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Creating Weld Beads

Weld beads are covered in Chapter 20, but the assembly feature side of weld beads is covered here again, from a slightly different perspective. Although the SolidWorks Help refers to a Fillet Weld Bead feature, there is actually a difference between the Fillet Bead tool and the Weld Bead tool.

When comparing the functionality in the Weld Bead and Fillet Bead features, even the SolidWorks Help for the Fillet Bead recommends using the Weld Bead tool instead of Fillet Bead to insert weld beads.

The Weld Bead feature does offer some advantages over the Fillet Bead feature:

1. The same interface in parts and assemblies

2. A minimal effect on performance of even a large number of weld beads

3. A basic weld symbol is created and applied automatically

4. It works with weldable gaps

5. The Smart Weld Selection tool speeds up selection significantly

6. Weld properties serve to evaluate mass, production time, and cost

7. Weld information can be pulled onto drawings

To be clear, the Fillet Bead feature is only for weldment parts, and it creates a body with additional volume. The Weld Bead feature is for weldments and assemblies, and creates a cosmetic display body, not something that affects mass properties.

The workflow to create a weld bead is as follows:

1. Select the weld path(s). The weld path can be a set of edges (they must be between two bodies or parts) or a set of faces (they must be from adjacent parts).

You can select multiple weld paths, and the paths don't need to touch. The weld path appears as bright pink for an active path, or orange for an existing path listed in the PropertyManager.

The Smart Weld Selection tool creates new weld paths automatically based on your selections, and greatly simplifies face or edge selection for weld bead creation. Just roughly sketch with the pencil where you want the weld to go, and SolidWorks automatically selects the faces or edges to make that weld happen.

2. Set the size of the weld.

3. Define the weld symbol that includes all of the details about the weld for the welder on the drawing.

4. Set the length limit of the weld.

5. Establish requirements for intermittent weld from the options given.

The PropertyManager for a weld bead made in a multi-body part is shown in Figure 11.5.

Notice that the welds are organized by size and type within the Weld folder. Fillet Weld is the default weld type if you don't specify another type.

The PropertyManager looks the same for the weld bead done in a multi-body part as it does in an assembly. The results also look the same. Figure 11.6 shows the Weld folder in an assembly with a Fillet Weld feature in it, and a length of weld bead. Aside from the duplicate names, none of this has anything to do with the Fillet Bead feature that is only available in weldment parts.

To edit the weld bead, you have to right-click the Weld Bead item listed under the size of the Fillet Weld in the Weld folder. This brings you back to the original Weld Bead PropertyManager.

You can manage other weld properties by right-clicking the size of the weld and selecting the Properties option. The Weld Bead Properties dialog box appears, as shown in Figure 11.7.

If you have used previous versions of SolidWorks, then you will agree that this version offers the most successful Weld Bead feature to date.

FIGURE 11.5

Creating a weld bead

FIGURE 11.6

Results of the weld bead

FIGURE 11.7

The Weld Bead Properties dialog box enables you to set many options

Working with Envelopes

Envelopes in SolidWorks are regular parts that are treated in a special way. Envelopes are meant to be used as selection volumes, so that you can make selections based on whether other parts are inside, outside, or crossing the envelope boundary. You can make an envelope in place in the assembly or you can make an envelope from an existing part. Envelope parts do not count toward BOM part counts or material properties.

To create an envelope, select Insert⇒Envelope, and then choose either New or