SOLIDWORKS – Bug Rover _ Part 2 – Lever Design

In this 2nd part of design work for the Bug Rover, I’ll show you the next 2 main components: The Lever and The Lever Cap. Let’s start:

THE LEVER

STEP 1

Create new part

STEP 2

Create the following 2 sketches:

STEP 3

Use the previous 2 sketches to create a Project Curve

STEP 4

On the Projected Curve create a middle point:

STEP 5

Create the 4 new datum planes necessary for the construction of the next features, as follows:

STEP 6

On Plane 1, Right Plane and Plane 2, draw the needed sections for the definition of the lever’s form, as follows:

STEP 7

Using the 3 previoulsy created sections, create a Lofted Boss feature as shown:

STEP 8

Create a dimensionless profile big enough the cover one half of the current body and cut-extrude it through all.

STEP 9

On the circular section, sketch a circle of Ø120, then extrude it 30mm straight ahead in direction 1 and put it 55mm backwards at 20° in direction 2.

STEP 10

In similar way as done at the previous step, on Plane 3 sketch a circle as 5mm offset inwards from the outer edge and cut-extrude it in 2 direction, as through all in direction 1 and 50mm at 20° in direction 2.

STEP 11

Use the front surface to draw a horizontal construction line, then create a new datum plane having the reference the constucton line and front surface:

STEP 12

Draw a circle of Ø55 on the Plane 5, then Extrude it in both diretions, 85mm upwards and 25mm downwards:

STEP 13

Delete the unnecessary faces created by the previous extrude feature:

STEP 14

Add chamfers as follows:

STEP 15

Create a 2,5mm thin feature as 2,5mm deep cut extrude on the top side of the boss created at Step 12.

STEP 16

Add 5 fillets as shown:

STEP 17

Use the Right Plane to mirror the current body:

STEP 18

On Plane 4 sketch a circle of Ø140 in the origin point and extrude it in both directons, 40mm ahead and 60mm backwards

STEP 19

Make 3 new sections as 5mm inward offset from the initial sketches done at Step 6

STEP 20

With previously created sections, add a Lofted Cut feature as follows:

STEP 21

On planar surface from the middle boss, sketch a 5mm offset circle from the outer edge and cut-extrude it through all.

STEP 22

Create another extrude feature on the front side as shown:

STEP 23

Remove material on front side with a circular extrude 13mm deep

STEP 24

Sketch a Ø9 circle on inner planer surface, and cut-extrude it up to next

STEP 25

Circular pattern the previous cut-extrude around the outer surface for 8 instances:

STEP 26

Add chamfer on the inner edges

STEP 27

Add fillets as shown:

STEP 28

Add appearance

…with a better rendering in KeyShot the final part could look like this:

THE LEVER CAP

STEP 1

Create a new part

STEP 2

On Right Plane draw the following sketch and create a complete revolved feature:

STEP 3

Draw a construction circle of Ø105mm and a cicle of Ø9mm on the front face, then cut-extrude it through all

STEP 4

Create a counterbore on the previous feature as shown:

STEP 5

Add chamfer on the upper counterbore edge

STEP 6

Circular pattern the last 3 features around the outer circular surface for 8 instances

STEP 7

Add fillets

STEP 8

Add appearance

…with a better rendering in KeyShot the final part could look like this:

This design work is also available as video version on my YouTube channel as embedded below:

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