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Introduction to
Solid Modeling
Using SOLIDWORKS® 2020
William E. Howard
East Carolina University

Joseph C. Musto
Milwaukee School of Engineering
PREFACE
As design engineers and engineering professors, the authors have witnessed incredible
changes in the way that products are designed and manufactured. One of the biggest
changes over the past 30 years has been the development and widespread usage of
solid modeling software. When we first saw solid modeling, it was used only by large
companies. The cost of the software and the powerful computer workstations required
to run it, along with the complexity of using the software, limited its use. As the cost
of computing hardware dropped, solid modeling software was developed for personal
computers. In 1995, the SOLIDWORKS® Corporation released the initial version of
SOLIDWORKS® software, the first solid modeling program written for the Microsoft
Windows operating system. Since then, the use of solid modeling has become an
indispensable tool for almost any company, large or small, that designs a product.

While 2-D drawings can be an effective tool to document and communicate design
details, a solid model’s usefulness extends throughout the design process. The solid
model data can be saved in a format from which a physical model can be made with
a 3-D printer. Structural, thermal, dynamic, and fluid flow analysis can be performed
with finite element analysis (FEA) and other simulation software. The images on the
cover of this book show the solid model of a mechanical device known as a Geneva
mechanism. The Geneva mechanism is used to convert a continuously rotating input
motion from a motor into a “stop/start” indexed rotation. By creating the solid model
of the mechanism, and using add-on software for motion simulation, a digital prototype
of the working mechanism can be created, operated, analyzed and optimized before it
is constructed.

SOLIDWORKS is a registered trademark of Dassault Systémes SolidWorks Corporation.

ix
x   Preface

Motivation for This Text

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

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

Philosophy of This Text

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

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

• The exploitation of the parametric features of a solid model, to not only provide
an accurate graphical representation of a part but also to effectively capture an
engineer’s design intent,
• The use of solid models as an analysis tool, useful for determining properties of
components as well as for virtual prototyping of mechanisms and systems,
• The integration of solid modeling with component manufacturing, including
the generation of molds, sheet metal patterns, and rapid prototyping files from
component models.
Through the introduction of these topics, students will be shown not only the
powerful modeling features of the SOLIDWORKS program, but also the role of the
software as a full-fledged integrated engineering design tool.
 Preface   xi

The Use of This Text

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

While these tutorials offer a level of detail appropriate for new professional users,
this text was developed to be used as part of an introductory engineering course,
taught around the use of solid modeling as an integrated engineering design and
analysis tool. Since the intended audience is undergraduate students new to the field
of engineering, the text contains features that help to integrate the concepts learned
in solid modeling into the overall study of engineering. These features include:
• Video Examples: Short video tutorials accompany multiple chapters.
These videos introduce students to the concepts of solid modeling and the
SOLIDWORKS commands that they will use in the chapter following the step-
by-step tutorials. These videos cover:
— Getting started with modeling (Chapter 1);
— Making 2-D drawings (Chapter 2);
— Using symmetry when creating parts (Chapter 3);
— Creating parts with lofts and sweeps (Chapter 4);
— Making assemblies from part files (Chapter 6);
— Making parts with 3-D printing (Chapter 13);
— Setting up the SOLIDWORKS interface (Appendix A).
• Design Intent Boxes: These are intended to augment the “keystroke-level”
tutorials to include the rationale behind the sequence of operations chosen to
create a model.
• Future Study Boxes: These link the material contained in the chapters to
topics that will be seen later in the academic and professional careers of new
engineering students. They are intended to motivate interest in advanced study
in engineering, and to place the material seen in the tutorials within the context
of the profession.
While these features are intended to provide additional motivation and context for
beginning engineering students, they are self-contained, and may be omitted by
professionals who wish to use this text purely for the software tutorials.

New in This Edition

This new edition of the text has been fully updated for the SOLIDWORKS 2020
software package. All tutorials and figures have been modified for the new version
of the software. Additionally, all videos have been updated to reflect the latest
software.
xii   Preface

The Organization of This Text

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

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

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

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

Chapter 4 Chapter 5
Chapter 11
Advanced Parametric
Analysis of
Part Modeling
Mechanisms
Modeling Techniques

Chapter 1 Chapter 3 Chapter 12

Basic Part Additional Design of
Modeling Part Modeling Molds and
Techniques Techniques Sheet
Metal Parts
Chapter 6 Chapter 7
Creation of Advanced
Assembly Assembly
Chapter 2 Models Operations Chapter 8
Engineering Assembly
Drawings Drawings

Chapter 9 Chapter 10
Generation Solution of
of 2-D Vector
Layouts Problems
 Preface   xiii

Resources for Instructors

Additional resources are available on the web at www.mhhe.com/howard/2020.
Included on the website are tutorials for three popular SOLIDWORKS Add-Ins:
SOLIDWORKS Simulation®, SOLIDWORKS Motion™, and PhotoView 360™,
the video examples, and the book figures in PowerPoint format. Instructors can also
access PowerPoint files for each chapter and model files for all tutorials and end-
of-chapter problems as well as a teaching guide (password-protected; contact your
McGraw-Hill representative for access).

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

At SOLIDWORKS Corporation, Marie Planchard has provided continuous support

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

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

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

Ed Howard
Joe Musto
PART ONE
Learning SOLIDWORKS®
CHAPTER
Basic Part
1
Modeling Techniques
Introduction
Solid modeling has become an essential tool for most companies
that design mechanical structures and machines. As recently as the Chapter Objectives
1990s, this would have been hard to imagine. While 3-D modeling
software existed, it was very expensive and required high-end In this chapter, you will:
computer workstations to run. An investment of $50,000 or more ■■ be introduced to the
was required for every workstation with software, not including role of solid modeling
training of the operator. As a result, only a few industries used solid in engineering design,
modeling, and the trained operators tended to work exclusively
with the software. The dramatic performance improvements ■■ learn how to create
and price drops of computer hardware, along with increased 2-D sketches and
competition among software vendors, have significantly lowered create 3-D extruded
the cost barrier for companies to enter the solid modeling age. The and revolved geometry
software has also become much easier to use, so that engineers from these sketches,
who have many other job functions can use solid modeling when
required without needing to become software specialists. The ■■ use dimensions and
SOLIDWORKS® program was among the first solid modeling relations to define
programs to be written exclusively for the Microsoft Windows the geometry of 2-D
environment. Since its initial release in 1995, it has been adopted sketches,
by thousands of companies worldwide. This text is laid out as ■■ add fillets, chamfers,
a series of tutorials that cover most of the basic features of the and circular patterns of
SOLIDWORKS program. Although these tutorials will be of use to features to part models,
anyone desiring to learn the software, they are written primarily for
freshmen engineering students. Accordingly, topics in engineering ■■ learn how to modify
design are introduced along the way. “Future Study” boxes give a part models, and
preview of coursework that engineering students will encounter
later, and relate that coursework to the solid modeling tutorials. In ■■ define the material
this first chapter, we will learn how to make two simple parts with and find the mass
SOLIDWORKS software. properties of part
models.

SOLIDWORKS is a registered trademark of Dassault Systémes SolidWorks Corporation.

3
4   Part One  Learning SOLIDWORKS

1.1 Engineering Design and Solid Modeling

The term design is used to describe many endeavors. A clothing designer

creates new styles of apparel. An industrial designer creates the overall look and
function of consumer products. Many design functions concentrate mainly on
aesthetic considerations—how the product looks, and how it will be accepted in
the marketplace. The term engineering design is applied to a process in which
fundamentals of math and science are applied to the creation or modification of a
product to meet a set of objectives.

Engineering design is only one part of the creation of a new product. Consider a
company making consumer products, for example bicycles. A marketing department
determines the likely customer acceptance of a new bike model and outlines the
requirements for the new design. Industrial designers work on the preliminary
design of the bike to produce a design that combines functionality and styling that
customers will like. Manufacturing engineers must consider how the components
of the product are made and assembled. A purchasing department will determine
if some components will be more economical to buy than to make. Stress analysts
will predict whether the bike will survive the forces and environment that it will
experience in service. A model shop may need to build a physical prototype for
marketing use or to test functionality.

During the years immediately following World War II, most American companies
performed the tasks described above more or less sequentially. That is, the design
engineer did not get involved in the process until the specifications were completed,
the manufacturing engineers started once the design was finalized, and so on.
From the 1970s through the 1990s, the concept of concurrent engineering became
widespread. Concurrent engineering refers to the process in which engineering
tasks are performed simultaneously rather than sequentially. The primary benefits
of concurrent engineering are shorter product development times and lower
development costs. The challenges of implementing concurrent engineering are
mostly in communications—engineering groups must be continuously informed of
the actions of the other groups.

Solid modeling is an important tool in concurrent engineering in that the various

engineering groups work from a common database: the solid model. In a 2-D CAD
(Computer-Aided Design) environment, the design engineer produced sketches of
the component, and a draftsman produced 2-D design drawings. These drawings were
forwarded to the other engineering organizations, where much of the information
was then duplicated. For example, a toolmaker created a tool design from scratch,
using the drawings as the basis. A stress analyst created a finite element model,
again starting from scratch. A model builder created a physical prototype by hand
from the drawing parameters. With a solid model, the tool, finite element model, and
rapid prototype model are all created directly from the solid model file. In addition
to the time savings of avoiding the steps of recreating the design for the various
functions, many errors are avoided by having everyone working from a common
database. Although 2-D drawings are usually still required, since they are the best
way to document dimensions and tolerances, they are linked directly to the solid
model and are easy to update as the solid model is changed.
 Chapter 1  Basic Part Modeling Techniques   5

A mechanical engineering system (assembly) may be composed of thousands of

components (parts). The detailed design of each component is important to the
operation of the system. In this chapter, we will step through the creation of simple
components. In future chapters, we will learn how to make 2-D drawings from a
part file, and how to put components together in an assembly file.

1.2 Part Modeling Tutorial: Flange

This tutorial will lead you through the creation of a simple solid part. The part, a
flange, is shown in Figure 1.1 and is described by the 2-D drawing in Figure 1.2.

FIGURE 1.1 FIGURE 1.2

Begin by double-clicking the SOLIDWORKS icon on your desktop. The Welcome

dialog box opens, as shown in Figure 1.3. From this box, we can begin a new
document (part, assembly, or drawing) or select a recently-opened document. Click
Part from the New group. If the Units and Dimension Standard box appears, as
shown in Figure 1.4, select “IPS” as the units and “ANSI” as the standard. Click OK.

FIGURE 1.3 FIGURE 1.4

6   Part One  Learning SOLIDWORKS

VIDEO EXAMPLE 1
In this chapter, we begin by making and dimensioning 2-D sketches and then creating 3-D
features from extrusions of the sketches.
Creation of the simple part shown here, with the dimensions as shown in the drawing to
the right, is demonstrated in a video at www.mhhe.com/howard2020. (We will learn to make
drawings from 3-D parts in Chapter 2.)

In this chapter, we will be making adjustments to the SOLIDWORKS interface. These adjustments
are summarized in Appendix A and in Video Example 7, which is available at www.mhhe.com/
howard2020.

The Units and Dimension Standard box only appears the first time SOLIDWORKS
is opened. The selections become the default values for all new files. In this chapter,
we will see how to set these values for individual files and to change the default
values.

Note that you can return to FIGURE 1.5

the Welcome dialog at any
point by selecting the icon
shown in Figure 1.5.
 Chapter 1  Basic Part Modeling Techniques   7

FIGURE 1.6

Before we begin modeling the flange, we will establish a consistent setup of the
SOLIDWORKS environment. The default screen layout is shown in Figure 1.6. The
graphics area occupies most of the screen. The part, drawing, or assembly will be
displayed in this area. At the top of the screen is the Menu Bar, which contains the
Main Menu and a toolbar with several commonly-used tools such as Save, Print,
and Redo. Note that if you pass the cursor over the SOLIDWORKS button in the
Menu Bar, the Main Menu will “fly out,” or be temporarily displayed, as shown in
Figure 1.7. The fly-out feature is designed to save room on the screen. However,
since we will be using the menu often, we will disable the fly-out so that the menu
is always displayed.

Move the cursor over the SOLIDWORKS button to display the menu. Click on the
pushpin icon at the right side of the menu, as shown in Figure 1.8, to lock the
display of the menu.

FIGURE 1.7 FIGURE 1.8

The CommandManager contains most of the tools that you will use to create FIGURE 1.9
parts. When working in the part mode, there are two categories of tools that we
will use extensively: Sketch tools used in creating 2-D sketches, and Features
tools used to create and modify 3-D features. Clicking on the Sketch and
Features tabs at the bottom of the CommandManager, as shown in Figure 1.9,
changes the tools on the CommandManager to those of the selected group. By
default, there are several other groups available besides the Sketch and Features
groups. To simplify the interface, we will hide these groups for now.
Exploring the Variety of Random
Documents with Different Content
PAGAN SONGS[1]
 [2]
KUPALO
(Fragment)

I
On Ivan-Kupalo
Ivan was bathing.
And he fell into the water
On the Day of Kupalo.

II
Hai! On the Day of Ivan-Kupalo
A beautiful maid her fortune sought.
She plucked the flowers to make her garlands—
The Malva-flower and Lewbistok—
She strewed them on the river’s breast.

“Float, my wreath, with the wave’s swift flowing,

Straight to the window of my love—
Float to the heart of the one I love,
And bring good fortune with thee!”

The wreath is floating,

Carrying with it
The heart of the maid.
At the bend of the river,
’Tis swamped by the wave—
Kupalo, Kupalo,
No fortune gave!

That night the maiden

Trezilie[3] sought.
In the midnight hour
She dug them up.

She made a brew

In the dead of night,
And ere the dawn
The poison drank.
 SONG TO VESNIANKA (SPRING)
(Fragment)

O Lady Vesnianka,
Where didst thou spend the winter?

“In the forest, upon the oak,

I was spinning the thread for a shirt.”

· · · · ·

O Spring, the beauty! Vesnianka!

Fly to us with the sun.
 VESNIANKA—CHILDREN’S SONG
Vesnianka came,
And brought Paradise.
All is blooming, everywhere.
Beauty in the meadows lies,
Joy is in the fields and air,
In the woods is Song.

Let us garlands make

On Vesnianka’s Day.
Join hands, and in a ring
Interweaving, let us play
Jumping high, the while we sing
In the woods our Song!

All of beauty, life,

Goes when winter’s here.
Bloom will perish, birds grow dumb,
All things lovely disappear.
But the time has not yet come
To leave off our song.
 HYEEVKA—SONG OF THE WOODS
What did she bring us, the beautiful Spring?
Fair tresses, maiden’s beauty.
A maiden’s beauty is as dew in summer
Washed in a spring, dried in an oven,
Set on a table, wrapped in paper.

Springtime! And now what is it she brings us?

She brought us Strength, beauty of boys.
Beauty of boys is as dew in summer
Washed in a rain-pond, dried on a fence,
Set on a table, wrapped in rags.
WEDDING SONG CYCLE
 THE WEDDING OF MARUSENKA
(From various districts. A selection of folk-songs made into a
song cycle, some being fragmentary)
 I
WOROTA—THE GATES
Marusenka with her father pleadeth:
“My beloved father, close the gates,
Close the gates!
Do not let the Duke[4] come nigh—
Let not Wasylenko by.”

“Child beloved! Nay—he entreats

That I let him in, let him in.
Like the khmel, like the hop vines
Round the gates, see, he twines!
At the Table, like barwēnok.... Who allowed
Him to sit there? Proud—
Like a falcon,[5] proud!”
 II
The sun as a wheel now mounts the skies:
Marusenka’s ensphered by Paradise.

“This Eden, O maiden, who gave to thee?”

“God and my father!” sayeth she.
 III
In the orchard, in the cherry orchard
We passed but now, young Wasyl stood.
He raised his cap in a lightsome mood.
He raised it and listened; he thought he heard
Song of a bird, song of a bird—
Sweet, sweet song of Zuzula[6] winging.
But see! It was maids weaving wreaths and singing.
 IV
THE COMING OF MEESCHANI ON SUNDAY
TO THE WEDDING
(The Meeschani or Master Merchants of old held themselves in
high esteem, looking down upon the peasants)

Let us drive—we will drive across the fields;

Drive uphill and down the dales,
Across the sands, across the stones.
They will hear us coming in the vales;
The sands shall murmur, the stones shall prattle,
As ’neath our horses’ feet they rattle;
We will be talked of everywhere.
Ah, how the villagers will stare:
“See now, Meeschani driving there!”
 V
CEREMONY OF THE WREATH-WEAVING
The Kalina[7] grows in a little valley;
It has blossomed with a white, white flower.
The bridesmaids went to pluck a bough
But empty-handed come they now.
Its plucking lay not in their power.
But there went Marusenka,
There the little Duchess went.
The Cranberry her blossoms lent.

Home came Marusenka to the bright Room of Welcome.

Home to the pretty maidens then came she.
Before her little face she set the flowers,
And she looked at them long and earnestly.

Then of her father asked Marusenka:

“Like this Kalinonka shall I be?”
“As long as thou stayest by my hearth-side,
Child, thou’lt be like that Cranberry.

“But when thou goest upon thy journey

Thy beauty, alas, will fall from thee.
O youthful one, from thy braids so golden
Thy beauty swiftly away shall flee!”
 VI
THE WREATH
Wreath, my wreath
Of Barwēnok,[8] Kryschati![9]
I have woven you, just you alone.
I have not worn you out with wearing;
Saturday afternoon I wore you,
On Sunday all the dear day long,
On Monday just one little hour ...
I would have you painted, that I might keep you
To dance beneath but one night more;
I would have you gilded, that so enwreathèd
I might walk as in days of yore.
 VII
[10]
BAKING THE KOROVAI
My Korovai, so heaven-sweet!
Moulded with water from seven wells;
Made out of seven stacks of wheat.

And now our oven with golden shoulders,

Our big oven with silver wings
The festal loaf shall bake for us,
The Korovai shall make for us.
 VIII
To her little brother the Duchess cried:
“Brother, I pray thee, saddle thy horse!
Haste to the fields that stretch so wide,
Get for me the horses black,
Drive them before thee on the way back.
Then let them loose among my flowers.
Let them browse as around they course,
And what they eat not in my bowers
The while they do in my garden stay
On their clutching hoof they may carry away.
Let the stamping feet on my flowers fall
That none be left when I am gone;
No joy be there for my bridesmaids all—
So lonesome Mother won’t weep for me:
‘There are her flowers—but where is she!’”
 IX
PUTTING ON THE PEREMITKA
(The enveloping hood or white scarf, the mark of the wife)

The white Pava[11] is flying—

See all the waiting ring there,
The maids who laugh and sing there—
But all the girls it passes,
Passes by them all
To fall
On Marusenka only.

“Decide now if thou dost regret,

Young Marusenka,
What thou hast done! The maids that jest,
Of their long plaits are still possessed.
They will not take thee back now,
Marusenka!”
 X
SONG OF THE BRIDEGROOM’S FRIENDS
“Open the gates—the little gates!”
“Who is it calls? Who is it waits?”
“Attendants of the bridegroom we—”
“Ah, well! Now what may your gift be?”

“We offer you our golden bees—”

“Think you so small a thing would please?
Have you naught else for offering?”

“Behold the great gift that we bring:

The maiden, wearing on her brow
The Ruta-wreath,[12] comes with us now.”
 XI
DEPARTURE
Clanged the keys on the table;
Outside the horses neighed.
“O my mother, my dear mother!”
Cried the little maid.

“’Tis all over, all over!

No more am I free.
So sad is it to be married!”
And she wept bitterly.

“Send you your dear daughter

Far away?” mournèd she.
“But I follow, my husband,
Lo, I follow thee!

“The man whom I wed now

A stranger is he.
Yet knoweth my father
To whom he gives me!”
 XII
THE MOTHER
When the bridal party is going to the bridegroom’s house

As it came to the dawning I awoke:

Swift I looked in the Courtyard grey—
There but now her fine sleigh stayed,
While the prancing horses neighed
That bore my Marusenka away.

“Am I no more your child?” she said,

“That from your side you send me so
Just ere the coming of the night?
Give me a friend in this my plight—
My songster Solowi[13] must go.

“For its sweet piping I would hear

At peep of day to waken me—
She, my new mother, will not call,
Instead, she slanders—cruel words all—
‘Useless this bride as rotten tree!’”