Josh Meacham

joshmeacham@hotmail.com

Engineering 4610 Project

(Spring 2011)
Objective:

! The Engineering 4610 class is designed for students to be able to work on

advanced solid modeling in an application of their own choice. I have decided to use my

time in this class to work towards an associate level certification in SolidWorks. In order

to obtain the necessary skill level to successfully complete this exam, I have schedule

three projects designed to improve my skills in this application. Because the overall

objective of these projects are to transition through the material covered in the exam, I

have set structured deadlines that must be observed, regardless of wether the project is

finished.

! The certification from SolidWorks will also be bundled with a portfolio that will be

compiled throughout the semester. Each project will include a final review of the

progress complete in the allotted time, and an evaluation of the skills used to complete

each project. Because the portfolio section of this project will be equally valuable, I have

scheduled a final week to compile drawings and peer reviews of my work. This

documentation will also provide SUU with a sample outline for other students who may

be interested in fulfilling the requirements for the Certified Solid Works Associated

(CSWA) exam.
The Certification Exam:

! Schroff Development Corporation has produced an examination guide for

studying for the CSWA exam. I have reviewed this material in its entirety and have

designed my projects to improve the skills I feel necessary for the exam. I would

strongly suggest that students wishing to prepare for the exam in a similar way do so as

well. I have completed one semester of SolidWorks training through SUU, and therefore

feel the topics I would like to cover may be different than those of another student.

! The CSWA exam can be proctored through SUU, and is available at anytime via

an online testing environment. The majority of the test will require the student to

successfully draw and assemble a project in the specified amount of time, and then

evaluate the drawings volume and center of mass. These two variables will be used to

grade the final assembly, and therefore there are many ways in which the assembly

may be completed. While this is true, donʼt forget that there will also be multiple choice

questions about specific methods and tasks.

Project Based Learning:

! Because much of the success in taking the CSWA exam comes from

successfully applying solid modeling skills in both an efficient and effective manner, a

project based learning environment will be most beneficial in preparing for the exam.

While it is not important that each project be physically produced, fully functional, or fully

designed, it is important that specific skills mastered. Each project will require specific

objectives to be met, follow a predetermined task list, and adhere to a ʻskill setʼ

schedule based more on practice than completion. Also, a review must be completed at

the end of each project to determine how successful the student is at applying these

skills. In some projects, peer review will be required to determine if proper design theory

and intent were applied. In any of their stages of completion, the processes will be

beneficial in acquiring a collection of studies for a portfolio to be assembled in the final

weeks of the semester.

! Project A

! ! Basic Part Modeling and Assembly

- Mg Midget Front and Rear Disc Brake Modification

! Project B

! ! Advanced Part Modeling and Assembly

- Mini Tear Drop Trailer Design

! Project C

! ! Assemblies, Constraints, and Configurations

! ! -Rat Rod I Beam Torsion Suspension Design

Project A: Basic Part Modeling and Assembly

! 2 Week Session

! Estimated lab time: 12hrs

MG MIDGET FRONT AND REAR DISC BRAKE MODIFICATION

Objective:

- Use 2D sketch tools, Extruded Boss/Base, Extruded Cut, Fillet, Mirror,

Revolved Base. Chamfer, Reference geometry, Plane, Axis Calculate the

overall mass and volume of the created part, and locate the Center of mass for

the ! created part ! relative to the origin.

- Identify the Sketch plane, part Origin location, part dimension, geometric

relations, and design intent of the sketch and feature.

- Assign and edit material to a part, apply the Measure tool to the part or

assembly, locate the center of mass, and the Principal moments of inertia

relative to the default coordinate location, and Origin.

- Recognize the various drawing name views by their icons and identify the

procedures to create them.

Tasks:

- Determine design intent and develop criteria for manufactured parts

- Dimension existing parts in hand drawn sketch

- Create 3d Models of existing parts and transfer into assembly environment.

- Create multiple configurations showing modified rotors and develop machining

instructions.
 - Design Caliper mounting brackets using 3d Sketching environment.

- Constrain parts in assembly relative to coordinate planes and distances

Resources:

! - Existing parts for dimensioning (brake rotors)/ physical parts or factory specs.

- Tolerances required for parts operation

- Materials required to manufacture parts

- Calipers to be used in modification, (some specs may require physical parts

because some tolerances may be do to casting procedures that may not be

uniform)

Documentation:

- Rotor modification instructions for machine shop

- Caliper mounting brackets and .dxf files required for CNC.

- Assembly Drawing using multiple views as required for assembly.

- Project Review Sheet

Notes:
Project B: Advanced Part Modeling and Assembly

! 2 Week Session

! Estimated lab time: 13hrs

MINI TEAR DROP TRAILER DESIGN

Objective:

- Create model in a 3D sketching enrollment, use linear and circular pattern,

Reference geometry, locate the center of mass for individual parts.

- Create a coordinate system location in an assembly.

- Specify document properties: Select unit system, and set precision.

- Use Sheet Metal Tool to develop scale drawings

- Analyze flow using proper Evaluation Wizards.

Tasks:

- Determine design intent and develop criteria for manufactured parts

- Dimension existing parts in hand drawn sketch

- Create 3d Model of existing trailer base and transfer into assembly

environment. (use mirror tool in assembly environment)

- Use “Bottom Up” design solid for trailers shape and then shell the solid.

- Create Sheet Metal Drawings from solid model.

- Design fenders using loft tool

Resources:

- Existing trailer to be used as base

 - Various ʻtear-dropʼ designs for aesthetic criteria of project

- Material sourcing for production cost estimate.

Documentation:

- Scale drawings of sheet metal parts to be used for production

- Exploded view and assembly drawing of shell

- Flow analysis evaluation of chosen aesthetic design

- Bill of Materials and production estimate.

- Project Review Sheet

Notes:
Project C: Advanced Assemblies and Configurations

! 3 Week Session

! Estimated lab time: 24 hours

RAT ROD I BEAM TORSION BAR DESIGN

Objective:

- Build a bottom up assembly with the following Standard mates: Coincident,

Concentric, Perpendicular, Parallel, Tangent Distance, Angle, and Aligned, Anti-

Aligned options.

- Create parts referencing dimensions in an assembly.

- Comprehend basic Engineering analysis definitions.

- Apply SimulationXpress/COSMOSXpress to a simple part

Tasks:

- Determine design intent and develop criteria for manufactured parts

- Dimension existing parts in hand drawn sketch

- Create 3d Model of I Beam and Wishbone insert as first part in the assembly

- Create Sub-Assembly of Torsion Adjuster and insert into main file

- Use “Bottom Up” design for torsion arm and require brackets for torsion bars

- Simulate Range of motion to determine validity of design

Resources:

- ʼ36 Chevy I Beam and Wishbone

- Vw torsion assemblies

- Sample torsion designs and theory

Documentation:
 - Assembly drawings for torsion adjuster

- Complete Assembly Drawing with required views and configurations

- Peer Review from experienced hot rod builder

- Project Review Sheet

Notes:
Project Review Sheet: SAMPLE

Design Intent:

______________________________________________________________________

______________________________________________________________________

______________________________________________________________________

______________________________________________________________________

Was the project completed? Y/N

Did the project meet the design intent?

! If no, why?

! ________________________________________________________________

! ________________________________________________________________

What changes might you make to the Design Process?

______________________________________________________________________

______________________________________________________________________

______________________________________________________________________

______________________________________________________________________

______________________________________________________________________

What SolidWorks tools were most beneficial in designing this project? If using 3d

modeling was not beneficial to the design of this product please explain why.

______________________________________________________________________

______________________________________________________________________

______________________________________________________________________

______________________________________________________________________
Project Schedule:

Week 1 - 3

! Review and research material for CSWA exam; determine method for preparing
for exam, and develop projects that will fulfill requirements similar to the tutorials
provided in the exam study guide.

Week 4

! Finish project proposal and determine which projects with best suite time
constraints. Meet with Richard Cozzens about SolidWorks Seminar and verify testing
procedures. Finish full review of exam guide and model objectives accordingly.

Week 5

! Session 1
! ! Project A1: Complete design intent evaluation and develop hand drawings
! ! with proper dimensions of brake rotors. Source rear rotors and purchase
! ! rear caliper to be used for rear caliper bracket.
! Session 2
! ! Project A2: Complete solid models of rotor assemblies with both
! ! configurations and prepare machining instructions.
Week 6
!
! Session 1
! ! Project A3: Design front and rear caliper bracket using purchased calipers.
! ! Create .dxf files for water-jet , and send off for production. Determine
! ! necessary ! hardware for mounting and create a Bill of Materials.
! Session 2
! ! Project A4: Complete Documentation including all required drawings and
! ! review sheet. Document production results and product cost.
!
Week 7

! Session 1
! ! Project B1: Determine design intent and volume requirements for tear
! ! drop trailer. Dimension existing trailer base and develop sketch of
! ! proposed final product. Create 3d model of trailer base. (Note: This need
! ! not be functional as axle, wheels, and springs will be for clearance only;
! ! the trailers shell is the design project)
! Session 2
! ! Project B2: Create 3d Solid of Trailer using either loft tool or SolidWorks
! ! utilities. Utilize the Sheet Metal Part Tool to create Full Size 3d Prints. This
! ! trailer will be a cargo-only design, and requires only one rear hatch. Insert
! ! hinge and latch from library.
Week 8

! Session 1
! ! Project B3: Design Fenders using multiple planes to be utilized in creating
! ! fiberglass mold. Compile Assembly Drawings for trailer assembly and
! ! preform Flow Analysis.
! Session 2
! ! Project B4: Complete Documentation and Review, Print Full Size Prints for
! ! trailer panels, and produce Bill of Materials and evaluate cost.

Week 9
!
! Session 1
! ! Project C1: Dimension Parts from various sources to provide information
! ! for a ʻfunctionalʼ design experiment. This project is a practice in motion
! ! and exact dimensions may not be required. Draw I Beam and Wishbone
! ! and insert into assembly.
! Session 2
! ! Project C2: Create separate assembly for torsion adjustment blocks in a
! ! ʻweld onʼ configuration.
Week 10
!
! Session 1
! ! Project C3: Create torsion bar part in 2pc to allow for motion study.
! ! Combine assemblies and create 3d model of torsion arm “top downʼ in the
! ! assembly, using line drawings in motion study before solid is created.
! Session 2
! ! Project C4: Revise torsion blocks and create build sheet with required
! ! hardware and production files.

Week 11
!
! Session 1
! ! Project C5: Finish assembly and create final production part for torsion
! ! arm.Determine best production method for torsion arm and source
! ! production with required files to acquire estimates.
! Session 2
! ! Project C6: Complete Documentation, include assembled view in multiple
! ! configurations for ease of multiple motion view. Compile proposed
! ! production schedule and submit for Peer Review.
Week 12

! Session 1
! ! Compile portfolio and clean up production drawings complete throughout
! ! the semester. Create detailed view drawings of unique parts and provide
! ! photographs of production samples or renderings.
! Session 2
! ! Complete Portfolio and revise project proposal to be used as student
! ! sample. Finish overview for SolidWorks exam.
Week 13
!
! TAKE CSWA EXAM!