What's the best approach to modeling a weldment that's made up of a variety of different sizes of square & rectangular tubing, flat stock, & sheet metal components?
By using Configured Profile, We can insert variety of Profiles with Variety of Sizes in Weldment.
Kindly follow the below Procedure for creating Configured Weldment Profile in solidworks,
1. Create a folder, inside the 1st folder create another one New folder.
2. Open New Part file, save the part file in .SLDLFP format.
3. Create variety of profiles in different sketches, Refer below screen shot
4. Create multiple Configuration with respect to Sketch.
5. Pick 1st configuration and go to Feature manager design tree. Right click the respective sketch and give "Add to library" and Suppress other sketchs. move to Next Configuration, right click respective sketch and give "Add to library".
Now You can able to have variety of Profiles in Single Sketch. Kindly refer the attached file
View the attached video file for weldement best practice.
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I would create the main structural weldment part using 3d sketch. Then insert this into an assy. into this main assy you can add your sheet metal parts or other weldment structures and sub-assy's.
I don't work with sheet metal, but I often have plate and flat stock in my projects. I have created rectangular sketches and saved them as library feature parts, so plate and strap are weldments also. See this Discussion: Using Plate in Weldments .
with regards to mating the assembly if you are using round type weldments with sheet metal, as above image, be very cautious of using tangent mates between parts!
the slightest design or dimensional change will turn your assembly into a birds nest even when fully defined. I make use of work planes to mate sheet metal to round type weldments within assemblies, as these are much more stable and allow for designing for change.
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