Hi friends, Welcome to Solidworks tutorials for beginners and in this tutorial you are going to see how to use Solidworks boundary cut feature tool for creating complex product designs. Boundary cut feature tool is just like Boundary boss or base tool, but function just opposite to it. Boundary boss helps to add materials between two profiles; instead of adding boundary cut removes the materials from in two directions. You have to specify the two boundaries and apply cut feature tool to remove material even in complex manner.
What is SolidWorks Boundary Cut Feature?
SolidWorks boundary cut is a cut feature tool which helps to cut a solid model by removing material between profiles in two directions. You have to create sketch profiles in two boundaries of the solid model. Boundary cut tool is located in features command manager or cut feature from insert menu. Using the this tool, you can cut solid model design in very complex manner through curves, normal to sketch profiles, apply curvy feature to holes, tangent to faces, using direction vector etc. Solidworks boundary cut applications are creating different cross-section curved holes, mold design, complex shape face material removal etc.
Note: This is just tutorial showing how to use Boundary cut tool, not showing any product drawing or designing in it. If you are advanced SolidWorks user please avoid it. This Solidworks tutorial is for beginners, students or people likes to learn about SolidWorks.
Open SolidWorks CAD software. Click on the ‘New’ button from the quick access toolbar or from file menubar. From that, select ‘Part’ and click ‘OK’. Then you can see the Main user interface of SolidWorks modeling software.
File -> New -> Part -> OK
Select the default “Right Plane” from the Features DesignTree manager. Go to Heads-up toolbar and click on “View Orientation” and click on “NormalTo”. Then you can see the Top plane view changes from isometric to XY plane.
Step 2: Sketch the Profile
Go to sketch command manager and click on ‘center rectangle sketch tool’. Then draw a rectangle by setting the center on origin and drag outward direction.
Step 4: Sketch Two Circle Profiles on Opposite Faces
Again, select one of the faces of rectangular plate and go to sketch toolbar to select the ‘circle sketch tool’. And draw a circle on the face by setting the center on the top edge 200 mm away from the origin. Using Smart dimension, you can set the circle diameter as ‘40 mm’ and distance from the center of the circle and origin is ‘200 mm’. It is shown in the below figure:-
Click on the “Exit the sketch” button and select opposite face and apply ‘NormalTo’. Then draw another circle profile having diameter ‘80 mm’ and 200 mm away from the origin as shown in the below screenshot.
Click on the ‘Exit the sketch’ from the sketch toolbar.
Click on “Insert Menu” and from drop down menu, select “Cut” feature. Again you can see side drop down menu and select “Boundary cut” from it.
Then, you can see the Boundary cut property manager.
Step 5: Apply SoildWorks Boundary Cut Feature
You can see the two direction boxes in Boundary cut property manager such as “Direction 1 and Direction 2”. In “Display” tab, you can see the mesh preview and mesh density. Adjust the mesh density to get smooth curve or boundary cutting using this tool. In the “Direction 1 or Direction 2” tab, you can see the draft angle and tangent length setting box and setup the draft angle and tangent length to get proper boundary cut between the profiles as you created. Let us see how to apply this between two circular profiles.
Open the “Direction 1” tab and first click on the sketch 2.
Then select the ‘sketch 3’ and you can see the boundary cut preview here.
Click and hold on the green point using mouse pointer and make it is same direction for getting smooth profiles. If you set green points between the profiles in different angle to get twisted or irregular boundary cut. Here I am making to same direction to get smooth curve.
Then on each sketch apply “Normal to profile” option which is shown in the screenshot.
After that, apply draft angle as ‘1 degree’ and tangent length as ‘1.2 mm’.
Step 6: Click OK
Click on green tick button on the Boundary cut property manager to make it ‘ok’. Then you can see the final image like seen on the below screenshot.
This way you can apply Solidworks boundary cut feature tool to create complex surface cutting. There are lot of applications for this cut feature tool and you will see each one of the in the upcoming Solidworks tutorials.