Revolved cut in Solidworks - Real Business Scenario

Scenario Mode

👤 Your Role: You are a mechanical design analyst at a manufacturing company.

📋 Request: Your manager wants you to analyze the impact of using a revolved cut feature on a cylindrical part to reduce material and weight while maintaining strength.

📊 Data: You have the 3D model of a solid cylinder with dimensions: diameter 100 mm, height 150 mm. The revolved cut is defined by a sketch of a profile revolved 360 degrees around the cylinder's central axis, removing material from the inside.

🎯 Deliverable: Create a report showing the volume before and after the revolved cut, the percentage of material removed, and a visualization of the part with the revolved cut applied.

Sample Data

Feature	Diameter (mm)	Height (mm)	Cut Profile Radius (mm)	Cut Depth (mm)
Original Cylinder	100	150	0	0
Revolved Cut	100	150	30	50

1

Step 1: Calculate the volume of the original solid cylinder.

Volume = π x (Diameter/2)^2 x Height = π x (100/2)^2 x 150

Expected Result

Volume = 3.1416 x 50^2 x 150 = 1,178,097 mm³

2

Step 2: Calculate the volume of the revolved cut material removed. Assume the cut profile is a semicircle with radius 30 mm revolved 360 degrees along the height with depth 50 mm.

Cut volume = (1/2) x π x (Cut Profile Radius)^2 x Cut Depth = 0.5 x π x 30^2 x 50

Expected Result

Cut volume = 0.5 x 3.1416 x 900 x 50 = 70,686 mm³

3

Step 3: Calculate the remaining volume after applying the revolved cut.

Remaining volume = Original volume - Cut volume = 1,178,097 - 70,686

Expected Result

Remaining volume = 1,107,411 mm³

4

Step 4: Calculate the percentage of material removed by the revolved cut.

Percentage removed = (Cut volume / Original volume) x 100 = (70,686 / 1,178,097) x 100

Expected Result

Percentage removed ≈ 6%

5

Step 5: Create a 3D visualization of the cylinder with the revolved cut applied, showing the hollowed section inside.

Use SolidWorks Revolved Cut feature with the semicircle sketch revolved 360 degrees around the central axis, depth 50 mm.

Expected Result

3D model showing the cylinder with a hollow semicircular groove cut along the height.

6

Step 6: Prepare a report dashboard summarizing original volume, cut volume, remaining volume, and percentage removed with the 3D visualization.

Dashboard components: Text boxes for volumes and percentage, embedded 3D model viewer for visualization.

Expected Result

Clear report showing all calculated values and the visual model for easy understanding.

Final Result

-----------------------------
|   Revolved Cut Analysis    |
|---------------------------|
| Original Volume: 1,178,097 |
| Cut Volume:      70,686    |
| Remaining Volume:1,107,411 |
| Material Removed: 6%       |
|                           |
| [3D Model Visualization]  |
-----------------------------

✓The revolved cut removes about 6% of the material volume.

✓This reduces weight while maintaining the external shape.

✓The 3D visualization confirms the hollow semicircular groove along the cylinder height.

Bonus Challenge

Analyze how changing the cut profile radius to 40 mm affects the volume removed and percentage material reduction.

Show Hint

Recalculate the cut volume using the new radius and compare with original volume.

Practice

1.

What does the Revolved Cut feature do in SolidWorks?

easy

A. Adds material by extruding a sketch

B. Mirrors a feature across a plane

C. Creates a flat surface on a part

D. Removes material by rotating a sketch around an axis

Solution

1. Step 1: Understand Revolved Cut purpose

   Revolved Cut removes material by spinning a sketch around a defined axis.

2. Step 2: Compare with other features

   Extrude adds material, mirror duplicates features, and flat surface creation is unrelated.

3. Final Answer:

   Removes material by rotating a sketch around an axis -> Option D

4. Quick Check:

   Revolved Cut = Remove by rotation [OK]

Hint: Revolved cut spins sketch to remove material [OK]

Common Mistakes:

• Confusing cut with extrude
• Thinking it adds material
• Mixing with mirror feature

2.

Which of the following is the correct syntax to start a Revolved Cut in SolidWorks?

Insert > Cut > Revolved Cut

easy

A. Insert > Boss/Base > Revolved Cut

B. Insert > Hole Wizard > Revolved Cut

C. Insert > Cut > Revolved Cut

D. Insert > Surface > Revolved Cut

Solution

1. Step 1: Recall menu path for Revolved Cut

   The correct menu path is Insert > Cut > Revolved Cut.

2. Step 2: Eliminate incorrect options

   Boss/Base adds material, Surface is for surfaces, Hole Wizard is for holes, not revolved cuts.

3. Final Answer:

   Insert > Cut > Revolved Cut -> Option C

4. Quick Check:

   Menu path = Insert > Cut > Revolved Cut [OK]

Hint: Revolved Cut is under Insert > Cut menu [OK]

Common Mistakes:

• Choosing Boss/Base instead of Cut
• Confusing Hole Wizard with Revolved Cut
• Selecting Surface instead of Cut

3.

Given a sketch of a semicircle with radius 10 mm and an axis along the diameter, what will be the result of a Revolved Cut feature?

medium

A. A solid hemisphere cut with 10 mm radius

B. A hollow sphere cut with 10 mm radius

C. A full cylinder cut with 10 mm radius

D. A hollow cylinder cut with 10 mm radius

Solution

1. Step 1: Understand sketch and axis

   A semicircle revolved around its diameter axis creates a solid hemisphere shape.

2. Step 2: Identify cut shape

   The Revolved Cut removes material in a solid hemisphere form, not a hollow sphere or cylinder.

3. Final Answer:

   A solid hemisphere cut with 10 mm radius -> Option A

4. Quick Check:

   Semicircle revolve = solid hemisphere cut [OK]

Hint: Semicircle revolve around diameter = solid hemisphere cut [OK]

Common Mistakes:

• Thinking it creates a hollow cylinder cut
• Confusing cylinder with sphere
• Assuming full cylinder cut

4.

Why does a Revolved Cut fail when the sketch is not closed?

medium

A. Because the sketch cannot form a solid profile to revolve

B. Because the axis is missing

C. Because the sketch is too complex

D. Because the material thickness is zero

Solution

1. Step 1: Understand sketch closure requirement

   Revolved Cut needs a closed sketch to create a solid profile for cutting.

2. Step 2: Identify failure cause

   An open sketch cannot form a solid shape when revolved, causing the feature to fail.

3. Final Answer:

   Because the sketch cannot form a solid profile to revolve -> Option A

4. Quick Check:

   Closed sketch needed for revolve [OK]

Hint: Sketch must be closed to revolve cut [OK]

Common Mistakes:

• Blaming missing axis instead of open sketch
• Assuming complexity causes failure
• Confusing material thickness with sketch closure

5.

You want to create a groove inside a cylindrical part using Revolved Cut. Which two things must you ensure before applying the feature?

hard

A. The sketch is closed and the part is flat

B. The sketch is closed and the axis is defined

C. The sketch is open and the axis is undefined

D. The sketch is open and the part is hollow

Solution

1. Step 1: Identify sketch requirements

   The sketch must be closed to form a valid profile for cutting.

2. Step 2: Confirm axis definition

   A clear axis must be defined to revolve the sketch correctly.

3. Final Answer:

   The sketch is closed and the axis is defined -> Option B

4. Quick Check:

   Closed sketch + defined axis = successful revolved cut [OK]

Hint: Always close sketch and define axis before revolved cut [OK]

Common Mistakes:

• Using open sketches
• Not defining axis
• Assuming flat or hollow part is required