2. CAD softwares

I used Solidworks and Fusion 360 because :

SolidWorks is used in the industrial equipment industry to design and develop machinery, tools, and other equipment. The software helps in creating 3D models of the equipment, simulating its performance, testing for safety and durability, and optimizing its design for efficiency and productivity.

Autodesk Fusion 360 is a cloud-based software application that helps users design, engineer, and manufacture products. It has features for 3D modeling, simulation, and collaboration. 

2.1. SOILDWORKS

SOLIDWORKS is a widely used 3D CAD (Computer-Aided Design) and CAE (Computer-Aided Engineering) software primarily used for designing and engineering products. It helps engineers and designers create precise 3D models and assemblies, supporting the entire product development process from initial design to manufacturing. SOLIDWORKS is known for its parametric design capabilities, allowing users to make changes and see how they affect other parts of the design.

2.2. Process & Steps

Step 1: Prep & choose a plane
• Start a new Part, units: mm.
• In the FeatureManager, select Front Plane → Sketch. You should see the three orthogonal planes (Front/Top/Right).
• Tool palette and gained an understanding of orthogonal views, which help in accurately visualizing and designing objects from different perspectives.


Step 2: Sketch the base outline
• On the Front Plane, use Sketch → Circleand draw a circle from the origin. Add Smart Dimension for the required size.



Step 3: Add bolt-pattern references & holes (in sketch), then cut
• Add a second (smaller) construction circle to act as a PCD for holes.




• Draw one small circle for a hole on that PCD, then use Sketch → Circular Pattern(Equal spacing, 360°, Instances = 6 or 8 as needed) to pattern it around.





• Exit Sketch → Features → Extruded Cut; select the hole circles and set Through All (or a depth > plate thickness) to make the through-holes in the flange.


Step 4.Create the Base Flange + Hub as Solids
• For the flange disc: with the large outer circle sketch visible, do Features > Extruded Boss/Base to the desired thickness.
• For the raised hub: sketch a circle on the top face and Extruded Boss/Base it upward to form the center boss. (You end up with a flange + cylindrical hub.)





Step 5. Build the Tapered Square Boss on the Hub
• On the hub’s top face, use Sketch > Center Rectangle, add dimensions, then apply Features > Boss-Extrude.
• To achieve the taper:
  • Enable Draft inside Boss-Extrude and set the required angle, or
  • Extrude a straight prism first, then apply Features > Draft to the four side faces.
• The result forms a tapered “frustum-like” square boss, seamlessly integrated on top of the cylindrical hub.


Step 6. Add the Top Pad and Edge Breaks
• On the tapered boss, sketch a slightly larger square and use Boss-Extrude to create a shallow pad (~5 mm thick).
• Break the sharp corners using Features > Chamfer (Distance × Distance; e.g., 10 mm on four edges). Fillets can also be applied on other edges if desired.




Step 7. Finish the Flange Details & Additional Features
• If more flange holes are needed, place one on the bolt circle and use Features > Circular Pattern to replicate the Cut-Extrude feature around the axis.
• Additional features shown in the image:
  • Sketch a rectangle on the top face and Boss-Extrude
  • On the front face, sketch a smaller rectangle and Cut-Extrude it to create a hollow section. Then sketch small circles and Cut-Extrude to make the ring of screw holes.
  • Apply Fillet/Chamfer to edges as required for smooth transitions and aesthetics.




Step 8. Finalize
• Single Solid Body – Shows the flange assembly as a unified solid body with all bosses and cuts merged. Ensures the design is complete before final touches.





• Final Output & Feature Tree – Displays the complete part with all features, fillets, and chamfers applied. Can also include appearances or shadows for a quick render preview.







• The finalized part is now ready for manufacturing, simulation, or as a completed project submission.





• Step 5: 3D Model




Part1 by uthayavelraj on Sketchfab

2.3. Challenges & Solutions

🔹 Challenge: Sketch Over-Defining or Under-Defining

✅ Solution:Use the “Display/Delete Relations” tool to identify and fix conflicting constraints. Always start with simple, fully defined sketches and add dimensions systematically.

🔹 Challenge:Performance Lag in Large Assemblies

✅ Solution: Use “Large Assembly Mode,” suppress unnecessary components, and enable lightweight components. Consider using SpeedPak configurations to simplify geometry without losing references.

🔹 Challenge: Feature Failures Due to Sketch Changes

✅ Solution: Use robust design practices like fully defining sketches, avoiding unnecessary external references, and employing design tables or configurations for controlled variations.

🔹 Challenge:File Compatibility and Version Issues

✅ Solution: Always save in backward-compatible formats (e.g., STEP or IGES) when sharing with users on older versions. Use the “Pack and Go” feature to include all dependencies when transferring files.

🔹 Challenge: Difficulty in Creating Complex Surfaces or Organic Shapes

✅ Solution:Leverage the “Surface” tools instead of solid features for complex forms. Use tools like “Boundary Surface,” “Loft,” and “Filled Surface” combined with guide curves for smoother, more controlled geometry.