How to model Earphone in SolidWorks?
This tutorial illustrates how to model an earphone using surfacing methods. Since a lot of persons doesn't know about surfacing model therefore i tried to perform every function step by step. If you have any problem struggling with that even after my efforts, just let me know. I will help you as much as I can.
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Step 1:
Start Solidworks in Part mode. Select front plane and then sketch.
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Step 2:
Draw entity using splines like this one. For this sketch i have used two spline and a centre line along right plane. The two splines are having tangent relation.
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Step 3:
Now select revolve surface under surfaces tab. Revolve the profile along the centre line.
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Step 4:
Under surfaces tab select Reference geometry >> plane. Now select Right plane as the first reference and offset it by considerable distance.
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Step 5:
Now select plane1 and then sketch.
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Step 6:
Draw a circle like this one.
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Step 7:
Under sufaces tab click Extruded surface.
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Step 8:
Extrude it in both direction with a considerable distance.
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Step 9:
Now select front plane and then sketch.
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Step 10:
Draw two spline cutting the surfaces.
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Step 11:
Under surfaces tab select trim surfaces.
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Step 12:
Select the surfaces under the splines and remove them.
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Step 13:
Under surfaces tab select lofted surface.
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Step 14:
Select both edges.
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Step 15:
Under Start/End constraints change start and end constraint to tangency to face. Click OK.
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Step 16:
We have basic shape of the earphone. I have decreased the radius of the extruded surface Because it was a little larger.
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Step 17:
Select section view in standard views.
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Step 18:
Select front plane for section and click OK.
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Step 19:
Under surfaces tab select offset surface.
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Step 20:
Select the top face and change the distance to minimum i.e. about 1.5mm in my case.
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Step 21:
Now select Top plane and then sketch.
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Step 22:
Draw a circle.
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Step 23:
Under surfaces tab select trim surfaces.
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Step 24:
Trim the inner portion of the top-most face.
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Step 25:
Again top plane and then sketch.
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Step 26:
This time draw a circle considerably smaller than last one.
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Step 27:
Select trim surface under surfaces tab.
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Step 28:
Select the outer portion of the offsetted surface.
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Step 29:
Click OK and the area is trimmed.
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Step 30:
Under surfaces tab select boundary surface.
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Step 31:
Select both edges.
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Step 32:
Select tangency to face for both edges.
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Step 33:
Click OK.
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Step 34:
Now under surfaces or feature tab select reference geometry and then axis.
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Step 35:
Select top plane and origin. This will create an axis perpendicular to top plane and passing through origin.
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Step 36:
Now select top plane and then sketch.
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Step 37:
Make a circle for hole.
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Step 38:
Now click linear sketch pattern in sketch tab.
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Step 39:
Select the circle to entity to pattern.
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Step 40:
Adjust the distance and increase the number of instances.
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Step 41:
Now select circular sketch pattern.
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Step 42:
Now select the 2nd circle to pattern.
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Step 43:
Repeat the same step for other circles increasing the number of instances each time.
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Step 44:
Under surface tab select trim surface.
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Step 45:
Now select keep selection.
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Step 46:
Select the excluded surface of holes.
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Step 47:
Click OK and the surface is trimmed.
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Step 48:
Now select top plane and then sketch.
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Step 49:
Use slot tool to make 2 slots.
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Step 50:
Now select trim surface in surface tab and select remove selection. Select the surface bounded in slots and click OK.
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Step 51:
Now we have the space for the air.
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Step 52:
Select knit surface under surface tab.
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Step 53:
Select all surfaces one by one and then click OK.
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Step 54:
Under surface tab select thicken.
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Step 55:
Select the surface. It will select Knit surface feature. Change the thicken distance to 1mm and outside direction. Click OK.
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Step 56:
Now we have solid body of the earphone. We will now seperate the bodies.
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Step 57:
Select top plane and then sketch.
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Step 58:
Change view to hidden with shaded line.
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Step 59:
Offset the edge by 0.50mm and then draw two straight line horizontally. Trim other entities.
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Step 60:
Select revolved surface in surface tab.
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Step 61:
Select axis1 and click OK.
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Step 62:
Go to insert menu then feautres >> split.
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Step 63:
Select the revolved surface as the trim tool and click cut part.
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Step 64:
Now check both the bodies and click OK. This feature will generate two split bodies by the revolved surface.
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Step 65:
Now hide the revolved surface.
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Step 66:
Again select section view about front plane in standard view toolbar.
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Step 67:
Select reference geometry and then plane under surface or features tab.
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Step 68:
Select top plane and then offset it by a distance so that it will lie in the upper body.
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Step 69:
Select the plane2 and then sketch.
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Step 70:
Draw a circle larger than the region bounded by the holes.
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Step 71:
Under features tab click extruded boss/base feature.
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Step 72:
Under direction1 select up to body.
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Step 73:
Select the upper body and enable thin feature by a distance of 0.50mm. Click OK.
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Step 74:
Now we have the body for the speaker of ear phone.
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Step 75:
Now click file save.
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Step 76:
Enter any file name for the part document. I entered earphone for myself.
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Step 77:
After saving part click insert>>feature and then split.
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Step 78:
Again select revolved surface2 from the surface bodies under tree view and click cut part.
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Step 79:
Double click the cut body1 and save it.
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Step 80:
Repeat the same step for the other body and click OK.
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Step 81:
Now right click the split2 feature and then select create assembly.
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Step 82:
Click browse.
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Step 83:
Now save the assembly file for the splitted part document.
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Step 84:
Now the assembly file will open.
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Step 85:
Right click the upper body and select float.
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Step 86:
Move it and then rotate it to have a better view.
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Step 87:
Here is the rendered image of the earphone. This one is not much better than the last one but you can make one better if done with care.