BACKGROUND:

Earlier this week, we had a customer with several design problems. As could be expected, SolidWorks provided a timely and efficient solution. First, they needed a sheet metal part that had a specific top profile. The reason for this was that it had to fit in an assembly between several other components. From the top, the part had to look like this:

In most cases, this would be a simple task. Create a sketch that matched this top profile and use the “create base flange/tab” feature to extrude this a given distance. The other option would be to create a
base flange/tab and create an edge flange off each side. It should noted that the critical dimensions of the drawing are the dimensions from the first view. Seeing the part from a side view, you can see there also needed to be an angle cut as shown:

MANUFACTURING LIMITATIONS

If the only issue was that they needed to know precisely what the folded model looked like, there would be no problem. Any sheet metal modeling software could create a part for them. The problem was that because this part was so large that there were manufacturing limitations on cutting the blank. As it turns out, the limitation of the manufacturing tools made it necessary that all of the cuts to the blank would have to be straight lines. Here the task put in front of SolidWorks was to build a part that met specific folded profile dimensions, (see top view), but have this profile be able to be cut from a part blank that contains only straight edges (when unfolded). The customer needed to know what the geometry would look like precisely when folded, given their specific manufacturing limitations, so that they could accurately see if there was any interference in the assembly.

SOLIDWORKS PROVIDES A NO GUESSWORK SOLUTION:

SolidWorks provided a timely no guesswork solution by using the “unfold” and “fold” command found in the sheet metal tools. What makes these commands so powerful is that it allows us to first flatten, add features (in the flattened state), then re-bend the part according to the original specifications. After creating the vertical profile, we used the “unfold” command to essentially roll back the piece to its unbent state. After making a triangular cut to the flattened piece, we used the “fold” tool to re-bend the part.

Using the “unfold/fold” command, SolidWorks managed to eliminate the guesswork that often is associated with making models that are based on real world manufacturing limitations. Below we have a final drawing of the bent part. Notice the angle variation going from the left to the right side of part. Had we done a simple extruded cut on an already folded part, we would not have been able to account for the change in angle in the transition section of our piece. Again, SolidWorks provides a fast and efficient modeling solution.

Above a drawing of the blank and below a side view of the folded part:

Yesterday we shipped Microsoft SQL Server 2008 Standard Edition DVDs to all of our SolidWorks Enterprise PDM customers. I personally did not see them but I have been told if you hold the up to the light they look rainbowy.

SQL Server 2005 will still be supported for the foreseeable future. Typically SolidWorks drops support for Microsoft products after Microsoft itself drops support. Thus if you are not experiencing any lost revenue in waiting to upgrade, I recommend not upgrading “just because it is there”.

Look for some performance enhancements, better memory management, data compression and an easier UI after the upgrade.

3DVision Technologies Corp. is thrilled to add the uPrint Personal 3D Printer to its product offerings.

The uPrint, a desktop-sized printer priced at $14,900, joins Dimension’s (a business unit of Stratasys, Inc.) already market-leading line of 3D Printers. Designed for the desktop, uPrint requires only a 25 x 26in footprint and features an 8 x 6 x 6 in. build envelope.

The uPrint builds models with ABSplus making it ideally suited for testing the form, fit and function of models and prototypes. uPrint also features a soluble support removal system, allowing for hands-free removal of the model support material.

As a personal 3D printer, uPrint makes 3D printing immediate and convenient through every design iteration. There’s no waiting in queue for a shared printer and no waiting for models to arrive from an outside service.

“This new technology will accelerate designers and engineers CAD designs from model to production. It is going to provide our customers with a better way to work,” said Todd Majeski, President and CEO of 3DVision Technologies.”There is nothing more powerful than a design going from a flat image on a screen to a 3D model that everyone on the team can examine at every angle.”

The uPrint is available for purchase immediately through 3DVision Technologies.

Visit http://www.3dvision.com/Seminars/uPrint.php  for a complete list of upcoming dates and locations to view this new technology first hand. For questions please call Carrie Cavanaugh at 513-745-2700.

The MVSWUG group meeting that was scheduled for today. Has been postponed due to weather.

Same time, place and great speaker …just now it will be Monday February 2nd instead.

The majority of companies that integrate vibrating equipment in their designs face tough challenges to overcome harmful deflections originating from resonance. In such cases, it becomes imperative that the design team either use physical prototypes and shaker tables to evaluate the design integrity or to simulate such behavior virtually.

I put together a case-study on a model to show how harmonic analysis can be easily performed on SolidWorks geometry using SolidWorks Simulation (previously called COSMOS). The tool can help isolate the harmful frequencies in the operating range of the excitation source such as a motor. The user can suitably alter the design based upon the response pattern indicated by Simulation.

Interestingly enough, there is another application for harmonics – where companies desire large deflections. For instance, a company manufacturing sieves would design their automated equipment to operate at frequencies that instigate resonance. Resonance would cause large deflections, and hence help the sieve to sift material through. SolidWorks Simulation would also help understand what the resonating frequencies of the design are, and the resulting deflections because of resonance.

Making the right choice in operating ranges can make a world of a difference between a good design, and a chattering, loud, ready-to-break-down design!!

Miami Valley SolidWorks User Group Agenda
January 28th, Gander Mountain, Huber Heights, Ohio

5:30pm – 6:00pm Registration, food, and networking
6:00pm – 7:15pm Jeff Sweeney will show us DriveWorks
7:15pm – 7:25pm Break
7:25pm – 8:10pm Question and maybe answers of issues that you have with SolidWorks
8:10pm – 8:20pm Discussion about next meeting date and what we would like to cover
8:20pm – 8:30pm Wrap-up, prize giveaways.

Please RSVP Randy Adams

I haven’t figured out what I want to show with DriveWorks yet. Any requests?

SolidWorks Enterprise PDM SP2 was released yesterday. Christmas has finally come!

Sadly I am swamped with other projects so I don’t have a review for it yet. You might have to wait until after SolidWorks World.

If you cannot wait ’till the review I do have one warning for you. Service pack 2 removes the ability for file property changes to be seen in eDrawings [in for an example drawing titleblocks]. In other words if you make changes to the datacard or if a transition changes the datacard, these changes will NOT appear if you open the file in eDrawings/preview.

Cross your fingers for a hot fix.

In the past 2 years we’ve really seen some major changes in the reasons that people are investing in 3D printers. While many people still think of rapid prototyping/3D printing as a way to build a concept model for customers we are finding that most companies that employ this technology are using it for far different purposes.

I have 1 customer that uses their Dimension 3D printer just to make molds for vacuum forming for package inserts. They used to have to get expensive molds made which also took quite a long time to produce. Now they can build one overnight, come in the next morning, vacuum form over it and test it for fit that same day. Lots of companies are using Dimension 3D print models to make fixtures. The ABS plastic is durable enough that the models can often be used as the final fixture. In some cases, such as a car assembly line, the customer might build the fixtures out of plastic first to do a test run to check for clearances before sending out for the final metal fixtures to be made. And other companies are building models so their production department can make sure there won’t be any problems during assembly.

But whatever you think you might use a Dimension printer for, it probably will only account for a fraction of what you end up using it for. Once you bring this technology in house it just opens up a world of uses for these durable models. Test for form, fit and function so you can speed your time to market, lower development costs and produce higher quality products.

What are you using your Dimension printer for? I would love to hear some of your stories.

Karen Dumont
Account Manager – Dimension
3DVision Technologies