Mastering Autodesk Inventor® 2009 and Autodesk® Inventor LT 2009

Curtis Waguespack Loren Jahraus, P.E.

Sean Dotson, P.E. Dennis Jeffrey

Bill Bogan Shekar Subrahmanyam

Andrew Faix Bob Van der Donck

Seth Hindman

® WILEY

Wiley Publishing, Inc.

Contents

Introduction xxiii

Chapter i • Inventor Design Philosophy i

Moving from the AutoCAD Environment 1 Using the Inventor Graphical Interface 3

Tool and Browser Panels 5 Pulldown Menus 7 The Model Browser 8

Learning the File Types in Inventor 10 Using DWG Files in Inventor 11 Creating DWG Files from Inventor Drawings 12 Moving from AutoCAD to Inventor 12

Building a 3D Virtual Prototype 13 What Is a Virtual Prototype? 14

Understanding Parametric Design 15 Understanding Functional Design 16 Understanding Solids vs. Surface Modeling 18 Best Practices in Autodesk Inventor 20

Creating a Data Management Structure 21 Selecting the Proper Project File Type for Your Designs 21 Developing an Efficient and Stable Part-Modeling Workflow 22 Developing Assembly Structure for Maximum Efficiency 22 Establishing Standards for Documentation 23 Digital Communication 24

The Bottom Line 24

Chapter 2 • Data and Projects 27

Creating a Data Structure 27 Setting Up the Ideal Directory Structure 27 Preparing Parts for Reuse and Revision 32 Exploring Project File Types 33

Creating the Project File 34 Creating a Single-User Project 36 Working in Collaborative Environments 43 Creating a Multiuser Project 44

The Bottom Line 47

Chapter 3 • Sketch Techniques 49

Application Options and Settings for Parts and Sketches 49 Creating a New Part File from a Template 53

Preserving Design Intent 55 Creating a Basic 2D Sketch 56

Exploring the 2D Sketch Commands 57 Using Sketch Object Modifiers 59 Setting Sketch Constraints and Dimensions 60 Adding Dimensions to Sketches 64 Anchoring the Sketch 66

Using Construction Geometry 71 Creating Sketches from Auto CAD Geometry 75 Creating and Using 3D Sketches 78

Creating a 3D Spline 78 Using the 3D Coordinate Triad and Precise Redefine Functions 79

The Bottom Line 84

Chapter 4 • Basic Modeling Techniques 87

Exploring Application Options and Settings for Part Modeling 87 Specifying Global Settings 87 Specifying Document-Specific Settings 88

Creating Basic Part Features 93 Simplifying Your Sketches 94 Creating a Part Using the Same Workflow 95 Creating the Second Feature 98 Creating a Placed Chamfer Feature 99 Creating a Sketch-Based Hole Feature 100 Mirroring Features 102 Creating a Placed Hole Feature 103 Creating a Rectangular Hole Pattern 104 Creating a Second Extruded Cut and Associated Lip 106

Modifying Existing Part Features 109 Creating and Using Work Features I l l

Work Plane Tangent to Cylinder 112 Sketching on a Work Plane 114 Creating Text in a Sketch 114 Embossing Text 116

The Bottom Line 117

Chapter 5 • Advanced Modeling Techniques 119

Complex Sweeps and Lofts 119 Creating and Using Sweeps 119 Sweep Type Options 121 Loft Features 124

Turned Parts and Threads 128 Revolved Cylindrical Parts 129 Extruded Cylindrical Parts 130 Creating Threaded Features 130

Cast and Plastic Parts 132

CONTENTS i XV

Derived Part Creation 132 Part Tolerances 134 Setting Global File Tolerances 135 Overriding Current Tolerances 136 Parameters and iProperties 136 Part Parameters 137

Assembly Parameters 139 Part Analysis 139

Construction Environment 140 Working with Base Solids 144

Activating the Solids-Editing Environment 145 Troubleshooting Failures 146 The Bottom Line 147

Chapter 6 • Sheet Metal 149

Getting to Know the Features 149 Starting with a Base 149 Creating Flanges 150 Adding, Removing, or Deforming Material 152

Using Sheet Metal Templates and Rules 155 What Are Sheet Metal Rules? 156 Unfolding Your Part 158 Working with Styles and Templates 161

Authoring and Reusing Punches 161 Punches and iFeatures 161 Creating Successful Punches 162 Alternate Representations 163 Placing Your Punch 163

Leveraging the Flat Pattern 165 Flat Pattern Edit Features 165 What's Stored Inside? 166 Manufacturing Your Flat Pattern 167

Sheet Metal iPart Factories 167 Consuming Sheet Metal Rules 167 Folded and Flat Members 168

Modeling with Non-Sheet-Metal Features 169 Selecting Problematic Features 169 Surface-Based Workflows 170

Working with Imported Parts 170 Setting Yourself Up for Success 170

Annotating Your Sheet Metal Design 171 Creating a View of Your Sheet Metal Design 171 Bend, Punch, and Flat Pattern Annotations 172

Harvesting Legacy Sheet Metal Templates 175 Parameter Indirection 176 The Hidden Tools of Harvesting 176

Style Library Manager 178 The Bottom Line 178

Chapter 7 • Part and Feature Reuse 181

Working with iParts 181 Creating and Modifying iParts 182 Using iParts in Designs 187

Working with iFeatures 188 Creating iFeatures 188 Creating Punch Features 190

Reusing Existing Geometry 193 Copying Features 193 Cloning 194 Copying Sketches 195

Introducing Content Center 197 Configuring Content Center 197 Using Content Center 198 Customizing Content Center 201

The Bottom Line 205

Chapter 8 • Assembly Design Workflows 207

Understanding Subassemblies 207 The Power of Subassemblies 207 Flexibility 209

Top-Down Design 210 Developing an Efficient Assembly Workflow 210

Adaptivity 213 3D Constraints 216

How Constraints Work 216 Degrees of Freedom 217 Types of 3D Constraints 217 Motion Constraints 220 Transitional Constraints 220 Driving Constraints 221 Redundant Constraints and Constraint Failures 222 Contact Solver 223

Assembly Features 223 Managing the Bill of Materials 225

Parts-Level BOM Control 225 Assembly-Level BOM Control 225

Assembly Reuse and Configurations 232 Copying Designs 232

Representations 234 View Representations 235 Positional Representations 235 Level of Detail Representations 238

CONTENTS : XV11

iAssemblies 239 The Bottom Line 243

Chapter 9 • Large Assembly Strategies 245

Selecting a Workstation 245 Physical Memory vs. Virtual Memory 245 64-bit Systems vs. 32-bit Systems 246 Hardware 246

Working with Performance Settings 248 Working with Drawing Settings 248 Working with Model Display Settings 250

Working with General Settings 251 Working with System Settings 253

Large Assembly Best Practices 254 Working with the Model 254 Reducing Assembly Constraints 255 Opening the Model 259 Working with Large Assembly Drawings 260

Managing Assembly Detail 262 Level Of Detail Strategies 263 Substitution Level Of Details 264 Subassembly Level of Details 265

Simplifying Parts 267 Removing or Suppressing Unneeded Features 267 Working with Colors 268

The Bottom Line 268

Chapter 10 • Weldment Design 269

Exploring Weldment Design Methodologies 270 Modeling Preparations 272 Cosmetic Welds 274 Creating Weld Beads 278 Creating Fillet Welds 278

Creating Intermittent Fillet Welds 281 Creating Groove Welds 282 Performing Machining Operations 285 Exploring Weld Properties and Combinations 286

Weld Properties 286 Replication 286 Groove and Fillet Weld Combinations 287 Split Technique 287

Using the Weld Symbol 290 Bead Property Report and Mass Properties 291 Drawing Documentation 292

Weldment Design Stages 294 End Fill 296

Drawing Weld Symbol 297 Caterpillar 297

Bill of Materials and Parts List 298 The Bottom Line 301

Chapter n • Functional Design 303 Geometric Modeling vs. Functional Design 304

Design Requirements 304 Design Accelerators General Introduction 305

Design Accelerators Input 305 Design Accelerators Output 306 Design Generators and Content Center 310 Prerequisites for This Chapter 310

Bolted Connections 311 Calculators 316

Weld Calculator 316 Generators 320

Gear Generator 320 Key Connections 325 Shaft Generator 328 Cam Generator 335 Spring Generator 339

The Bottom Line 343

Chapter 12 • Documentation 345

Working in the Presentation Environment 345 Creating a Basic Explosion 345

Using the Drawing Manager 348 Creating Templates and Styles 349 Creating Drawing Views and Annotations 359

The Bottom Line 388

Chapter 13 • Inventor Tools Overview 391

AEC Exchange 391 AutoLimits 392

Creating AutoLimits 394 Editing AutoLimits 394

Design Assistant 395 Using the Find Files Command 397 Using the Where Used Command 398 Renaming and Performing Other Operations on Files 399 Using Pack and Go 400

Drawing Resource Transfer Wizard 402 Style Tools 405

Using the Style Library Manager 405 Using the Style Management Wizard 406

CONTENTS XIX

Supplier Content Center 408 Task Scheduler 409

Creating a Task for Migrating Files 410 Performing Sequential Tasks 412 Performing Custom Tasks 413 Tweaking Multiprocess Settings 413

iProperties 414 Copying iProperties to Drawings 415 Creating Expressions with iProperties 416 Working with the DA and iProperties 417 Creating Design Property Reports 418

Measure Tool 418 Using Measurement Helpers 418 Measuring in Assemblies 419

The CIP and CER 420 Participating in the CIP 420 Participating in CER 420

Miscellaneous Tools 421 Using the Autodesk Multi-Sheet Plot 421 Using the Add-in Manager 421 Using the Project Editor 422

The Bottom Line 422

Chapter 14 • Exchanging Data with Other Systems 425

Importing and Exporting Geometry 425 DWG 426 Mechanical Desktop DWG 429 STEP and 1GES 430 SAT 433

Using Inventor File Translators 434 Pro/ENGINEER 434 Unigraphics and Parasolids 435 Solidworks 436 IDF Board Files 437 Placing Components from Other CAD Systems 437

Working with Imported Data 438 Working in the Construction Environment 438 Editing Imported Data 442

Viewing DWF Markup 443 Using Feature Recognition 447 The Bottom Line 452

Chapter 15 • Frame Generator 455

Accessing the Frame Generator Panel Bar 455 Exploring the Frame Generator File Structure 456 Exploring the Anatomy of a Frame Member 456

Inserting Frame Members 458 Specifying a Structural Shape 458 Changing the Orientation 458 Selecting Placement Geometry 460 Aligning Frame Members 464

Adding End Treatments 466 Miter 466 Trim to Frame Member 469 Trim and Extend to Face 469 Notch Frame Members 469 Lengthen-Shorten Frame Member 471

Maintaining Frames 471 Remove End Treatments 472 Frame Member Information 472 Refresh 472

Performing Analysis 472 Model Tab . . 472 Beam Calculation Tab 474 Beam Graphs 477 Column Calculator 478 HTML Results 478

Publishing Frame Members 478 Authoring a Part 479 Publishing a Part 482

The Bottom Line 482

Chapter 16 • Inventor Studio 485 Exploring the Inventor Studio Environment 485 Creating and Managing Studio Styles 486

Surface Styles Dialog Box 487 Lighting Styles Dialog Box 493 Scene Styles Dialog Box 500 Composing and Rendering Images 503

Animating with Studio 508 Using Animation Commands 509 Using Video Producer 517 Rendering Video or Animations 520

The Bottom Line 521

Appendix A • The Bottom Line 523

Chapter 1: Inventor Design Philosophy 523 Chapter 2: Data and Projects 524 Chapter 3: Sketch Techniques 527 Chapter 4: Basic Modeling Techniques 528 Chapter 5: Advanced Modeling Techniques 529 Chapter 6: Sheet Metal 530

CONTENTS : XXI

Chapter 7: Part and Feature Reuse 533 Chapter 8: Assembly Design Workflows 534 Chapter 9: Large Assembly Strategies 535 Chapter 10: Weldment Design 536 Chapter 11: Functional Design 538 Chapter 12: Documentation 539 Chapter 13: Inventor Tools Overview 540 Chapter 14: Exchanging Data With Other Systems 541 Chapter 15: Frame Generator 543 Chapter 16: Inventor Studio 544

Index 549