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Using the End Cap feature

The End Cap feature closes off an open-ended Structural Member. You can add multiple end caps in a single End Cap feature. The PropertyManager and the end product are shown in Figure 20.13.

FIGURE 20.13

Using the End Cap feature

The end cap using the Outward option sits on the outside face of the member, and overlaps the thickness of the member by the inverse of the Thickness Ratio that is applied in the Offset panel. If the Use thickness ratio option is turned off, then it functions as an offset from the outer faces of the member from which it is created. When this option is turned on, the thickness ratio can range from zero to one. For a value of zero, it is flush with the outer faces of the member, and for a value of one, it is flush with the inner faces of the member. Using the Inward option, the cap fits inside the hole in the member.

Working with the Gusset feature

The Gusset feature creates a three-, four-, or five-sided gusset in a corner between Structural Members, as shown in Figure 20.14. You can place the gusset at specific locations along the edge in the corner, or offset it by a specific dimension in a specific direction by using the settings in the Parameters panel. You can control the size and thickness of the gusset in the Profile panel. There is no sketch for this feature type; it is simply created from the parameters that you enter in the PropertyManager interface. Again, if you need to make multiple Gusset features in succession, you can use the pushpin icon to keep the interface displayed until you close it by clicking the red X icon.

FIGURE 20.14

Using the Gusset feature

Using Non-Structural Components

Non-structural components are frequently needed in weldments, and include items such as feet, plates, brackets, mounting pads, and castings. Simpler items that can be easily modeled in place can be placed directly into the weldment part. You can also insert parts into the weldment using the Insert Part feature, and move them into place by using dimensions or mates. In general, if any item is actually welded into the weldment, then you should place it in the weldment part; however, items that are bolted on should probably be placed into an assembly. Of course, this probably depends more on your company's documentation standards, part-numbering standards, and assembly processes than on software capabilities.

When adding a plate such as the footplate shown in Figure 20.15, the geometry is added using the standard Extrude feature, except that the Merge option is deselected by default. This ensures that non-structural components that are manually modeled, such as this part, are created as separate bodies, and not merged together with the existing structural items.

FIGURE 20.15

A footplate added to the weldment

Using Sub-Weldments

From a modeling point of view, sub-weldments are generally used for either organizational or performance reasons to group together elements of a weldment or to break a larger weldment into more manageable pieces. This is in much the same way that subassemblies are created for the same purposes within larger assemblies. From a fabrication point of view, sub-weldments are also used to break a large weldment into pieces that can be transported or handled.

To create a sub-weldment, you can select several bodies from the cut list, and then select Create Sub-Weldment from the RMB menu. (You can also select the bodies from the graphics window if you use the Select Bodies selection filter.) This creates a separate folder for the sub-weldment bodies. You can then right-click the sub-weldment folder and select Insert Into New Part.

Working with Cut Lists

The cut list that is maintained in the model FeatureManager is simply a replacement for the Solid Bodies folder. It has most of the same functionality as the Solid Bodies folder, as well as a few additional items. The Cut List folder symbol in the FeatureManager can appear in one of two potential states; these symbols