Challter 20

\Veldments

Objccth'es: In this chapter you wilileam:

• About Weldment 100ls • How to define the basic weldment framework using J DSkctch

• How to insert a Structu r,tI Member

• How to insert a Fillel Bead feature • How to insert a TrimlE%lend fea ture • How to insert an End Cap feature

• How 10 insert a Gusset feature • How to apply Wcldmen t 10 part design

rNTROD UCTJON

Weldments playa significant role in joining structural members. and hence are of vital importance in the civil engineering diseipline. Also. weldments consti tute one of the several aspects of the manufacturing process which requires specific allention. We will now consider weldments. Weldments functionality enables you to design a weldment structure as a single multibody part. The basic approach is to use 20 and 3D sketches to define the basic framework. Then create structural members containing groups of sketch segments. Features that can added include gussets. end caps. etc., using tools on the Wcldmcnts tool bar. This chapter also considers creating weldments from a part design.

CREATING PARTS WITH A J·D SK.:T CH

Since the paths of weJd mcl'llS are mainly in 3~ . a good grasp of the 30 Sketch tool is a prerequisite for creating weldments. From the main menu. select the 31)Sketch 1001 (see Figure 20-1) by clicking on the Sketch tab of the CooulIIllldManager. Select the Line Tool . NOlI' Ihal beside the cursor. Ihe plane that the line will be displayed .

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Figure 20· 1 3DSketch tool

20·1

,\ Comprehensh-e Introd uctIon to Solid Works 2013

Tutoria l t

Model a bent tube wi th 0.5 inch outer diameter and 0.375 inner diameter to jOin the ends

of twO tubes as shown in Figure 20-2 . Follow the route shown by the center lines 111

Figure 20-2 and add I inch radius fillets to the corners.

',",

Figure 20-2 Speci fi ed ro lJle

Solution 1. Select the 30 Skctch 10 01 by clicking on the Sketch ta b of the

Comma ndManager . 2. Select the Line Tool. Note that beside the cursor. the plane that the line will be

displayed. 3. Press the tab key until when the plane selected is YZ

4. Sketch a line 12 in long from the origin along Y

5. Sketch a line 8 in long along Z 6. Press the tab key until when the plane selected is ZX 7. Sketch a line 10 in long along X 8. 3DSketch I is complele (see Figure 20-3). 9. Ell it 3DSketch

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Figure 20-3 3DSketch of route

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Wt'ldlllt'nlS

10. Click the top "ertex of the verticallinc which is 12 in long 11. Click Features> Refere nce Geometry 12. Select top vertex and vertical line connected to it. fo r Selections

13. Select No rmal to Curve to complete defining I'lane I 14. Select Plane! 15 . Right-click and select Sketch tool to sketch the two circles with 0.5 inch outer

diameter and 0.375 inner diameter. as Sketch I: dimension them (see Figure 20·4). 16. Exit Sketch

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•

(oj -----J!... (b) ____ --J

Figure 20-4 Normal plane and sketches for two circles

17. Click Featu res> Sweep 18. Select Sketch I as the Profil e and 3DSketchi as the Path (sec Figure 20-5) 19. Click OK

. . ~

- . -- . --~ . ~n_ .... _ ~

(a) Preview (b) Pan Figure 20-5 Part for Exercise I

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A Comprencnsh'c l nlroduClion 10 SolidWorks 2013

Tutorial 2

Model a bent tube with 0.5 inch outer diameter and 0.375 inner diameter to join the ends

of two tubes as shown in Figure 20-6. f-ollow the route shown by the center lines in Figure 20·6 and add I inch radius fi llets to the corners.

I,,,,

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Figure 20·6 Path for a bent tube model

Solution 1. Select the 31>Sketch 1001 by clicking on the Sketch lab of the

Command Manager. 2, Select the Line Tool. NOIe that beside the cursor, the plane that the line will be

displayed. 3. Press the tab key unt il when the plane selected is YZ 4. Skelch a line 3 in long from the origin along Y 5. Press the lab key unt il when the plane selected is ZX 6, Skl:\(.: h a line 3 in long along X 7. Join vertical and hori1.(}n lal lines 8. 3IJSkeich I is complete (see Figure 20-6). 9. Exit 31>Skelch 10. Click the left vertex of the horizonlalline which is 3 in long I I. Click "-e~\tures > Reference Geometry 12. Select lop ,"ertcx and vertical line connected 10 it. for Seleclions 13. Select Normal to Cun'c to complete defining Plane 1 14. Select Plane I 15 . Right-click and sclt'Cl Sketch tool to sketch the two circles with 0.5 inch outer

diameler nnd 0.375 inner diameter. as Skelch 1; dimension them (see Figure 20-7).

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Wt/dments

16. Exit Sketch

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• •

(0) (b)

'co "'41 T~ -"---(e) (d)

Figure 20-7 Part for Exercise I

Tutorial 3

Model handlebarS tube with 25.4 mm outer di3mcter 3nd 23.4 mm inner di3meter to join the ends of two tubes as shown in Figure 20-8. Follow the: route shown by the center lines in Figure 20-8 and add fillets to the comers as specified .

•

r Figure 20-8 Specified route

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A Comp~hI'nslve Introduction to SolidWorks 20U

Solutio n 1. Selt."Ct the 3 DSketch tool by cl icking on Ihe Sketch tab of Ihe

Command Manager .

2. Select the Line Tool. Note Ihat beside the cursor, the plane that the line will be

di spl3ycd.

3. Press the tab key unl il when the plane selected is YZ

4. Sketch 3 line 160 mm long from Ihe o rigin along Z 5. Sketch a line 120 mm klllg from the origin along Y 6. Sketch a line 80 mm long from the origin aiong -Z 7. Press the lab key until when the plane selected is ZX

8. Sketch a line 200 mm long along-X

9. Add Fillets to the comers as spc:cified

10. J DSkelch I is complete (see Figure 20-9). I I . Exit J DSketch

•

Figure 20-9 3DSke\ch of roUle

12. Click Ihe end of the 160 mill long line

13. Click Features > Rererenee Geometry

14. Select lop \'erle." and vertical line connected 10 ii, for Selections

IS. Select Normal to Cune to complete defining Pla ne I 16. Select Pla nel

17. Right-cl ick and select Sketch tool to sketch the IWO circks with 25.4 mm outer

diameter and 23.4 mm inner diameter. as Sketch I; dimension them (see Figure

20- 10)

18. Exit Sketch

20-6

•

Figure 20-10 Nonnal plane and sketches for two circles

Figure: 20-11 shows the preview while Figure 20- /2 shows the linal mcxlel.

•

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--Figure 20-11 Preview of mcxlel

Figure 20- 12 Model of handlebars

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Weldmcnu

Now that we have a good grasp of 3DSketch tool which is a prerequisite for creating weldments. it becomes logical to now present weldmenl tool bar.

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A Comprebensino lnlroduction to SolldWorks 2013

WELDM ENTS TOOLBAR Thc Weldments toolbar provides 10015 for c re3ting weldment p3rls. The main lools 3re:

I~I Weldml'nt

IIiII Structural Membtr

101 Gusset

lral ":nd Cap

I ~I Fillet Read

l'fpl Trim/Extend

STR UCT URAL M EMBER

The first step is to define the paths for which di fferent profiles will be created. The p3ths

are created using 3DSkctch.

~ .

I. Click the MY·TEI\WLATE lab.

2. Double-click ANSI·MM ·PART. 3, Click Top 1)lanc.

4 . Using J DSkelch mod~. sk~tch and dim~nsion the (Op path (3 rectangle. 20 in by

12 in). Th is is in the X-V plane (sec Figure 20- 13).

5. Exi t 30Skclch mode. This is necess3ry to c re::lIc a Group of st ructural members .

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• Figure 20- 13 Top path (a rec tangle. 20 in by 12 in) in the X-V planc

6. Click Top Plane.

7. Click 3DSkeich in CommandFeaturc

20~

"

Wt'ldmellts

8. Pick one of the vertices of the Top rectangular feature and Sketch a line (switch to

YZ plane by pressing Tab key) 9. Sketch the other legs and use relations to make all four legs parallel and equal

10. Dimension one of them to be 10 in II. Add a relation that one of the legs and the tOP members are perpendicular (90")

(see Figu res 14- 14 and 14-15). The complete sketch is shown in Figure 20- 15.

/ ~ Figure 20-14 3DSketch in Cornm:lndFeature necessary for creating weldments

Figure 20-15 Add relations between all legs and top path

12. EII ]t 3DSketch 13. Click Structural ~·l ell1 ber toolbar.

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A Comprehenslre Introduction to Solid Works 21)1 3

14. In the Selection rollout. specify the profile of the structural1l1ember by selecting (see Figure 20- 16);

15. Standard . Select ansi inch. J 6. Type. Select a Profile Type. square tube. 17. Size. Select a Profile, such as 2 x 2 x 0.25. 18. Select all 4 members of the Top elements as Group! 19. Clkk New Group button and select 31 ! 4 legs as Group2 20. C lick OK

2 1. In the Settings rollout. 22. Select Apply corner treatment and click End Meter

..... __ ...

...... -. ""~ ..... ..... "" .... ---- . . -

Figure 20- 16 Structural Member tool

Expanding the ellt list shows that there are 8 multl·bodics; these also are included in the Structural Memberl if it is expanded as shown in Figure 20-1 i.

20·10

, ra (il s..-. 'fp mlll -"""", Iii e~ Oi""(9)

t:! 5'".<1 ..... _ 1(1 ) !ill t:! 5t".<t ..... _l[~) t::l t:! Sbco:' .... _ 1(3)

~ t:! Sbc<t ..... _ l[.)

IiiJ t:! Sbc<t ..... _l(5) - IF'I Sb co:' .... _ 1(6) "' ~ t:! SbCO:l ..... _ ,(7)

tJ t:! Sbc<t ..... _l(8)

<t . J=M.>l«"- <n<t sprii<d>

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Figure 20- [7 Cut list fo r 8 multi-bodies struetura[ members

TRIMMING THE STRUCTURAL MEMBERS

Wcldmcnts

There arc cases in which structural members have to be trimmed. For example. if instead of defining Group I and Group2 at the same time of defining structural members, they are defined as two different structural members then the need for trimming may arise. This scenario is shown in Figure 20- [8. Notice, there are Structural Memberl and Structural Member2 . However, trimming is now needed because some so lid bodies are

entering into other solid bodies, which is not allowed in practice.

• " • o , " • • ." "

Figure 20- [8 Structural Member requiring trimming operation

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A Comprchcnsi\"C Introduction to SolidWorks 2013

23. To trim, 24. Click TrimlExtend 25 . Accept Corner Type as End Trim (see Figure 20-19) 26. Select one of the vertical legs as the Bodies to be Trimmed 27. Select the Bodies radio button for Trimming Boundary 28. Click the bounding surfaces

..... ,...., ,

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Figure 20-19 Tri m/Extend option

Repeat the process for all other legs.

ADDING END CA PS TO STRUCTURAL.. MEMBERS

Let us add end caps to close the open end s of the segments of the structural members of interest. In thi s example, the bottom ends of the four legs need to be capped so they should be selected one at a time (see Fi gure 20-20).

29. Click the End Cap option of the Weldments toolbar 30. Click the face (strip) that defines the cross section of the leg structure as the

I'ammeter 31 . Selcct Thickness direction to I nward to make thc end cap nush with the original

ex tent of the structure. 32. Set the thickness to 0.25 in 33. Select Usc thickness ratio 34. Set Thickness Ratio to 0.65 (Try other values and observe the preview). The

capped legs are shown in Figure 20-21 .

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Wcldmcnts

Figure 20-20 End cap option

Figure 20-21 Structural Members with end caps

ADDING GUSSETS TO STRUCTURAL MEMBERS

Gussets features which may be triangular or polygonal profiles can be added 10 two adjoining planar faces. Let us add gussets to the corners of the four legs.

35. Cl ick Gus~t option of the Weldmcnts too lbar 36. Click the two faces (Face<l> and Face<2» as shown for the Supporting Faces

(see Figure 20-22) 37. Under Profile, Click Triangular Profile 38. Set Profile Distancel and Profile Distance2 to I in each 39. Se lect Thickness to inner Side 40. Set Gusset thickness to 0.25 in 41 . Select Profile Locates at Mid I'oinl for Location

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A Comprchcnsi\"C Introduction to SolidWorks 2013

Repeat steps 35--4 1 fo r each leg

. ....... , . _'.... AI '" ._ . " I

20[

-- 8 -

Figure 20-22 Gusset option

ADDING FILLET BEADS TO STRUCT URAL MEMBERS

Fillet beads fea tures can be added to two adjoining planar faces. Let us add fillet beads to the corners of the four legs.

42 . Click Fillel Bead option of the Weldments toolbar 43 . Click Gusset face 44. Click the two faces (Face<1> and Face<2» as shown for the Supporting Faces

(see Figure 20-23)

Repeal for each leg

Figure 20-23 Fillet bead option

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Wcldmcnts

WELDMENT OF PARTS

In this subsection, it is demonstrated that weldment can be applied to part design. We will first create a part which is made up of an inverted channel shape as the base and two vertical brackets. Fi gure 20-24 shows Sketchl for the base, whi le Figure 20-25 shows the

extruded base of Sketch I.

120

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8 Figure 20-24 Sketch I for the base

Figure 20-25 Extruded base of Sketch I

A rectangul ar sketch, Sketch2, 70 mm by 10 mm which is offset 15 mm from the horizontal top edges is used to create a slot as shown in Figure 20-26 and Figure 20-27.

20-15

A Comprrhenslve Int roduction to SolidWorks 2013

r- ,

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Figure 20~26 Sketch2 fo r slot through the base

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•

Figure 20-27 Extrude-cut for the sial

EXirude-cut is mirrored about the centre of the base to create two slots.

Assembly versus Solid Bodies

When an Assembly of parts is created_ the weldmenl tool does not work. Howe\ler. when Solid Booies are created_ Weldmenl tool funct ions appropriately. The point made here is important: use sol id bodies for weldmenl of parts. The principle is now illustrated.

The edges of the Extrude-cut feat ures are extmcted using Con\'ert Entilies tool and used to create side features by extrusion. The l\'lcrgc Resul ts options are unchecked during ex trude opemtion in order to create solid bodies.

20-16

Weldmenls

I. Click the bottom face of the horizontal upper por1ion of [he base created.

2. Be in sketch mode and select the jOll r edges of IIII' rigll' slol (Exlrude -elll fcatll re)

already created.

3. Click the Conl'e rt E ntities tool 10 create a rectangular p rol1le

4. Clic k the Extrude HosslHase tool ; ensure that Ihe Merge Resul ts options are

unchecked

Figure 20-28 Base and side features as three solid bodies

Fillet beads are now created for the 11'.'0 lIertical feature s.

5. Click We:ldmenl tool to enable the weldment enllironment

6. Click Fillet Bead /ooJ and select one face of the lef! side (ta tun as well as the

top of the base

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-- •

Figure 20-29 First fillet bead is crealed for Ihe top-left IIcr1ical feature

7. Click Fillet Bead tool and select one face of the: left side feature as well as the

top of the base

20-17

A Comprehensh"e Int roduction 10 SolidWorks 201 3

-­.t: .-,- - ,# ,

-- •

Figure 20-30 Second fillet bead is cre:lted for the top-left vertical feature

8. Click HUrt Read [001 and select one face of the left side feature as well as the top of the ba~

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-- • ----.: -,_ .. , , I"

•

Figure 20-3 1 Third fillet bead is created for the to":;;;",'~"'~ical';;;:;;;,e 9. Click Fillet Read tool and select one face of the left side feature as well as the

lOp of the base

20-18

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-- •

Figure 20-32 r"l)urlh (jllel bead is created fo r the top-left vert ical feature

WeJdmenls

10. Click Fillet Head \001 and select one facE' of the right sidE' feature as well as the tOp of the base

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Figure 20-33 Fi13t fille t bead is created for thc top-right ;;;;:;:~l feature

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A Comprehensh·c Jnlroduction to SolidWorks 20lJ

I 1. Click Fillet Bead 1.001 and st:lect one face of the right side feature as well as the top of the base

...... ' , ... - '

-- • ----

•

Figure 20-34 Second fillet bead is created for the top-right venical feature

12. Click Fillet Bead tool and select one faC"e of the right side reature as well as the

top of the base

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, ... - '

•

-- •

Figure 20-35 Third fillet bead is created for the top-right vertical feature

2G-20

Wl'ldm(' nl~

13 . Click Fillet Dead 1001 and select one fare of the right side feature as well as the

tOP of thc base

---­" .-

--

•

•

Figure 20-36 Fourth fill et bead is created for the ; ::;;-;;;;, venical feature

The completed weldmen t model is shown in Figure 20-37. It is important to nOle that there are I J members in the ..... e ldrnent CUt l i ~t (see Figure 20-38): Ilrree from the part model andJoli reach from the fillet beads around the IWO venical features 13 + 4 + 4 =111.

Figure 20-37 Completed weldment of base and two side fe3tures

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A Comprehensi\'C Introduction 10 SolidWorks 201 J

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lIiI. FikI BucfI _.-Figure 20-38

Summary

In this chapter. we have described methods for creating weldments from defined paths using the 3D Sketch tool. and also creating weldments from part designs. These are two approaches. The first approach is considered the choice for modeling trusses. The second approach is the choice when we are modeling solid parts and intend welding some of the pans together. Weldments arc extremely useful in modeling trusses and beams for stress analysis using the finite element method. FEM.

20-22

Weldments

Exercises

I. Create the truss structure shown in Figure P- 1. The material is steel pipe. NPS 1 ~

Schedule 40.

''''00

" Figure P-I

2. Create the truss structure shown in Figure P-2. The material is Steel pipe. NPS l ~

Schedule 40 .

• • Figure P-2

3. Creale the truss structure shown in Figure p o}. The material is steel pipe. NPS I ~

Schedule 40.

• 15

Figure P-3

20·23

"

"

"

A Comprehensin Inl roduellon to Solid Works 2013

4, Create the truss structure shown in Figll rc P-4. The material is steel pipe. NPS l ,\'j

SchOOlile 40.

, •

Figure P-4

"

" 5. Create the truss structure shown in Figure P-5. The material is steel pipe, NPS I){ ,

Scht:duk 40.

•

" •

Figure P-5

20-24

Wl'ldmenls

6. Create the truss structure shown in Figure P-6. The material is steel pipe. NPSI ~

Schedule 40.

I

, , , Figure P-6

"

" 7. Create the truss structure shown in Figure P-7. The material is steel pipe. N PSI ~ .

Schedule 40.

,

--

Figure P-7 " S. Create the truss structure shown in Figure P-8. The material is steel pipe. NPS 1 Yt .

Schedule 40.

o

o -o

Figure P-S

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A Comprrh(' l15in Inrroduction 10 SolidWorks 2013

" 9. Create the truss structure shown in Figure 1'-9. The material is steel pipe. NPS I X .

Schcdule 40.

Figure P-9

10. Creme ~ plaTe, 120 mm by 100 mm by JO mm thick. placed on top the two venicaJ

brackets shown in Figure 9-1 0. Create fillet beads \0 hold the plate to the top faces of the vert ical brackets. Refer to the section on weldment of pans.

Figure P- JO Assembly of base and side features

20-26