PROJECT - FRENCH CURVE, ELLIPSE GUIDE, AND SHIP CURVE LASER MACHINING

Project uses Alias as a synthesis of various other file inputs (Adobe Illustrator, Solidworks) for laser machining.  Each student will need to utilize a 24inch by 12inch by 0.08inch cast acrylic piece of material by placing geometry for the laser machining layout.  Final steps include evaluating IGES export from Alias to DelCAM PowerMill to maintain layer names for machining operations.  A final DXF file will be submitted to the DAAP Rapid Prototyping Center for machining.

Make sure you start with proper construction settings!

Make sure you start with proper construction settings!

Click to download empty Alias file with Solidworks constrution settings.

Click to download empty Alias file with Solidworks constrution settings.

How to prepare geometry in Alias.

How to prepare geometry in Alias.

Ellipse entities made in Solidworks for export to Alias

Ellipse entities made in Solidworks for export to Alias

Importing Adobe Illustrator content into Alias

Importing Adobe Illustrator content into Alias

Exporting an IGES from Alias to PowerShape, then exporting a DXF from Powershape.

Exporting an IGES from Alias to PowerShape, then exporting a DXF from Powershape.

INTRODUCTION - SOLIDWORKS: SKETCHES, FEATURES, RELATIONSHIPS AND DIMENSIONING

Introduction to Dessault Solidworks interface with explanations of their online tutorials.  Sketches, parametric dimensioning and relationships are demonstrated.

Solidworks sketches and features
Solidworks sketches and features
Parametric relationships and smart dimensioning.

Parametric relationships and smart dimensioning.

Additional sketch entities and linear patterns.
Additional sketch entities and linear patterns.

INTRODUCTION - SOLIDWORKS: PARTS, ASSEMBLIES, AND SOLID BODY FILE EXPORTS

Introduction to parts versus assemblies, mate relationships, and the made simple solid body exports to 3D additive printing technologies.

Simple connector made with sketches and features.

Simple connector made with sketches and features.

Advanced connector made with same concepts. 

Advanced connector made with same concepts. 

Introduction of parts and assemblies.

Introduction of parts and assemblies.

Very simple and direct solid body export to STL file. 

Very simple and direct solid body export to STL file. 

PROJECT - HANDLE WITH DESIGN ITERATIONS

Applying current strategies to design handle objects for iteration study.
Simple construction geometry built for aligning surfaces symmetrical to the y0 plane. 

Simple construction geometry built for aligning surfaces symmetrical to the y0 plane. 

Front and rear section swept surfaces built aligned to symmetry plane with fillet surfaces.

Front and rear section swept surfaces built aligned to symmetry plane with fillet surfaces.

Using construction history for design iterations.

Using construction history for design iterations.

PROJECT - CRANK ROCKER ASSEMBLY VIA SOLIDWORKS

Introduction to use of Parts and Assemblies with Linked Values and Global Variables.  Making a quick kinetic simulation based solely on mating constraints.

Building the various parts to be used in a Solidworks Assembly.  Remember proper use of "Save As Copy..."

Building the various parts to be used in a Solidworks Assembly.  Remember proper use of "Save As Copy..."

Building the base plate that is properly fixed and oriented.

Building the base plate that is properly fixed and oriented.

Adding the crank and rocking pivot.

Adding the crank and rocking pivot.

Adding links and cross bar.

Adding links and cross bar.

Driving data with Linked Values and Global Variable with Equations.

Driving data with Linked Values and Global Variable with Equations.

VARIOUS UNIQUE WORKFLOWS - ALIAS AND SOLIDWORKS

Special feature unique to Alias and Solidworks and demonstrations of their interconnectivity.

Exporting any view in Alias as planar-ized vector content that can be opened in applications as Adobe Illustrator.

Exporting any view in Alias as planar-ized vector content that can be opened in applications as Adobe Illustrator.

Quick overview of the Alias Hardware Shade.

Quick overview of the Alias Hardware Shade.

PROJECT - SAND CASTING MATCHPLATE - SOLIDWORKS (CAD) AND POWERMILL (CAM)

This project introduces the design challenge of the parting plane, necessary draft, and use of fillets.  A reference IGES file is supplied as size parameter that will need to be imported into Solidworks.  Remember the following criteria:

  • Start with the IGES reference file to keep geometry properly centered and constrained in size.
  • Draft angles of extruded features need to be at least 3 degrees (preferably 5 degrees) in the proper direction.
  • Inside fillet radii need to be larger than 0.035inches.
  • Outside fillet radii need to be larger than 0.015inches.
  • The final outside perimeter fillet needs to be exactly 0.0625inches.
Save this IGES file into your Solidworks session to make sure the design is properly constructed properly. 

Save this IGES file into your Solidworks session to make sure the design is properly constructed properly. 

Overview of importing IGES reference file into Solidworks and discussion of design constraints and parameters. 

Overview of importing IGES reference file into Solidworks and discussion of design constraints and parameters. 

Bringing in your file as an IGES and bringing in the reference machining technology

Bringing in your file as an IGES and bringing in the reference machining technology

Performing the roughing strategies. 

Performing the roughing strategies. 

Semifinish and Finish Strategies

Semifinish and Finish Strategies

Corner finishes and final flat finish

Corner finishes and final flat finish

Machine Time preparation and time restrictions

Machine Time preparation and time restrictions

PROJECT - DUSTBUSTER SPEEDFORM - ALIAS AND SOLIDWORKS

This project is the culmination of leveraging every the NURBS surface generation in Alias to downstream data flow to Desault Solidworks.  A reference set of images for a digital cabriolet method is provided in a link below:

  • Start with these pink foam reference images, and begin building principle surfaces in Alias.
  • With all principle surfaces trimmed with a proper single membrane volume, export the NURBS surface data from Alias as an IGES file.
  • Open the IGES file from Alias in Solidworks, make sure you sucessfully import the data and convert it to a single part soldibody.  Make sure to save the .sldprt file.
  • Separate the Soildworks file into multip0le solid bodies as needed adding as much detail as you can. experiment with various features in Solidworks.
  • Make sure you submit a zip archive, of the exported iges file from alias and the .sldprt file from solidworks onto blackboard.
Starting with orthographic views then building corresponding geometry.

Starting with orthographic views then building corresponding geometry.

Building the top and bottom surfaces.

Building the top and bottom surfaces.

Building the front, rear, and side surfaces.

Building the front, rear, and side surfaces.

Trimming the primary surfaces.

Trimming the primary surfaces.

Building the handle with direct surface modeling.

Building the handle with direct surface modeling.

Exporting NURBS surface data as an IGES then using various features in Solidworks to prepare a DelCAM PowerMill session.

Exporting NURBS surface data as an IGES then using various features in Solidworks to prepare a DelCAM PowerMill session.