Revolved Surface. The part contains a plane that is offset 10.5 mm below the Top
reference plane. The sweep path is created on this plane.
Note The extruded surface from step 2 has been hidden for clarity.
4 Fit spline.
7 Sweep path.
Click Fit Spline £J on the Spline Tools toolbar, or click Tools, Spline Open the existing sketch named
Tools, Fit Spline.
Sweep Path.
Under Parameters, clear the Closed spline check box. 8 Fit spline.
Select Constrained and select the line and arc in the graphics area. Use Fit Spline Q to create a spline,
constrained to the lines and arcs.
Click OK.
9 Exit the sketch.
Introducing: Revolved Surface works exactly like its solid counterpart except that
Revolved Surface it produces a surface instead of a solid, it does not cap the ends, and it
does not require a closed loop sketch.
Where to Find It • Click Revolved Surface gjj on the Surfaces toolbar.
10 Sweep profile.
• Or, click Insert, Surface, Revolved.
Open the existing sketch named
Sweep Profile.
Revolved surface.
Click Revolved Surface g| on
the Surfaces toolbar.
Select the vertical centerlinc.
Set the Angle to 360° and click
OK.
Note One difference between the
revolved solid feature and the
revolved surface feature is the default angle. With the solid it is 360° Note the Pierce relation between
With the surface it is 180°. the profile sketch and the path.
11 Fit spline.
Use Fit Spline |£j to create a
spline, replacing the lines and arc.
12 Exit the sketch.
36 Basic Surfacing 37
Basic Surfacing
Lesson 2 S o l i d W o r k s 2009 T r a i n i n g M a n u a l Lesson 2
16 Trim.
Click Trim Surface Й on the
Introducing: Swept Surface works exactly like its solid counterpart except that it
Surfaces toolbar.
Swept Surface produces a surface instead of a solid, it does not cap the ends, and it
does not require a closed loop sketch. For Trim Type, select Mutual
Where to Find It • Click Swept Surface Щ on the Surfaces toolbar.
and select the three extruded
• Or, click Insert, Surface, Sweep. surfaces.
Click Remove selections.
13 Swept surface. In the illustration at the right,
Using the profile and path created the purple selections are the
in the previous steps, sweep a portions of the surfaces that will be removed.
surface as shown. Use the default
settings. Click OK.
Note 17 Examine the Surface Bodies folder. 3 Surface aocfesO)
The extruded and revolved surface ф SurfacevRevolvel
bodies have been hidden for The mutual trim operation also knit the trimmed
: ф Surface-Sweepl
clarity. surfaces into a single surface body. :
ф Surface-Trtn!
14 New sketch. 18 Second mutual trim.

Open a sketch on the Front reference Trim the previously trimmed and
plane and create the profile sketch as knit surfaces with respect to the
shown. Use sketch mirroring to create the swept surface.
necessary symmetry. Click Keep selections.
The purple selections are the
Note The 65 mm long construction line portions of the surfaces that will
is Collinear with the highlighted be kept.
edge of the extruded surface as
shown at the right. Click OK.
19 Third mutual trim.
Trim the results of the previous
step with respect to the revolved
surface.
Edge Click Remove selections.
15 Extruded surface.
The purple selections are the
Click Extruded Surface |S»J Vertex
portions of the surfaces that will be
on the Surfaces toolbar.
removed.
Using the end condition Up
Click OK.
To Vertex, extrude two
surfaces as shown. 20 Results.
The results of the three trimming
operations are shown at the right.
38 Basic Surfacing 39
Basic Surfacing
Lesson 2
21 Fillet. _
Click Fillet (в| on the Features
Filleting Surfaces Surfaces are filleted using the same command as for solids. However, toolbar.
surface behave a little different than solids. The difference depends on
whether the surfaces are separate, discrete surfaces, or whether they Create a 3 mm fillet on the two
have been knit together. edges as shown in the
illustration at the right.
Rules There are a couple of simple rules that make filleting surfaces very
straightforward:
• If the surfaces are knit, select and fillet the edge, just like you
would with a solid. This is the simplest, most straightforward case. 22 Thicken.
• If the surfaces are not knit, use a Face Fillet between the individual Click Insert, Boss/Base, Thicken or click
surfaces. Thicken Щ on the Features toolbar.
a If the surfaces are not knit, after they are filleted, the result is knit. Set the Thickness to 1 mm and verify that
Filleting will automatically trim the filleted surfaces and knit them thickness is being added to the inside of the
together with the fillet, forming a single, composite surface. surface body.
• When using a Face Fillet on surfaces, preview arrows will appear
indicating the side of the surface to which the fillet will be applied.
This is because when filleting untrimmed surfaces, there can be
multiple solutions. Click Reverse Face Normal (7J to reverse the
arrows. For example, as illustrated below, an intersecting cylinder
and curved surface can yield four different results, depending on
which side of the surfaces the fillet is located.
23 Section view.
Create a section view parallel to the
Front reference plane. The exact
location of the section plane is not
important as long as you can clearly
see the bottom edge of the part that
resulted from the thicken feature.
The system thickens a surface by

offsetting the surface body and then
lofting faces between the edges. The
resulting faces are knitted and made
into a solid.
Because of the offset operation, the
bottom edge of the part is not flat.
41
40 Basic Surfacing Basic Surfacing
Lesson 2 S o l i d W o r k s 2009 T r a i n i n g M a n u a l Introduction to Surfacing
Introducing: Cut The Cut With Surface command uses a surface body to cut a solid
Cutting the Bottom One approach to cutting the bottom edge flat is to use Insert, Cut, With
with Surface body. The surface must extend all the way through the solid, preferably
Surface and use the reference plane Offset Plane (see step 6 on
with room to spare.
page 37) as the cutting tool. The problem with this approach is it cuts
off too much of the part. We need a way to cut only around the Where to Find It • Click Cut With Surface g | on the Features toolbar.
perimeter. • Or, click Insert, Cut, With Surface.
26 Cut with surface.

Click Insert, Cut, With Surface.
Select the radiated surface as the
cutting tool.
Verify that the cut is going towards
the correct side of the surface and
click OK.
Introducing: Radiate The Radiate Surface command creates a surface by radiating the 27 Hide the radiated surface.
Surface edges of solids or surfaces parallel to a selected plane. Right-click the Surface-Radiate 1 feature and select Hide @ from the
• Click Radiate Surface g) on the Mold Tools toolbar. shortcut menu.
Where to Find It
• Or, click Insert, Surface, Radiate. 28 Section view.
Customize the Surfaces toolbar and add Radiate Surface gj to it. Use a section view again to verify that the bottom
Tip edge of the part is now flat.
24 Radiate surface.
Click Insert, Surface, Radiate.
For the Radiate Reference
Direction, select the planar face
as shown. The radiated surface 29 Full round fillet.
will be created parallel to this Add a full round fillet to the edge
face. of the round opening in the bezel.
Select the outermost edge of the
part and observe the radiate direction arrow.
Click Flip Radiate Direction © so the surface will be constructed
towards the interior of the part.
Set the Radiate Distance to 5 mm and click OK.
25 Results. 30 Save and close the part.
Basic Surfacing 43
42 Basic Surfacing
aSSSSSn ,o Surfing S o l i d W o r k s 2009 T r a i n i n g M a n u a l
Exercise 3: Use surface commands to create a

Basic Surface thin walled solid model.
Modeling Disclaimer: The primary purpose
of this exercise is to give you the
opportunity to practice using some of
the surfacing commands. In reality,
there is no compelling reason to build
this part using surfaces. The steps in
the procedure may be somewhat con-
trived so that certain commands will
be utilized.
This lab reinforces the following
skills:
• Extruded Surface on page 11.
• Delete Face on page 17.
• Revolved Surface on page 36.
• Extend Surface on page 46.
• Swept Surface on page 38.
• Filleting Surfaces on page 40.
• Thicken on page 16.
Units: millimeters
Procedure Open a new part using the Part_MM template and name it Baffle.
Sketch for extrude.
Create a sketch on
the Front reference
plane using this
geometry.
'^ ' R76
Extruded surface.
Extrude a surface 127 mm using
the end condition: MidPlane.
44 Exercise 3: Basic Surface Modeling 45

Basic Surfacing
3 Trim the surface.

Create a sketch on the Top Extend surface.
reference plane as shown. Extend the top edge of the revolved surface so that • м
it extends well beyond the extruded surface.
Click Trim Surface @ on the
Surfaces toolbar or click Insert,
Surface, Trim.
The active sketch is automatically ©Ottra
selected as the Trim tool. OuptopoM

OUPtosuface
16
Click Keep selections and select ©Sam surfaca
the inner portion of the surface. Ouiur
Click OK. 6 Trim surface.

Trim both the extruded and revolved surfaces,
leaving the portions shown.
Tip Mutual Trim can be used.
4 Revolved surface.
Sketch on the Front reference
Sweep surface.
plane and revolve the geometry
as a surface. Create a reference plane normal to the surface edge and sketch a
12 mm long line as shown.
Using the line as the sweep profile and the surface edge as the sweep
path, create the surface shown.
Tip For the path, open a 3D sketch and use Convert Entities Щ to copy the
• 076-
edges into the sketch.
Introducing: Extend You can make a surface larger by extending it along selected edges, or
Surface all edges. The extension can be an extrapolation of the existing surface,
or a ruled surface that is tangent to the existing surface.
The Same surface option attempts to extrapolate the curvature of the
existing surface. On analytical surfaces this option works very well and
results in a seamless extension. On algorithmic surfaces this option is
typically only useful for short distances.
The Linear option (tangent extension) works on any type of surface but 8 Knit surface.
often creates a broken edge. Combine the trimmed and swept surfaces into a single surface using
Knit Surface.
Where to Find It • Click Extend Surface @ on the Surfaces toolbar.
• Or, click Insert, Surface, Extend.
46 Exercise 3: Basic Surface Modeling Exercise 3: Basic Surface Modeling 47

9 Surface fillet. Exercise 4: Use surface commands to

Halyard Guide model the halyard guide.
Add a fillet of 3 mm radius to the
surface edges as shown in the This lab reinforces the
illustration. following skills:
• Swept Surface on page 38.
• Planar Surface on
page 12.
a Knit Surface on page 15.
• Filleting Surfaces on
page 40.
10 Thicken surface. Units: millimeters
Create the first feature by adding Procedure Open a new part using the Part_MM template and name it
1.5 mm thickness to the inside of the Halyard Guide.
surface with Insert, Boss/Base,
Thicken Щ. 1 Sketch first guide curve.
Open a sketch on the Right
reference plane, and create the
sketch shown at the right.
32
-зв-
Offset plane.
Create a plane offset 6.5 mm below
the Top reference plane.
12 Save and close the part.
Exercise 4: Halyard Guide

Exercise 3: Basic Surface Modeling
Sketch second guide curve. 7 Add relations.

Open a sketch on the offset plane (Plane 1 in Add Pierce relations between
the illustration above), and create the sketch the ends of the tangent lines and
shown at the right. the second and third guide
curves.
Add a Coincident relation
between the arc and the end of
the first guide curve. The sketch
should be fully defined.
8 Sweep a surface.
Sketch third guide curve. Using the profile, path, and three
Open another sketch on the guide curves, sweep a surface.
offset plane, and sketch a Important! Use Path Tangent for the
vertical centerline from the Start tangency type.
Origin.
Sketch a second vertical
centerline whose lowermost end
is aligned with the Origin.
Sketch an arc tangent to the 9 Trim the surface.
centerline. Trim the swept surface
using the Top reference
Add Symmetric relations between the arc in this sketch and the arc in plane as the trim tool.
the sketch of the second guide curve.
Keep the uppermost portion
Sketch the path. of the surface.
Open a sketch on the Top
reference plane, and sketch a
Vertical line starting at the
Origin.
Add a relation so the length of
the line is driven by the guide
curve sketches.
Sketch the sweep profile.

Open a sketch on the Front
reference plane, and sketch an
arc centered on the Origin.
Sketch two tangent lines as
shown.
50 Exercise 4: Halyard Guide Exercise 4: Halyard Guide

10 Sketch. 14 Thicken.
Open a sketch on the Top Create the first feature by
reference plane. thickening the surface
2.5 mm.
Convert the edge of the
trimmed surface, and Check the preview to ensure
complete the sketch using the the material is added to the
dimensions given. correct side.
11 Planar surface.
Click Planar Surface gj to
create a planar surface using
the active sketch.
15 Mirror body.
12 Second planar surface. Use Insert, Pattern/
Mirror the first planar Mirror, Mirror to create
surface to create the second the other half of the guide
one. and Merge result.
13 Knit the surfaces and fillet

the edges. 16 Fillet the edges.
Knit the three surfaces Add a 0.5 mm radius
together, and then fillet the fillet to the edges of the
edges shown with a 4 mm part.
radius fillet.
Exercise 4: Halyard Guide Exercise 4: Halyard Guide

17 Countersunk hole.
Add four countersunk holes for M4 flat head machine screws using the
Hole Wizard ffi.
Tip Use mirroring in the sketch to facilitate creating all four holes in one
feature.
Lesson 3
Solid-Surface Hybrid
Modeling

• Modify a solid using surface bodies.
• Interchange between solids and surfaces.
• Use surfaces as construction geometry.
• Make copies effaces of a solid model fur use in surface modeling
operations.
54 Exercise 4: Halyard Guide 55

Solid-Surface Hybrid Modeling Solid-Surface Hybrid Modeling
Hybrid Hybrid modeling brings together two

Modeling different modeling methods: solid
modeling, which is best at prismatic
shapes and shapes with flat ends, and
surface modeling which is best at
making shapes one face at a time.
Often a hybrid approach is the best
option because using only solids can be
inefficient and awkward, and surfaces
alone take far too long to model.
Deciding which approach to use requires recognizing the strengths and
weaknesses of various approaches, and applying them as the situation
dictates.
In general terms, hybrid modeling can be broken into several
categories:
Surface used to modify a solid
This includes features such as Replace Face, Cut With Surface, and
any of the Up To Surface or Offset From Surface end conditions. The
Filled Surface also has the ability to integrate itself directly into an
existing solid.
Interchangeability between solids and surfaces
This includes Delete Face (changes a solid into a surface body),
Thicken (changes a surface body into a solid), Knit Surface and
Offset Surface techniques for copying faces of solids).
• Surfaces as construction geometry
This category includes techniques such as Intersection Curve, using
surfaces used to trim other surfaces, and creating ruled surfaces to
establish draft angle references around parting lines, or as tangency
references for commands like Filled Surface.
• Creating solids directly from surfaces
This includes techniques such as bodies to create a solid, or using
Thicken on an open surface body.
56 Hybrid Modeling 57
Using Surfaces In this lesson we will use existing surface geometry to modify a solid Display Notice that after you create the
to Modify Solids body to create the shape of an electric guitar body. We will employ feature, the display appears mottled
several methods that all achieve the same result: where the solid and surface faces
coincide. This is due to the faces
• Extrude a solid using the Up To Surface or Up To Body end being in exactly the same location
condition. and having different colors. The way
• Extrude a cut using the Up To Surface or Up To Body end SolidWorks displays surfaces makes
condition. small approximations which cause
• Cut With Surface. one or the other surface sit on top at
• Replace Face. any given point. To avoid this affect,
Complex modeling is often an exercise in multiple methods, and you can hide the surface body. However, since we will be exploring
having several ways to accomplish any task helps. other techniques that will use the surface body, do not hide it at this
time.
Procedure Follow these steps to leam several techniques to create the part shown.
3 Edit the solid feature.
1 Open part. Edit Extrude 1 and change the end
Open the existing part named condition to Blind with a Depth of
Guitar_Body. 4 inches.
This part contains a surface body that
has already been created, along with a
sketch of the overall outer shape of
the guitar body.
Extrude up to surface. 4 Sketch.

The easiest and often the most Open a new sketch on the end face
efficient hybrid method is to extrude of the newly edited solid.
a solid up to a surface body.
With the face still selected, click on
Select the sketch named Guitar Convert Entities to convert the
Body Outline. edges to sketch entities.
Click Extrude Boss/Base |Mj on the
Features toolbar.
Use the end condition Up To Body (Up To Surface will also work) and
select the Top Surface Knit body from the graphics window or from S Cut up to surface.
the FeatureManager. Click Extruded Cut Щ on the
Note The message: "The end face cannot terminate the extruded Features toolbar.
feature" means that the sketch is bigger than the surface and Use the end condition Up To Body
SolidWorks does not know what to do outside of the surface (Up To Surface will also work) and
boundaries. To avoid this knit several surfaces into a larger surface select the Top Surface Knit body
body, and then extrude up to the body rather than an individual face or from the graphics window or from
feature. the FeatureManager.
58 Using Surfaces to Modify Solids U s i n g S u r f a c e s to Modify Solids 59

6 Results. 10 Replace face.

The Top Surface Knit surface body Click Replace Face ( | on the Surfaces toolbar.
has been hidden for clarity. In the upper selection list, Target faces for
replacement, select the planar face of the solid.
These are the old faces that will be removed.
In the lower selection list, Replacement
surface(s), select the Top Surface Knit body.
Click OK.
7 Suppress the extruded cut feature. Note The name that appears in the selection list may not match the actual
name of the surface body, regardless of whether you select it from the
8 Cut with surface. Surface Bodies folder or the graphics window.
Click Cut With Surface Ш on the
Features toolbar, or click Insert,
Cut, With Surface.
Select the Top Surface Knit body.

The direction of the arrow indicates
the material that will be removed.
Click OK.
Introducing: Replace Face is a very powerful hybrid modeling technique. It is one R e p l a c e m e n t surface
Replace Face of the few functions that can add and/or remove material in a single
operation.
Replace Face can replace faces of solids or of surfaces, but the body Interchanging Working with solids can only take you so far, and sometimes you may
Between Solids need to use a different approach. This is what temporarily changing a
replacing the face must be a surface body.
and Surfaces solid model into a surface model accomplishes.
On complex projects you should plan your work so you do not wind up
frequently switching back and forth between solids and surfaces and
wasting a lot of rebuild time.
11 Suppress the Replace F a c e l feature.
Where to Find It • Click Replace Face Ц| on the Surfaces toolbar.

• Or, click Insert, Face, Replace.
9 Suppress the S u r f a c e C u t l feature.
60 Interchanging Between Solids a n d S u r f a c e s 61

U s i n g Surfaces to Modify Solids
Lesson 3
S o l i d W o r k s 2009 T r a i n i n g M a n u a l S o l i d W o r k s 2009 Training M a n u a l Lesson 3
Solid-Surface Hybrid modeling
12 Convert the solid body to a surface body.

Click Delete Face ffl on the Surfaces toolbar. We have used several techniques on this part. There will be situations
Select the face shown below and select the Delete option. in consumer product design where you will likely need each one of
these techniques. As to which technique is better, there is no single
Click OK.
answer that would be valid in all cases.
This will decompose the solid body into a surface body.
I
13 Trim the surfaces.
Use Trim Surface with the Mutual trim type to trim both surfaces.
Performance Although each of the techniques just demonstrated yields equivalent

Implications results in terms of geometry, some techniques exact a higher toll than
others in terms of system performance and rebuild times.
While results may differ on different computers, the following is a
14 Thicken into a solid. representative example of the rebuild times for three of the techniques,
The surface body created by the mutual trim made an enclosed surface, as measured by the Tools, Feature Statistics command.
but it did not make it back into a solid body.
Technique Rebuild Time (rounded)
Click Insert, Boss/Base, Thicken gj. After you select the enclosed
surface body, there should be an option Create solid from enclosed Extrude Up To Surface 15 seconds
volume. Make sure this option is selected.
Replace Face 22 seconds
Trim, Knit, and Thicken 24 seconds
62
Interchanging Between Solids a n d Surfaces
P e r f o r m a n c e Implications 63
3 Edit an existing sketch.

Surfaces as One of the keys to any sweep operation is
Edit the sketch spline_grid.
Construction creating the required curves to use as the
Geometry P guides. In this example, a decorative I
a mo r
4 Create spline.
metal piece is modeled by sweeping a circle I Click Spline 0 and sketch a spline whose shape
along a curved path. The path is created by is approximately the same as the one shown in
finding the intersection between two the illustration at the right, attaching to lines and
reference surfaces. endpoints. The spline should have 7 interpolant
points.
Thanks to Jason Pancoast at

Computer-Aided Products, Inc.
for submitting this example.
Stages in the The major steps in this operation are:

Process
Create a revolved surface. 5 Add relations.
This will use a sketched spline. To maintain symmetry in the spline, add
Create a helical surface. Symmetric relations between the spline points
and the horizontal construction line.
This is done by sweeping a line along a straight path, with twist control.
Generate intersection curve.
Find the intersection between the two reference surfaces. This is the
path for the twisted sweep.
Sweep one of the "spokes".
A circular profile is swept along the intersection curve.
Pattern the "spokes".
A circular pattern of the swept feature completes the part.
Procedure To save time, we will begin by opening an existing part

1 Open part.
Open the existing part named Wrought
Iron. This represents the base of an
ornamental object such as the base of a
lamp. A sketch is also included.
2 Hide solid.
Right-click the revolve feature, and select Hide |e-|
Surfaces as Construction Geometry 65

64 Surfaces as Construction Geometry
Lesson 3 S o l i d W o r k s 2009 Training Manual S o l i d W o r k s 2009 Training M a n u a l Lesson 3
6 Dimension. 8 Revolve surface.

•— CO ^
Use ordinate dimensions to dimension the Select the vertical centerline at
ч
spline points. the zero datum, and click
Revolved Surface 1*1 on the
Surfaces toolbar.
Set the Angle to 360°.
-54
Click OK.
-32
200
9 Sketch the sweep path.

Open a new sketch on the Front reference plane.
.11
Show the sketch of the revolved surface.
Select the vertical centerline, and click Convert
Entities to copy it into the sketch.
7 Vertical relation.
Select the upper end spline handle (arrow)
and add a Vertical relation. 10 Exit the sketch.
Repeat the procedure for the lower end spline
handle.
-54
11 Sketch the sweep profile.

-32
Open a new sketch on the Top reference plane.
Sketch a line from the bottom end of the sweep
path along the horizontal direction.
/11 12 Exit the sketch.
. . u
66 Surfaces as Construction Geometry Surfaces as Construction Geometry 67

Lesson 3
13 Sweep a surface. C Surface-Sweep

Sweep a surface using the • x
profile, path, and twist
control settings as shown.
No guide curve is
required to create this
helical sweep. [WflbngPath v| I
14 Intersection curve.
Hold down Ctrl and select the two surfaces.
Click Intersection Curve Щ.
The system generates the intersection in a 3D
sketch, and automatically puts you into Edit
Sketch mode.
15 Exit the sketch.
Exit the 3D sketch and hide the two surface
bodies.
16 Show the solid body.

Right-click Revolvel and select Show
Create a plane normal to the top end of the
intersection curve, and sketch a 6 mm circle.
68 Surfaces as Construction Geometry Surfaces as Construction Geometry 69

Lesson 3
Lesson 3 S o l i d W o r k s 2009 T r a i n i n g M a n u a l Solid-Surface Hybrid Modeling
Solid-Surfece Hybrid Modeling
Procedure To save time, we will start with the countersunk holes already inserted
Making Copies Many times in hybrid modeling you need to work on a copy of a face of
into the part.
of Faces a solid. There are two techniques you can use to make copies:
Open part.
• Offset Surface
• Knit Surface Open the existing part named
HandleJJrip.
Introducing: Offset The Offset Surface command creates a new surface body from an
Surface existing set of faces. The faces may be solid or surface faces. When
offset surfaces fail, it is usually because the offset distance is greater
than the smallest curvature on the face. In this way it is similar to
offsetting a sketch.
To create a copy of a face, use an offset distance of zero.
Where to Find It • Click Offset Surface Щ on the Surfaces toolbar. Copy the surfaces.
• Or, click Insert, Surface, Offset. Click Offset Surface Щ on the
Surfaces toolbar.
For Offset Distance, enter
0.00 mm.
Select the faces of the two
countersinks and click OK.
Note The reason we did not use Knit
Surface to copy the faces is because the two faces are disjoint and
cannot be knit together.
Extend surface.
Click Extend Surface @ on the
Surfaces toolbar.
Select one of the copied surfaces.
For the End Condition, select
Distance and enter a value of
6.00 mm.
The distance isn't critical as long as
it is sufficient to penetrate beyond the uppermost face of the part.
For Extension Type, select Same surface.
Click OK.
Repeat.
Repeat the previous step for the
other copy of the countersunk face.
71
70 Making Copies of Faces Making C o p i e s of F a c e s
Exercise 5: A finial is a decorative end cap, in this case for a

Finial Wrap curtain rod. This finial model has several features
which will be completed over the course of
several exercises. In this exercise, you will create
the wrapped pattern around the lower band on the
finial.
From a design point of view, a real part would not
likely have such a conglomeration of style
elements, but bringing them together allows one
part to serve as a showcase for several
techniques.
This lab reinforces the following skills:
• Wrap which was covered in the Advanced
I v .
Part Modeling course.

• Loft which was covered in the Advanced Part
Modeling course.
• Extend Surface on page 46.
• Replace Face on page 60.
Units: millimeters
Procedure Open the existing part named PiniaLWrap.
Notice that there is existing solid geometry and two sketches. The
sketches have been provided in order to get consistent results.
Create two copies of surface.
Using Offset Surface or Knit Surface, create
two separate copies of the highlighted
cylindrical face shown in the illustration at the
right.
Two copies are needed because you will create
two Wrap features, each of which consumes
one surface body.
Hide bodies.
Hide the solid body and the all of the surface bodies except one of the
copied surfaces.
72 Making C o p i e s of Faces E x e r c i s e 5: Finial Wrap 73

6 Thicken the surface bodies.

Wrap feature.
Create two Thicken features, one from each surface body.
Click Insert, Features, Wrap or click Wrap ftjl
on the Features toolbar. ШШВЯ&Я^Щ T h i c k e n 1:
• Thickness = 1.25 mm
For the Source Sketch select the sketch
• Merge results = cleared
Wrap_Sketchl. ©SQt*
Select the Scribe option. The Scribe option •Reverse oVecHon
creates split lines on the target face.

For the Face for Wrap Sketch (the target face) If
ThickenS:
select the copied surface. • Thickness = 1 mm
The long rectangle represents the cylindrical surface flattened onto the • Merge results = selected
sketch plane. • Feature Scope = Selected
bodies; Thicken 1
Click OK.
7 Create a split line.

Open a new sketch on the Top reference plane, and
sketch a line approximately as shown.
Create a split line on the outer face of the solid body.
Scribe
4 Delete face.
Delete the portion of the cylindrical surface
outside of the scribed pattern.
8 Change view.
Note Use the Delete option. Change to a Back view and then press the down
Click OK. arrow three times rotating the view 45°.
Results
5 Repeat.
Repeat steps 3 through 4 using the second copied surface and
Wrap_Sketch2.
Exercise 5: Finial Wrap

74 E x e r c i s e 5: Finial W r a p
9 Loft a surface. 12 Replace face. . — Replacement surface
Loft a surface between the split line and Replace the face of the solid
the edge at the intersection of the two with the lofted surface body.
bodies. Hide the remaining surface
Use Curvature To Face for both the body.
start and end constraints. The surface color has been
Which Face? The lofted surface is being created changed here for clarity. ^ ^ ^ ^ ^ ^ ^ ^ ^ N
— Target f a c e
between two edges. In a solid model,
every edge is the boundary between two 13 Pattern the body.
faces. So which of the two adjacent faces is being used for the Make a Circular Pattern with a total of 9 instances of the body around
Curvature To Face constraint? a temporary axis.
Look at the constraint arrow. It indicates which face is being used for
the curvature matching. The length of the arrow indicates the amount of
influence the reference face has on the resulting surface.
If the constraint arrow is pointing in the wrong direction, click the Next
Face button in the PropertyManager.
14 Merge the new bodies with the

Incorrect F a c e
existing body.
10 Results. Show the Revolves solid body.
The surface color has been changed Click Insert, Features, Combine.
here for clarity.
Select all solid bodies either from the
Solid Bodies folder or from the
graphics window.
Click OK.
The color of the patterned wrap
11 Extend the surface. features has been changed for
The lofted surface will be used to illustration purposes.
replace the face of the solid. In order
to do that, the lofted surface must to
extend past the solid body.
Click Extend Surface @.
Extend the surface past the sides of
the solid using the Same surface option
77
76 E x e r c i s e 5: Finial Wrap E x e r c i s e 5: Finial W r a p
Lesson 4
Repairing and Editing
Imported Geometry

• Have a basic understanding of the issues and factors that affect the
transfer of CAD data between systems.
• Import solid and surface geometry from other sources.
• Diagnose and repair problems with imported geometry using
Import Diagnostics.
• Repair and edit imported geometry using manual, surface modeling
techniques.
Exercise 5: Finial Wrap 79

Repairing and Editing Imported Geometry Repairing and Editing Imported Geometry
Importing Data Models imported from one C A D system to another do not always
translate without error.
Importing data is very much like translating spoken languages. The
translated words do not always carry the same meaning as the original.
What do we do when there is no exact word or phrase for that which we
are translating? Generally we have to use a word or phase that is close
in meaning, even it is not an exact match. C A D systems have the same
difficulties when features in one system do not have equivalents in the
other system.
What to Import? This depends on what you need to achieve. Typically, the goal is to
create a solid. However, sometimes there are other objectives. Many of
the solid-surface hybrid techniques introduced in the previous lesson
work very well with imported surface bodies. These techniques
include:
• Replace Face
• Cut With Surface
• Any of the Up To Surface or Offset From Surface end conditions
• Construction geometry for Intersection Curves or as a reference
for designing tooling.
In these cases, a knit surface is all that is needed.
Wireframe Geometry If at all possible, leave all wireframe geometry out of the translation.
Imported splines, lines, arcs, points and curves represent substantial
overhead and a drain on system resources.
File Format If you have a choice of what type of format you import, there are some
distinct advantages to using some formats over others. Formats that
lend themselves to solid bodies such as Parasolid, ACIS and STEP are
preferred over IGES for solid body translation.
Parasolid is the native modeling kernel for SolidWorks. A Parasolid file
is not a translation but a direct read into SolidWorks. Therefore, if the
Parasolid format is available, it would be the first choice of any 3D
format to bring into SolidWorks.
Even though the Parasolid file format supports exchange of solid data
between Parasolid-based systems, this data only defines the solid body
itself (faces, edges, and vertices), and does not include historical data
on how the solid was created.
Why Do Imports Imported files fail to produce solid bodies for several reasons. A basic
Fail? understanding of the causes makes it easier to troubleshoot import
failures.
One of the primary difficulties is that different C A D systems use
dissimilar mathematical representations, or algorithms, for representing
3D objects. It is this difference that creates interoperability problems
when sending or receiving 3D models. More specifically:
80 Importing Data 81
Different tolerances Extend surfaces

A l l C A D systems do not work to the same precision. The error caused Surfaces that are too short to reach the next surface can be extended to
by rounding off values in the sending system may cause the entities to get within the range of the stitcher.
be outside the tolerance of the receiving system to stitch them together. Trim surfaces
Some C A D system have the capability to change the file tolerance for Surfaces that extend past the desired boundary can be trimmed
file output, or for that matter, adjust the modeling tolerance before manually.
beginning the model. Knowing what these setting are and setting up Delete surfaces
some preferences before exporting the model may greatly reduce the Some surfaces may be too hard to fix. Another approach is to delete the
amount of cleanup needed in SolidWorks once the file is imported. problem surface and replace it with something better.
Translation mapping Filled surfaces
Not all C A D systems support the same features. If a receiving system The Filled Surface command can be used to create both planar and
doesn't support a 3D entity the import will either fail or not be an exact non-planar patches to close holes in the model.
match of the model sent.
Workflow When you import legacy data into SolidWorks a number of events take
Missing entities place. In general, the workflow is:
There are times when surfaces do not translate between systems
1. Import the file using those options that will achieve the best
leaving a missing surface in the imported model. If the hole is
possible result. This includes options both in the sending as well as
sufficiently large, the automatic healing tools may not be able to close
the receiving system.
the hole.
2. Run Import Diagnostics to further clean up the data.
Resulting The different types of problems caused by the translation process are 3. Use manual techniques in SolidWorks to fill and repair any gaps or
Problems generally: holes to create a solid or knit surface body.
Gaps Stages in the
Localized gaps can occur between coincident vertices and edges that Process The steps in importing a solid model into SolidWorks are listed below.
fall outside the modeling tolerance of the receiving system.
Localized gaps can also occur between mating edges of faces. Import
Face edge abnormalities Importing is done through translators capable of reading the file format
of another C A D program or through a neutral format.
These include self-intersections, gaps and multiple tiny edges. Stitch and knit
Repairing Models There are several ways to close up the imported surfaces. Stitching and knitting forms the individual elements of the imported
file into a single solid. SolidWorks options are normally set to try to
Change the import type
stitch and knit together the elements of the model automatically during
There are generally several translators available between the sending
the import process.
and receiving systems. If one type does not give satisfactory results, try
New part document
another.
You have the option of specifying a document template or allowing the
Change tolerance
system to use the default template. This choice is determined by the
Several import methods allow the stitch tolerance to be adjusted, by
settings in Tools, Options, System Options, Default Templates.
loosening the tolerance, edges that were beyond the range to stitch can
now be stitched automatically. Diagnose ЙШШШШШШ^^^^^^^ШвШЯ^Л
If SolidWorks cannot stitch Do vou wfch to run Import Diagnostics on Ms part?
In some cases, the sending C A D system can be set to a tighter tolerance together the individual elements
and the model can be re-imported. to form a solid, there are several •t)ant ask ma again.
Import as surfaces diagnostic tools available to help
If the automatic repair cannot form a solid, import the model as determine the problem.
surfaces and repair the errors. Knit and thicken to create the final solid.
82 Importing Data 83
Importing Data
Lesson 4 S o l i d W o r k s 2009 Training Manual Lesson 4
If you choose not to run import diagnostics you can run it later by right- Use verification on rebuild.
clicking on the import feature and selecting Import Diagnostics from Click Tools, Options, System Options, Performance.
the shortcut menu.
Select the Verification on rebuild option and click OK.
If you click Don't ask me again, the automatic prompt is disabled.
Press Ctrl+Q. This does not reveal any errors.
Banished messages are placed into a list in Tools, Options, System
Options, Advanced where they can be reactivated if needed. Make sure to turn the Verification on rebuild option off before
continuing.
Note Import Diagnostics is only available if the Imported feature is the
only feature in the part. Tools, Check.
Click Tools, Check, and check the model.
Heal
Import Diagnostics provides some automatic tools to heal and repair Click on the faces in the Result list and they
problems in the geometry. If these fail or only repair some of the will highlight in the graphics area. Although
problems, we manually intervene to create missing elements or to three results are listed, two point to the same
repair geometry that prevents stitching. face
FeatureWorks® Most imported bodies have only one feature. FeatureWorks provides a Tools, Check will check a model, but by
tool to recognize features and breakdown the part into those individual itself it cannot repair the model.
features. Generally FeatureWorks is more appropriate and successful Import Diagnosis is a tool that can both find
with prismatic parts than with free-form consumer parts. Therefore, and repair errors, so we will employ that now.
FeatureWorks is beyond the scope of this course and will not be
covered here. For more information about FeatureWorks, please refer
to the self-study book CAD Productivity Tools Step-By-Step. Introducing: Import Import Diagnostics is a tool that helps locate and fix problems with
Diagnostics imported geometry. In order for Import Diagnostics to work, the
Repairing and In spite of the lack of a feature history, there are options available for Imported feature must be the only feature in the tree.
Editing editing and modifying imported parts.
Where to Find It • Click Import Diagnostics [Ш] on the Tools toolbar.
Imported In the following case study and exercises we make two assumptions: • Or, click Tools, Import Diagnostics.
Geometry • Or, right-click on the Imported feature in the FeatureManager and
1. You will be prompted to select a document template for the new
part. select Import Diagnosis.
2. You will be prompted to run Import Diagnostics.
Import Diagnostics. ,' Impart Oiayiiostics
1 Open file. Right-click the Importedl feature and select

Open the file named Import Diagnostics.
baseframe.STP. This identifies a third faulty face. Hovering the
2 New SolidWorks document. cursor over one of the fault symbols in the fl^Face<l>
Select the Part_MM template. PropertyManager shows a tooltip of what is wrong ijjj Face<2>
Fa»<3>
with each face.
3 Import diagnostics.
You will be asked if you want to
run Import Diagnostics on the
> Gap* between faces [0
part.
Click No.
Normally we would click Yes. However, we want to examine the part
using a few other tools and techniques first. We will run Import
Diagnostics later.
| WMntpttoHealAl J
84 R e p a i r i n g a n d E d i t i n g Imported G e o m e t r y Repairing a n d Editing Imported G e o m e t r y 85

Lesson 4
S o l i d W o r k s 2009 T r a i n i n g M a n u a l Repairing and Editing Imported Geometry
7 Attempt to heal all. m Closing holes in a part.

Click the Attempt to Heal All button. This may or may not solve 100% In preparation for modeling a core and cavity mold, through holes in
of the imported problems, but any manual work that it saves is a the part have to be closed off. Surfaces are used to do this. However,
benefit. when the edges of the hole are not planar, creating a surface patch
requires a special tool. This and other techniques relating to modeling
Import Diagnostics is able to repair two of the surfaces but one is still mold tooling is addressed in the course Mold Design Using SolidWorks.
faulty.
Introducing: Filled The Filled Surface feature constructs a surface patch with any number
8 Accept the results. Surface of sides, within a boundary defined by existing model edges, sketches,
Click OK to accept the results of Import Diagnostics. or curves.
Nothing that you do with Import Diagnosis can be undone except by Filled Surface requires a boundary of surface edges or sketch entities.
reimporting the data. There is no feature history of what it has done It may even work without a closed loop. If surface edges are selected,
behind the scenes. boundary conditions such as Contact (CO continuity), Tangency (CI
9 The remaining faulty face. continuity), or Curvature (C2 continuity) may be selected.
The remaining faulty face is a three-sided The Filled Surface can knit itself into the surrounding surface bodies,
patch with a singularity, which we have
knit an enclosed volume into a solid or integrate itself directly into a
already identified in a previous lesson as
solid body.
sometimes being problematic.
The Filled Surface works by creating a four-sided patch and trimming
10 Delete Face.
it to fit the selected boundary.
Click Delete Face [5) and using the Delete
option, delete the face and turn the solid Where to Find It • Click Filled Surface ® on the Surfaces toolbar.
model into a surface body. • Or, click Insert, Surface, Fill.
11 Patch the hole.

Options for Faulty faces can also be deleted from the Import Diagnostics The first choice for patching a gap like this
Deleting Faces PropertyManager by right-clicking a faulty face in the list and selecting is the Filled Surface feature.
Delete Face. However, there are differences:
Click Filled Surface ® on the Surfaces
1. Using the Delete Face command creates a DeletePace feature in toolbar.
the history tree. Deleting the face through Import Diagnostics
does not. Under Edge settings, select Tangent and
2. Deleting the face through Import Diagnostics turns the solid click Apply to all edges.
Imported 1 feature into a Stirface-Imported 1 feature. Select the three edges of the open area and
3. The Delete Face command has options for patching or filling the click OK.
resulting gap. Deleting the face through Import Diagnostics only
deletes the face. There are no options to patch or fill the gap. In this case, however, Filled Surface gives
us a poor quality face.
Patching Holes There are situations where special tools are needed to fill in areas of a
model with surfaces. For example: We need to look for another answer.
• Blending shapes. 12 Undo.

Sometimes the shape you need cannot easily be created using fillets, Click Undo S3 to delete the surface.
sweeps, or lofts. This will be addressed in Lesson 6: Blends and
Patches.
Consistency When the system creates the Filled Surface, the result is analyzed to
• Repairing gaps or incorrect geometry in imported surfaces. Notification determine if it is consistent with input parameters such as Tangent. If it
Sometimes imported surfaces lack the completeness or precision to be is not, the system issues a notification in the form of a tooltip in the
knit into a solid. In these situations tools are needed to fill in missing graphics window.
surface patches.
86 Repairing a n d Editing Imported G e o m e t r y 87

Repairing a n d Editing Imported G e o m e t r y
15 Remove boss and counterbored hole.

13 Loft the patch. On this part, we want to remove the small boss, the through hole, and
Lofting a patch will result in a surface with a the corresponding counterbore. The part in this area has a curved face.
singularity, but the only other alternative is a
I
revolved surface which also has a singularity. In
this case, the loft works well, although it requires
the correct combination of options.
(All
Click Lofted Surface [ф| on the Surfaces toolbar. Start согнЬ-аМ:
JTangency To Face «•* j
For the Profiles, select the two open edges that
meet at a common vertex. 1 -
1
Щ
El Apply to el
For the Start/End Constraints, select Tangency

| Tangency To Fate vi
To Face.
III м -* 16 Delete face.
Ц
Leave the Tangent Length vectors at their default Click Delete Face
values of 1.
Gude curves Irftjence Select all the faces of the affected features. There F*w<l>
For the Guide Curves, select the third open edge. should be nine selected faces all together. Fa»<2>
FeteO>
Fen><«>
Set the Guide curves influence to Global and set Use the Delete and Patch option and click OK. F*»<S>
Face<6>
the Edge Tangency type to Tangency To Face. Face«7> J !
ml
Click OK. EdgeO>-T«ngerit-Tang
OoM*
©Delate and Patch
ODebteandRl
Q Show preview
4
i^'/ 17 Results.
The Delete Face command
results in a perfectly smooth face,
as if there had never been
anything there at all.
14 Knit the surface bodies into a solid. 18 Edit the SeleteFaceB feature.
Click Knit Surface Щ.
We will now examine what
Knit the two surface bodies together and turn the resulting enclosed happens behind the scenes by
volume into a solid body. repeating the process manually.
Edit the DeleteFace2 feature and use the Delete option instead of
Editing Imported This imported part has some features we would like to eliminate. There Delete and Patch.
Parts are no features in a tree that can be deleted to do this, and we will not 19 Results.
do it by cutting and filling with solids. First, we will show an The result this time is a surface body instead of a solid.
automated way of doing this, and then go back through and see how to There are gaps in the surfaces where the feature faces
do this with a little more manual control. were.
88 R e p a i r i n g a n d Editing Imported G e o m e t r y Repairing a n d Editing Imported G e o m e t r y 89

Exercise 6: Import legacy data that has bad

Introducing: Delete The Delete Hole command is similar to Untrim Surface except that it Import geometry and use a combination
Hole only works on closed interior loops. Diagnosis of automatic and manual
techniques to repair the defects.
Where to Find It • Select the edge of a closed interior loop on a single surface body
and press Delete on the keyboard. This lab reinforces the following
• Or, select the edge and click Delete (Xj on the Standard toolbar or skills:
Edit menu. • Importing a Parasolid file.
• Import Diagnostics on
20 Delete Hole. page 85.
Select the edge of the hole and press Delete. • Delete Face on page 17.
The system will prompt you, asking if you want to Units: millimeters
delete the feature or delete the hole(s). Procedure
Click Delete Hole(s) and click OK. 1 Open file.
Open the existing Parasolid file named
There is one more method to examine.
repair2.x_b.
It is found in the Exercises folder of this
lesson.
Note If you are prompted to select a template, choose
P8J7t_MM.
2 Run Import Diagnostics.
If you are not prompted to run Import
Diagnostics, run it manually by right-clicking the Surface-
Imported 1 feature and selecting Import Diagnostics from the
shortcut menu.
3 View orientation.
The view orientation of the imported part is not convenient for the
purposes of this exercise. To change it, follow these steps. It is not
necessary to close the Import Diagnostics PropertyManager to do this.
1. Change to a Top view.
Hold down the Shift key and press the right

arrow once.
90 Repairing a n d Editing Imported G e o m e t r y E x e r c i s e 6: Import D i a g n o s i s 91

S o l i d W o r k s 2009 Training M a n u a l S o l i d W o r k s 2009 T r a i n i n g M a n u a l
3. Press the spacebar to open the View Orientation Faulty face.

window. Click on the face symbol in the
4. Click once on the Front view to highlight it in the list list and the remaining faulty face
5. Click Update Standard Views Щ. highlights in the graphics area.
6. When asked if you really want to change the standard
Heal all again.
views, click Yes. Click Attempt to Heal All.
The system repairs the remaining
R e m a i n i n g faulty
7. Change to an Isometric view. faulty face and the surface body is face
8. Click New View Щ. Name the view Alt_Iso. automatically knit into a solid
9. Click Reset Standard Views Щ. The body.
predefined views are set back to their
Click OK to close the Import Diagnostics PropertyManager.
standard orientations but the user-defined
view, Altjtso, maintains its customized 8 Closer look.
^4
orientation. The patches and the original face
Problem area. with the gap are all planar. This
Import Diagnostics found one can be determined by right-
gap between faces. Click on the clicking one of the faces and
gap symbol in the list and the seeing if the Insert Sketch Ш
open edges highlight in the command appears on the shortcut
graphics area. menu. If it does, the face is planar. Coplanar-» ^Г^Г^ГВ
Simplify the Since the faces are all planar, and in fact, are coplanar, they can be
5 Heal all. Geometry merged into a single face.
Click Attempt to Heal All.
The system patches the gap with 9 Delete and patch.
multiple faces. However, the Click Delete Face gj.
repair is incomplete. The system Select the patches. There were
issues this message: twelve in this example.
The last operation to repair a You will have to zoom in tightly
face failed. You can remove
to see all of them. Some are very
the failing face from the
small.
manually. Use the option Delete and Patch
and click OK.
92 E x e r c i s e 6: Import D i a g n o s h E x e r c i s e 6: Import D i a g n o s i s 93
10 Results. Exercise 7: This demonstrates some techniques for

The separate faces are replaced with a single face. Using Import modifying imported models. A surface
Surface and is imported from a Parasolid (x_t) file
Replace Face and used to replace a face in the solid.
• Delete Face on page 17.
• Import Surface, on page 96.
• Move/Copy Bodies which was
covered in the Advanced Part
Modeling course.
• Replace Face on page 60.
Units: inches
Procedure
1 Open file.
Open the existing Parasolid file named
Button.x_t. It is found in the Replace
Face folder.
Note If you are prompted to select a template,
choose Part_IN.
The face to be replaced is highlighted in
11 Save and close the part. blue.
2 Delete faces.
Before we can replace the face, some
fillets have to be deleted.
Click Delete Face Щ on the Surfaces
toolbar.
Select the faces shown.
Be sure to zoom in on the corners.

There are some small faces there.
You will select a total of seven
faces.
Select the option Delete and
Patch, and click OK.
E x e r c i s e 6: Import D i a g n o s i s E x e r c i s e 7 : U s i n g Import S u r f a c e a n d R e p l a c e F a c e
Import Surface.
Import a surface into the part using Insert,
Features, Imported.
Select the Parasolid file named New Surface.
The surface color was changed for clarity.
Move the surface.

Click Insert, Features,
Move/Copy, or click
Move/Copy Bodies §j on
Select the imported
surface.
Use the Translate option.
Enter 2.5" for Delta Y.
Click OK.
Replace face.
Replace the top face of the part with the imported surface.
Click Insert, Face, Replace, or click Replace Face @sj on the
Surfaces toolbar.
E x e r c i s e 7 : U s i n g Import S u r f a c e a n d R e p l a c e
4 Fillets and shell.

Exercise 8: This lab includes two small exercises in
Add fillets with a radius of 12 mm and a shell of 3 mm to complete the
Using Surfaces using surfaces to create solids.
body.
to Create Solids • The first one creates a solid by lofting
between two surfaces.
• The second uses the method of knitting
surfaces to combine multiple bounding
surfaces into a solid.
• Lofting between surfaces.
• Importing an IGES file.
• Filled Surface on page 87.
Units: millimeters
Lofting Between Lofting can be accomplished using sketches, faces or surfaces. In this
Surfaces example, lofting is performed between two surfaces to form a solid.
1 Open part.
Open the existing part named
LOFT_STJRF. The part consists of
two imported surfaces.
Repair and Knit Knit surface allows you to combine several surfaces into a single,
Surface larger surface or in some cases, a solid. For a solid, the surfaces must
comprise a closed volume. If surfaces are missing from the imported
data, the gaps must be filled.
1 Import an IGES file.
Click File, Open, or click Open g). Set Files of type: to IGES Files
(*.igs;*.iges).
Select the file Surface Repair.IGS.
2 Click Options.
Verify that the option Try forming solid(s) is selected and click OK.
3 Click Open from the Open dialog.
If you are prompted to select a template, choose PartJTN.
4 Import diagnostics.
If prompted to run import diagnostics, click No.
98 Exercise 8: Using Surfaces to Create Solids Exercise 8: Using Surfaces to Create Solids 99
Results. 9 Repeat.
^ Surface Repair
The individual surface patches are knit into ill |д] Annotations
Repeat this process for the remaining three openings.
a single imported surface. However, there til H Lights, Cameras and Scene
are some gaps. IS Й Surface Bcrfesfl)
Important! When doing the last opening, also select the option Try to form solid.
J= Material <not specified> This will thicken the resulting knit surface into a solid.
*$c Front Plane
10 Results. Surface Repair
Top Plane
Although the graphics look the same, a ffl Щ Annotations
<$> Right Plane
solid has been formed. Only by looking at щ g | ughts, cameras and Scene
L Origin
the Solid Bodies folder can you tell the щ (J| sold BorlesO)
ф Suface-Importedl
model is now a solid. §S Material <™* spetifled>
; FrontPlane
^ Top Plane
<$> Right Plane
L Origin
ф Surface-Imported 1
ф Surface-Fil
Click Filled Surface S. [ ф Surf есе-ЯК
Set Edge settings to ф Surface-f=€3
Tangent. ф Surface-Fit*
Select the Apply to all 11 Save and close the part.

edges check box.
Select edges.
Right-click one of the edges
of the opening, and select
Select Open Loop.
Select the Merge result

check box.
Click OK.
Results.
A surface patch is created to
fill in the opening. It is shown
here in a different color for
illustration purposes.
Since the Merge result option
was selected, the new patch
has automatically been knit to
the existing surface.
100 Exercise 8: Using Surfaces to Create Solids Exercise 8: Using Surfaces to Create Solids 101
Lesson 5
Advanced Surface Modeling

• Use sketch pictures to capture the design intent of a surface model.
• Create extruded, ruled, lofted, swept, and planar surfaces.
• Modify surfaces by trimming.
• Create filled surfaces for blending.
• Convert surfaces into solids.
• Dynamically edit a model using lnstanl3D.
• Replace a face of a solid using the Filled Surface command.
102 Exercise 8: Using Surfaces to Create Solids 103

Advanced Surface Modeling Advanced Surface Modeling
Stages in the Some of the key stages in

Process the modeling process of this
part are given in the
following list:
Capture the design intent.

The industrial designer provided concept sketches of the remote
control. These were scanned to create image files that can be inserted
into a sketch. The sketch pictures will serve as a guide when modeling
the remote control.
Parting lines and draft angles.
As a general rule you should begin modeling by defining the parting
line and setting up the draft angles using reference surfaces. With the
vast majority of free-form parts, you must build draft in as you model.
Generally you cannot add draft later as a local feature.
Splines.
Consumer products are characterized by smooth, curvature continuous
shapes that cannot be modeled using lines and arcs. Splines are the
curves that in turn create the surfaces.
Lofted and swept surfaces.
One portion of the remote control will be lofted using a series of
profiles and guides. Another portion will be swept using guide curves.
Blending surfaces to fill in gaps.
Not all the necessary surfaces can be created using loft or sweep. The
remaining portion will be created as a filled surface.
Knitting.
Once the surface model is complete, the surfaces are knitted into a
solid.
Symmetry.
The knitted solid is mirrored.
Associativity and design changes.
After evaluating the model, we will change the underlying curves.
104 Stages in the P r o c e s s 105

Using Sketch We will start the modeling process with a couple of sketches of the 4 Transparency.
Picture to Capture design concept provided by the industrial designer. These will be used Expand the Transparency options. Select User Onw*
OFrom
Design Intent as guides as we create the basic curves. defined and click the white background area of the
picture to define the transparent color.
01
Set the Transparency slider to 1.00.
Procedure Open a new part using the Part_MM template and name it jZ M « r ^ t o l e r a r K e :
RemoteJUontrol. Click OK.

ф Тгалфагелсу:
Side view sketch. 146-

Open a sketch on the -70-
Right reference plane. 5 Top view sketch.
Open a sketch on the Top reference plane.
Sketch a horizontal line
Insert the image Remote-top-view.tif.
as shown. This reference line will be used in subsequent operations.
This picture will also come in large. And it is
Sketch picture. rotated.
Click Tools, Sketch Tools, Sketch Picture. • M ©©
In the Case Study folder for this lesson, browse to Rotate the image by setting the Angle to 90°.
p L i
[u.OOmm
the Remote Control\ Sketches from Ш folder. The result should match the illustration at the
|3 |l>.00mm
у
right.
Select the image Remote-side-view.tif and click [o.OOoeg
Open. P-j [| lOTS.Mmr

Make sure Lock aspect ratio is selected and
scale the image to approximately the correct
The picture will come in very large. Note that the yTJ |^72.00тт
size by setting the Width to 146 mm.
Width is over 1,000 millimeters.
Fine tune the position of the picture by
dragging and resizing it.
3 Resize the picture.

Line it up with the reference line in the first
Make sure Lock aspect ratio is checked and scale the image to sketch.
approximately the correct size by setting the Width to 146 mm. Set the Transparency to 1.00 and select the white background of the
picture as the transparent color.
Fine tune the position of the picture by dragging kg» and resizing -4 it.
The objective is to line the picture up with the sketched reference line.
-70-
S t a g e s in the P r o c e s s S t a g e s in the P r o c e s s 107

106
Sketch the parting line. Change the dimensions.

Open a new sketch on the Right reference plane. Fine tune the parting line geometry by editing the dimension values as
shown below. Notice that the spline updates accordingly.
Use Convert Entities (0 to copy the reference line from Sketch 1 into
the active sketch.
Using tangent arcs and lines, sketch the parting line shown here in
MA. SO
green for clarity.
Dimension the sketch. 10 Extrude a surface.

Sketchl is hidden for clarity. Do not worry about the values of the Extrude the parting line
dimensions. Your values may vary. The goal right now is to partially sketch so that it extends
constrain the sketch. (The outermost ends of the lines are under beyond what will be the
defined.) edge of the model.
A distance of 40 mm
4.96221 - works well.
R30.22910
-21.38860
It is only necessary to
extrude in a single
direction because we are
R28.20213
going to take advantage of the part's symmetry and use mirroring.
11 Hide surface.
In the graphics area, right-click the extruded surface and select Hide I
Note The dimensions are shown in 5 decimal places just to illustrate that we from the shortcut menu. This will make it easier to see what we are
are not worrying about the exact dimension values at this time. sketching in the next step.
Fit spline.
Click Fit Spline В on the Spline Tools toolbar.
Clear the Closed spline check box. •&e«geomcBY
•<*«d<H>«
Right-click the line and select Select Chain. ©CaiMfraned
UQConelMHed
The system creates a spline and converts the O N
original sketch entities to construction geometry.

The spline is related to the original sketch entities
by a FitSpline relation as indicated by the &.
symbols.
108 S t a g e s in the P r o c e s s S t a g e s in the P r o c e s s 109

Lesson 5 Lesson S
12 Sketch a 4-point spline for top Ruled Surfaces In general, a Ruled Surface can be thought of as an
view of parting line. infinite number of line segments connecting
Make both ends Coincident to the corresponding points on opposite sides of the surface.
ends of the reference line in In the case of a SolidWorks ruled surface, one edge is
Sketch 1. defined by the edge or edges of existing surfaces or
solids. The other edge is calculated by the system based
Make the tangent handles at both on the options you choose.
ends Perpendicular to the
reference line in Sketch 1. • Tangent to Surface. The ruled surface is tangent to the surfaces
that share an edge.
Turn on the curvature combs.
• Normal to Surface. The ruled surface is normal to the surfaces that
Adjust the positions of the points share an edge.
and drag handles until you are
• Tapered to Vector. The ruled surface is tapered to the specified
satisfied with the spline and how it vector.
fits the sketch. When finished, exit
• Perpendicular to Vector. The ruled surface is perpendicular to the
the sketch. specified vector.
13 Show surface. • Sweep. The ruled surface is built by creating a swept surface using
Show the parting surface that was selected edges as guide curves.
hidden in step 11.
Unlike other types of surfaces, for the Ruled Surface, you do not need
14 Hide. to create sketches.
Hide the two sketch pictures.
Ruled surfaces are frequently associated with creating drafted surfaces,
15 Trim the parting surface. and are often used as construction or reference surfaces.
Click Trim Surface ®.
Introducing: Use the Ruled Surface to create surfaces that are either perpendicular
For Trim Type, click Standard. Ruled Surface or tapered away from the selected edges.
For the Trim tool, select the sketch we just created in step 12.
Where to Find It • Click Ruled Surface (.g on the Surfaces toolbar.
Click Keep selections and click in the selection list. Identify the
• Or click Insert, Surfaces, Ruled Surface.
portion of the parting surface that you want to keep.
Click OK to complete the trimming operation.
P o r t i o n of s u r f a c e y o u w a n t to keep
T r i m tool
Results
S t a g e s in t h e Process Ruled Surfaces

110 111
16 Ruled surface. 17 Offset plane.

Click Ruled Surface gj on the Surfaces toolbar. Create a plane offset from the Top plane. This will be used for
In this case we want to create a reference surface щ*~. •• * sketching the area around the keypad.
that follows the edge of the parting surface and O Tangent to Surface
In this case, the offset was 12.2 mm. Depending on how you scaled the
O Normal to Surface
that has 3° of draft with respect to the Top © Tapered to vector
sketch picture, your results may differ.
reference plane. We will use this surface in O Perpendoiar to vector
Offset p l a n e 12.20
subsequent steps to help define the geometry of Osweep
the part.
4$ |j2.oomm
For Type, select Tapered to Vector.
For Distance enter 12 mm. The distance is not locdeo Top P l a n e
critical. We just need something big enough to
work with easily.
For the Reference Vector, select the Top Note From the looks of the sketch picture, it appears the upper face of the
reference plane and click Reverse Direction. remote control is angled with respect to the Top plane. However, we
Set the Angle to 3.00°. checked with the industrial designer and were told that the two should
indeed be parallel.
For Edge Selection, select the edge of the
trimmed surface.
Verify that the ruled surface tapers outward. If it does not, click Lofting The surface that will actually be part of
Alternate Side. Surfaces the finished model is one half of the
upper part of the housing. This will be
a lofted surface and to create it, we
need several profile and guide curves.
18 New sketch.
Create a new sketch on the offset plane that was
created in step 17.
Sketch a 3-point spline for outline of the keypad
area.
Make both ends Coincident to the reference
line in Sketch!.
Make the handles at both ends Perpendicular to
the reference line in Sketchl.
Click OK. Turn on the curvature combs. Adjust the

positions of the points and drag handles until
you are satisfied with the spline and how it fits
the sketch. When finished, exit the sketch. This
will be one of the guide curves.
Note Since the spline is not dimensioned, it is under
defined and appears blue in the sketch.
112 113
Ruled Surfaces Lofting Surfaces
20 Second profile curve.

19 First profile curve.
Repeat the preceding procedure for the profile
Create a new sketch on the Right reference plane.
curve on the front end of the remote control.
The profile is a 2-point spline. Creating this is a multistep process:
This time use a 5.00° angle.
1. Sketch the spline. The ends are 2-point S p l i n e
Coincident to the end of the guide
curve (the 3-point spline in step 18)
and the corner of the ruled surface. 21 Offset plane.
Note For clarity, the sketch picture is not Create a plane offset 19 mm from the Front plane. This will be used
shown. for sketching a third profile curve.
2. Make the spline tangent to the edge

of the ruled surface. This is necessary
to maintain the 3° draft angle when
we loft the surface.
3. Sketch a construction line tangent 22 Third profile curve.

to the other end of the spline. Create a new sketch on Plane8 and switch to a Front view orientation.
Create an angular dimension Sketch a 2-point spline.
between it and the plane the 3-
point spline (the guide curve) is Add Pierce relations between the ends and the guide curve and the
on (step 17). edge of the ruled surface.
Set the angle to 2.00°.

4. Display the curvature combs
and show the sketch picture.
Adjust the lengths of the tangent
handles until you are satisfied
with the shape of the spline.
Tip The PropertyManager is very useful for making

small adjustments to the length of the tangent
handles. Si \-T6M
Si; ;-7,м_
Sketch two construction lines tangent to the spline and dimension their
angles as shown.
Display the curvature combs and adjust the lengths of the tangent
5 handles until you are satisfied with the shape of the curve. In this case,
I RMatAIHardw | the sketch pictures do not offer any guidance so use your best
judgement.
5. Exit the sketch.
Lofting S u r f a c e s 115
114 Lotting Surfaces
23 Loft the surface. 26 Use selected plane.

Select the three profile In the PropertyManager, select the Use selected
curves. plane check box.
For Start/End Constraints, Select the Front reference plane and click OK. 0° Scetdtf !
SketfJi9
SketthS i|
select Normal To Profile for
both.
For Guide Curves, select
0
Sketch6 (step 18) and the
edge of the ruled surface.
For the edge tangency, select
Tangency to Face.
For Sketch6, select None.
Click OK.
24 Evaluate the results. 27 Show sketch.
Looking at the Front view, the surface In the next step we will edit the new loft section. Before we do that,
does not look rounded enough in the show the sketches for the second profile and the guide curve.
area indicated. 28 Edit the sketch of the new loft section.
View the sketch relations. If there are not
already Pierce relations between the
ends and the guide curve and the edge of
the ruled surface, add them.
Sketch construction lines tangent to each
end of the spline. Add Parallel relations
between them and the construction lines
25 Add a loft section. in the second profile.
Right-click the lofted surface, and Display the curvature combs and adjust
select Add Loft Section from the the spline until you are satisfied with the
shortcut menu. shape.
The system generates a section plane Exit the sketch to rebuild the lofted surface.
and a profile curve through the
surface.
You can move and rotate the plane by Modeling the We will use a similar approach modeling the lower half as we did for
dragging it. Lower Half the upper half. Namely, we will use the sketch picture as a guide to help
establish the shape of the part. However, instead of lofting, we will use
a Swept Surface with the Guide Curves option and Filled Surface.
116 Lofting Surfaces M o d e l i n g the L o w e r Half 117

Lesson 5
29 Ruled surface.
Create a second ruled surface also with Introducing: Partial Sketching a partial ellipse is similar to sketching a centerpoint arc:
3° of draft. This time, it should extend Ellipse
• Position the cursor where you want the center and drag the mouse
upwards from the edge of the parting
to establish the length of the major axis. Then release the mouse
surface.
button.
This will be used as a reference when • Next, drag the outline of the ellipse to establish the length of the
modeling the lower half of the remote minor axis.
control. • Finally, click where you want the ellipse to start, and drag the
30 Spline. mouse to establish the length of the circumference.
Open a new sketch on the Right reference plane. Show the side view
sketch picture. Important) To fully define an ellipse you must dimension or otherwise constrain
the lengths of the major and minor axes. You must also constrain the
Create a 5-point spline. You need Coincident relations between the orientation of one of the two axes. One way to do this is with a
endpoints and the corners of the ruled surface. Add Tangent relations Horizontal relation between the ellipse center and the end of the major
between the spline and the edges of the ruled surface. axis.
Display the curvature combs and adjust the shape of the spline until Where to Find It a Click Tools, Sketch Entities, Partial Ellipse.
you are satisfied. Then exit the sketch. • Or, click Partial Ellipse @ on the Sketch toolbar.

Open a new sketch on Plane3.
The sweep profile is a partial ellipse. Sketching this is a multistep
process:
This is the second guide curve for the sweep. 1. Click Partial Ellipse @ on the Sketch toolbar.
Sketch a partial ellipse as shown. It should be
31 Offset plane.
approximately the lower-right quarter of a
Create a plane offset 44.5 mm from the Front plane. This will be used
complete ellipse.
for sketching the sweep profile.
It is good if the start point of the ellipse is
Offset p l a n e —•> at Front P l a n e
below the end of the minor axis.
Sketch it out in space so as not to inadvertently
-Jp ' capture and unwanted relations.
•tfff^44,50 ~ 2. Add a Horizontal relation between the center

'' ''''^ПТГТТТ and the point at the end of the minor axis.
Note: Sketch relations have been turned on for
32 Sketch the sweep path.
Open a new sketch on the Right
reference plane. Sketch a
horizontal line through the origin
One end of the line is coincident
with the end of the spline. The
other end is coincident with
Plane3.
Exit the sketch.
118 M o d e l i n g the L o w e r Half M o d e l i n g the L o w e r Half 119

Sketch construction lines from the end of the 35 Trim surface.

minor axis to the center and then to the end point Trim the 3° draft reference surface using
of the ellipse. 3.00°
Plane3 as the trimming tool.
This will serve as one of the reference
Dimension the angle between them and set the
value to 3.00°. surfaces for the filled surface.
K e e p this p i e c e
Add a Pierce relation between the end point 36 Extrude a surface for the second reference.
of the ellipse and the bottom edge of the ruled Open a new sketch on the Right reference plane.
surface. Use Convert Entities В to copy the sketched
guide curve into the active sketch.
Sketch a vertical construction line, coincident to
Plane3, and use it to trim the converted curve.
Extrude a surface about 12 mm in the direction
shown. Do not use draft.
5. Add a Coincident relation between the other 3.00°
end point of the ellipse and the end of the major 37 Filled surface.
Click Filled Surface ® on
Then add a Pierce relation between the end point
of the ellipse and the sketched guide curve. For Edge settings, select
Tangent and click Apply to
34 Sweep the surface. all edges.
Select the profile, path, and both
guide curves to sweep the surface. Select the edges of the three
surfaces.
Note An extra guide curve callout has
been shown for illustration Click OK.
purposes.
Preparation for To properly blend a filled surface to its adjacent boundaries, you should Consistency Just as we saw with the filled surface in Lesson 4: Repairing and
Using Filled not rely on using curves for boundaries. It is much better to use the Notification Editing Imported Geometry, the system issues a consistency
Surface edges of surfaces. This however, usually requires you to create notification indicating that the filled surface results may not be
reference surfaces prior to using the Filled Surface command. consistent with the tangent constraints. Is this a problem? To find out
we will use Deviation Analysis to analyze the filled surface.
Deviation Analysis The Deviation Analysis tool can be used to determine the angular
difference between faces along common edges. A 90° value indicates
perpendicular faces, 0° indicates tangency.
Deviation Analysis was introduced in the Advanced Part Modeling
course.
M o d e l i n g the L o w e r Half 121

120 M o d e l i n g the L o w e r Half
38 Knit surface. Note It is more accurate to analyze the

Deviation Analysis only works on edges that are common to two edges one at a time than all three
faces. Therefore, to use it to measure the deviation between the filled together. That is because the number
surface and the adjacent surfaces, we first have to knit them together. of sample points is distributed along
the total length of the edges and
Click Insert, Surface, Knit or click Knit Surface Щ on the Surfaces sample points might not fall exactly
toolbar. on the ends of the edges which is
Select the swept surface, the filled surface, the extruded reference where the maximum deviation
surface, and the ruled surface. Click OK.
39 Deviation analysis. Dragging the slider to increase the number of sample у
Click Tools, Deviation Analysis, or click points also increases accuracy.
Deviation Analysis ® on the Tools toolbar. Click OK to exit the Deviation Analysis command.
Select the edge between the filled surface and the 41 Delete the knit surface.
lofted surface. The knit surface was only necessary for the deviation analysis.
Click Calculate.
Conclusion The consistency notification is correct in that the filled surface is not
perfect. However, for our purposes, the average deviations of 0.03°
0.06°, and 0.06° on the three edges are acceptable.
Note Depending on how your sketched the spline for the top view of the
parting line (step 12 on page 110) the results of your filled surface and
therefore your deviation analysis may be different.
42 Hide and show surfaces.

Hide the reference surfaces and show the lofted surface.
40 Repeat. |лу»«»г»
Clear the selection list and repeat
the process for the other two
edges one at a time.
122 Conclusion 123

M o d e l i n g the L o w e r Half
43 Zebra stripes. 46 Results.

Click Zebra Stripes | § | on the View toolbar. The resulting planar surface fits exactly
across the opening of the lofted surface.
Evaluate the quality and smoothness of the surfaces. Pay particular
attention to the filled surface and how it blends with the swept surface. 47 Knit surfaces.
Click Insert, Surface, Knit or click
Knit Surface Щ on the Surfaces
toolbar.
Knit the planar surface together with the
swept, lofted, and filled surfaces.
48 Another planar surface.
Open a new sketch on the Right reference plane and sketch a rectangle
somewhat larger than the outline of the part.
Click Planar Surface @- The system automatically creates a planar
Introducing: Curve Through Reference Points creates a curve feature through
surface using the active sketch.
Curve Through sketch points, vertices, or both.
Reference Points Click OK.
Where to Find It • Click Insert, Curve, Curve Through Reference Points.
• Or, click Curve Through Reference Points g) on the Curves
toolbar.
44 Click Curve Through Reference

Points Ш-
Select the two vertices shown, creating
a straight spline.
Note This would also work as a sketch line,
but the Curve Through Reference 49 Trim surface.
Points is faster, particularly if the line Using the knit surface as the trim tool,
does not lie on a plane. trim the planar surface keeping the inside
45 Planar surface.
portion.
Click Insert, Surface, Planar or click 50 Knit surfaces.
Planar Surface @] on the Surfaces Click Knit Surface III.
toolbar. Select the knit surface and the trimmed
Select the curve you just created and surface.
the open edge of the lofted surface. Select the Try to form solid check box.
Click OK.
Click OK.
124 Conclusion 125

Conclusion
Lesson 5 S o l i d W o r k s 2009 T r a i n i n g M a n u a l Advanced Surface Modeling
Dynamic Feature The curve that ultimately controls the outline of the е <$ suface-Trimi
51 Results.
Editing remote control is the parting line and it is embedded ^мя**
The resulting solid doesn't look much
under the trimmed surface.
different from the surfaces. However, the
FeatureManager design tree indicates that When you edit this sketch, the part is rolled back and all the geometry
a solid body now exists in the part. disappears.
Note If the Solid Bodies folder does not
appear, right-click in the FeatureManager
and select Hide/Show Tree Items.
52 Mirror.
Click Mirror Щ on the Features
toolbar. Select the planar face Fixing the overall shape of the remote control would take a long
(step 48) as the Mirror Face/Plane. process of trial and error because you would be working blind.
Expand the Bodies to Mirror list and Dynamic feature editing enables you to make changes to features and
select the solid body. sketches without rolling back the part. This way you can see the effects
of the changes as you make them.
Make sure Merge solids is selected
and click OK. Introducing: lnstant3D enables you to dynamically edit features. When you drag the
lnstant3D entities of a sketch, either with or without opening the sketch itself, the
preview updates when you release the mouse button after dragging.
Design Let's evaluate the design so far. There are three areas that don't look Where to Find It • Click lnstant3D (§J on the Features toolbar.
Changes quite right.
1. The curves of the parting line and the edge of the area where the 1 Click lnstant3D § ) .
keypad goes do not compliment each other well. Expand the Surface-Trim 1 feature and show the underlying sketch.
2. Also, the front end of the remote control isn't rounded enough.
Adjust the shape of the spline by dragging the interpolant points.
3. The area where the keypad goes is boring - it is flat.
Before —
D r a g t h e s e two points
Design Changes 127

126 Design Changes
/
2 Dynamically edit a sketch. 5 Create a plane.
Expand the lofted surface feature and double-click the sketch that Create a reference plane parallel to the
defines the edge of the flat area where the keypad will go. Front plane, passing through the
Tip Use viewports to see the top and front views at the same time. centerpoint of the arc you just sketched in C e n t e r p o i n t of a r c
step 4.
First a r c
Tip If you decide to dimension the

sketch, turn off lnstant3D for
improved performance. With
lnstant3D on, the model will 6 Sketch a second arc.
rebuild each time you add a Create a new sketch on Plane4, the
dimension. plane you just created.
Edit the other sketches. Sketch a Centerpoint Arc IS). The
4
Repeat this procedure as necessary to edit two endpoints have Pierce relations
the other sketches that make up the lofted with the edges of the planar face.
surface.
Create a reference point on the arc.
Note This is an exercise in judgement and Relate it to the arc in the previous
esthetics. There is no unique right or wrong sketch with a Pierce relation.
solution.
Add a Coincident relation between
Replacing a Face We will create a new, concave face to replace the planar face. the arc's centerpoint and the Right reference plane
Sketch an arc. 7 Exit the sketch.
Open a new sketch on the Right
reference plane.
Sketch a 3 Point Arc @ and
dimension it as shown.
The endpoints have Coincident
relations with the vertices at the
ends of the planar face.
Exit the sketch.
128 Design Changes Design Changes 129

11 Dome.
8 Filled surface. _
K E B I Create a concave Dome feature about
Click Filled Surface © on the
1.65 mm deep. The exact depth is not
Surfaces toolbar.
critical.
For Edge settings, select Contact.
Select the two edges of the planar

face.
Under Constraint Curves, select
the two arcs.
Under Options, select Merge
result.
Click OK.
The planar face is replaced with the
concave face.
Merge Result The behavior for this option depends on the boundaries. When all the
boundaries belong to the same solid body, you can use the filled surface
to replace a face of the solid. This streamlines your work, eliminating
the need to use the Replace Face command.
9 Sketch.
Open a sketch on the Right
reference plane.
Sketch a line tangent to the
silhouette edge as shown.
Split the line and change the left-most portion to construction
geometry.
Adjust the angle of the line so it barely intersects the bottom of the
front portion of the remote control.
10 Cut through all.
Click Extruded Cut gj. Since this is
an open profile, the end condition will
be set to Through All automatically.
The goal is to create a small flat spot
so the remote can be set on a table
without falling onto its side.
If the area of the cut is too big or too
small, use lnstant3D to adjust the sketch dynamically.
Design Changes
130 Design Changes
Exercise 9: Use surface features to create a solid

Mouse Model model. In this exercise you just create
the shape. In a later exercise you will
split out the individual parts.
This lab reinforces the following
skills:
• Splines and Projected Curves,
which were covered in the
Advanced Part Modeling course.
• Lofting Surfaces on page 113.
Design Intent • The part is symmetrical with respect to the Right reference plane.
Units: millimeters
Procedure Open a new part using the Part_MM template and name it Mouse.
Draw layout sketch.
On the Top reference plane,
sketch a rectangle as shown.
Exit the sketch.
Name it Size Reference.
This sketch will help you
sketch the free-form splines
approximately the correct
size.
Sketch the bottom edge.
Open a new sketch on the Top reference plane, and sketch
a 5-point spline as shown to represent the bottom edge of
the mouse.
Draw only half of the outline, and make it somewhat
peanut-shaped.
Make sure that the endpoints of the spline are Coincident
with the corners of the rectangle in the Size Reference
sketch.
132 Design Changes

Exercise 9: Mouse Model 133
4 Add relations. 6 Adjust the shape of the spline.

Adjust the shape of the spline by dragging the interpolant
Use relations on the handles at the ends of the spline to
create tangency across the line of symmetry. There are points. It is not necessary or desirable to adjust the handles
several ways to do this. You can: on the three interior interpolant points.
7 Exit the sketch.
• Add Horizontal relations to the spline handles;
Name it Bottom Edge.
• Or, add Collinear relations between the spline handles
and the rectangle in the Size Reference sketch;
• Or, add Tangent relations between the spline and the
rectangle in the in the Size Reference sketch.
Use whichever technique you prefer.
8 Sketch top profile of the parting line.

5 Tangent relation.
Open a new sketch on the Top reference plane.
To make the spline tangent to the rectangle, sketch a short construction
line Tangent to the spline itself, not to a handle or a spline point. Sketch a spline which lies slightly outside of the
Bottom Edge sketch.
Add a Vertical relation to the construction line.
The endpoints of this spline should have Vertical
Make the endpoint of the construction line Coincident with the
relations with respect to the ends of the spline in the
rectangle in the Size Reference sketch.
Bottom Edge sketch and should be dimensioned as
shown.
Add relations to the end handles as you did in
step 4.
Notice the use of Show Inflection Points on the
spline to help define the area of slightly reversed
convexity.
9 Exit the sketch
Name it PL Top Profile.
Tangent Vertical Coincident
Making the spline tangent directly to the side of the rectangle in the
Size Reference sketch gives very little control over the point of
tangency and makes the shape of the spline difficult to control.
135
134 Exercise 9: M o u s e Model
Exercise 9: Mouse Model
10 Sketch the side profile of the parting line. 14 Create third loft profile.
Open a new sketch on the Right reference plane, and draw a spline as Create a new plane parallel to
shown. the Front reference plane
through a spline point from the
The ends of the spline should have Vertical relations with respect to the
Bottom Edge sketch.
endpoints of the spline in the PL Top Profile sketch.
Rename this plane M i d Plane.
Add a Horizontal relation to the handle at the end of the spline furthest
from the Origin.
" i
15 Intermediate profile.
Open a new sketch on the M i d Plane reference plane.
Sketch an arc.
Add a Coincident relation between the bottom endpoint and the spline
point the plane was created from.
Add a Pierce relation between the top endpoint and the PL Curve.
Draw a construction line between the endpoints of the arc.
11 Exit the sketch. Using the Smart Dimension tool, select the construction line, and then
Name it PL Side Profile. hold down the Shift key and select the arc. This will give a dimension
12 Click Insert, Curve, Projected. as if the Min arc condition in the dimension properties was used.
Use the Sketch onto Sketch Make this dimension 1.25 mm.
option
Select the PL Side Profile and PL
Top Profile sketches.
Rename the projected curve PL
Curve.
13 Create loft profile sketch.
Open a new sketch on the Right reference plane, and sketch a pair of
arcs as shown.
The arc near the Origin should be tangent to a line 15 degrees from
horizontal and the other arc should simply have a radius of 10 mm.
Both arcs should be coincident to the ends of the Bottom Edge sketch
16 Exit the sketch.
and be pierced by the PL Curve.
Name it Intermediate Profile.
Note Using the SeleetionManager, multiple, disjoint profiles in a single

sketch are manageable and valid.
136 Exercise 9: Mouse Model Exercise 9: M o u s e Model 137

18 Draw the top shape of the mouse.

17 Create the surface loft.
Open a sketch on the Right reference plane and sketch a partial ellipse
Use the SelectionManager to select open profiles at «S X at an angle.
the ends. The Intermediate Profile sketch will not
require the Selection Manager. Optnimp<i> Sketch a construction line from the center of the ellipse to the end of
Opanloop<2> the minor axis to control the angle.
For Guide Curves, select PL Curve and Bottom •I Add Pierce relations between the endpoints of the ellipse and the PL
Edge.
E l Curve. Add a Coincident relation between the end of the major axis
For Start/End Constraints, use Normal to Profile and the rightmost endpoint of the ellipse.
i Normal To Proffc v]
for both ends so that it is smooth across the plane of
symmetry. (§) Г°'°«Ч
Click OK. SoWfctoH

End constraint:
fWmel To Profte
® LT
Ц
[To l*xt Gutd* v.j
19 Extrude a reference surface.

Filled Surface, requires a
V i e w w a s rotated for clarity.
reference surface to define the
tangency condition along the
top.
Extrude the partial ellipse
sketch away from the rest of the
You can use the optical properties of a color to make it easier to model. The distance doesn't
Lighting and Color
evaluate the quality and smoothness of a surface. Typically this means matter.
Tips
increasing the Specularity setting to 1.00. However, under certain
lighting conditions, this can result in strong highlights that completely Creating the Top There are several ways of
wash out the color of the surface. Surface of the creating the surface on the
You can mitigate this effect by adding color to the directional light. In Mouse top of this mouse. The
the illustrations below, the color assigned to the part is Red = 33, Green easiest is probably to loft
= 177, and Blue = 170. By assigning that same color to the from the edge of the
Directionall light, the highlights can be toned down. extruded surface to the edge
of the lofted surface. The
image to the right shows that
this is possible, and gives a P r e v i e w of Loft S u r f a c e
reasonably nice shape, but

notice the mesh lines at the ends. This creates a singularity which may
cause problems in filleting, shelling, offsetting, or even in machining
from this data. Degenerate surfaces should be avoided when possible.
Although they sometimes function without errors, it is best practice to
complete the task another way.
Exercise 9: M o u s e Model 139

138 Exercise 9: M o u s e Model
22 Clear the Knit surfaces option.

20 Filled surface.
Click Filled Surface ®.
Edit the M i r r o r 1 feature and clear the Knit surfaces options.
Select the edge of the extruded surface and the Click OK.
edge of the lofted surface. Edge<2>Cixrt«rt-Si- 23 Planar surface.
Select the edges of the lofted surface
Use the end condition Tangent for the extruded
and mirrored loft on the bottom and
surface and Contact for the lofted surface.
create a planar surface.
Notice that with Optimize surface selected, the
[ uB emateFace
surface again becomes degenerate. This is because
[Tangent
the Optimize surface option applies a simplified
• *6plY to al edges
surface patch that is similar to a lofted surface. O Optimize surface
0 Show* preview
Clear Optimize surface and you will get a better, Qftvyfewgresn
24 Knit.
four-sided patch. Knit the five surface bodies into a
Click OK. solid.
Optimize surface selected Optimize s u r f a c e cleared

21 Mirror the surface bodies.
Hide the extruded surface.
Click Mirror on the Features toolbar.
Select the Right reference plane as the
mirror plane.
In the Bodies to Mirror selection list,
select the lofted and filled surfaces to
be mirrored.
Click the Knit surfaces check box. Click OK.
Note Notice that even with the Knit surfaces option ysufeceBoctosO)
checked, the Mirror command still produced two <£> Suface-Extrudel
separate surface bodies. The mirrored loft was knit ф Mtrroriri]
ф мггогцг]
to the original loft, and the mirrored fill was knit to
the original fill, but the fill was not knit to the loft.
For this reason, when mirroring multiple surface bodies it is
recommended that you leave the Knit surfaces option cleared and just
manually knit the surfaces together. This way there is no confusion
about what will or will not be knit by the Mirror feature.
140 Exercise 9: M o u s e Model Exercise 9: M o u s e Model

S o l i d W o r k s 2009 T r a i n i n g M a n u a l S o l i d W o r k s 2009 Training M a n u a l
Exercise 10: We have been faxed this drawing of the preliminary design for a bar of Initial sketches.
Bar Of Soap bath soap. Use surface modeling techniques to build a solid model of it There are three sketches in the
for volumetric analysis and tooling design. Layout Sketches folder. Given the
way the customer's drawing was
dimensioned, the right-side sketch is
under defined.
Create three new

sketches for lofting a
surface. Fit S p l i n e
The two lines are tangent
to the arcs in the front
and side sketches.
Create a spline to fit the
curve in the Top Layout
Sketch.
T a n g e n t to s i d e s k e t c h
Loft with guide curves.

Loft a reference surface using the two lines
as profiles and the spline as a guide curve.
Extrude a surface.
Create a spline to replicate the
upper-right quadrant of the Front
Layout Sketch.
Extrude a reference surface a
This lab reinforces the following skills: distance of about 12 mm.
• Splines which were covered in the Advanced Part Modeling course.

• Swept Surface on page 3 8.
• Trim Surface on page 12. Extrude another surface.
a Knit Surface on page 15. Create a spline to replicate the upper
Units: millimeters left quadrant of the Side Layout
Sketch.
Procedure Open an existing part named 100 gram Bar of Soap.
Take advantage of the symmetry in the part. Build one quarter and then
distance of about 12 mm.
mirror it.
142 E x e r c i s e 10: B a r o f S o a p
E x e r c i s e 10: B a r o f S o a p 143
11 Sweep surface.
Filled Surface.
Open a sketch for the profile.
Create a Filled Surface tangent to
Use Convert Entities to copy
the three reference surfaces.
the edge of the reference
surface into the active sketch.
Drag the endpoint of the
converted edge and add a
Vertical relation between it
and the centeipoint of the arc.
Likewise, convert the edge of
the other extruded reference
Hide the surfaces. surface to create the sweep
Hide all four surface bodies so it will be easier to work on the lower path.
portion of the part.
12 Trim surface.
Reference surface. Open a new sketch on the Top reference plane.
Open a new sketch on the Right reference
plane. Sketch a spline for the trim contour and trim the swept surface.
Use Convert Entities to copy geometry

from the Side Layout Sketch.
Create the 8.2 mm radius sketch fillet as
shown in the drawing on page 142.
R9.20
Create a spline to fit the converted
geometry and extrude a reference surface.
Reference surface.
Create a spline to replicate the
lower-right quadrant of the Front
Layout Sketch.
distance of about 12 mm.
13 Split lines.
Use split lines to split the two
10 Loft a reference surface. extruded reference surfaces. The
Create two profile sketches as IPrrtl»3MtfrtT)i
split lines should line up exactly
you did in step 2 on page 143. with the vertices of the trimmed
Use the edge of the filled surface surface.
as the guide curve. Note Since the reference surfaces are
two separate surface bodies, it
will take two operations to split
the faces - one for each surface.
E x e r c i s e 10: B a r o f S o a p 145
144 E x e r c i s e 10: B a r o f S o a p
14 Loft surface. G u i d e #1 17 Knit.

Profile #1
Loft a surface using the edges profile # 2
Knit all of the surface bodies (not including the reference surfaces) into
of the existing surfaces for
a solid.
profiles and guides as shown in
the illustration at the right.
For Start/End Constraints,
use Tangency To Face.
For Guide curves influence,
use To Next Guide.
Guide #2
For Guide tangency type, use
Tangency To Face.
15 Evaluate the results.
Hide the reference surfaces.
Show the filled surface, the trimmed surface, and the lofted surface.
Show the Front Layout Sketch and the Side Layout Sketch.
18 Evaluate the section view.

Display a section view using the
Right reference plane.
Show the Side Layout Sketch.
Verify that the results are consistent
16 Mirror.
Mirror the filled surface, the trimmed surface and the lofted surface, with the section view in the drawing
first with respect to the Right reference plane, and then with respect to the customer supplied.
the Front reference plane. 19 Save and close the part.
146 E x e r c i s e 10: B a r o f S o a p E x e r c i s e 10: B a r o f S o a p 147

Create a variable pitch helix.

Exercise 11: In this exercise you will create the helical scroll
Click Insert, Curve, Helix |B| and use the
Finial Scroll for a decorative feature on the bottom of the
Variable Pitch option.
finial.
Set the Start angle to 0.00° and the direction to IpthardRevrAtKri
Clockwise.
• Variable pitch helix, which was covered in OcamtntMch
Use the circle created in step 2 and the Region
the Advanced Part Modeling course.
Parameters listed below: Region Paramtvt:
DK
• Swept Surface on page 38. па 1 Е З И
Revolution Diameter Pitch n a n
• Filled Surface on page 87. am
• Trim Surface on page 12. 1 0 108 mm 30.5 mm
• Curve Through Reference Points on 2 1 95 mm 20 mm
• • м г » (fraction
page 124. 3 2 74 mm 5 mm Start anoto:
Units: millimeters
4 3 58.5 mm 1.5 mm ©Oodaasa
OCotntwdodontto
Procedure Open an existing part named Finial_Scroll.
1 Custom view.
Since we will be working on the bottom of the part, a
custom view, Bottom_Iso has already been created.
Convert entities.
2 Sketch a circle. Open a sketch on the Right reference plane.
Open a sketch on the bottom
face and sketch a circle. Select the helix created in the previous step and
use Convert Entities to project it onto the sketch
Add a Coincident relation plane.
between the center and the
Origin. Exit the sketch.
Add a diameter dimension of Loft between sketch and helix.

108 mm. Create a lofted surface between the sketch and
Exit the sketch. the helix. Use the default settings.
Hide.
Hide the helix.
148 E x e r c i s e 11: Finial S c r o l l 149

E x e r c i s e 11: F i n i a l S c r o l l
7 Sketch a line. 12 Knit the planar surface and trimmed loft.

Change to a Left view. Click Knit Surface i l l -
Rotate the view by pressing the up arrow Select the planar surface and the trimmed, lofted
three times. surface and click OK.
Open a new sketch on the same face that was 13 Show.
used to sketch the circle for the helix. Show the swept surface.
Sketch a vertical line of approximately the 14 Trim the swept surface.
length shown, with the outer end pierced by the edge of the helical Use the surface that was just knit together as a trim
surface. tool to trim the swept surface.
8 Create a swept surface. Keep pieces as shown.
Create the swept surface using the straight line as
the profile and the edge of the helical surface as
the path.
15 Trim the lofted surface with the swept surface.
For Start/End Tangency, use Path Tangent for
Create another trimmed surface using the swept
both. Otherwise there will be a gap between the
surface as the trim tool and keeping the section of
lofted and swept surfaces.
the lofted surface as shown.
9 Create a planar surface.
16 Knit surfaces.
Switch back to the Bottomjso view. Knit together the two surface bodies used in the
Select the two edges shown to create a planar last step.
surface. SolidWorks will make the surface even 17 Sketch a circle.
if the boundary is not closed, as long as the On the Right reference plane, sketch a circle
entities are coplanar. whose center is Coincident with the Origin.
Define the diameter by making the circle
10 Trim surface.
Coincident with the vertex on the knit surface.
Using the swept surface as the trim tool, trim the
lofted surface.
Trimming the overlapping surfaces might be 18 Extrude a surface.
done more efficiently as a single mutual trim, but Extrude the surface 76 mm.
for visualization and simplicity, we will do them
as a series of standard trims.
Note The names of bodies in the Solid Bodies and Surface Bodies folders
change with each feature that affects the body. This constant renaming
can get confusing.
For simplicity and clarity we will identify surface bodies by referring to 19 Trim surfaces.
the feature that first made the faces. Trim the new extruded
11 Hide. surface and the scroll surface
Hide the swept surface and the solid body. using the Mutual option,
keeping the outside of the
scroll and upper part of the
extruded surface as shown.
150 E x e r c i s e 11: F i n i a l S c r o l l E x e r c i s e 11: Finial S c r o l l

20 Cap the end. 27 Combine solids.

Click Planar Surface @ on the Surfaces toolbar. Click Combine on the features toolbar.
Select the edge of the trimmed, extruded surface. Select the two solid bodies and click OK.
21 Close the profile.
Click Curve Through Reference Points [QJ on
the Curves toolbar, or click Insert, Curve, Curve
Through Reference Points.
Select the two vertices shown and click OK.
22 Cap the other end.

Select the curve from step 21 and the edge of the
trimmed helical surface.
23 Hide.
Hide the Curve 1 feature so it doesn't get in the
way in the next step.
24 Filled surface.
Create a Filled Surface using the edges around the
opening indicated. Use Contact for all edges.
25 Knit.
Knit together the scroll surface, two planar
surfaces and the filled surface.
Click the Try to create solid option.
26 Show.
Expand the Solid Bodies folder and show the solid body Revolve2.
152 E x e r c i s e 11: F i n i a l S c r o l l E x e r c i s e 11: F i n i a l S c r o l l 153

4 Exit the sketch.

Exercise 12: This lab reinforces the following
skills: Rename it Side Profile.
Handle
• Lofting Surfaces on page 113. 5 Sketch the second spline for a projected curve.
• Filled Surface on page 87. Open a new sketch on the Top reference plane.
• Curvature continuous filets, The sketch is displayed below in two different views to show it in its
which were covered in the normal projection and also how it relates to the previous sketch.
Advanced Part Modeling
course.
Design Intent The design intent for this part is as follows:

1. Part is symmetrical.
2. Surfaces are smooth.
3. A l l fillets are curvature continuous with a radius of 1.75 mm.
Units: millimeters
Procedure A d d Horizontal
Open a new part using the Part_MM template and name it Handle. relation to this
Create a size reference sketch. spline handle
Open a new sketch on the Right reference plane.

Create the sketch shown below. The sketch consists of three concentric
Г A
circles and a vertical line.
127 Where the spline meets the plane of symmetry, add a Horizontal
035.50—\
relation to the spline handle.
032 .
Make sure that the other end of the spline is longer than the previous
sketch so the projection works properly.
013.50 —' Exit the sketch.
Rename it Top Profile.
Exit the sketch. Projected curve.
Use the Top Profile and Side Profile sketches to create a projected
Rename it Size Reference Sketch.
curve, using the Sketch on Sketch option.
Sketch a spline for a projected curve.
Open a new sketch on the Right reference plane. Keep the spline close
to the 32 mm diameter circle, and use the spline handles to give it some
curvature at the ends.
Tip You can temporarily disable automatic sketch relations by holding

down the Ctrl key while sketching or dragging.
154 E x e r c i s e 12: H a n d l e 155

E x e r c i s e 12: H a n d l e
8 Create center profile sketch. 12 Exit the sketch

Open a new sketch on the Right reference plane. Rename it Guide Curve.
Ц
Sketch a spline that follows the 35.5 mm circle from the Size 13 Create the lofted surface.
Reference Sketch. For the Profiles, select the Center Profile sketch
and the projected curve.
Add Coincident relations between the ends of this spline and the ends
of the spline in the Side Profile sketch. Set Start/End Constraint for the Center Profile
to Normal To Profile.
Again use spline handles to control the shape at the ends of the spline.
Note Pay attention to which profile you select first so
This spline defines the shape of the surface at the plane of symmetry -
you will know whether the tangency condition for Start constraint;
the silhouette edge. {NormalTo Profile
the Center Profile sketch is the Start constraint
or the End constraint.
©Lizziz:
For the Guide Curves, select the Guide Curve 0 Apply to al
sketch. End constraint:
Set the Guide curves influence to Global.
9 Exit the sketch.

Rename it Center Profile.
10 Hide and show.
Hide all of the sketches except the Center Profile.
Make sure the projected curve is visible.
Note The ends of the lofted surface form a singularity. In this case we will
allow this to remain, although if we were shelling the part we would be
wise to trim off the ends and use Filled Surface to recreate better faces
in these areas.
156 E x e r c i s e 12: H a n d l e E x e r c i s e 12: H a n d l e 157

14 Sketch for construction surface. How Many Curves? There are no hard and fast rules to determine how many constraint
Open a new sketch on the Right reference plane. curves are needed. The objective is to have enough to adequately define
the curvature of the filled surface without having so many that the
Sketch and dimension an arc as shown, with its endpoints Coincident
surface becomes over constrained and unsolvable or unstable. Some
to the corners of the lofted surface.
experimentation may be required.
16 Create a series of planes.

Make the planes offset from the Front reference plane. The values
used in this example are shown below. Since your part may have a
somewhat different shape, your offset values may have to be different.
15 Create the construction surface.

Extrude the surface away from the lofted surface. The distance doesn't
matter since this is only a construction surface.
17 Create a series of arcs.

In the example shown here, there are six curves that bulge a distance of
1.25 mm. Depending on the shape of your part, you may need more or
fewer constraint curves with different values for spacing or the size of
the bulge.
Constraint Curves The next step is to create a surface that seals up the side and front of the
part. The shape of the face will make it difficult to do as a loft or sweep.
The surface should bulge out slightly, carrying the curvature of the
extruded construction surface around to the sides of the part.
The best way to accomplish this will be to use constraint curves in the
Filled Surface command. These constraint curves will be placed on
planes parallel to the Front reference plane.
158 E x e r c i s e 12: H a n d l e E x e r c i s e 12: H a n d l e 159

18 Folder. 21 Mirror and make it solid.

Without renaming individual features, group the planes and sketches There are many ways to
into a new folder called Constraint Curves. accomplish this basic task and it
doesn't really matter how you do
19 Filled Surface. it. So we won't provide detailed,
For the Patch Boundary select the outer edge of the lofted surface and step-by-step instructions here.
the edge of the construction surface.
The Curvature Control setting should be Contact for the edge of the
lofted surface and Tangent for the edge of the extruded surface.
Select the arcs for the Constraint Curves.
22 Fillet.
As you select the constraint curves, the preview of the filled surface Create a curvature continuous
will change, and in some situations, may disappear altogether. You may face fillet with a radius of
have to experiment with selecting the curves in different order until you 1.75 mm.
are satisfied with the results. A curvature continuous fillet
Click OK. makes the edges of the part look
smoother than a default constant
radius fillet.
20 Hide.
Hide the extruded, reference surface.
160 E x e r c i s e 12: H a n d l e E x e r c i s e 12: H a n d l e

Lesson 6
Blends and Patches

• Blend smoothly between shapes.
• Use curvature continuity on Fill, Loft and Boundary surfaces.
• Repair areas of the model by trimming and recreating geometry.
• Use tangency weighting effectively.
• Use the Freeform feature.
E x e r c i s e 12: H a n d l e 163
162
Blends and Patches Blends and Patches
Complex Complex blending is one of

Blends the most difficult things to
achieve in working with
surface models. Examples
of complex blending
include T, X, K or Y shaped
intersections. In this case
study you will learn how to
make attractive blends.
Blends like this are not
made with fillet features,
but by trimming out an area
of the bodies to be blended
and then using a
combination of features to smooth the transition.
v —
T Blend ¥ Blend K Blend Modified K Blend
Note The images in this case study and the corresponding lab exercise were
captured from the SolidWorks display using RealView Graphics.
Highly reflective materials make it easier to detect flaws in surface
smoothness and transitions. Ideally you should not be able to see a
disruption in the reflection at the seam between surfaces.
If the Image Quality setting in Tools, Options, Document Properties
is low, this has a definite impact on the perceived quality of the surface
and transition. Also be aware that there is often a visible gap between
surface bodies that are not knit together. Quality of a transition is best
examined when adjacent surfaces are knit together.
Tip If you are using a computer which is incapable of using RealView
Graphics, you can get some of the same benefits by adding lights with
high specularity.
164 Complex Blends 165

Stages in the For this lesson, we will start m Fill in the patch.
Process with the frame with all of its Irregularly shaped patches like this one ideal for
tubes in place as separate the Filled Surface command. The best patches
bodies, but without result from the use of the Curvature edge setting.
connections between the There are times when the Curvature setting will
tubes. Blends will be tackled not work, and you must settle for Tangency. Use
in order of complexity, leaving the evaluation and analysis techniques discussed
some blends for exercises at earlier to determine if tangency is good enough.
the end of the lesson.
For this lesson we will work
on the various blends between
Procedure Keep in mind that small differences in sketching under defined, free-
the tubes of a bicycle frame. Rather than work on the entire frame at
form shapes may result in significant differences between the example
once, we have broken it into a number of separate parts. This was done
model and your model. If you are having difficulty getting a particular
only for convenience and performance.
step to work, use the built example file as a reference.
• Trim the tubes back to accommodate the blend.
1 Open part.
The first decision is how far back along each part
Open the existing part named Bicycle_Frame.
should the blend begin and the shape of the target
area. Transitions that are too short may pucker and be For reference, the various parts of the frame are identified below:
difficult to control. Transitions that are too long may
add to much mass to the joint.
Trim to create distinct edges on each entity.

The blend must be done in segments since it is not
possible to blend all the entities together in one
feature. This technique requires the trimmed edges to
be left in segments rather than one continuous edge.
Having edges broken up in this way is usually not
considered desirable, but in this case it is necessary.
Loft to create an enclosed perimeter.

The segmented edges are used to create simple lofts
which create an enclosed perimeter or boundary for a
more complex patch. These simple lofts usually use
two edges from adjacent tubes and curvature
weighting, but in some cases it is necessary to use a Note The two Dropouts are the only solid bodies in the part. The rest of the
guide curve or an intermediate profile to get the geometry is made of surface bodies.
correct shape. 2 RealView.
Click View Settings | F l on the on-screen View toolbar, and select
RealView Graphics (©) from the list.
166 Complex Blends Complex Blends 167

Lesson 6
Tube centerlines. Alternately, you could add a connector,

Show the Tube clear the Apply to all option, and control
Centerlines sketch. the curvature weighting separately.
The trouble spot to watch out for is in the
area of the tightest curvature, under the Top
Tube and in front of the Seat Tube. If you
push the weighting too much in that area,
you will see some puckering and bad seams
appear.
Click OK.
Trim the intersection between the Top Results.

35.50
Tube and the Seat Tube. This example was done using the default
Open a sketch on the Bight reference plane. curvature weighting of 1.
Sketch the entities as shown to trim the Feel free to experiment with different
tubes. values. With blends of this type, there is no
single, correct answer.
The major axis of the ellipse is 61 mm. The
minor axis is 35.5 mm.
Note The trim contour extends almost to, but not
past the centerline of the Seat Tube.
Normally a sketch such as this would not be
fully defined. We have done so here to make Splitting Trim When you trim a surface, any joints in the trim tool will create
it easier to reproduce the examples as they Boundaries corresponding vertices in the trim boundary. In the illustrations below,
appear in the book. the trim tool, a circle, has been broken into four arcs using Split
Exit the sketch and hide the Tube Entities 0. In the resulting trimmed surface, the trim boundary is
Centerlines sketch. likewise broken into four segments, each corresponding to one of the
arcs in the trim tool sketch.
Use Trim Surface and select the pieces to
keep.
Create a loft.
Loft a surface between the two open edges.
For the Start/End Constraints, use
Curvature To Face for both ends.
Adjust the Tangent Length arrows as This technique is useful because it allows us to create lofted surfaces
necessary, either by dragging or by using between portions of an edge rather than the entire edge as we did in
the spin boxes. step 5.
This example was done using the default
curvature weighting of 1.
You may have to drag the connector points to either the top or the
bottom of the intersection to prevent the loft from twisting.

Blends end Patches Blends and Patches
7 Trim the intersection between the Top 10 Continue lofting.

Tube, Down Tube, and Head Tube. Loft two more surfaces like the last one, one
Open a sketch on the Right reference plane. between the Top Tube and Down Tube, and
another between the Down Tube and Head
Sketch a spline and two arcs.
Tube.
Use Split Entities I/] to break the arcs and
spline at the locations indicated by the
arrows.
Use Trim Surface and select the pieces to
keep.
8 Results.
Tip Lofts like the one between the Top and
Down tubes may tend to create a sharp V-
shape in the middle. You can control this by
using Add Loft Section or by manually
creating a plane, sketching a section, and
adding it to the loft.
This technique was shown in step 25 on
page 116 of the Advanced Surface Modeling
lesson.
Begin lofting.
The next step is to begin lofting pairs of edges. 11 Filled surface.
Use Curvature To Face for the Start/End Constraints and adjust the We now have an area bounded by surfaces. In this ,/ *
weighting to your satisfaction. Watch the face and the mesh lines for situation, a Filled Surface is the best choice.
signs of puckering, which will indicate that the tangency weighting is For Edge settings, use Curvature and click Edge <2> Curvature-
сфе<3> Curvature-
too great. Apply to all edges Edge <4> Curvature -
<5>Cunraaye.
| Питие face |
[Curvature
(Зла*у teal edge*

Qcjrtrnue surface
0S»w preview
Qpresnewipefh
It is best if the edges being lofted are close to the same width. It is not
easy to predict the resulting widths of the segmented edges when
placing the split points, but you can go back and edit them after the loft
is created.

12 Mirror the filled surface. 13 Hide bodies. Huifc , Show Uutliev
If the patches on both sides are We are saving the task of blending the Chain Stays
symmetrical, you can mirror the filled to the Bottom Bracket for a lab exercise. To get
surface body you just created to the other them and the other bodies out of the way while we surte-тгмК)
! ft plan tinmhitr
side of the frame. work on the next blend, remove everything except Svfaa-Mwrtcft
SiffKCftl
S^face-lofH
the Bottom Bracket, the Down Tube, and the
curved portion of the Seat Tube from view.
Hide/Show Bodies The Hide/Show Bodies command provides a graphical way to change
the visibility of solid and/or surface bodies. It is particularly handy
because you do not have to right-click each body individually.
When you click View, Hide/Show Bodies, the PropertyManager
appears. Any bodies that are already hidden are shown as translucent in
the graphics area. Bodies that are already visible appear normally.
Selecting a visible body hides it. Selecting a translucent body makes it
visible.
Introducing: You will have to customize the View menu because the Hide/Show
Hide/Show Bodies Bodies command is not displayed by default.
• Click View, Hide/Show Bodies.
Tips 1. You can drag the cursor from left to right to define a box selection 14 Trim all the tubes around the Bottom
or from right to left to define a cross selection. Bracket.
2. Define a keyboard shortcut for View, Hide/Show Bodies. For Open a sketch on the Right reference
example, you might use Ctrl+H. plane.
Sketch two lines. They do not have to
connect.
Employing the same technique as in
step 7, use Split Entities to divide the
lines so the trim boundaries will be
segmented.
Trim the Down Tube and the curved portion of the Seat Tube.

Lesson 6
Trimming the The Bottom Bracket is a more difficult surface to trim. The 17 Wrap.
Bottom Bracket method that we have been using trims by projecting a Select the sketch you just made. This will be
planar sketch onto the surface. On a cylinder, however, if the Source Sketch.
the trim goes around more than 180°, the projection method Click Insert, Features, Wrap, or click
will not work. Wrap Ш on the Features toolbar.
In this case, we will trim the Bottom Bracket using the When you select the face of the Bottom
Wrap feature with the Scribe option. Bracket the system automatically selects the
Wrap Feature The Wrap feature takes a flat sketch and wraps it around a cylindrical Scribe option. Emboss and Deboss are only available with solid
or conical surface, embossing (adding material), debossing (removing bodies.
material) or scribing (splitting faces). The sketch must be a single or Click OK.
multiple closed loop, (not an open loop), and must be on a plane that is
parallel to a plane that is tangent to the surface. You may have to tweak the 80 mm dimension to get the scribed curve
in the correct location.
Introducing: Isolate The Isolate command enables you to make all bodies except the
selected ones to be hidden or transparent, enabling you to focus on the 18 Delete face.
selected bodies. If a part contains many bodies, Isolate is an efficient Delete the face inside the scribed curve. Notice
way to hide all of them except the one you want to work on. that the edges of the remaining surface are
broken into segments.
When you isolate one or more bodies, a popup toolbar appears. Click
19 Exit Isolate.
Exit Isolate to return the display to its original state.
Click Exit Isolate on the popup toolbar.
Where to Find It • Right-click the body in the graphics area, and select Body, Isolate
The Seat Tube and the Down Tube reappear,
from the shortcut menu.
restoring the display as it was prior to step 15.
15 Isolate. 20 Loft.
Right-click the Bottom Bracket and select Body, Isolate from the Using the same technique we used in step 9, loft
shortcut menu. Now the Bottom Bracket is the only body visible. surfaces at the intersections between the Seat
Tube, the Down Tube, and the Bottom Bracket.
16 Trim the Bottom Bracket.
Open a sketch on the Top reference plane.
Change to the Top view.
Sketch an ellipse positioned and
dimensioned as shown.
21 Fill the patches.
The centerpoint and the major axis are Use Filled Surface again to patch the
Coincident with the Right reference hole, then mirror the other side.
plane.
Use Curvature to Face for the Edge
The 80 mm dimension is from the settings.
temporary axis in the Bottom Bracket.
Notice the four split points indicated by
red arrows.
Add Symmetric relations between the split points and the centerlines.
Exit the sketch.

22 Save and close the part. 2 Customize the settings.

We will pick this part back up again for Under Color scheme settings, click Viewport Background.
some of the exercises after this lesson,
Click Edit and change the color to white.
but for now we will move on to
smoothing patches. Under Background appearance, click Plain (Viewport Background
color above).
Click OK.
3 Turn RealView off.
4 Examine the part.

A quick examination
shows that the trouble
spot is in front of the
Smoothing Often you will build a model
finger grip area.
Patches and one area just will not
transition as well as you need it
to. Or you may receive an
imported model which has some
rough spots on it which need to
be fixed. In situations like these, Running Deviation Analysis on the trouble spot quantifies just how
there are techniques which bad the situation is. The maximum deviation of over 14° is
enable you to patch over the unacceptable.
rough transitions, replacing
them with smoother geometry.
Three Alternative In this lesson we examine one such situation and repair an unacceptable
Approaches transition between faces. We will try several approaches that do not
work, and some that do work, but are not acceptable. The reasons for
trying several approaches are:
• To compare functions that initially may seem equivalent.
• To examine techniques and options that may make a feature work
when otherwise it would not. 5 Split out the affected area.
• And to provide more tools for real-world modeling problems, Create a Split Line using the sketch in the part called Split Sketch to
which more often than not are an exercise in alternative approaches. split the faces as shown.
The faces to be removed have been colored red for clarity.
Procedure Open the existing part named Plastic_Part. This is a simplified part,
with most of the finishing details removed.
Color settings.
Click Options [Hi on the Standard toolbar.
On the System Options tab, click Colors.
Since the part is blue, we want to change the color scheme so the
highlight color will be a contrasting color.
Under Current color scheme, select Green Highlight from the list.
176 Smoothing Patches Smoothing Patches 177

Blends and Patches
Blends and Patches
Delete faces. Try using Tangency To Face.
Use Delete Face to remove the faces inside the split area. This works, but it leaves a small ripple in the face
which is easier to see using either RealView
Loft the patch.
Graphics (leftmost image), or View, Display,
This is a four-sided area, so we should be able to patch it with a lofted Zebra Stripes (rightmost image).
surface.
A l l four sides are composed of multiple edges, so you will need to use
the SelectionManager.
1. Click Lofted Surface |<f) on the Surfaces toolbar. Make sure the
Profiles selection list is active.
In the graphics area, right-click and select
SelectionManager from the shortcut menu.
i B r Z S B 53
Editing the connectors can help smooth some of this ripple, but
Click Select Group Щ and select the two edges cannot eliminate it completely. The result is not good enough.
that make up one of the long sides of the opening.
8 Delete.
Click the right mouse button OK " 3 , or click OK Delete the lofted surface.
on the SelectionManager. We will try two more approaches.
9 Filled surface.
Click Filled Surface @.
Repeat this for the other long side of the opening.
Right-click one of the edges and select Select
Note The long sides as are used as profiles and the short
sides as guide curves because guide curves do not Open Loop from the shortcut menu.
have the Curvature To Face option available, but The default Edge setting which is Contact gives
profiles do. a nice preview. However, if you change the Edge
setting on the long sides to Curvature, the
Click in the Guide Curves selection list to preview disappears indicating that Filled Surface will not work with
activate it. Using the SelectionManager, repeat the this option.
selection process for each of the two guide curves. Tip To assign the Curvature option to multiple edges at the same time,
press Ctrl and select the edges in the selection list of the
PropertyManager. Then choose Curvature from the Edge settings
list.
The Tangent option does not give us a preview either.
Set the Start/End Constraints to Curvature To
Face for both profiles. 10 Cancel.
The preview disappears. This indicates that the Click Cancel to abort creating the filled surface.
loft will not work with these options. We have one approach remaining.
Smoothing Patches 179

178 Smoothing Patches
Introducing: Boundary Surface is in some

Boundary Surface ways similar to a loft and in some The preview of the Boundary Surface displays
Curvature C o m b s
ways similar to filled surface. In curvature combs on the mesh lines. This is useful
most cases, it delivers a higher in some cases, but you may want to turn them off.
Mtxhdensty:
quality result than the loft

You can do this by clearing the Curvature combs
command. D*ebra stripes
option in the Boundary Surface (TJCurvaTureconibs
The boundary surface is limited to PropertyManager. 0№ecHcril
four-sided patches. It uses pairs of 0r*ecttor.2

Scale:
parallel edges in two directions. Most importantly, the boundary
surface feature lets you create surfaces that can be tangent or curvature
continuous in both directions (all sides of the surface).
Where to Find It • Click Boundary Surface ® on the Surfaces toolbar.
• Or, click Insert, Surface, Boundary.
The gap that we need to fill is four-sided, so it fits the requirements for 12 Results.
a boundary surface. Visually, the finished feature looks good.
But appearances can be deceiving. We
11 Boundary surface. .'• Boundary-Surf at
will employ more analytical evaluations.
If
Click Boundary Surface g| on the Surfaces
toolbar.
Again, use the SelectionManager to select the
edges, just like with the loft in step 7.
Curvature To Face
13 Knit.
TarajercMuence{%):
Click Knit Surface Щ.
Select the two surface bodies and click OK.
In order to run Deviation Analysis on the edges, the surfaces must be
Direction 2
knit. If you try to run Deviation Analysis on an edge that isn't knit,
OKciiwWijanca you will receive the message:
Laminar edges cannot be evaluated.
For the Tangency Type, use Curvature on the This means Deviation Analysis cannot be used on an edge that is the
long sides and None on the short sides. boundary of only one face.
Leave the Tangent influence (%) set to 0.

Click OK.
180 Smoothing Patches 181

Smoothing Patches
Blends and Patches
Blends and Patches
16 Change the curve's influence.

14 Deviation analysis. .'• Bouiidrtty-burfacei
Remember that in step 11 we selected the long

Click Deviation Analysis ( The analysis looks good.
sides for Direction 1. We want to change the
influence of the long sides. 0H curves influence
Edit the Boundary_Surfaoel feature and change 0penC>euB4^v«rure<

the Tangent influence (%) setting to 100.
Click OK. [Cwveture To Face
T*rv^Wtuence(%l:
15 Click View, Display, Zebra Stripes.

The zebra stripe display appears to show some
problems. You may want to change the settings to
make the discontinuity more apparent.
Note The supplied part has a saved view orientation 7?T.
named Zebra_Stripes that was used for the With this change, the zebra stripes now show curvature continuity
illustration below. across the edges.
17 Turn off Zebra Stripes and save and close the part.
If you want, edit the Surface-Knit feature and select the Try to form
OsttwlcifMp solid option to make the part into a solid.
0СиЬ>ПНа
Remember, there are three boundary conditions zebra stripes can help
you identify:
• Contact (CO continuity) - the stripes do not match at the boundary.
• Tangent (CI continuity) - the stripes match, but there is an abrupt
change in direction or a sharp corner.
• Curvature continuous (C2 continuity) - the stripes continue
smoothly across the boundary. Freeform Using the Freeform feature you can modify a face of a surface or solid
The illustration above shows tangency, but not curvature continuity. Feature You have direct, interactive control of the deformation by creating
control curves and control points, then pushing and pulling the control
points to modify the face. You can select groups of points from a single
curve but you cannot select groups of points from multiple curves.

182 Smoothing Patches
Blends and Patches
Blends and Patches
The Freeform feature is most commonly used for: 4 Freeform feature.

Click Insert, Features, Freeform, or click • x •»
• Shapes that are very organic. Freeform (g on the Features toolbar.
• Shapes that may be difficult to model using sketched features such
as sweeps or lofts. Under Face Settings, select the flat face of the
• Making adjustments to improve the results of other commands such solid.
as Filled Surface.
Introducing: Freeform, unlike Boundary Surface, is not limited to a four-sided Mesh Orientation With faces that are other than
Freeform face. However, you can only modify one face at a time. Freeform is a four-sided (what is often
hybrid tool in that it will operate on both solids and surfaces. referred to as an n-sided face)
Where to Find It • Click Freeform £) on the Features toolbar. the mesh lines are oriented in a
• Or click Insert, Feature, Freeform or Insert, Surface, Freeform.
rectilinear pattern. For this
exercise, this causes a problem
For this example, we return to the finial part we because the curves we add to
have worked with already. We have worked on the control the deformation of the
scroll at the bottom as well as the wrapped pattern face follow the mesh lines. And ICCTWuW Contact
that is just above it. for this particular part, we want
For this example, we look at the leaf pattern on top those curves to follow the edges
of the finial. of the leaf, not a rectilinear pattern.
The solution is to create a four-sided face.
Cancel.
Cancel the Freeform feature.
Delete.
Delete the extruded feature we created in step 3.
Create a new sketch.
Open a new sketch on the Front reference
plane.
Open part.
Offset the existing Leaf Outline sketch to
Open the existing part named Knial_Leaf.
the outside by 2.50 mm.
Suppress.
Sketch a line across the bottom to close the
To reduce the demand on system resources, suppress all the existing
profile.
features with the exception of the Leaf Outline sketch.
Extrude. Sketch a short line at the tip of the leaf as
Extrude the offset splines 12.5 mm using the Mid indicated by the red arrow in the image.
Plane end condition. Trim off the corner of the splines. Now when
Clear the Merge result box. we create the extruded feature, it will be four-sided which will give us
the mesh orientation we want.
Click OK.
184 Freeform Feature 185

Freeform Feature
Blends and Patches
Blends and Patches
Extrude. 11 Add points.

Extrude the offset splines 12.5 mm using the Mid There are three ways to switch from adding curves am pom
0svjptofli
Plane end condition. to adding points: TrkvJorlontotkjn:
OaoM
Clear the Merge result box. • Click the Add Points button in the О м »
PropertyManager. ©Curvo
Click OK. • Or, click the right mouse button *Q after the
QTiUdfafcws sattriton
last curve is placed.

• Or, if the ' ' Q has disappeared, right-click in the graphics area and
select Add Points from the shortcut menu.
Add three points to the first, third
9 Freeform feature. and fifth curves that were added
Click Insert, Features, Freeform, or click in step 10. You can only see the ° ^ ? " -
| с ж < а
Freeform S on the Features toolbar. points on one curve at a time.

Under Face Settings, select the flat face of the The second and fourth curves
solid. have been placed to anchor the
Notice how the mesh lines follow face in between the other curves,
which will be used to give the
the contour of the edges of the
face some shape.
face.
The Mesh density can be Click the right mouse button
controlled in the Display section after the last point is placed.
of the PropertyManager.
12 Select a point.
Select the center curve, and the points on that curve become
visible. Select one of the points on the curve. Notice the
triad appears.
10 Add curves. Move the point using the triad to get a feel for how it works.
Click Add Curves.
Click Undo *».
Place five curves roughly equally
spaced across the width of the
leaf as shown. A curve's relative Using the Triad There are several ways to use the triad;
position in the mesh cannot be
• Each arrow represents a direction, and if you pull on the
moved once it is created.
arrow, the point will only move in that direction. This
However, if you place a curve in
makes working in 3D much easier.
the wrong position, click
• Between each pair of arrows is a plane. If you select and
Undo •» and place it again.
drag the plane, you move the point parallel to the plane.
The curves should go from the top to the bottom of the leaf. If the • If you select the dot at the vertex of the triad, you can move the
curves are previewing perpendicular to the ones shown, press Tab on point freely in 3D space.
the keyboard, or click the Flip Direction button in the • If you press Ctrl and select multiple points, you can drag them
PropertyManager, and they will change directions. simultaneously.
Tip You can use the mesh display as a guide to help position the curves.

186 Freeform Feature
Lesson 6
• The orientation of the triad can be controlled in If you move a point too far and the preview mesh disappears, it
the Freeform feature's PropertyManager. r indicates you have created an invalid surface. In the illustration below,
Qsnvtogecmcry
• j the surface is self-intersecting.
• Global, Surface or Curve orientation options Triad onantatton: j
determine if the triad uses the part's origin, the ©C*M I
normal to the surface at the point or the normal OCurva J

to the curve at the point. When using Surface 0 Triad fofoKtehKUan |
or Curve options, the triad will reorient after
being moved. JOM
• Triad follows selection means that the triad

will either snap to the selected point (when
checked), or remain in an arbitrary position
(when cleared).
• The spin boxes enable you to move the triad by discreet amounts by
Undoing Changes There are several ways to undo changes in the Freeform feature.
typing in values, or using the arrows or the thumb wheel.
a Use the Undo button *> at the top of the PropertyManager
Tip Pressing the Alt key while using the arrows or the thumb wheel
• Right-click in the graphics area and select Reset Curve from the
reduces the increment by a factor of 10. Pressing Ctrl increases the
shortcut menu.
increment by a factor of 10. So if the default spin box increment is
• Delete points or curves that have been moved by selecting the point
10 mm, pressing the Alt key reduces that to 1 mm. Pressing the Ctrl
or curve and pressing Delete.
key increases it to 100 mm.
• Press Ctrl+Z. Note: Ctrl+Y will redo an undone edit.
Moving Control Be careful to avoid
Points introducing ripples into the 13 Select multiple points.
surface. The Freeform Hold down Ctrl and select all the points on the center
surface works like a spline
curve.
in that pulling a control
point on one side of a fixed Drag the blue arrow to move the points outward from
point can cause the surface the part.
to dip on the other side of You may find you need to add points or remove
the fixed point. Notice the dips indicated by the red arrows. points to keep the shape smooth.
If you are trying to create a localized deformation, one tip to minimize
ripples is to split the surface into a smaller face and deform only the
small piece.
14 Deform the first and fifth
Just as with splines, smoothness is the key to a good surface, and to get curves.
smoothness, it is best to use as few control points possible. Follow the same steps of
Currently there is no way to move a moving points, and if
point's position relative to the mesh once necessary, adding more, to
it has been placed. If you place a point at deform the surface until
the middle of a curve (meaning the 50% you are satisfied with the
position in the mesh), it will always shape.
remain in the middle of the curve It is supposed to resemble a
regardless how it is moved with respect
leaf.
to the overall part. If you move the point
to one end of the curve, you will notice
that behind the moved point the mesh is spread out and in front of it the
mesh is compressed.
188 Freeform Feature 189

Freeform Feature
Lesson 6
Boundary The callouts around the edges of the Freeform feature determine the 16 Adjust the points to give some shape to the edge.
Conditions relationship of the finished face to the original. The gap and overlap will be taken care of when the feature is finished.
• Contact
Contact means that the new face touches the ШШ
edge of the original face, with no other шшагиагут—-г^Д
relation other than the fact that they touch.
This is CO continuity.
Tangent means the new face remains

tangent to the original face. This is C 1 е д Ш й
continuity.
Curvature means that the new face matches

the curvature of the original face at the (сй^Жм^ьи:
edge. This is C2 continuity. 17 Click OK.
I Examine the results.
Moveable means that the edge can move

by extending or trimming back the adjacent [саамлн^лъ •
surface.
• Moveable/Tangent combines the properties of both conditions.
15 Add another three points to the edge.

Set the boundary condition of the outer edge of the leaf to Moveable/
Tangent.
Click Add Points.
Add three points along the outer edge of the leaf.
ICorttniardCwaad: ~vi IQxVnHlContact v]
ICWir«iM>*jwiyêriiiant vf
190 Freeform Feature FreeformFeature 191

Blends and Patches
Blends end Patches
19 Apply a fillet to the edges. Comer Blends There are situations where fillets
Use a variable radius fillet to may be too complex and will not
break the edges of the leaf and work. Or, the fillets may work but
round out the stem slightly. the result is not what you want. The
corners indicated in the illustration
Note The success or failure of the at the right represent one such
fillet depends on how the surface situation. The complexity usually
was deformed. It is possible to arises from a combination of two
introduce areas in the surface factors:
where the local radius of
curvature is less than that of the • More than three edges meet at a
fillet. Use Offset Surface to test vertex.
and diagnose any problems. • The fillets are of mixed convexity - some concave, some convex.
Sometimes these situations can be handled using a blending technique.
20 Arrange bodies.
Move, rotate, mirror and Stages in the The general approach to blending this type of corner is to:
copy bodies to arrange the Process u F i||et what you can.
leaves into a bunch. Do not under estimate the FilletXpert. Many times this will give
you a solution that is acceptable for some applications. Even if it
isn't the perfect solution, the fillets give you surfaces you can
reference when blending.
• Cut out the ugly part.
This involves deleting the small patches of the fillets and then
trimming the remaining faces to create a nice boundary for the
blend.
• Blend a patch.
Usually this is done using a filled surface but in some situations,
21 Combine all solid bodies. one of the other approaches we have covered in this lesson may
Unsuppress the other solid bodies and combine work better.
everything into a single body. Procedure Open the existing part Blended_Corner.
22 Save and exit the part.
Corner Blends 193

192 Freeform Feature
Lesson 6
1 FilletXpert. 4 Delete faces.

Click Fillet ®. Click Delete Face Щ.
Click FilletXpert. Set the Radius to 2.5 mm. Manuel Select the six faces as shown at the
right.
Select the Pocket feature and the two edges as
shown below and click OK. Use the Delete option.
Click OK.
Face curves.
Click Face Curves |g on the
Sketch toolbar, or click
Tools, Sketch Tools, Face
Curves.
Select the fillet face shown

and then select the vertex.
2 Results.
After processing, the FilletXpert Tip Selecting the vertex
creates two separate fillet features. automatically selects the
Position option.
While not a perfect blend, this may
be good enough for some Notice the colors of the two
applications. face curves. Based on the color scheme we are using (Blue Highlight),
one is pink and one is blue. In this case, we want the pink one, not the
blue one.
Clear the check box for the blue iso-curve.
Click OK.
Edit sketch.
3 Change view.
Change to a Right side view and then Creating the face curve automatically created a 3D
rotate it downward by pressing the down sketch.
arrow twice (30°). Edit the 3D sketch.
Select the edge of the fillet and click Convert
Entities.
Important! The face curve and the converted edge must be in
the same sketch.
194 Corner Blends Corner Blends 195

7 Trim Entities. 12 Trim Surface.

Trim the converted edge to the intersection of the face Trim the surface, keeping the piece shown.
curve.
8 Trim Surface.
Trim the surface, removing the
piece bounded by the face curve
and the trimmed converted
edge. 13 Exit Isolate.
Click Exit Isolate on the popup toolbar to show the surface
body you hid in step step 10.
There are now two faces superimposed on each other.
Alternative Although this technique for trimming the face of the fillet works well,
Approach you may find situations where it is awkward or doesn't work as well as The mottled color of the highlighted face is an excellent
you would expect. For that reason, we will examine a somewhat indicator that two faces are superimposed and are
different approach to trimming one of the other faces of the fillet. coincident.
14 Delete Face.
9 Copy the surface. Delete the untrimmed face of the fillet.
Click Offset Surface g|j on the Be sure to use the Delete option, not the default Delete and
Surfaces toolbar. Patch.
For Offset Distance, enter
15 Knit.
0.00 mm.
I *„ j ГгШпт Knit the trimmed surface with the rest of the surface model. We have
Select the face of the fillet and now replaced the original face of the fillet with the trimmed one.
click OK.
10 Isolate.
Spline on Surface The highlighted edge of the opening shown in the -j ШШ_
Right-click the offset surface and select Body, Isolate from the illustration at the right also has to be trimmed, however, \*fw
shortcut menu. Now only the copied surface is visible. in this case, we cannot use a face curve. Instead, we will щ
11 Face curve. sketch a spline directly on the surface and use that as the *^
Click Face Curves i«g on the Sketch toolbar. trim tool.
Create a face curve located by the vertex shown.
Introducing: Spline When you sketch a spline on a surface, the spline points are constrained
on Surface to the surface on which they are sketched. When you drag the spline
points, they move along the surface.
Use Spline on Surface for:
• Part and mold design, where surface splines enable you to create
more visually accurate parting lines or transition lines.
• Complex sweeps, where surface splines facilitate creating guide
curves bounded to surface geometry.

Where to Find It • Click Tools, Sketch Entities, Spline on Surface. 20 Create a new sketch.
• Or, click Spline on Surface |Sj on the Sketch toolbar. Open a new sketch on the planar
face that forms the bottom of the
Note Spline on Surface does not appear on the Sketch toolbar by default.
Pocket.
You will have to customize the toolbar to add it.
Click Convert Entities to copy the
edges into the active sketch.
16 Spline on surface.
Click Tools, Sketch Entities, Spline on Surface.
21 Delete entities.
This creates a new 3D sketch. Delete the curves on the four short
Sketch a 2-point spline between the two vertices as edges as indicated in the illustration
shown. at the right.
17 Add relations.
Add Tangent relations between the 2-point spline and the
edges of the fillets. 22 Sketch splines.
Sketch 2-point splines between the
open vertices.
18 Trim surface.
Trim away the small sliver leaving
a smooth edge.
23 Add relations.
Add Tangent relations between
the splines and the converted
19 Repeat. edges.
Repeat the process we just followed to prepare the
opening for the patch on the other side of the part.
I" 24 Delete face.

Exit the sketch and delete the planar
face.
Remaining Edges There are still two edges of the
openings that need to be cleaned up.
25 Planar surface.
Select the sketch and click Planar
Surface 0.
Click OK.

Lesson 6 S o l i d W o r k s 2009 Training M a n u a l S o l i d W o r k s 2009 Training M a n u a l
Blends and Patches
26 Knit.
Exercise 13: In this lab you will create
Knit the new planar surface together with the other surface body.
Bicycle Frame blends between different
27 Filled surface. tube arrangements.
Click Filled Surface @.
This lab reinforces the
Right-click an edge of one of the openings and following skills:
select Select Open Loop from the shortcut
• Trim Surface on
page 12.
Tip One of the benefits of working with a knitted • Lofting Surfaces on
surface model is the ease of selecting an open page 113.
loop as compared to manually selecting many • Filled Surface on
edges, some of which may be small. page 87.
For Curvature Control, use Tangent and click Apply to all edges. Units: millimeters
Click Merge result.
1 Open part.
Click OK. Open the existing part named Blcycle_Ppame_Lab.
28 Repeat. 2 Create simple blend using a loft.
Create another filled surface Select the open edges of the surfaces on
for the other opening. either side of the break in the Seat Tube as
In addition to clicking indicated.
Merge result, click Try to Use Lofted Surface to create a blend.
form solid.
Use Curvature To Face for the Start/End
Constraints on both profiles.
Use the mesh display to make sure the loft is
not twisting.
Adjust the connectors to straighten the lofted
surface if it does twist.
Use the Tangent Length values to adjust the
shape of the blend to your satisfaction.
3 Create sketch for trimming.
Open a new sketch on the Bight reference plane.
Create a sketch similar to that shown. A straight
line and a partial ellipse are used here.
Do not overlap the ellipse with the blend on the
other side of the tube.
200 Corner Blends E x e r c i s e 13: B i c y c l e F r a m e

4 Trim. Create the sketch to trim the

Trim the surfaces using the sketch from Seat Stays.
step 3, keeping the pieces shown. Note Some of the other surface bodies
Pieces to keep' have been hidden for clarity.
Open a new sketch on the Seat
Stay Plane created in step 6.
Sketch and dimension lines as
shown.
5 Loft. Use either Split Entities or
Loft a surface using the two closed loop edges collinear lines to create six break
as profiles. points as indicated by the red
arrows and the orange dots.
Constraints on both profiles. The 685 mm dimension is attached to the pari Origin.
Adjust the connector so that it is on the plane The lines are symmetrical about the centerline.
of symmetry.
Trim the surfaces. P i e c e s to keep
Use the Tangent Length values to adjust the Select the pieces to keep as shown
shape of the blend to your satisfaction.
6 Define a plane.
Show the Tube Centerlines sketch.
Define a plane that is 90" to the Right reference plane and that passes
through the centerline of the Seat Stays.
Name the plane Seat Stay Plane.
This plane will be used for the sketch that will trim the Seat Stays.
* 2 + * ; J - IT- v - • » - <*• 9 Loft.

* Seat Stay Plane Loft a surface using the two edges of the
Seat Stays as profiles.
/
/
Constraints on both profiles.
/
/ Use the Tangent Length values to adjust

a the shape of the blend. It is important to use
/ the same value for both the Start Tangent
Length and the End Tangent Length to
keep the surface symmetrical.
A value of 9 was used for this illustration.
^ C e n t e r l i n e of the S e a t S t a y s
•Right "rsontetric
202 E x e r c i s e 13: B i c y c l e F r a m e
E x e r c i s e 13: B i c y c l e F r a m e
10 Loft another surface. 15 Trim the Bottom Bracket.

Loft a surface between two edges as shown. Using the offset surfaces created in step 14,
Use Curvature To Face for the Start/End trim the Bottom Bracket. This will require
Constraints on both profiles. two operations because two trim tools are
necessary.
A value of 1.5 for both the Start Tangent
Length and the End Tangent Length was When selecting the pieces to keep, be sure
used for this illustration. to select the faces of the blend between the
Seat Tube, the Down Tube, and the Bottom
Bracket.
11 Mirror. 16 Hide.
Since the sides of the blend are symmetrical, Hide the two offset surfaces.
and the trim sketch was symmetrical, the 17 Trim the Chain Stays.
lofted surface can be mirrored using the Open a new sketch on the Right reference plane.
Bight reference plane.
Show the Tube Centerlines sketch.
At this point the blend areas are fully
surrounded by trimmed tubes and lofted or Sketch a line perpendicular to the centerline of the Chain Stays and
mirrored surfaces. dimensioned from the center of the Bottom Bracket as shown.
Trim the two Chain Stays.
12 Filled surface.
Initiate a Filled Surface feature. Select all the edges around the patch,
and set the edge conditions to Curvature for all edges.
18 Loft.
Loft a surface between the end of the Chain
stay and the trimmed hole in the Bottom
Bracket.
13 Mirror. Use the SelectionManager to select the edges
Mirror the filled surface with respect to the Seat Stay Plane. on the Bottom Bracket.
14 Offset. Try to use Curvature To Face, but if that
Offset the two Chain Stays using an Offset does not work, use Tangency To Face.
Distance of 4 mm to the outside.
Examine the preview closely while rotating
These offset surfaces will be used to trim the view. Move the connector on the Chain Stay and adjust the
openings in the Bottom Bracket. Tangent Length values to adjust the shape of the blend.
A value of 0.5 for the Start Tangent Length (Bottom Bracket) and 1.5
for the End Tangent Length (Chain Stay) was used for this
illustration. Your values may be different.
204 E x e r c i s e 13: B i c y c l e F r a m e 205

E x e r c i s e 13: B i c y c l e F r a m e
S o l i d W o r k s 2009 T r a i n i n g M a n u a l S o l i d W o r k s 2009 Training M a n u a l
19 Mirror. Exercise 14: In this part you will patch

Mirror the lofted surface with respect to the Patches unwanted areas of a model and
Right reference plane. replace them with improved
shapes.
This lab reinforces the
following skills:
20 Planar surfaces. • Freeform on page 184.
With a single Planar Surface
feature, select the edges around Units: millimeters
the five openings in the frame as 1 Open part.
shown in the image to the right. Open the existing part named Grip.
The single feature will create all Examine the part.
of the planar surface bodies, Notice the rounded end of the grip. On both sides there are small
even though they are not dimples. These were created by the loft features and they need to be
coplanar. smoothed over.
21 Knit and solidify the part.
Select all the surface bodies
except the two offsets of the
Chain Stays.
An easy way to select them all is
to expand the Surface Bodies
folder and Shift-select the
bodies in the list. Then Ctrl-
select to deselect the two offset surfaces.
Select the Try to form solid option.
The bumps are due in part because of
22 Shell. a singularity. The singularity was
Shell the frame at 1.5 mm thickness, selecting the planar faces for the caused by the way the lofts were
openings on the Head Tube, Seat Tube, and Bottom Bracket. made.
We will also add a thumb rest as shown in the image below.
206 E x e r c i s e 13: B i c y c l e F r a m e E x e r c i s e 14: P a t c h e s

Sketch. 10 Filled surface.

Open a new sketch on the Top reference Using the edges of the newly
plane. trimmed reference surfaces and the
lower edges created by the Split
Sketch a circle dimensioned as shown. The 028.50 L i n e l feature, create a Filled
center has a Vertical relation with the Origin. 3.50 Surface using Curvature for all
four edges.
4 Split line.
Using the circle, create a Split Line feature to Do not click OK yet.
split the top and bottom faces of the part.
The part was mirrored across the plane of 11 Compare.
symmetry, so you will need to select four Switch to a Right side view and
faces. compare the preview to Sketch3.
5 Delete four faces. The surface curves out too far.

Select the four faces inside of the split line Cancel the Filled Surface
and delete them. command.
12 Constraint curve.
Open a new sketch on the Right reference
plane.
Show two hidden surface bodies.
Use Convert Entities to copy Sketch3
Expand the Surface Bodies folder
and select the Surface-Sweep 1 and into the active sketch and then hide
the M i r r o r l [4] surface bodies. SketchS.
Insert a Split Entity point on the converted
Right-click and select Show Bodies.
spline and make it coincident with the
Copy surface. model edge using a Pierce relation.
Make a copy of the two surface bodies
that were shown in step 6. Delete the rest of the copied spline.
Hide the Surface-Sweep 1 and the M i r r o r l [4] surface bodies. Exit the sketch.
Trim the surface. 13 Filled surface.

Reusing the circle sketch from the Split Try the Filled Surface again,
L i n e l feature, trim the copied surfaces using the sketch from step 12 as a
leaving the pieces shown. Constraint Curve.
The results are much better.
Show sketch.
Switch to a Right side view.
Expand Folder 1 and Surface-Loft 1, and
show Sketch3.
This represents the desired shape of the end
of the grip.
208 E x e r c i s e 14: P a t c h e s E x e r c i s e 14: P a t c h e s

14 Patch the top using the same procedure. 15 Open a new sketch.
Hide the trimmed reference surfaces, and show Open a new sketch on the Top
Ruled Surfacel and M i r r o r l [3]. reference plane.
Trim Ruled Surface 1 and M i r r o r l [3] using Sketch and dimension the lines and
13
the circle sketch from the Split L i n e l feature. arcs as shown.
Create the Filled Surface without using a Add Vertical relations between the
constraint curve. centers of the two arcs and the part
Origin.
Hide the reference surfaces.
The 102 mm dimension is from
the part Origin.
Strategy The intent is to use a Freeform feature to create the thumb rest.
16 Split line.
Split the upper faces and delete the pieces inside the split line.
However, the Freeform feature requires a single face and the area we
want to modify spans two faces. The Freeform feature does not create 17 Filled surface.
a surface from edge selections, it modifies an existing face. Create a Filled Surface using
If we split the upper faces of the part we end up with a multiple faces Curvature matching on all edges.
(two) within a four-sided boundary. That will not work for a Freeform Right-click on one of the open edges
Tip
feature. and select Select Open Loop.
18 Freeform feature.
Click Insert, Features, Freeform.
Select the filled surface that was just created.
19 Turn on symmetry.
This will keep the changes to the face symmetrical.
So we will delete the faces inside the split line and replace them with a Whether you select Direction 1 Symmetry or Direction 2 Symmetry
single, four-sided surface which we can then modify using the depends on which edge you selected first when creating the filled
Freeform feature. surface.
210 E x e r c i s e 14: P a t c h e s 211

E x e r c i s e 14: P a t c h e s
20 Add curves. 24 Move points.

Under Control Curves, click Add Set the Triad orientation to Global.
Curves. We are trying to create a scooped shape
Place five curves approximately as for a thumb rest. Adjust the curves by
shown. If the preview of the curves is moving the control points until you are
going the wrong way, press Tab. satisfied with the results.
Tip To move multiple points at the same
time, hold down Ctrl and select the
control points.
When you are done, the Freeform surface should look approximately as
21 Add points. shown below.
When you are done adding curves,
When you are satisfied, click OK.
switch to Add Points mode.
Place control points along the plane of
symmetry for every curve.
The plane will highlight when the point |&»л|»и»\|Ос«*аа:,у|
will be placed properly.
22 Add more points. 25 Knit into a solid.

Also add a pair of points to the second, Knit all the surface bodies except the construction surfaces into a solid
third, and fourth curves as shown. body.
When a Symmetry option is selected,
placing a control point to one side of the
plane of symmetry places a symmetrical
point on the other side of the plane as
well.
23 Set edge constraints.

Set the edge constraints to Curvature.
212 E x e r c i s e 14: P a t c h e s E x e r c i s e 14: P a t c h e s 213

Exercise 15: The corner indicated by the red 4 Remove the corners from the model.
Comer Blend circle indicates where four edges Delete the unwanted faces of the fillets.
of mixed convexity come
together.
Create this corner using a
combination of filleting and
blending techniques. 5 Trim the openings.
Using face curves, converted edges, and splines on
This lab reinforces the following surfaces, trim the edges of the openings.
skills:
• FilletXpert.
m Face Curves.
m Spline on Surface on page 197. 6 Filled surfaces.
Create tangent filled surfaces to patch the
Units: millimeters openings.
1 Open part. Use Merge result and Try to form solid as
Open the existing part named Corner_Blend appropriate to create a finished solid model.
7 Add a counter bored hole for an M6 socket

head cap screw.
Center the hole on the flat face of the boss.
For the End Condition use Through All.
2 Fillet.
Create a 4 mm radius fillet on the edge as shown. 8 Edit the revolved feature.
Change the Revolve Type to Mid-Plane.
Change the Angle to 120° and rebuild the
part.
FilletXpert.
Use the FilletXpert to add
2.5 mm fillets to the
remaining edges by selecting 9 Shell.
the two faces that form the Use a Thickness of 1.5 mm and remove
pocket. the bottom face and the two side faces.
While not a perfect blend,

this may be good enough for
some applications.
214 E x e r c i s e 15: C o r n e r B l e n d E x e r c i s e 15: C o r n e r B l e n d

10 Move face.
Move the end face of the hole to shorten the boss by
38 mm.
Use the Offset option to avoid having to specify a
direction.
Lesson 7
11 Pattern the body.
Use a circular pattern to make a total of Master Model Techniques
three bodies.
12 Combine the bodies. Upon successful completion of this lesson, you will be able to:
Use the Combine feature to join
• Create and propagate changes from a surface master model.
the three patterned bodies into a
single solid body. • Create and propagate changes from a solid master model.
• Add various features commonly associated with plastic consumer
products.
217
216 E x e r c i s e 15: C o r n e r B l e n d
Lesson 7
Master Model Techniques Master Model Techniques
Introduction to Master model is a technique of driving many parts from a single part
Master Models which contains overall size, location and gross geometry for an entire
assembly. Geometry detail is generally found in the individual part
files. Master model techniques can also be employed in an in-context
assembly environment, but in this course we are focused on individual
part techniques.
When using a master model, there are four basic techniques you can
employ:
• Insert Part
• Insert into New Part
• Split Part
• Save Bodies
In-context assemblies, also called top-down assembly modeling, are
covered in a different course, Advanced Assembly Modeling.
In this course we will address two methods in detail:
• Using Insert Part with a surface master
A s u r f a c e m a s t e r m o d e l a p p r o a c h u s i n g Insert, Part
218 Introduction to Master M o d e l s 219

Using Split with a solid master Naming Bodies With push-type operations, the bodies are transferred to the children but
the features are not. It is best practice to name the bodies, to make it
A s o l i d m a s t e r m o d e l a p p r o a c h u s i n g the Split feature a n d S a v e B o d i e s
easier to identify them in the child part.
P a r e n t multibody part
The following chart summarizes the properties of the various functions.
Push Operations Pull Operations
Split Save Bodies Insert, Part Insert into New Part
Works for:
Solid bodies only Solid Bodies folder All solid and/or Solid Bodies and
only surface bodies, axes Surface Bodies
C h i l d r e n c r e a t e d from the s o l i d m a s t e r m o d e l
and planes, cosmetic folders and individual
( E a c h is an individual part file) threads, sketches, and bodies
coordinate systems.
The techniques available for surface master models are:
Creates feature in parent?
• Insert, Part
• Insert into New Part Yes Yes No No
Both of these are also available with solid master models. Creates feature in child?
Some techniques are available for solid master models only, and are not Yes - Stock Yes - Stock Yes -Part Yes - Stock
available for surface master models. Specifically:
Invoked from:
• Split
• Save Bodies
Parent Parent Child Parent
Transmitting For the Insert, Part method you have the option of transferring with it Find parent from child document?
Curve Data any combination of the following: Yes Yes Yes Yes
• Solid bodies • Surface Bodies
Find child from parent document?
• Axes • Planes
• Cosmetic threads • Absorbed sketches Yes Yes No No
• Unabsorbed sketches • Custom properties
• Coordinate systems • Model dimensions Are links broken by renaming parent?
However you cannot transfer curve entities. No No Yes Yes

A technique to transmit curve data from parent to child is to create a 3D Are links broken by renaming child?
sketch and copy the curve into the sketch using Convert Entities, and
Yes Yes No No
then make sure that the unabsorbed sketch is transmitted to the child.
Push and Pull type Master model techniques are divided into two groups: Can broken links be repaired?
Operations Yes Yes Yes Yes
• Functions that push bodies from the parent to the child.
• Functions that pull bodies into the child from the parent. Can you specify where
in the feature history the part is saved out?
Push-type functions only work on solid bodies.
Yes - a feature resides Yes - a feature resides No - configurations No
Of these functions, only Insert, Part is invoked from the child in tree where body is in tree where body is could be used to do
document, the rest are invoked from the parent. saved saved this
220 Introduction to Master M o d e l s Introduction to Master M o d e l s 221

Surface Master In this example, we look at a simple application of

Push Operations Pull Operations Model the surface master model technique. This
Technique assembly is made of only two pieces, but the
Split Save Bodies Insert, Part Insert into New Part technique can be extended to models with many
Can configuration of parent be specified? more parts and more parametric sophistication,
including configurations for a family of sizes.
No No Yes No Both parts here were created from the same
master model, and then reassembled in an
What happens when the number of bodies in the parent changes? assembly.
The Split feature can The Save Bodies Any Delete Body Any Delete Body
reassign relation- feature can reassign feature in the child feature in the child
Procedure Open the existing part named Speaker_Surface_Master.
ships to child parts in relationships to child which cannot find a which cannot find a
response to changes parts in response to parent body will fail parent body will fail
in the split geometry changes in the until edited and until edited and Examine the master model.
or the number of bod- number of bodies. closed. Some features closed. Some features Notice that each feature of
ies. (For more infor- (such as Rib) are (such as Rib) are importance is named. This master
mation, see Split sensitive to the sensitive to the model is meant to drive all major
Feature below.) presence of multiple presence of multiple outside shape changes for the entire
bodies. bodies. product from a single location.
Split Feature Editing the Split feature can cause the number of bodies in the parent to
change. When the Split feature was used to save bodies, SolidWorks
can attempt to reassign the split bodies to existing files. You can also
reassign the bodies to existing files manually.
Depending on the changes to the parent, some sketch relations may be
lost or go dangling, or some features might show an error. For example,
if a fillet references edges that, as a result of editing the Split feature, New part.
are now divided between two bodies, the fillet will indicate an error.
Open a new part using the Part_MM template.
Summary of The best choice of the four methods is Insert, Part because it offers the
Recommendations use of configurations and the children inherit the greatest number of Name it Speaker_Houslng.
entities. Insert the master model into the new part.
Click Insert, Part, and browse for the
The major disadvantages of using Insert, Part are:
Speaker_Surfaoe_Master.
• From the parent document, it is impossible to tell where the part has
been used. However, SolidWorks Explorer has a Where Used For the Transfer options, make sure Surface is
• scadbccte
function. selected. EO&jrfecetocles
• If the parent is renamed using Windows Explorer, the link is Under Locate Part, clear the Launch move
•Axes
•Wanes
broken. Rename the parent using SolidWorks Explorer. dialog option. • cosmatk: threads
• You cannot directly specify where in the parent's history the body •AbscAad sketches
comes from, although configurations give you a way to accomplish Make sure that the master model is inserted at the •uriabwued searches
the same thing. new part's origin. •OHtoai proparttes

•côrdnate svsteate
Split is the best choice to cut a solid model into multiple bodies. •mdetdawwns
iLecatatPert
•laundrraovecMog

222 Introduction to Master Models
Lesson 7 S o l i d W o r k s 2009 T r a i n i n g Manual S o l i d W o r k s 2009 T r a i n i n g M a n u a l Lesson 7
The surface bodies are listed in two в & Suttee ЯаАкЩ Delete unnecessary bodies.
d> <SB4ewJurfecej eeAa»-<f*ce of Berfle>
different locations in the ф <SpeetarJutanj eesbai>-<lr0i>)d Bafflo>
For this part, we will only need three of
FeatureManager of the child part. ф <3pt4*»r>rficoJ1o*er>-<Raso> the six surface bodies.
<$ <Sp«4te><tmJ4istc«>.<Mvar Mounts[l]>
Ф <Tcm*etJ*feceJ*a*er>-<Dibef Mcwts[2]>
1. In the normal Surface Bodies <$» <5ee*k*tJu*eceJAe»er>-<Sutac&*}m\> Delete the surface bodies that are
folder at the top of the ^ftcrtflono
highlighted in the illustration.
>&!»•«•»
FeatureManager. J& RKjhtPlkne
U OrkjK
2. In a folder under the inserted part H ф ieeMmJufecejeeetei ->
feature. Sl&SufoaM^fi)
ф <Sf*mjLMtacaJ4a**>-<fK*olBoffk>>
This enables you to distinguish ф <ftooW>jrfocoJla»tB f>-<lnioteoffrt№
Ф <SPMfe* JurFaceJaM«f>-Oaso>
between surfaces that were brought rt> <Spt4l«y><fKeJ4astor>.<r>hwMouKj[l]>
ф <Sp«^>*foceJflester>-<r*AW Hounu(2]>
in from possibly different sources c£ <SpeokerJufoteJAa*er>.<Sutfaee4!f*l>
and surface bodies that were created 10 Trim the surfaces.
locally in the current part. Although it may be tempting to use a Mutual trim on
this part, use multiple Standard trim features instead.
4 Another new part.
You may find that the mutual trim fails after
Open a second new part using the Part_MM template. dimensions in the master model are changed.
Name it Speaker_Baffle. 11 Knit the surface bodies into a solid.
5 Insert the master model. Use the Try to form solid option.
Repeating the procedure in step 3, insert the master model at the new
part's origin.
12 Shell.
Use a Thickness of 3.5 mm and remove the front
Propagating Trimming the surfaces will be more reliable and robust if the surfaces
face.
Changes actually penetrate rather than just touch each other.
Ignore the warning.
We could extend the surfaces in each child part but it is best practice to
perform operations that apply to every child part at the master model
level. This saves work and ensures consistency across all the child 13 Speaker baffle.
parts. This is one of the primary reasons for using the master model Switch back to the Speaker_Baffle document
technique. window.
6 Master model. 14 Trim surfaces.

Switch to the Speaker_Surface_Master document window. The end result should look like the
image at the right.
7 Extend the highlighted edges.
Using Extend Surface, extend the Note For illustration purposes, the
highlighted edges about 5 mm each. portions that have to be trimmed
away are shown here as transparent.
Remember that Extend Surface only
works on a single surface body at a time,
and these edges are on three different
surface bodies. You will need to use three
features to extend all the edges.
8 Speaker housing.
Switch back to the Speaker_Housing
document window.
224 Surface Master Model Technique Surface Master Model Technique 225
18 Move body.
15 Knit the surface bodies into a solid.
Use the Try to form solid option. Click Move/Copy Bodies (8| on the Features
toolbar.
16 Ruled surface.
Click Insert, Surface, Ruled Move the extended ruled surface 3 mm in the Z
Surface or click Ruled Surface @ direction using the Delta Z option in the
on the Surfaces toolbar. PropertyManager.
Select the three tangent edges on the This will allow us to create a small edge around
back of the baffle as indicated in the the part.
image at the right.
For Type, select Tapered to Vector. 19 Cut.
Using Cut with Surface, cut the solid with the
Set the Distance to 25 mm. surface.
For the Reference Vector, select the The arrow points to the material that will be
Front reference plane. removed.
Set the Angle to 20°.
Select the edges and verify that the
surface tapers inward.
Select Trim and knit and click OK.
20 Shell.
Shell the model using a Thickness of 4 mm,
removing the back face of the baffle.
17 Extend surface.
Extend the bottom and back
edges of the ruled surface 3 mm.
Note The solid body has been hidden
21 Clean up the left over bodies.

Right-click on the Surface Bodies folder and select Delete Body.
Rename the feature Clean Up.

226 Surface Master Model Technique
22 Create an assembly. 24 Changes.

Click Make Assembly from Part |S§. Make the following changes to the master model and watch them
propagate through the parts and into the assembly:
Use the Assembly_MM template.
1. In the sketch of the Pace of Baffle
Place both parts at the assembly origin.
revolved surface, change the 25 mm
dimension to 50 mm.
Click through the other windows to
watch the parts update.
23 Changes.
Tile the windows (master model, housing, baffle and assembly).
•H""«Mc ЧилмМс
228 Surface Master Model T e c h n i q u e Surface Master Model Technique 229

25 Save and close the parts and 2 Extrude the parting surface.
assembly. Reuse the original parting sketch • gj^JS^Se" extrude a surface.
a n d
Use Mid Plane as the end condition and set the Depth such that it
extends beyond the body of the part.
3 Split the part.

Click Split Щ or click Insert, Features, Split.
Working with a in this section we will: Select the parting surface as the trim tool.
Solid Master • Split the part into separate bodies, each representing major
Model components of the remote control;
• Shell the part;
• Define the basic geometry and shape of the keypad;
• Create specialized features called fastening features;
• Save the individual bodies as part files.
Splitting the Part Splitting a part into multiple bodies was covered in the Advanced Part
Modeling course.
In this case study we return to the RemoteControl from
Lesson 5: Advanced Surface Modeling. Click Cut Part. The system computes the intersection of the trim tool
with the part and calculates the results.
We want to create both bodies but we do not want
to save them as separate part files at this time.
Select the check boxes for both bodies but leave
the file name set to <None>.
For Resultant bodies state, make sure the • Сопяяио* bodies
Consume cut bodies option is cleared. n Copy ojttom propertjej to
Click OK.
Hide the parting surface.
230 W o r k i n g with a S o l i d Master M o d e l 231

W o r k i n g with a S o l i d M a s t e r M o d e l
Lesson 7 S o l i d W o r k s 2009 T r a i n i n g M a n u a l S o l i d W o r k s 2009 Training M a n u a l Lesson 7
Rename the solid bodies. Dissolve the library feature.

Expand the Solid Bodies folder. Upper Housing Right-click the library feature and select Dissolve Library Feature
from the shortcut menu.
Rename the bodies Upper Housing
and Lower Housing. Extrude a cut.
Draft i n w a r d
Extrude a cut Through All in both
Change the colors of the upper and directions. Use 1.00" of draft.
lower housing bodies so it will be
easier to tell them apart. A s l i v e r f a c e is left if the cut is not
Lower Housing e x t r u d e d i n b o t h directions.
Hide the L o w e r Housing.
Modeling the To save time we will use a library feature for the sketch of the holes for
Keypad the keypad. The sketch is straightforward and creating it step-by-step
contributes nothing to this case study about working with a master
model.
Draft o u t w a r d
S Shell.
Shell the Upper Housing using a
Thickness of 2 mm.
Reference plane.
Create a reference plane offset 6 mm from Plane 1 in the direction
shown.
The new plane is shown in the illustration below as Plane5.
If the plane is not already named Plane5, rename it so that it is.
Note The 6 mm dimension was obtained by adding 0.2 mm to the sum of

2 mm, the shell thickness, and 3.8 mm, the dimension on the arc that
was used as a constraint curve in the filled surface (step 4 on page 128).
232 W o r k i n g with a S o l i d M a s t e r M o d e l W o r k i n g with a S o l i d Master M o d e l 233

7 Intersection curves. 10 Cut with surface.

Click Cut With Surface Щ on the Features
Open a sketch on Plane5.
toolbar. Under Surface Cut Parameters, select
Click Intersection Curve (Sj on the Sketch toolbar. the planar surface and the cutting surface.
Select the two faces as shown on the inside of the Upper Housing. Under Feature Scope, click Selected bodies and
OAltedU
select the Auto-select check box.
Click OK. [3Auto*f*Kt
Turn off the Intersection Curve tool and hide Plane5. Question: Since the surface we are using is planar, why not just cut using the
reference plane, Plane5?
Keypad.
Change the two intersection curves to construction geometry and Answer: The extent of the cut is limited by the
sketch the outline of the keypad as shown in the following image. Use boundaries of the surface. Planes are
an ellipse and a rectangle and trim as necessary. infinite. If we cut with the reference
plane, the entire body would have been
Tip Show the keypad sketch (step 2 on page 232) to help locate the center cut, not just the areas around the
of the ellipse and the rectangle. Also, use a Center Rectangle |И]. keypad holes.
Note The intersection curves are used as a guide to make sure the keypad
doesn't interfere with the inside of the housing. 11 Thicken.
Click Thicken (Oj) on the Features toolbar.
Select the planar surface.
Set the Thickness to 2 mm.
Clear the Merge result check box.
Examine the preview.
Select either Thicken Side 1
T h i c k e n in this
or Thicken Side 2 as
direction
9 Planar surface. necessary so that the surface
Click Planar Surface gj on is thickened away from the
the Surfaces toolbar. solid body.
Create a planar surface using Click OK.
the active sketch. 12 Rename.
Name the solid body
Keypad.
234 W o r k i n g with a S o l i d M a s t e r M o d e l W o r k i n g with a S o l i d M a s t e r M o d e l 235

S o l i d W o r k s 2009 Training M a n u a l Lesson 7
13 Offset the edges.

Open a new sketch on the uppermost Finishing Touches In the next section of this case study we will explore some specialized
face of the Keypad. This will be the features that are common to plastic parts. They are the:
sketch for the buttons.
• Mounting boss
Note The Upper Housing is shown
• Snap hook
transparent for illustration purposes.
• Snap hook groove
Click Offset Entities Щ. • Lip and groove
Offset the bottom edges (because of the draft angle) of the keypad
holes 0.25 mm. Hide and show bodies.
Hide the Upper Housing and
Since the buttons have to be smaller than the holes, offset to the inside the Keypad.
of the holes.
Show the Lower Housing.
Rotate the view so you can see
the underside of the Lower
Housing.
Hole for fastener.

Open a sketch on the Top reference plane and
sketch a 6.35 mm diameter circle as shown.
The distance from the origin is not critical but
it should be located near the rear of the
remote.
Tip Press the Enter key to repeat the previous command Add a Coincident relation between the
14 Extrude a boss. circle's center and the Right reference plane.
Extrude the sketch using Offset From
Extrude a cut as follows:
Surface and an Offset Distance of
2.5 mm. • The From position is Offset 19 mm from
the sketch plane.
Set the Draft Angle to 1.00° and
• The End Condition is Through All.
make sure the draft is inward.
O f f s e t f r o m this • The Draft Angle is 1.00°.
Select Merge result and use the surface • Select the Draft outward check box.
Feature Scope to select the Keypad. • For Feature Scope, select the Lower Housing.
15 Dome. Shell.
Create a 1.25 mm dome on the top of the round button. The Shell the Lower Housing
dome goes upwards. using a Thickness of 2 mm.
16 Fillet.
Add 0.50 mm radius fillets to
the edges of the keypad buttons,
shown here in red for

4 Clearance hole.
Select the planar face at the bottom of the cut Appearance.
made in step 2. Show the Upper Housing.
Click Hole Wizard (fj on the Features toolbar. Make the Lower Housing
semi-transparent. A
• Hole Type = Hole transparency of 0.75 works
• Standard = ANSI Metric
well.
• Type = Screw Clearances
• Size = M3 Mounting boss.
• Fit = Normal Click Insert, Fastening
• End Condition = Through All Feature, Mounting Boss, or
• Feature Scope = Lower Housing click Mounting Boss (A) on the Fastening Features toolbar.
Add a Concentric relation between the locating Select the face.
point and the edge of the cut feature. Change to a bottom view orientation
Select the inside face of the Upper Housing. One technique is to select
the face through the fastener clearance hole.
Mounting B o s s The next step in the process is to create a mounting boss. The mounting
boss goes on the inside of the Upper Housing and it receives the M3
fastener that goes through the clearance hole we created in step 4.
The mounting boss is shown in red in the illustration below.
® JE«je<t>
Define the direction.

To define the direction of the mounting boss, select the Top reference
plane and click Reverse Direction. This orients the mounting boss
correctly with respect to the pull direction of the mold.
Introducing: Fastening Features streamline creation of common

Fastening Features features for plastic parts. You can create:
Mounting Boss
Snap Hook
Snap Hook Groove
Vent (also useful in sheet metal parts)
Lip/Groove
Where to Find It Click Mounting Boss iSj, Snap Hook HDJ, Snap Hook
Groove H | , Vent if], or Lip/Groove gj on the Fastening Features
toolbar.
Or, click Insert, Fastening Feature, and select either Mounting
Boss, Snap Hook, Snap Hook Groove, Vent, or Lip/Groove.

9 Position the boss. 13 Results.

To position the mounting boss, select the edge of the clearance hole. Click OK.
The mounting boss is added to the inside of the Upper Housing.
10 Define the height.

To define the height of the mounting boss, click Select mating face,
and select the planar face on the inside of the Lower Housing as
shown.
Set the Diameter to 9.00 mm and the Draft Angle to 2.00°. Note The mounting boss is shown in red for illustration purposes.
Reveal The next step in the process is to create

© Select пиша face
an appearance gap or reveal between the
A,—[wutrji upper and lower housings.
Reveals are often used in plastic parts to
prevent an edge-to-edge joint between
two parts. Edge-to-edge joints often
emphasize any differences between the
parts at the parting line. Reveals are also
11 Fin parameters.
To orient the fins, select the Right reference plane. often used to call attention to an edge or separation between surfaces.
Set the other Fins options as follows: We will use the Lip/Groove feature to create the reveal.
• Draft Angle = 2.00° 1 Appearance.

• Height= 9.50 mm Remove the transparency from the
a Width = 1.50 mm Lower Housing.
• Length = 8.00 mm
• Number of fins = 4 The Lip/Groove feature manages
the appearance of the bodies
automatically to make it easier to
12 Pin or hole? Mo«inanqHoie/Wn
select faces and edges.
A mounting boss can have a pin or [Of*.
a hole. ©Hot*
Pin I Parameter*:
In this case we want a hole. ]© Enter dtameter Lip/Groove.

Ю Select tr*tJn»3 edge
Click Insert, Fastening Feature, Lip/Groove, or click Lip/Groove Si
• Select Hole -*i k j 2.20
on the Fastening Features toolbar.
• Select Enter diameter
• Diameter = 2.20 mm
•
•
Depth = 21.00 mm
Draft Angle = 1.00°
4 1 №
240 W o r k i n g with a S o l i d M a s t e r M o d e l 241

Lesson 7
3 Select bodies. 5 Groove edge selection.

Select the Upper Housing for the body to Click in the edge selection list of the
receive the groove. PropertyManager.
Select the Lower Housing for the body to Press G on the keyboard to activate the
Г 1 Lower Hourtic.
receive the lip. magnifying glass. This makes selecting the edge
Ф [ ]Т0РРИЯ8
easier.
Select the Top Plane to define the direction of
the lip and groove. If all the selected faces on which to create the lip Click the inside edge of the Upper Housing.
and groove are planar and have the same normal, the default direction
is normal to the planar faces and you do not need to select a plane.
In this case, the faces are not planar so we need to select the parting
plane of the part.
6 Lip face and edge selection.

Under Lip Selection, click in the face selection list.
4 Groove face selection. The system makes the Lower Housing opaque and makes the Upper
Under Groove Selection, click in the face Housing transparent.
selection list.
Rotate the view by holding down the Shift key and pressing the up
The system makes the Lower Housing Q Tangent propagation arrow twice.
transparent. ©I
Select the face that forms the edge of the Lower Housing.
Rotate the view by holding down the Shift key
Click in the edge selection list of the PropertyManager.
and pressing the up arrow twice. 0 Tangent rjopegabon
Click the inside edge of the Lower Housing.

Select the face that forms the edge of the Upper
Housing.
• S e l e c t this f a c e

Uaster Model Techniques
Lip and groove parameters.

The Link matched values option automatically Introducing: Draft The Draft Analysis tool is useful in determining whether the part has
ties together related values such as the draft Analysis sufficient draft to be removed from the mold based on a set draft angle.
angle. Where to Find It • Click Draft Analysis Ш on the View toolbar.
• Groove width = 1.00 mm • Or, click View, Display, Draft Analysis.
• Spacing between lip and groove = •[г!мгмп J *
0.00 mm 10 Appearance.
• Groove draft angle = 1.00° Hide the Upper Housing.
• Upper gap between lip and groove =
0.00 mm
Lip height - 2.00 mm
QLMiMtchedvaues
•
0 S h o w ргаИеи
• Lip width = 1.00 mm 0 Maintain exttlng wal f км
• Lip draft angle = 1.00° (Linked to Groove
draft angle.)
a Gap between lip and groove = 1.00 mm
11 Draft analysis.
Make sure Maintain existing
Click Draft Analysis [№] on the
wall faces is checked.
View toolbar, or click View,
Click OK. Display, Draft Analysis.
Note The cut faces of the section view For Direction of Pull, select the
have been colored for clarity. Top reference plane.
Message. Set the Draft Angle to 1.00°.
When you click OK, the system issues the following message:
Select the Face classification
Unable to maintain the existing side wall faces. Additional check box.
non-drafted faces have been added to the model. These will
have to be drafted manually or the feature re-modeled using The green faces have positive draft
a different method. with respect to the pull direction.
This means that when creating the lip, the system was not able to The red faces have negative draft.
extend the existing faces on the inside of the Lower Housing. The yellow faces require draft.
N e w , non-drafted f a c e s a d d e d t o the m o d e l Click Cancel.
Draft Because the system added non-drafted faces when creating the lip, we
will add draft to them using the Draft feature.
The Draft features tapers selected faces in the model by a specified
Introducing: Draft
angle with respect to the pull direction of a mold. You can add draft
using a Neutral Plane or a Parting Line.
• Click Draft |Щ) on the Features toolbar.
Edit feature. Where to Find It
• Or, click Insert, Features, Draft.
Edit either the Lip&Groove 1 -Groove or the Lip&Groove 1 -Lip
feature and clear the Maintain existing wall faces option. This
prevents the message from reappearing when the part is rebuilt.
W o r k i n g with a S o l i d M a s t e r M o d e l 245
244 W o r k i n g with a S o l i d M a s t e r M o d e l
r
Lesson 7
12 Parting line draft. 1 Offset plane.

Click Draft [Ц on the Features toolbar. Show the sketch that was inserted as
a library feature for the keypad
For Type of Draft, select Parting
cutout (step 2 on page 232).
Line.
Create a plane that is parallel to the
For the Draft Angle, enter 1.00°.
Front reference plane and that
For Direction of Pull, select the Top passes through the point at the
reference plane. center of the circular keypad.
Click Reverse Direction.
For Parting Lines, right-click the model edge shown and click Select 2 3D sketch.
Tangency. Open a new 3D sketch.
Click OK. Insert two points. Make them
Coincident with the inside edges of
the Lower Housing and also
coincident (On Plane) with the
offset plane.
Exit the sketch.
3 Snap hook selections.

Click Insert, Fastening Feature, Snap Hook, or
click Snap Hook gQon the Fastening Features
toolbar.
Select one of the points in the 3D sketch.
Select the Top reference plane to define the •Reverse * е й о п
vertical direction of the snap hook. •S] 1»ЦНЯапе

0 Reverie Ck>«Ctkn
The clearance hole for the M3 fastener needs draft also. But that Select the Right reference plane to define the ®Btmbo4rh*cH
requires a separate operation because that part of the mold pulls in the direction of the hook. OsekKtirMtlngfece
opposite direction. We will skip adding draft to that face because it isn't
critical to the objectives of this case study. Examine the preview. -11.25mm
Click Reverse direction if the hook is pointed the 1

wrong way.
Snap Hook and Snap hooks and their corresponding grooves are common features in / [i,75«nn.
Groove plastic parts enabling quick assembly without the need for tools or Click Enter body height.
fasteners. •j 0.6Smm
-I 1.50mm
H—<+-
246 W o r k i n g with а S o l i d Master M o d e l 247

Lesson 7
4 Snap hook dab. Snap hook groove.

Enter the Snap Hook Data as follows: You must create a snap hook before you can create
• Depth at top of the hook = 1.25 mm a snap hook groove.
• Hook height = 1 mm Click Insert, Fastening Feature, Snap Hook
a Hook lip height = 0.38 mm Groove, or click Snap Hook Groove ilJ on the
• Body height = 1.75 mm Fastening Features toolbar. «3 ||!~»№»ж]
• Hook overhang = 0.65 mm
• Depth at base of the hook = 1.5 mm Select the Snap Hook 1 feature.
• Total width = 4 mm Select the Upper Housing as the solid body that
• Top draft angle = 2.00° the groove will be applied to.
Note The dimensions of the snap hook groove are
driven by the snap hook. The values in the
PropertyManager are offsets, or clearances, so you
can make the groove slightly larger than the hook.
Enter the dimension values as follows:
• Offset height from Snap Hook 0.125 mm
• Gap Height = 2.50 mm
• Groove Clearance = 0.125 mm
• Gap Distance = 0.125 mm
• Offset width from Snap Hook = 0.125 mm
Click OK.
Second snap hook groove.
Repeat this process for Snap HookS. The results are shown below.
Click OK.
5 Repeat.
Create a second snap hook using the second point in the 3D sketch.
Section v i e w
Note The cut faces of the section view have been colored for clarity.
Saving the Bodies Save Bodies allows you to save individual solid bodies as part files.
and Creating an You can indicate which bodies you want to save. Optionally you can
Assembly generate an assembly from the saved parts.
To review Save Bodies and Create Assembly, see Advanced Part
Modeling, Lesson 1: Multibody Solids.
6 Show solid body.
Show the Upper Housing.

SolidWorks 2009 Training Manual Lesson 7
Lesson 7
S o l i d W o r k s 2009 T r a i n i n g Manual
9 Save bodies. SolidWorks Master model techniques create external references between the parent
Right-click the Solid Bodies folder and select Explorer P a r ta n
d the children. These external references can be broken by
Save Bodies from the shortcut menu. improper file management practices.
Save the three solid bodies as: Rule #1 The most important rule to follow when working with parts that have
• K eypad external references is:
• Upper Housing • Do not use Windows Explorer to rename or copy SolidWorks files.
• Lower Housing Use SolidWorks Explorer.
If prompted for a document template, specify the Using SolidWorks Explorer you can:
Part_MM template.
1. Where Used: This lists all the documents where a specific part or
Create an assembly as follows: •corouwojt bodes
assembly is used.
CMoribcOttari: 2. Rename: This renames one or more selected documents and most
1. In the Create Assembly group box, click
importantly, updates all the references.
Browse. The Save As dialog opens.
3. Pack and Go: Gathers all related files for a model design (parts,
2. Browse to where you want to save the
assemblies, drawings, references, design tables, Photo Works data,
assembly.
COSMOS data, etc.) into a folder or a zip file.
3. Name it Remote_Control_Assembly, and №mote_Ccntrd_Assen»jlr I
click Save. For more information about SolidWorks Explorer refer to either the
Click OK to close the PropertyManager. Advanced Assembly Modeling or the SolidWorks File Management
course manuals.
10 Save and close all the files.
11 Launch SolidWorks Explorer.

Click Tools, SolidWorks Explorer.
Browse to the folder where you saved the child parts and assembly for
the remote control. In this example they were saved in the Case Study
folder for this lesson.
7 ScAdV/oik» SMJCI SolidWarks Explorer ) » - • *

( Ж
Q.RW.J
lame - See DatoModKad Attnbutu Fu| petti
Щ tD La*»n03 •
Keypad*** 11.. So№... 12/гУ2006 A CASoloV/o*. 2007 T raring FIm v^dvani
щ £j LeoonfE Lower Hrutngridprt U. SoidW... 12/672006 5.Ю4БРМ A CVSofrMakt 2007 TiarwtgFin\A&Vant
Ш £3 Le*ton0S Rairx^.Con^SLDPRT 97... SoteW... 12/2/2006 Ш37 44 AM A C:\SofeWorkt 2007 Tiatwig FtefSAdvarx
RatM*_Cor*oL/Uten>^ IE... SofdW... 12/6/2006mD2PM A CAScidWork* 2007 TiamgFlMSAdvani
S C3 Ca*e£iud)> Slr^toiKw>MlStrAFP 11... SoidW.. 7fltW2D051224:10 PM A C:\ScidWakt 2007 TranhpFlmSAdvan.
® O B ui Part* Upper Houw^ddprl 12.. $<**•/... 12Л/2006 3:02:46 PM A CASofcJWoAi 2007 TiamgFin\Advani
й t_> RertnuiDinuoi
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^ Lwm H outing tldprt
ф Rsrrx*e_Ccrtral SLDPflT
0вгтк«_Сгх*о1_А»МР*»у ridewn
|H Sk4^taK^p4>dSLDLFP
^ Upper Housing ttdprt
^ Spaato_5«<fan.Matl«.SL0PRT
CSSolcWocke 2009TtereTC HesVAdvoreod S lelooo McdofcvÛssonOTSCowi Stua/flawto Ccmd
250 SolidWorks Explorer 251

W o r k i n g with a S o l i d Master Model
M a s t e r Model Techniques Master Model Techniques
12 Find where used. 14 Pack and Go.

Using the File Explorer in the left pane, select the master model In the File Explorer tab of the left pane, select the
Remote_Control. Remote_Control_Assembly.
In the right pane, click the Where Used tab. Click SolidWorks Pack and Go ф.
The system finds and lists all of the documents that reference In the Pack and Go window, click Flat View.
Remote_Control.
Notice the system has gathered all the referenced files, including the
master model.
SolidWorks Explorer )
Click Save To Zip File. By default the zip file is saved in the same
RM^rMHlSUIPRT
folder as the assembly.
g«]ljvillli l^tktwrttH lift I *v>»» I Click Save.
Dccumnl * FutpMri
ffi iÛtsonfM ftfeypplsldpl c\MidH^2007lianigllMachm
& O LB aort05 &lpiwtrMM*vjildpj| c\*oidNii«b2l>37b
B rpvjr*M\4c^^
Ж {£3 LaraonQG (uppvHauitigiktot cSirirwwnVt 2007 HeAetoencad «Ласа m«fatiy/fc»ion07\cMe «пеумасаа оиагоЛОрраг
В CD C * " Study
S! O Bui Part* QNootadvaaw OB atviB W
В t^HawefcCortro.
$Ka^*tprt
ÛtwHowtâtyrt vm^fJjorMJeM^.*im J935 и
^ flamto_D>r*oLSLOPRT tavpad.ddprt ' j s r » r a spMvwoiapartfricuBaint !«/:
ojfryjoijlatterJtoaUsm w к aaTOVraitapartponeiwnt
В
Щ SfcatchtaK«^SUXfP д:\мас«>о»»2
Spa*et_Surltc«_M«>**. SLDPR T UppwHpueya»alaprt [K3aj!

^ ,ftaiMlo.gjnJiotJeMeoa^.3g^ |lht»iotoj:on1fdJipp^J«W.3LO^
• LL.
V, C:\SataWati 2003 T i ^ f T n V № » x « d 5 ^ . C T M r ^ v / ^ « » » i 0 7 \ t > » St*>/Barol. C w ^ a r c a a J a M S l T i f f l T
Райг.4 Sato/Replace... |
13 Rename.
OSevetoMder.
When you click the Remote_Gontrol file in the ®5ауе1о2рва: |Sludr\
B en«wCortro№ao«»^^ B towee...
File Explorer tab of the left pane, a small toolbar appears above the file
•A4)p»fc I ] DAoHaifc ! I
name. @гЪМю>еа*Ше| ПЕе»|аг«»ре*авпа
Click SolidWorks Rename :jgi -

In the Rename Document window, rename Remote_Control to
Remote_Control_Ma£ter_Model. 15 Close SolidWorks Explorer.
16 Extract the zip file.

Папатак a\Sc*>Wc*i2vi)9Tiiv«erlMVk«V«c^
Тк |В|т|я> _СЪудс<,М^ш_Мс<|»5шгаТ
в I
To simulate sending the zip file to a different computer, extract it to the
C:\Temp folder.
-Updatewhereuted - - - -- - •- -
17 Tools, Options.
Uasdby • U»ed
Click Tools, Options, System Options, External References.
B*%g\icMMrkt2009b»MiBr)n mode!
Ег$0\*оНислЧ( ?OD9bereigraFAooVen^tun*eceiiioe№o^^ eiodelif Set Load referenced documents to All. This will cause all the
referenced documents to be opened when a part or assembly is opened.
DcmseiKhjno. Sdonunaertonxrid
Caned I
Click OK. The system updates all the file references.
252 SolidWorks Explorer SolidWorks Explorer 253

Lesson 7
Master Model Techniques S o l i d W o r k s 2009 T r a i n i n g M a n u a l
18 Open the copied assembly. Exercise 16: Use a solid model to drive the
Open the Remote_Gontrol_Assembly that you unzipped into the Solid Master parts of an assembly, and then
Temp folder. Notice the following: use file management techniques
Model
to change the names of the
1. The Remote_Control_Master_Model document is also opened.
individual parts while
2. The FeatureManager of the assembly indicates that the external
maintaining associativity.
references of the three child parts are in context.
19 External references.
In the assembly document click File, Find References.
This shows that the assembly was copied and all the references were Procedure Open the existing part named Mouse_Master_Model.
correctly updated.
Examine the part.
This is the continuation of the part
Hb^bnaVanrafwarice* ONettedvtw ©ITatvia*.
created in Exercise 9: Mouse Model
p e r biFvtiar - - - " • - • - - - --- on page 133 with one exception: a
ÔvtwtAfcrt
&U«v — 1
— — construction surface has been added
&\T«np ~~ """" -
uifinp ~ "
to eliminate the need for some
j^lipparHouitîiojrt &\т«*р tedious sketching.
|$ LOW Hoi^.ddprt u\f«np " -— - - -
Show the construction surface.

Expand the Surface Bodies folder
• - - ' * !
and show the Wheel Mount Split
I 1 1 O W L * ) ICopyFtes..., ! Ctee | | Hab j Surface.
Note The color of the surface body has
20 Save and close all the files.
been changed to clearly distinguish it
from the solid geometry.
Plan the Approach The part needs to be split into three pieces, the Top Cover, the Bottom,
and the Wheel Mount. The wheel itself will be added as a separate part
in the assembly.
The split will be completed in two Split features, the first splitting the
top and bottom, the second splitting the wheel mount from the top.
To split the Top Cover from the Bottom, we will use a surface
generated from the parting line.
254
E x e r c i s e 16: S o l i d M a s t e r M o d e l 255
SolidWorks Explorer
3 Copy parting line. Split the Top Cover into two

Open a new sketch on the Right pieces.
reference plane. Using the Wheel Mount Split
Surface, split the upper body into
Expand the Surface-Loft 1 two pieces.
feature and the PL Curve.
Do not split the Bottom.
Select the PL Side Profile sketch
and click Convert Entities. Tip It is easier to identify the bodies you
want to keep by selecting them in the
Drag the endpoints of the graphics than to click the check boxes in the Resulting Bodies panel
converted entities so they extend beyond the body of the part. of the PropertyManager.
4 Parting line surface.
Click OK.
Extrude a surface.
Hide.
Use Mid Plane as the end condition and drag the Depth such that it
extends beyond the body of the part. Hide the Wheel Mount Split Surface.
Save bodies.
Verify that there are three solid bodies in the Solid
Bodies folder.
Right-click the Solid Bodies folder and select
Save Bodies from the shortcut menu.
Save the three solid bodies as:
• Bottom
• WheeLMount
• Top_Cover
If prompted for a document template, specify the • c o r a m аЛЬхви
Part_MM template. OttntocotkNY
Note You do not have to use a surface to split a part. You can just use the
sketch. However most inexperienced users find it easier to visualize the Create an assembly:
split using a surface. 1. In the Create Assembly group box, click
5 Browse.
Split the Top Cover from the Bottom. I ôuso_AMent*,.ddasni
2. Browse to where you want to save the

Because the Wheel Mount Split Surface splits the Top Cover only,
assembly.
and not the Bottom, create the top-bottom split first.
3. Name the assembly Mouse_Assembly and
Click Insert, Features, Split. click Save.
Select the parting surface and click Cut Part. Click OK to close the PropertyManager.
Check the boxes next to both bodies in the Resulting Bodies panel.
Do not enter a name for cither body. This would save the bodies out as
separate files rather than just leaving them as bodies in the master part.
Make sure Consume cut bodies is cleared.
Click OK.
6 Hide.
Hide the parting line surface you created in step 4.
256 257
E x e r c i s e 16: S o l i d M a s t e r M o d e l E x e r c i s e 16: S o l i d M a s t e r M o d e l
10 Examine the files. 11 Modify each individual part.

There are now five documents open: Open each part individually and add a Shell feature using a Thickness
of 1.25 mm. Use the illustration below as a guide to which faces to
• Mouse_Master_Model remove.
• Mouse_Assembly
• Bottom Change the color of each part to aid identification.
• Wheel_Mount The assembly is shown in section view here for illustration purposes.
• Top_Cover
Minimize the Mouse_Master_Model window and then tile the
remaining four windows.
'Uomitrk •lieirnrtVIe
I *! , e m
* W c
: *ll«m«trlc
258 E x e r c i s e 16: S o l i d M a s t e r M o d e l 259

E x e r c i s e 16: S o l i d M a s t e r M o d e l
12 Make a change to the master model. 13 Rebuild.

Switch to the Mouse_Master_Model part. Exit the sketch and rebuild the part.
Change to a Right view. 14 Assembly.
Switch back to the MouseÂssembly that you created from the split
Hold down the Shift key and press the down arrow once.
parts.
In the loft feature named Surface-Loftl, there is a projected curve Rebuild the assembly. A l l the parts update.
named PL Curve, which has a sketch under it named PL Top Profile.
15 Save and close all the parts and assembly.
Edit the PL Top Profile sketch.
Tip Right-click the spline and select Display Control Polygon from the 16 Launch SolidWorks Explorer.
shortcut menu. Operations such as SolidWorks Rename <•<•) cannot be performed on
Note
Holding down the Ctrl key, select the three spline points as shown and files that are open.
drag them all downward about 6 mm. Use SolidWorks Rename (&) to rename Mouse_Master_Model to
You may also want to lengthen the tangent spline handle slightly to Mouse_Master_Model_Modlfied.
keep the shape of the mouse from getting too pointed at the end. Use SolidWorks Pack and Go ф to collect the master model, the
child parts, and the assembly into a zip file.
17 Close SolidWorks Explorer.
260 E x e r c i s e 16: S o l i d M a s t e r M o d e l 261

E x e r c i s e 16: S o l i d M a s t e r M o d e l

SolidWorks Advanced Surfaces

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SolidWorks Student Survey

In conjunction with your local reseller, we at SolidWorks Corporation

In the box labeled Training Manual Serial Number, please enter

We appreciate your assistance in helping us to improve the overall

© 1995-2008, Dassault Systemes COMMERCIAL COMPUTER

names of DS SolidWorks. Pending.

Introducing: Offset Surface 70

Repairing and Editing Imported Geometry

Why Do Imports Fail? 81

Stages in the Process 83

Repairing and Editing Imported Geometry 84

Introducing: Import Diagnostics 85

Options for Deleting Faces 86

Introducing: Filled Surface 87

Editing Imported Parts 88

Introducing: Delete Hole 90

Exercise 6: Import Diagnosis 91

Exercise 7: Using Import Surface and Replace Face 95

Introducing: Ruled Surface Ill

Lofting Surfaces 113

Modeling the Lower Half 117

Introducing: Partial Ellipse 119

Preparation for Using Filled Surface 120

Consistency Notification 121

Deviation Analysis 121

Introducing: Instant3D 127

Introducing: Draft Analysis 245

About This Course 3

Bold Sans Serif SolidWorks commands and options appear in

4 Windows® XP Use of Color 5

Face Plane or surface

Consider the two solids pictured below:

Both are composed of 6 faces, 12 edges, and 8 vertices. Topologically,

8 Solids and Surfaces 9

10 Solids and Surfaces Solids and Surfaces 11

Trim the surfaces.

Solids and Surfaces 13

Managing visibility of surface bodies ^ [ r f f l g i y i «йДЕДе®

10 Compare the two parts.

Where to Find It • Click on Delete Face g) on the Surfaces toolbar.

11 Delete all but one end of the cylinder. r

the Surface Bodies folder. * D"***** 1

Tip Place the 3D sketches in a folder for easier management.

Why Use Surfaces? 21

The concept of continuity can be explained using a series of spirals. In

28 W o r k f l o w with S u r f a c e s Exercise 1: Trimming Surfaces

9 Thicken into a solid.

6 Create another axis.

8 Trim the surfaces.

Exercise 1: Trimming Surfaces

Exercise 2: Starting with a surface model,

Using Trim Surface, Planar

Basic Surfacing The primary рифове of this

34 Similarities Between Solid a n d S u r f a c e Modeling 35

3 Second sketch. 6 Offset plane.

14 New sketch. 18 Second mutual trim.

The system thickens a surface by

26 Cut with surface.

Exercise 3: Use surface commands to create a

44 Exercise 3: Basic Surface Modeling 45

3 Trim the surface.

The active sketch is automatically ©Ottra

selected as the Trim tool. OuptopoM

Click OK. 6 Trim surface.