How to Solve SolidWorks Assignments with Accuracy and Efficiency

Before jumping into SolidWorks, it is crucial to thoroughly comprehend the assignment requirements and constraints. A successful design must balance multiple factors, including strength, heat dissipation, weight, and ease of manufacturing.

Breaking Down the Problem Statement

• Identifying Functional and Structural Requirements
• The design should be robust enough to withstand mechanical stresses, including bending and accidental drops.
• Structural analysis should be conducted to optimize strength without unnecessary weight additions.
• The material selection must balance cost, durability, and manufacturability.
• Evaluating Aesthetic and Ergonomic Factors
• The chassis should be sleek and appealing to consumers while ensuring a comfortable grip.
• Rounded edges and fillets should be applied strategically for both aesthetics and functionality.
• The chassis should integrate seamlessly with internal components, including buttons, PCBs, and the battery.
• Defining Heat Dissipation Strategies
• The CPU and battery are key heat-generating components that require efficient heat dissipation mechanisms.
• Thermal analysis should ensure that the material and design facilitate proper cooling without the need for additional heat sinks.
• Convective cooling should be considered to enhance the heat flow from the internal components to the external surface.

Developing an Optimized CAD Model in SolidWorks

With a clear understanding of the assignment’s scope, the next step is to develop an efficient 3D model in SolidWorks. This process involves carefully designing the external chassis while ensuring that internal components fit perfectly.

1. Creating the Initial Model

1.1 Understanding Design Parameters

• Utilize the given dimensions for the phone chassis and ensure proper tolerances for internal components.
• Set up the fundamental external structure using Extrude Boss/Base to create the base shape.
• Define the external thickness and ergonomic features such as curved edges and fillets.

1.2 Incorporating Internal Features

• Use Shell to create a hollow space inside the chassis while maintaining necessary thickness.
• Implement precise cutouts for buttons, ports, and internal mounts using Extrude Cut and Fillet tools.
• Design mounting points for key components like the battery, PCB, and speakers.

1.3 Enhancing Aesthetic Appeal

• Apply asymmetrical fillets for a modern and ergonomic appearance.
• Introduce subtle surface curves using the Loft and Sweep tools to make the phone more visually appealing.
• Ensure that button and port placements align with usability and ergonomic considerations.

2. Conducting Structural Analysis

SolidWorks Simulation is a powerful tool that enables designers to evaluate mechanical stress and deformation under different loading conditions.

2.1 Setting Up Structural Simulations

• Define two primary case loads: simple bending analysis and torsion-bending simulation.
• Establish boundary conditions, including fixed supports and applied forces at critical areas.
• Use Fine Mesh Refinement in high-stress regions like button cutouts to enhance accuracy.

2.2 Evaluating Bending Resistance

• Apply bending forces along the chassis to measure displacement and stress distribution.
• Identify weak points in the design and refine the geometry accordingly.
• Optimize fillet sizes and material thickness to improve strength.

2.3 Analyzing Torsional Stability

• Simulate torsional forces to determine how well the chassis resists twisting.
• Reinforce internal structures by adjusting thickness and slot placement.
• Use Von Mises Stress Analysis to identify failure-prone regions.

3. Performing Thermal Analysis for Heat Dissipation

Heat management is crucial in electronic devices, particularly for compact enclosures like phone chassis.

3.1 Applying Heat Loads

• Assign heat flux values of 5000 W/m² at the CPU region and 500 W/m² at the battery.
• Define convective heat transfer conditions with an ambient temperature of 20°C.

3.2 Assessing Thermal Distribution

• Identify areas with potential overheating issues using Thermal Analysis Simulation.
• Experiment with material choices to determine their impact on thermal resistance.
• Consider adding passive cooling features, such as small ventilation slots, if necessary.

Material Selection: Balancing Strength, Weight, and Thermal Conductivity

Material selection plays a pivotal role in determining the overall performance of a design. Let’s compare different materials based on key properties.

Evaluating Material Options

Why Aluminium 7075-O is the Best Choice

• Excellent thermal conductivity ensures heat dissipation across the chassis.
• Lightweight yet strong, making it an ideal candidate for mobile device casings.
• Moderate machinability, balancing production cost and precision.

Iterative Design Improvements and Optimization

Refinement of Component Slots

• Increased δ value from 2mm to 3mm for improved component fit.
• Expanded internal slots by 0.5mm to enhance manufacturing tolerances.

Strengthening the Chassis Structure

• Increased thickness from 10mm to 10.5mm to reduce bending deflection.
• Adjusted button cutouts and added fillets to stress-prone areas.

Validating Final Design

• Conducted final stress analysis, achieving a 13.5 MPa stress reduction.
• Ensured safe operational temperature within an optimal range.

Conclusion

Solving your SolidWorks assignment effectively requires a structured and strategic approach. By carefully analyzing requirements, building an optimized CAD model, and performing structural and thermal analysis, you can enhance the performance and durability of your design. Iterating improvements based on simulation results ensures better manufacturability and functionality. Whether designing a phone chassis or any mechanical component, the key principles remain the same—balancing strength, weight, thermal efficiency, and aesthetics. With the right workflow and attention to detail, you can confidently tackle any SolidWorks assignment, refining your skills while achieving high-quality results that meet both technical and practical requirements.