Pro e Guide

UNIVERSITY OF CAMBRIDGEDEPARTMENT OF ENGINEERING

PART 1A CAD COURSE

HANDOUTS

&

EXERCISES

K.M. Wallace Jan 2006P.J.G. LongD. Underhill

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Notes for students

1. Course content

The course comprises the 9 introductory lectures in LT1 followed by practical sessionsin the Design and Project Office (DPO). It represents the second ‘half’ of the Part1A Drawing Course and aims to give a introduction to the use of a modern CADpackage (Pro/Engineer Wildfire 2)

2. Course timetable

The timetable of exercises for the Lent and Easter terms is as follows (see thecontents page for further details):

LENT TERM

Week 1&2 Morning: Exercise 8: Constructing Simple Components

Afternoon: Exercise 9: Intersections, Part Drawing (1) and Patterning

Week 3&4 Morning: Exercise 10: Components and Part Drawing (2)

Afternoon: Exercise 11: Assemblies (1) and GA Drawings

Week 5&6 Morning: Exercise 12: Assemblies (2)

Afternoon: Exercise 13: Component Design

Week 7&8 Morning: Exercise 14: Dynamic Assembly (1)

Afternoon: Deferral Session

EASTER TERM

Week 1&2 Morning: Exercise 15: Dynamic Assmbly(2)

Afternoon: Exercise 16: Sheetmetal

The lectures for the course precede the scheduled morning and afternoon practicalsessions. i.e. at 11.05 and 14.15 on Thursdays, and 09.05 and 14.15 on Fridays.

3. Practical sessions As with short experiments, you are required to attend thetimetabled practical sessions and you must ensure that you have been signed-in by ademonstrator shortly after arriving in the DPO after the introductory lectures.

4. DPO drawing board/PC allocation Clusters of PC’s in the DPO are assigned tospecific lab groups as indicated on the attached sheet.

5. Marking Each drawing lecture and practical is self-contained, and drawings orprintouts should be marked by the end of each session i.e. the morning practicalshould be marked up by 13.00 on Thursdays and by 11.00 on Fridays, the afternoonpractical should be marked up by 16.30 on both Thursdays and Fridays.

All drawings or printouts must be posted into the IA Drawing ’postbox’ at the westend of the DPO by the end of the afternoon practical sessions.

Each exercise is marked as a short experiment: 2 marks for prompt attendance andsatisfactory work, 0 otherwise. All sixteen exercises must be completed to obtain the32 marks required to qualify. See ’A Guide to the Engineering Tripos, PartI’ or webpage: http://eng.cam.ac.uk/teaching/tripos/four year course guide-Part I.html forfurther details on Part I coursework marking.

As is the practice with IA and IB computing practicals, the marked coursework willbe retained and not returned.

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IA Drawing and IA Computing marks are displayed in the DPO. Please checkregularly that your marks have been entered. Contact Derek Underhill in DPO Officeif you have any queries about your marks.

6. Demonstrators Demonstrators are available immediately after the lecture andthroughout the practical sessions (Thursday mornings until 13.00 and afternoonsuntil 16.30; and on Friday mornings until 11.00 and afternoons until 16.30). Thedemonstrators are primarily there to offer help and advice, though they also attendto signing in and marking up - PLEASE use their help if you need it - you will not bepenalised.

7. Deferral Deferring one drawing exercise in the Lent term is possible if you elect tomiss a session for any reason. Deferred exercises may be completed and submittedwithout penalty but should ideally be completed within the two week ’cycle’ of thatparticular exercise. If this is not possible, it must be done in the deferral session atthe end of term. NOTE: exercises submitted after this date will not be accepted.Permission to defer a drawing exercise must be obtained beforehand from DerekUnderhill by e-mail (du203). The email should state the session you wish to deferand list the alternative sessions you can make.

8. Allowance for illness

For allowances for illness and other grave causes, see ’A Guide to the EngineeringTripos, Part I’ or web page:http://eng.cam.ac.uk/teaching/tripos/four year course guide-Part I.html.

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Contents

Introduction to CAD 11

1 Background 11

2 Overview of Pro/ENGINEER 11

2.1 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2.1.1 Datum Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2.1.2 Sketched (Base) Features . . . . . . . . . . . . . . . . . . . . . . . . . 12

2.1.3 Pick and Place (or Referenced) Features . . . . . . . . . . . . . . . . 13

2.2 Modification of Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Exercise 8: Simple Extruded and Revolved Parts 15

1 Key 16

2 Getting Started 16

3 Creating a Part 17

4 Task 1 (a) - Extruded Section 17

4.1 Starting an Extrusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4.2 Review/Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

4.3 Edit Profile Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

4.4 Save Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

4.5 Print Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

4.6 Exiting ProEngineer Wildfire . . . . . . . . . . . . . . . . . . . . . . . . . . 21

5 Task 1 (b) - Revolved Section 22

5.1 New part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

5.2 Revolved Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

5.3 Edit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

6 Task 2 - Woodruff Key 24

6.1 Woodruff start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

6.2 CUED Quick Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

6.3 Extruded Cut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

7 Task 3 - Keeper Plate 25

7.1 Open an existing file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

7.2 Create a ‘Round’ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

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7.3 Create a ’Chamfer’ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

7.4 Modify the Original Extrusion . . . . . . . . . . . . . . . . . . . . . . . . . . 26

8 Task 4 - Additional Components 26

9 Construction and Editing (aide-memoire) 31

Exercise 9: Intersections, Patterns and Part Drawing (1) 39

1 Key 41


3 Task 1 - Cylinder/ Domed-Cylinder Intersection 42

3.1 Start Domed-Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

3.2 Quick Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

3.3 Cylinder Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

4 Task 2 - Initial Drawing 43

4.1 Start a Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

4.2 First View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

4.3 Additional Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

4.4 Display Centerlines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

4.5 Drawing Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

5 Task 3 - Cylinder/Dome Intersection 46

5.1 Cylinder 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

5.2 Intersection Drawing Review . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

6 Task 4 - Parent/Child Relationships 48

6.1 Activate Domed-Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

6.2 Create a shell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

6.3 Check Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

6.4 Reordering Model Tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

7 Task 5 - Mounting Flange 49

7.1 Extruded Flange Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

7.2 Revolved Flange Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

7.3 Mounting Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

7.4 Patterned Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

8 Drawing 2 (Updated) 50

8.1 Tidy Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

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8.2 Isometric View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

8.3 Printing a Drawing - for information ONLY . . . . . . . . . . . . . . . . . . 52

Exercise 10: Assembly Components and Part Drawing(2) 53

1 Key 54


3 Task 1 Pulley 55

3.1 Start Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

3.2 Base Shape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

3.3 Belt Groove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

3.4 Keyway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

3.5 Fillets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

4 Task 2 - Shaft 57

4.1 Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

4.2 Base Shape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

4.3 Woodruff Keyway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

4.4 Hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

4.5 Cosmetic Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

4.6 Fillets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

4.7 Edit Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

5 Task 3 2D Drawing of the Pulley 60

5.1 Setting the overall Drawing Scale . . . . . . . . . . . . . . . . . . . . . . . . 61

5.2 Sectioned Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

5.3 Tidy Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

5.4 Isometric View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

5.5 Printing a Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

5.6 Shaft Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Exercise 11: Component Assembly and GA Drawings 67

1 Additional Parts 68

2 Sub-Assembly 68

2.1 Start Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

2.2 Initial Component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

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2.3 Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

2.4 Keeper Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

2.5 M12 Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

2.6 Simplification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

2.7 Roller Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

2.8 Woodruff Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

2.9 Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

2.10 Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

2.11 Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

2.12 Resume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

3 Main Assembly 73

3.1 Tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

3.2 Sub-Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

3.3 Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

3.4 Remove Cut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

3.5 Transparency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

4 Drawing 75

4.1 Load Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

4.2 Datum Planes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

4.3 Section View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

4.4 BOM Ballons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

4.5 Additional View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

5 Modified Pulley (Optional) 77

5.1 Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

5.2 Thicken Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

5.3 Mounting Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

5.4 Patterned Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

6 Drawing 2 (Optional) 78

6.1 Suppress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Exercise 12: Assemblies (2) 81

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Exercise 13: Component Design 83

Exercise 14: Dynamic Assembly (1) 87

1 Dynamic Analysis 89

2 Dynamic Model Assembly 90

2.1 Crankshaft Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

2.2 Piston Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

2.3 Conrod Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

3 Manipulation of Dynamic Assembly 91

3.1 Manual Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

3.2 Automatic/Driven . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

3.3 Results Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Exercise 15: Dynamic Assembly (2) 95

1 Key 96


3 Task 1 - Static Assembly 1 97

4 Task 2 - Static Assembly 2 97

5 Task 3 - Dynamic Assembly of lift mechanism 98

6 Task 4 - GA drawing 2 98

Exercise 16: Sheetmetal 99

1 Key 100


3 Sheetmetal Fundamentals 101

4 Task 1 - Extruded Bracket 101

5 Task 2 - Adding an additional Wall 1 102

5.1 Flat wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

5.2 2-D drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

6 Task 3 - Robot Chassis 104

6.1 Solid Model of chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

6.2 Conversion of chassis to sheetmetal . . . . . . . . . . . . . . . . . . . . . . . 105

7 Task 4 - ‘Ripping’ the 3-D model 105

7.1 Insert ‘rips’ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

7.2 Second Drawing Sheet + Development . . . . . . . . . . . . . . . . . . . . . 106

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8 Task 5 - Adding Tabs to the Chassis 106

8.1 ’Flat Wall’ Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

8.2 Bend relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

8.3 Drawing Update . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

9 Task 6 - Copying Tabs 107

10 Task 7 - Predefined wall extensions 108

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Introduction to CAD - (Pro/ENGINEER)

1 Background

Methods of Recording, Transferring & Illustrating DesignInformation

Method System Date Current Cost

Freehand Sketching Still the basis for most de-signers

3000 B.C. + Cheap

Isometric ∼ 1800 Decreasing

2D Drawing Manual ∼1700 Increasing

2D CAD Autosketch, CoCreate,Visio,ProCAD, etc

1960’s upto £2000

2/3D CAD AutoCAD, CADKey 1970’s Up to ∼£3000

3D Modellers CATIA, Unigraphics, Pro-Engineer, IDEAS

1980 → upto ∼£100,000

(PC Based - Solidworks,Solidedge, Pro/Desktop)

2000 upto ∼£5000

2 Overview of Pro/ENGINEER

Pro/ENGINEER (Pro/E for short) is a commercial CAD/CAM package that is widelyused in industry. It is one of the newer generation of systems that not only offer a full 3-Dsolid modeller, in contrast to purely 2-D and surface modellers, but also has parametricfunctionality and is fully associativity. This means that explicit relationships can beestablished between design variables and changes can be made at any point in themodelling process and the whole model will be updated. The version used in this course isPro/Engineer Wildfire 2 which has a new icon based user interface, a trend becoming morecommon in engineering applications.

The method of constructing a model of an object is very similar to that followed in theproduction of a physical component. For example the manufacture of the shaped block inFigure 7:1 would start with the choice of construction environment, the selection of a pieceof stock material followed by a series of manufacturing processes, e.g. milling, drilling,welding/sticking. Pro/E has direct analogues for most of these operations as various typesof FEATURES which can be combined to generate a complete representation of a PART,Pro/E’s terminology for a single component. Features fall into three main categories,Construction, Sketched and Pick and Place.

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Construction of a Part

Round/Fillet(P&P)

Protrusion(Sketched)

Chamfer(P&P)

Hole{P&P} Cut

(Sketched)Slot(Sketched)

Workshop

Select stock

Material

Cutoff length of

Stock Material

Turn. Mill, Drill, etc

to shape part

ProEngineer

Sketch Initial

Cross-section

Use Protrusion

(Extrude, Revolve etc)

to generate 3-D workpiece

Use Pick and place,

Sketched Feature

to create finished part

Figure 7:1: Comparison of physical and Pro/E methods of part construction

2.1 Features

2.1.1 Datum Features

These features are purely used as an aid to the construction of the part, a number ofvarious forms are available the most commonly used are the:

• Csys Coordinate systems which aid in the orientation of additional features and theassembly of the part in to subsequent assemblies. CSYS feature is normally the firstfeature in a part definition and is used as the basis for the placement of allsubsequent features.

• Datums These are an extension of the idea of construction lines as used on atraditional drawing. The most used type is a DATUM PLANE which allows a 2-Dreference plane to be defined in space. Additional forms include DATUM AXES,DATUM POINTS and DATUM CURVES. It is normal to add three DEFAULTdatum planes, immediately after the initial coordinate system, to effectively generatedefault x-y, x-z and y-z planes (called respectively Front, Top, Mid in the CUEDstandard part.)

2.1.2 Sketched (Base) Features

These features are so named because they all involve the use of the SKETCHER modewithin Pro/E, (see below for more details on its use). The main features that use thisfunctionality are:

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• Extrude/Revolve (Protrusions) Using these features material can be addedto/taken away from a part by sketching a cross-section and thenextruding/revolving/sweeping the section to produce a 3-D solid/cut. A additiveprotrusion is normally the first non-constructional feature in a part, and is used toproduce the base solid entity of the part.

• Sweep/Blend These features allow the user to define more complicated protrusionswith multiple cross-sections

• Style/Wrap More advanced Surfacing and distortion features

• Rib This allows the user to produce a thin rib or web. This is a specialised version ofthe protrusion function.

2.1.3 Pick and Place (or Referenced) Features

Pick and place features derive their form from existing geometry and do not need to besketched e.g. HOLES, ROUNDS and CHAMFERS. The action to produce the requiredeffect has been preprogrammed into Pro/E, thus only requiring the user to indicate theposition of the operation on the existing model.

2.2 Modification of Features The parametric nature of Pro/E means that themodification of features is relatively easy, individual features can be selected and theassociated parameters/dimensions changed. However, it should be noted that Pro/Eproduces a HISTORY based model in which features can be dependant on one or moreprevious features for their definition, e.g. a chamfer on an edge generated by a cut orprotrusion. These PARENT-CHILD dependencies mean that when a parent feature ismodified its children are automatically revised to reflect the changes.

Care should be taken not to remove references used by child features. In most cases it isbest to leave in definition of Pick and Place features until the end of the design to reducethese problems. This has a parallel in physical construction where the adding of chamfers,rounds and holes etc is left as late as possible to reduce measurement difficulties.

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Exercise 8


DRAWING COURSE

Introduction

This exercise gives a introduction to the use of an industrial standard solid modelling CADpackage, Pro/Engineer Wildfire.

Problem

Use Pro/Engineer Wildfire to model the following parts:

1. A Cylindrical Spacer using

(a) A extruded section.

(b) A revolved section.

2. Woodruff Key using an extrude followed by a cut.

3. Keeper plate produced by modifying an existing object. (a spacer)

4. Non-functional Block Example to see how many features can be combined toachieve the desired result.

N.B. Save your work at regular intervals and print out your work after eachitem has been competed to avoid clogging the printer at the end of the session.

PLEASE MAKE SURE YOU HAVE PUT YOUR NAME, LAB. GROUPAND COLLEGE ON YOUR PRINTOUTS. THESE SHOULD BE PUT INTHE ’POST BOX’ ONCE THEY HAVE BEEN SIGNED UP.

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1 Key

To aid in the use of this handout a number of conventions/fonts/abbreviations have beenused to indicate the difference between keyboard entry, menu titles, menu items etc. Theseare listed below:

Font Used Item

Bold/Times: menu item

CAPITALS: WINDOW/MENU TITLE

Italic: Keyboard inputs

Bold/Helvetica: Hint

Abbreviation Action

LMB Left Mouse Button

MMB Middle Mouse Button

RMB Right Mouse Button

Menu items followed by a → indicate that the user should follow the input to a cascaded orflyout menu. N.B. In many cases the choices required are the default and therefore do notneed to be individually selected.

Central to the use of the package is the ability to obtain the best view of the object you areconstructing, e.g. the orientation and the display mode. Access to commands affecting thedisplay are concentrated under the View pull down menu and the top icon bar. In additionthe orientation can be manipulated with a combination of the Ctrl/Shift keys and themouse.

Key/Mouse Action

(N.B. The Ctrl key can normally be released oncethe action has been initiated.)

Ctrl - Middle Mouse Button Zoom in/out

- Middle Mouse Button Spin

Shift - Middle Mouse Button Translate

2 Getting Started

• Close down unused programs, ProE imposes a large load on the system

• Select Start from the main icon bar and then select Pro/Engineer Wildfire 2from the Programs→3D Modelling submenu.

This will start the package, and set the working directory (where your files will be stored)to /userid/ProE/. Within this area are a number of predefined directories, ex8 11, ex12 13,ex14.., which will be used to store the work for each of the drawing exercises.

To change to the directory for this exercise select FILE → Set Working Directory (oruse the hotkey option cd) and then select the directory ex8 11 from the file browserwindow, close with OK.

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3 Creating a Part

Use the LMB to select NEW PART icon ( ) on the top menu bar, this will start anautomatic procedure to generate a new part using the default CUED settings.

After a few seconds a menu will appear prompting for the name of a part, typespacer1 xxx123 (where xxx123 is your userid) and then press ENTER or click (LMB) onOK.

This will initiate a procedure to set up the default coordinate system and datum planes(Front, Mid, Top) which will appear in the main window.

N.B. The brown Datum icons ( ) on the top icon bar can be used totoggle the display of datum features

ExtrudedSketched X-section

Cylindrical Spacer

(a) (b)

Figure 8:1: (a) Example Cylindrical Spacer (b) ‘Extrude Tool’ used to generate Spacer

4 Task 1 (a) - Extruded Section

The ”Extrude” function, often used to generate an initial part (c.f. the concept of stockmaterial in a workshop), is used to produce the basis of a cylindrical spacer, as shown infigures 8:1 (a) & (b).

4.1 Starting an Extrusion Create a base protrusion (stock material) by

selecting the Extrude Tool icon ( ) from the right hand icon-bar, this will initiate the

’Extrude Dashboard’ ( ) just below the message window.

• Create a Section

It is possible to use an exisiting sketch as the basis of a sketched feature, herehowever use the internal sketch option by RMB→Define Internal Sketch.

This will open a SECTION window and a prompt in the message window to ”Selecta plane or surface to define sketch plane”. Moving the mouse over the main windowwill highlight (in light blue) each of the possible sketch planes.

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Section Menu

Using the LMB, select the plane FRONT when highlighted or the Model Treewindow.

Immediately the menu will be populated with default values and also indicated onthe main window.

1. An arrow indicates the direction of view of the sketch plane

The direction can be changed using the Flip button, in this example anydirection will be suitable.

2. The sketchplane can be presented on the screen in any angle and a preferredorientation can be selected by using the reference and orientation menuitems. In most cases ProEngineer makes an intelligent guess at the requiredorientation and therefore the default can be accepted.

In this case choose the defaults, by selecting Sketch.

N.B. Sketch is highlighted on a raised button in the menu and can thusbe selected as the default option in the menu by pressing the MMB (withthe pointer in the main window), see above.

3. Dimension References

Reference Menu

To automatically dimension any entity drawn the system needs a localdimensioning reference. When the sketcher mode is entered a REFERENCESwindow is displayed which lists the entities that have been choosen as defaultreferences and indicated in the sketching window by brown dash-dot-dot lines.

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In this example the default references should be ‘F1(MID)’ and ‘F2(TOP)’ thusselect (LMB) Close . Any further drawing on this plane will be referenced tothis temporary coordinate system.(N.B. It can be useful at this stage to Deselect the Datum Plane icon to

simplify display)

4. Sketching a Section

Figure 8:2: Initial sketcher mode layout.

Using the sketch circle function, accessed via either the circle icon (3rd icondown) or by selecting the Circle entry on the floating menu (Opened by usingthe RMB while the pointer is over the main drawing window), draw twoconcentric circles, of arbitary size, centered on the intersection of the referencelines, see Figure 8:2.

To draw a circle move the pointer, (modified to a cross once the circle functionhas been selected) over the intersection, click/select (LMB) to set the centrethen drag the pointer and click/select to define the circle radius. Click LMBonce to place circle, click MMB once to end the operation and to return tostandard pointer.

To delete unwanted items, select the entity (line will turn red) and thenselect delete by holding down RMB → Delete. Multiple entities can beselected by dragging a boundary using the LMB

(Should artifacts be left on the window use VIEW → Repaint, the

Repaint icon on the top menu bar ( ) or the hot-key sequences (CTRL)+ R or vr) to refresh the screen.

Note :(a) The pointer has ‘intellegence’ and snaps as it approaches anintersection/circle centre/line etc(b)Pressing MMB once while drawing an entity will abort the operation andreturn to the standard select option.Once drawn the system will allocate default dimensions to the entities, whichare displayed in grey. The values are based on the screen resolution/setup and

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any previous components of the part.

(It is worthwhile spending some time familiarising yourself with thesketcher mode - add lines, rectangles etc and then delete them.)

Although the dimensions for our spacer are not correct at this stage the sketchis complete and the sketcher mode can be exited be selecting the ‘Tick’ at thebottom of the side icon bar or from the pull-down menu SKETCH → Done.This changes the colour of the extrusion to a transparent yellow and re-enablesthe protrusion dashboard.

• Solid/Surface ( )

Leave the default setting of the first and second dashboard icons, e.g. the ”extrude assolid” option (first icon) selected.

• Depth ( )

The left depth icon allows the user to select details of the extent of the extrusion,accept the default (”Extrude from sketch plane by a specified depth value.”)

Adjust the depth to 32 by chosing one of the following techniques:

1. Enter value in the field on dashboard

2. Selecting and dragging the square handle (small white square, on axis) on theextrusion in the main window. Note it can be difficult to acccurately choose avalue using this technique.

3. Double clicking, with LMB, on the dimension in the main window and enteringthe required value.

• Verify/Preview ( )

The defined feature can now be temporarily previewed by verify icon ( ), fromthe right hand end of the dashboard. If an error exists individual elements of theprotrusion can be modified by re-selecting the appropriate icon.

• Exit ( )

Once completed the protrusion can be accepted by selecting the tick ( ). N.B.Selecting the cross will cancel the generation of the feature.

4.2 Review/Display The Protrusion can now be rotated and/shaded to improvethe view of the feature.

1. Press the MMB to rotate the model. Use SHIFT and CTRL to zoom and pan.

2. Select Shading, Wireframe etc icons ( )

3. You can also reset the view and repaint it. These options are available by choosingVIEW pull down menu or from the icon bar ( ) ( ) .

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(a) (b)

Figure 8:3: (a) Editing the Outer diameter (b) Edit Definition, selecting Edit internal sketch

4.3 Edit Profile Dimensions There are several ways of modifying a featuresdimensions, including

1. Select the feature (Extrude 1) in the Model Tree or drawing screen, (Highlightprotrusion feature in light blue and select with LMB) and then using the RMB selectEdit. The defining dimensions are displayed in the main window, Select the value tobe modified (double click LMB) and enter the value at the prompt.

Modify the inner diameter to 13, the outer diameter to 40 and the length to 80. N.B.Dimension values switch from yellow to green when they have been modified.

To action the modifications select Regenerate from the EDIT menu, the image willanimate to the new dimensions.

(N.B. The regenerate function can also be actioned by (a) Using the hotkeys

rg (b) Selecting the Regenerate icon

2. Select the required feature and in the flyout menu (RMB) select Edit Definitionwhich will return to the protrusion dashboard. Where the feature can be edited andpreviewed prior to regeneration. If required the section can be redefined by selectingRMB→Edit Internal Sketch.

4.4 Save Part Use the FILE → Save function or save icon ( ) to save the partin its current form.

4.5 Print Screen To record the current work, arrange the windows on the desktopto show the main drawing window, with the part displayed, the MODEL TREE menu andthen select ( ) from the top icon bar. When the mouse pointer changes to a crossclick over the window and wait for a quiet beeb.

4.6 Exiting ProEngineer Wildfire If you need to exit ProEngineer, selectFILE→Exit. The system will then prompt the user to save each of the components,constructed to date, in turn.

(To speed the exit process type either a or q (save all items or discard all items,respectively) at the prompt)

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5 Task 1 (b) - Revolved Section

RevolvedSketched X-section

Cylindrical Spacer

Figure 8:4: Revolve Tool used to generate Spacer

This example demonstrates an alternative method of producing a spacer, using a revolvedcross-section to define the solid material. The procedure is very similar to the previousexample and therefore less explanation has been included

5.1 New part Select the NEW PART icon again and name the new partspacer2 xxx123. (xxx123=userid) Selecting OK will set up the default datum planes as in

the last Task

5.2 Revolved Feature Select the Revolve Tool icon ( ) and thensystematically work from left → right along the dashboard

• Section Use the internal sketch option (RMB → Define Internal Sketch) and chooseFRONT as the sketch plane and accept the defaults for the direction, reference planeand orientation.

Accept the default drawing references

Figure 8:5: Axis of rotation and cross-section for the revolved section.

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To complete the section it is neccessary to define both the axis of rotation and therevolved section

1. To define the axis of rotation select RMB → Centreline to choose thecentreline tool. To place select (LMB) the intersection of the reference line anddrag and reselect vertically above to produce a vertical centreline aligned to thereference origin.

2. Use either the Rectangle or line functions to sketch one side of the spacerparallel to the axis of rotation, see Figure 8:5

By default the soft dimensions chosen by the system are shown as oneradius + a thickness. To redefine dimensions, select the RMB →

Dimension tool and then select the two ends of the dimension requiredand then MMB to place the dimension.

3. Exit the sketcher mode using the ‘Tick’ at the bottom of the side icon bar

(a) (b)

Figure 8:6: (a) Use drag handles (white square) to dynamically adjust the angle of rotation(b) Preview of 360o revolved section

• Edit Experiment using the drag handle to adjust the angle of rotation and thenensure that the dimension field is 360o.

The dimension pulldown menu has standard dimensions and recently useddimensions, useful when switching between trial values.

• Preview ( ) Use the Verify/Preview icon to check the completed revolved entity

• Exit ( ) Exit the revolve tool

5.3 Edit . Using LMB to select and the RMB → Edit command change the innerradius to 16, the outer radius to 35 and the length to 80. Do not forget to regenerate(select , Regenerate from the EDIT menu) or hotkey ‘rg’ to update the values.

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Save Part Use the FILE → Save function or save icon ( ) to the save the part inits current form.

Print Display the main window and MODEL TREE menu on the screen and select thePrintScreen icon ( ).

ExtrudedSketched X-section

Circular Blank

Woodruff Key

ExtrudedCut X-section

Figure 8:7: Two Feature construction (Extrusion - Cut ) used to generate Woodruff Key

6 Task 2 - Woodruff Key

This Task demonstrates the use of multiple sketched features to define a Woodruff Key

6.1 Woodruff start Select the NEW PART icon again and name the new partwoodruff xxx123.( xxx123=userid) → OK.

6.2 CUED Quick Start To produce the initial circular protrusion select theCUED fast start option from the CUED menu, Extrude 2s, to start the sketcher mode fora two sided extrusion. . (Extrude 1s and Revolve 360 give similar quick starts for 1sided extrusion and revolve respectively)

Select the default drawing references by selecting Close or using MMB

• Section

Draw a single circle centred on the dimension references. Adjust the diameter to 16mm, by double clicking on the dimension in the sketcher display and entering 16 atthe prompt. Alternatively select the dimension with the LMB and then use RMB toaccess the floating menu, select Modify and use the resultant MODIFYDIMENSIONS window to adjust the value. Exit the sketcher mode using the ‘Tick’( ).

• Depth Set the extrusion to a blind depth of 4.

• Verify/Preview ( )

• Exit ( ) Once complete exit the Extrude tool.

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6.3 Extruded Cut The cut function is generated with the same extrude tool( ) as the extrusion.

• Section Select the same plane as before as the sketching plane, and accept thedefaults for the direction and orientation.

Accept the default dimension references.

Sketch an oversized rectangle covering the top section of the circular entity and setthe centre-of-circle to base of rectangle dimension to 1.5 (above or below the

centreline) and exit the sketch with ‘Tick’ ( ).

• Depth Set the extrusion to be a symmetrical two-sided, with a total depth of 8mm.

• Cut ( ) Switch from a material extrude to a cut by selecting the cut icon (radiobutton down).

• Preview ( ) Use the Verify/Preview icon to check the completed revolved entity

• Cut (material) Direction ( ) if required, use the material direction function toswap the side of the section that is cut.

• Exit ( ) Exit the extrude (cut) tool.

Save Part Save the completed part using the save icon ( ) or FILE → Save .

Print Display the main window and MODEL TREE menu on the screen and selectPrintScreen ( ).

7 Task 3 - Keeper Plate

This exercise demonstrates the reuse of existing data and use of ‘Pick-and-Place’ Features.

7.1 Open an existing file Use the FILE → Open or file open icon ( ) toactivate the FILE OPEN selection menu. Select the part file spacer1 userid and OK. Thiswill reopen the file with the previously saved parameters and place the window on the topof the desktop.

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7.2 Create a ‘Round’ Selecting the round tool icon ( ) or (INSERT→Round....) starts the ’round’ dashboard and a message prompt ‘Select an edge or chain of edges,or a surface to create a round set’.

• Radius Set the round radius to 3.5 mm.

• Edges Although there are a large number of options, accept the defaults and usingthe highlight/select function select the two outer edges of the spacer. N.B. the mostrecently accepted edge is highlighted in red and is dynamically adjustable.

• Review Check, preview and Exit round tool

7.3 Create a ’Chamfer’ The chamfer tool ( ) operates in a similar mannerto the round tool. Use it to add chamfers to each end of the bore.

• Style Select the chamfer style to 45 x D

• Size Set D to 1.0 mm

• Edges Select the two edges of the bore

7.4 Modify the Original Extrusion Select the original extrusion from themain screen or the MODEL TREE and RMB → Edit the length to 9 mm.

Save A Copy Generate a new part using the FILE → Save A Copy... commandsave the modified file with the name Keeper userid

Print Display the main window and MODEL TREE menu on the screen and selectPrintScreen. ( ).

8 Task 4 - Additional Components

Experiment using the methods you have learnt so far modelling one or more entities similarto that shown in figure 8:8. Use the supplied isometric paper or plain paper to sketch thestages of various operations on the entities prior to trying to model them.

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(a)

(b)

Figure 8:8: Non-functional Blocks. (a) Sketch using ‘isometric paper’ (b) CorrespondingCAD model


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28

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9 Construction and Editing (aide-memoire)

Base (Sketched) Feature Creation• Select (RMB) required feature icon and

wait for the dashboard to appear

⇓

• If an internal sketch is required, RMB→Define Internal Sketch

• Select (RMB) required drawing surface(typically a datum plane or existing sur-face)

• Accept the default references or selectand additional plane for orientation of thesketcher view.

⇓

• Accept (reset or augment) the sketchingreferences

• Sketch required section

• Exit sketcher with tick

• Select OK from the sketch menu to returnto the dashboard. (N.B. Selectable withMMB as it is the default option)

⇓

• Set additional feature parameters (typi-cally work from left → on dashboard.

• N.B. Additional options available from thepull down menus below the dashboardicons

⇓

• Preview the feature to allow the system tocheck the feature’s parameters fully beforeaccepting the feature

• Click resume to return to the dashboard orthe tick/X to exit the feature creation.

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Methods for Editing a Feature

EDIT• Select a feature. (N.B. If the model is com-

plicated it can be easier to select in themodel tree)

• Use RMB to select Edit, shows all the di-mensions used to define the feature in yel-low in the main drawing window.

• Use double click select to an dimension andthen edit the value in the edit box. (Di-mension will change green once it has beenedited)

• To action edit(s) select the regenerate icon,or use the hotkey rg

EDIT DEFINITION• Select a feature.

• Using RMB to select Edit Definition, re-turns the system to the feature definitiondashboard.

• Modify/Select feature options/parametersas if defining the initial feature. (N.B.Some changes may effect child features orreferences used by other components in anassembly)

• Preview the changes and re-edit required

• Exit the feature redefinition using the tickicon

EDIT INTERNAL SKETCH• Select the main feature (or internal sketch

from the menu tree) and RMB → EditDefinition returns the system to the fea-ture definition dashboard as above.

• Selecting RMB→Edit Internal Sketchover the main window or Sketch→Editfrom the dashboard PLACEMENT menureturns the system to the SKETCH menu.

• Selecting sketch initiates the Sketchermode with the original settings.

• Edit the sketch as required and exit usingthe Tick. (N.B. Deletion/modification of aline may cause child features to fail if theyare used as a reference.)32

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Exercise 9


DRAWING COURSE

Introduction

This exercise introduces some extensions to the techniques learnt in the previous lesson tomodel a water fitting. In addition, the the method of generating 2D drawings is introduced.

Problem

1. Cylinder/Domed-Cylinder Intersection

2. Initial Drawing

3. Extrusion using an auxiliary plane

4. Update Drawing Note the changes in the drawing and update the dimensions onthe drawing.

5. Parent/Child Relationships

6. Flange and Patterned Holes

PLEASE MAKE SURE YOU HAVE PUT YOUR NAME, LAB. GROUPAND COLLEGE ON YOUR PRINTOUTS

Overleaf are a number of questions designed to test your understanding of the tasks. Thequestions can be be answered during or after the whole exercise, but it is useful to refer tothem as you undertake individual tasks.

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Questions

1. Why do the two cylinders act differently when shelled?

• Rearrange Protrusions/Shell Features Select (RMB) individual features (e.g. theextrudes and shell) and attempt to rearrange the order by dragging and dropping them inthe Model Tree.

2. Why can you not place the shell before all the protrusions?

3. Why can one of the plain protrusions be placed before the domed cylinder and notthe other?

4. Why does the flange have to be added as an additional feature rather than as part ofthe first revolve with this type of model construction?

5. Why is the first of the mounting holes set at 55o and not 0o?

(N.B.) Write your answers on the back of your last drawing.

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1 Key


Font Used Item





Abbreviation Action





Model Manipulation

Key/Mouse Action





2 Getting Started

To start Pro/Engineer Wildfire login to the teaching system and

• Close down unused programs, Pro/E imposes a large load on the system


This will start the package, and set the working directory (where your files will be stored)to /userid/ProE/. Within this area are a number of predefined directories, ex8, ex9, ...,which will be used to store the work for each of the drawing exercises.


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Figure 9:1: Construction of the initial revolved feature and first extrusion

3 Task 1 - Cylinder/ Domed-Cylinder Intersection

Using the techniques described in exercise 8, produce a domed-ended cylinder, seeFigure 9:1, intersected by a second cylinder.

3.1 Start Domed-Cylinder Select the NEW PART icon again and name thenew part water fitting1 xxx123 → OK. (xxx123=userid)

3.2 Quick Feature To produce the domed-cylinder protrusion select the fast startoption from the CUED menu, CUED → Revolve360, which sets up the sketcher mode fora revolved extrusion.

• Domed-Cylinder Section

1. Insert a vertical centreline/axis-of-rotation vertical aligned to the verticalreference (From the ‘line’ pullout menu or RMB → Centerline).

2. Draw a half section of the cylinder, and set the defining dimensions to be a basediameter of 75 mm, a dome radius of 37.5 mm and an overall height of 100 mm.

N.B. To override the default radius dimension and generate a diameter is a4 click operation. Using the dimension tool select (1) a base corner of thecylinder (2) the centreline (3) the corner again and finally MMB to place

3. Exit Exit the sketcher mode using the ‘Tick’ ( )

4. Preview/Exit ( ) Accept Use the default 360o revolution, check the

completed entity and exit with the ( )

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Figure 9:2: Sketcher layout of cylinder

3.3 Cylinder Section Generate a intersecting cylinder by using the extrude toolto generate a protrusion from the MID datum plane.

• Start Extrusion ( )

1. Select the MID plane as the sketching plane and accept the default directions

2. Accept the default dimension references (REFERENCES →Close)

• Cylinder Geometry Sketch a small circle in approximately the right position andthen dimension as shown in Figure 9:2, i.e. horizontal offset 20 mm, diameter 15 mm,vertical position 20 mm and then exit the sketcher mode.

• Depth Set the extrusion to a blind depth of 75 mm.

• Preview and Accept ( , ).

If the screen becomes confused due to incorrect redrawing, select VIEW→Repaint,the repaint icon ( ) or ’vr’ to refresh the display

Save Part Use the FILE → Save function or ( ) to save the part in its currentform.

Print Display the main window and MODEL TREE menu on the screen and select( )

4 Task 2 - Initial Drawing

Even though the direct link from CAD to CAM (Computer aided manufacture) isincreasingly common there is still a need to produce 2-D drawings, in Pro/Engineer this is

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a relatively painless procedure as the hard work has already been completed in the modelgeneration.

In addition, when constructing a model it is often useful to be able to see a standard set oforthogonal views of the object or assembly being drawn. The drawing can aid withvisualisation and with design, a pencil sketch on paper is often faster than the generationof complex CAD constructions when trying to get a feel for orientation, and sizing etc. Theadvantage of the associativity of packages like Pro/Engineer mean that as features areadded or dimensions changed the model and drawing are both updated

4.1 Start a Drawing (By default the system attempts to draw the currentlyactive solid model, so to draw the water fitting, ensure that this is selected. If requiredreselect the window, use the WINDOW menu, or reload/open the model)

To open a new drawing select FILE→New→drawing. Enter the name of the drawing,wfitting and select OK

The NEW DRAWING menu should now appear, ensure that the default model field iswater fitting.prt, ensure the Empty with format option is selected and the format field isa4 part.frm. (Use the browse facility if required) Selecting OK will initiate the drawingwindow.

Figure 9:3: Initial General View and Orientated of master view

4.2 First View To generate and locate the first view

• Insert View select RMB → Insert General View or INSERT →Drawing View→ general.

• Placement The user is now requested to choose the location for the master view bya prompt in the message window ‘select CENTER POINT for drawing view.Selecting (LMB) a position near the bottom right of the drawing surface will result ina default (isometric) view being placed followed by the opening of the DRAWINGVIEW window, see Figure 9:4, set in the VIEW TYPES mode.

• View Orientation The Orientation functions can be used to obtain the direction ofa view. A number of predefined named views are available and normally enable the

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Figure 9:4: Setting initial view orientation

initial view to be placed simply. See the scrollable list shown when the views namesin model option is selected.

A suitable master view for this drawing is probably FRONT or BACK, select theview e.g. Front and then Apply. Review and correct if required. Select OK to exitback to the drawing.

4.3 Additional Views Additional views can now be added, with the vieworientated automatically. Using the default menu choices add two more views to yourdrawing.

• Add View Select the view you wish to project from using the LMB, the view will behighlighted with a dashed red box. Use RMB → Insert Projection View, ( ) orINSERT →Drawing View →Projection to initiate the generation of new views.

N.B. If an existing view is selected the system assumes that the next viewrequired is a projection.

• Placement Use the LMB over the drawing area to select the position of the twoviews, the system will ensure that the correct projection is shown.

• Relocate views Using LMB to select a view (highlighted in with a red box) andthen holding LMB down drag the view to the required location. Select with LMB ina clear area of the drawing to deselect a view. (If the view does not move deselect theLock View Movement option from the RMB context sensitive menu)

• Set Display mode Select the Hidden Line display option ( ) on theicon bar and deselect the datum icons to display a clean drawing. N.B. No Hidden(and Wireframe) can be used if required.

4.4 Display Centerlines Select VIEW → Show/Erase or ( ) to open theSHOW/ERASE window.

Select the axis icon and Show All, see Figure 9:5(a), confirm ‘Are you sure that you wantto show all?’ and then Accept All

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Figure 9:5: (a) Show-Erase Menu (b) Accept All

4.5 Drawing Dimensions To dimension the drawing use the same ‘Show and

Erase’ function ( ) as above (section 4.4). Select show ( ) and dimension

( ) → ShowAll → Accept All.

N.B. there may be duplicate or superfluous dimensions, these can be deleted by selectingRMB→Delete.

Print Display the main window and MODEL TREE menu on the screen and select

Print Screen ( ).

5 Task 3 - Cylinder/Dome Intersection

In this task the extrude function is used with an auxiliary plane together with a non-blinddepth. The cylinder intersects with the domed-end of the main cylinder and extends to75mm from the centerline. Figure 9:6 is an incomplete version of the drawing, sketch yourestimate of the line of intersection on each of the views, denote hidden lines of intersectionas dashed line. Check your answer once you have completed the next section.

5.1 Cylinder 2 The generation of the offset extrusion, (i.e. starting from a plane‘offset’ from another plane) is very similar to the that of a normal extrusion but with theadditional requirement of defining an new datum plane. Start an extruded feature with( ) or INSERT → Extrude ....

• Generate section

When prompted to ‘Select a plane...’ a new plane is required :

1. choose the Datum Plane Tool ( ) from the side tool bar.

2. Select the FRONT plane to complete the Reference in the DATUMPLANE→Placement window that opens

3. Set the Offset (Translation) to 75 mm → OK

4. Check (modify) the Sketch Orientation and then exit the SECTION window.

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Figure 9:6: Incomplete drawing of the second extrusion intersection

5. accept the default dimension references

6. Sketch a second protrusion, diameter 35 mm and tangent to the top of the dome.

The tangent constraint can be achieved either by adjusting the dimensionsor using a fixed constraint which adapts to future changes in dimensionsetc. To fix an tangent constrain select the constraint menu icon ( ) and

then the tangent constraint icon ( ). Selecting the top of the dome andthe circle of the cylinder will force a tangent constraint

Constraint Actions

Make lines vertical Make lines horizontal Perpendicular

Tangent Point in the middle of line Align line/point

Symmetry about C-line Equal lengths Parallel

7. Exit the Sketcher Mode with ‘Tick’.

• Depth select Upto Surface ( ), see Figure 9:7(a).

• Direction Ensure the extrusion is towards the existing model, us ( ), to flip.

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(a) (b)

Figure 9:7: (a) Set Material Depth (b) Completed Modified fitting

• Preview and Accept ( , ).

N.B. The combination of the datum plane and extrusion are combined as a Group,see the MODEL TREE. The group can be expanded to allow edit access to theindividual features. The group (as can other features) can be renamed with selectRMB→Rename

5.2 Intersection Drawing Review re-activate the ‘wfitting’ drawing andafter selecting no-hidden

Save and Print Screen

6 Task 4 - Parent/Child Relationships

Pro/Engineer is a history based CAD package, where features can be dependant onprevious features.(N.B. In most case, all features are children of the initial datum planes.)In this task the modified domed-cylinder is ‘shelled’ and the position of the shelloperation/feature is moved in the model tree.packages.

6.1 Activate Domed-Cylinder Ensure that the Water Fitting window isactive, select via the WINDOW pull-down menu.

6.2 Create a shell Activate the shell tool, ( ) or INSERT → Shell ....

Select (LMB) the flat surface at the base of the domed-cylinder, (note the selection filter,at the bottom right of the window, switches to surface). Complete the shell by setting the

(wall) thickness to 3.0 mm. ( , ) when complete).

6.3 Check Drawing Reload the Drawing window, and note that the drawing hasbeen updated.

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6.4 Reordering Model Tree Select the shell feature in the MODEL TREEmenu and the drag/drop, in the tree, before the various protrusions. Note the effect aftereach insertion.

Figure 9:8: Water fitting with mounting flange

7 Task 5 - Mounting Flange

The water fitting is designed to bolt to the end of a pipe with a flanged-joint. Using eithera extrude or a revolved section add an additional 20 mm thick x 120 mm OD flange to thebase of the domed-cylinder, see Figure 9:8, together with 4 x φ10.5 mm holes equi-spacedon a 100mm PCD.

7.1 Extruded Flange Notes

1. Although it may be possible to use an existing datum plane as the sketching plane itis recommended to use the end of the domed-cylinder. This will ensure that theflange remains attached if the cylinder length is altered.

2. Make the internal radius of the flange identical to that of the domed-cylinder byusing the ’equal dimension’ constraint. ( )

7.2 Revolved Flange Notes

1. In order that the flange is always attached to the end of of the domed-cylinder, evenif its dimensions are changed, ensure that

(a) The attachment edge is ‘aligned’ to the end of the cylinder

(b) The inner diameter is aligned to the inner diameter of the cylinder, as generatedby the shelling operation.

7.3 Mounting Holes Use the Hole Tool ( ) to model a simple φ10.5 mmdiameter clearance hole.

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Hole Type

Select a Simple Hole

Hole Dimensions Set the Diameter to 10.5 mm

Depth - Upto next surface ( )This option ensures the hole depth will be automaticallyadjusted if the surface is moved, e.g flange thickness ischanged.

Hole Placement

1. Select a point on the flat surface of the flange.

2. Select Placement Type Radial

3. Highlight the second reference field and select the axisof the domed cylinder unit as the Axial Reference

4. Set the Radius, (PCD/2) to 50 mm

5. Using <CTRL> and LMB, select a datum plane (typ-ically FRONT or TOP) as the angular reference andset the angle to 55o.

7.4 Patterned Holes The previous section (7.3) defined a simple hole on a PCDoffset at an angle (55o) from a datum. This angle can now be used to duplicate the holes.

Select hole feature from the model tree or from the main drawing window and then usingRMB → Pattern (or EDIT → pattern) activate the Pattern dashboard.

1. In response to the request to ‘Select dimensions to vary in the first direction’ selectthe offset angle of 55o. (It may be necessary to rotate the model around to see thisdimension clearly.)

2. A prompt will now appear requesting the dimension increment, enter 90.

3. At the Number of Pattern Members (1) field (second from left) enter 4

Exit the dashboard ( ) and after a few seconds the pattern should appear on the partand in the MODEL TREE.

8 Drawing 2 (Updated)

Reselect the window containing the drawing, and see that the drawing has been updated.

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8.1 Tidy Drawing The position of symbols and text can be moved using theLMB to select a item which can then be dragged to the required position. MMB to stop,LMB to exit move.

A large number functions are available via the RMB context sensitive menus, seeFigure 9:9, and from the INSERT and FORMAT menus. (See FORMAT → DecimalPlaces.. to change default number display and therefore implied accuracy)

(a) (b) (c)

Figure 9:9: Examples of context sensitive Pull out Menus, (a) On background (b) On selec-tion of 1 dimension (c) Multiple dimension selection

Use the functions, details about some are given below, to tidy the dimensioning etc. (Alsosee Figure 9:10)

• Cleanup Dimensions: Multiple selection → RMB automatically aligns dimensions ona user definable spacing.

• Move Item to View: Single or Multiple selection allows dimension etc to be switchedbetween views.

• Flip Arrows: Single or Multiple selection allows dimension arrows to be realigned

• Properties (Background): Allows sheet/layout to be changed

• Properties (Single): Change value, format, font etc.

• Text Style: Change text in multiple dimensions etc.

8.2 Isometric View The advantage of CAD is that it is relatively easy to addadditional views. It is often useful to add an Isometric view to aid visualisation. To add ageneral view select RMB → Insert Drawing View or ( ) Accept the default settings,except choose General instead of Projection, and Scale instead of No Scale. Place andorientate the view in a blank part of the drawing, see Figure 10:15.

Print Display the main window and MODEL TREE menu on the screen and select

Print Screen ( ).

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Figure 9:10: Example of a dimensioned drawing of the completed water fitting

8.3 Printing a Drawing - for information ONLY

**** USE Print Screen for this exercise (see above)****

N.B. By default the system prints the drawing that is visible on the screen, To printthe whole drawing either select VIEW→ ORIENTATION → View Refit or use LMB+ CTRL to zoom to the required view.

• Select the printer icon or Print from the File pull down menu.

• Select Generic Postscript

• Enter printer command, e.g. lp -dljmr1 for the laser printer on the teaching system.


52

Exercise 10


DRAWING COURSE

Introduction

These tasks build on the experience gained in Exercises 8 and 9, to model two componentsof the belt tensioner assembly drawn last term. The simplicity and power of CAD is thenused to modify the pulley and produce an detail drawing.

Problem

Use ProEngineer Wildfire to model draw the following sample parts:

1. Pulley

2. Shaft

3. Drawing of the Pulley

4. Drawing of the Shaft

N.B. Save your work at regular intervals and print out your work after each item hasbeen completed to avoid clogging the printer at the end of the session.

53

1 Key


Font Used Item





Abbreviation Action





Model Manipulation

Key/Mouse Action





2 Getting Started

To start ProEngineer Wildfire login to the teaching system and





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Figure 10:1: Section of the basic Pulley

3 Task 1 Pulley

Generate a model of a pulley, see Figure 10:1, using the following constructional steps. (Thepulley is identical in size to that used in Exercise 7, and will be used again in Exercise 11.)

1. Revolve general shape

2. Revolve a cut to generate the belt groove

3. Use a ‘both’ sided cut to produce the keyway

4. Add fillets (Round tool)

3.1 Start Part Use the New Part ( ) function to start a part calledpulley xxx123 (xxx123 = userid)

25

13

5

Ø20Ø36

Ø100

(a) (b)

Figure 10:2: Basic Pulley Section. (a) Section Dimensions & (b) Finished protrusion

55

3.2 Base Shape Use the CUED → Revolve 360 tool or the basic revolve tool

( ) to generate the basic pulley shape, Figure 10:2(a) for dimensions.

Occasionally it can be difficult to resize a complex sketch, where the system haschoosen oversized dimensions. Select all the dimensions and RMB → Modify. SelectLock Scale and adjust one dimension to keep the general shape.

3 3

Ø64

15°15°

(a) (b)

Figure 10:3: Belt groove. (a) Dimensions & (b) Pulley with the basic cut.

3.3 Belt Groove Again use the revolve tool, with the remove material option, togenerate the base shape of the belt groove in the pulley, see Figure 10:3.

Cut Section

1.8 (Depth 4mm)

(a) (b)

Figure 10:4: Keyway. (a) Dimensions & (b) Finished keyway

3.4 Keyway Use the extrude tool, ( ) with the remove material option, togenerate the keyway, Figure 10:4. Draw the section oversize and only modify the onecritical dimension. Use the ‘ Extrude on both sides...’ option ( ) for depth, by defaultthis sets the extrude depth symetrically about the sketch plane.

3.5 Fillets Use the round tool, ( ), to insert four 4 mm rounds in the groove andat the end of the pulley, see Figure 10:5(a).

Use <CTRL> LMB select on the second and subsequent edge selections to ensurethat all the rounds are part of one set, and are driven by one dimension

56

R4

R4

R4

(a) (b)

Figure 10:5: Casting/Machined Fillets (a) Fillet Positions (b) Finished Pulley

Print an image of the completed pulley, using the Print Screen command ( ).N.B. Arrange the windows on the screen so that the main window and model tree arevisible. Position the cross pointer over the window and select with the LMB.

Save the model using the FILE →save, ( ) or hotkey sequence sw, (Save Window).

Figure 10:6: Shaft

4 Task 2 - Shaft

Generate a model of the main shaft, see Figure 10:6 using the following constructionalsteps.

1. Revolve general shape

2. Use a ‘both’ sided cut to produce the keyway

3. Create a coaxial threaded hole

4. Add Cosmetic thread

5. Add fillets (Round function)

6. (Correct overall dimensions)

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Ø32

Ø25 Ø20Ø25

16 16 42 22

Ø16

15 (150)*

(See Note)

(a) (b)

Figure 10:7: Basic Shaft. (a) Section dimensions & (b) Extrusion

4.1 Start a new part shaft xxx123 (xxx123 = userid)

4.2 Base Shape Use the CUED → Revolve 360 function to generate the basicshape, see Figure 10:7 for dimensions. Exaggerate the initial sketch, do not try to draw theshaft to scale. When the section is complete and the required dimension locations chosenuse, either a critical dimension and the scale hint given above or accept the section andedit the dimension values in the main window. N.B. Leave the central section at 15 (NOT150) at this stage to aid future modifications and screen manipulation.

46

13

ø16 (Depth 3.5 mm)

(a) (b)

Figure 10:8: ‘Woodruff’ Keyway. (a) Section dimensions & (b) finished keyway

4.3 Woodruff Keyway Using a similar technique to that used to produce thekeyslot in the pulley, generate a slot for a ‘Woodruff’ key in the shaft.

Drill Ø10.2, 30 DeepTap M12x1.75, 24 Deep

Hole Placement and Dimensions Finished construction

58

4.4 Hole Use the hole tool ( ) to generate a threaded hole in the end of the shaft,Figure 10:9 shows the hole dashboard.

(a) (b)

Figure 10:9: Hole dashboard. (a) Placement options & (b) Shape Options

Adjust the hole parameters as below, note the use of the additional placement menu tochange the default ‘linear’ placement to ‘coaxial’:

Hole Type Standard Hole, ISO, Tapped Hole, M12 x1.75 , AddThread Surface, (Deselect Add Countersink)

Hole Dimension Leave as defaults, i.e. Thread depth = 24.48, HoleDepth=30.6, Internal angle 118.

Hole Placement Choose the shaft end with a single step as the PrimaryReference, i.e. surface from which the hole starts.Select Placement Type Coaxial and then select the Sec-ondary references menu and then select the axis of theshaft as the Axial Reference, using <CTRL> LMB.

Select Preview, (edit if required) and ‘Tick’ to complete.You will notice that the threadedportion of the hole is indicated in purple in the wireframe mode. This is described as acosmetic feature as it indicates the position but not the full details which would requiresignificant graphical processing.

N.B. A note is added to give information about the threaded hole. To switch this off

select TOOLS → Environment and then deselect 3D Notes( ) or use the

hotkey ’3d’.

Figure 10:10: External Thread - Cosmetic thread function

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4.5 Cosmetic Thread To add a cosmetic thread to the pulley end of the shaftcreate a cosmetic thread on an existing surface use INSERT → Cosmetic → Thread.This will initiate a Cosmetic Thread definition menu requiring the following elements to bedefined.

Thread Surf Select the cylinder surface on which the thread will run

Start Surf End of the shaft

Direction Along the shaft (use Flip if required)

Depth Blind → DONE and 20 long

Major Diam Enter 18

Note Params By default the system tries to create an internal thread,select Mod Params from the FEAT PARAM menu andthen modify the thread placement definition to A (exter-nal) in the Pro/Table spreadsheet. Select Save and thenExit from the Pro/Table pull down File menu. ThenDone Return.

Preview / re Define / OK the cosmetic thread.

Fillets - ‘Rounds’ functionR1

R1

R1

Fillet Positions Finished Shaft

4.6 Fillets Place three 1 mm rounds (Fillets) on the shaft to reduce the stressconcentration, using the default settings for the round tool. (Use <CTRL> to choosemultiple edges)

4.7 Edit Dimensions Now that the feature definitions are complete, use theEdit command to change the central section of the shaft from 15 mm to 150 mm. Noticethe additional scrolling etc required to obtain views at large scales.

Print Arrange the windows on the screen and print a copy.

Save the model.

5 Task 3 2D Drawing of the Pulley

Use the techniques learnt in exercise 9 to generate a 2-D drawing of the pulley.

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Figure 10:11: Dimensioned drawing of the Pulley

Start a Drawing To open a new drawing select FILE→New→drawing. Enter thename of the drawing, pulley and select OK

The NEW DRAWING menu should now appear, ensure that the default model field ispulley.prt, ensure the Empty with format option is selected and the format field isa4 part.frm. (Use the browse facility if required) Selecting OK will initiate the drawingwindow.

First View Generate and locate the first view

• Insert View select RMB → Insert General View or INSERT →Drawing View→ general.

• Placement Place a general (isometric) view (‘select CENTER POINT for drawingview’)

• View Orientation Orient the view as required using the predefined view names,e.g.Front.

• Scale, Display type etc

Adjust as required, see next section.

5.1 Setting the overall Drawing Scale To change the overall scale of adrawing double click LMB on the scale information at the bottom left of the main window.At the prompt line enter the value you require, 1.0 is a suitable scale for this drawing.

N.B. Normally drawings scales are limited to multiples of standard scales, e.g. 1:11:2 1:2.5 1:4 1:5 (1, 0.5, 0.4, 0.25, 0.2)

Additional Views Again using the techniques used in exercise 9 add additionalviews, to recap:-

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• Add View Select the view you wish to project from using the LMB, the view will behighlighted with a dashed red box. Use RMB → Insert Projection View, ( ) orINSERT →Drawing View →Projection.

• Placement Use the LMB over the drawing area to select the position of the twoviews, the system will ensure that the correct projection is shown.

• Relocate views Use the LMB to select a view (highlighted in with a red box) andthen holding LMB down drag the view to the required location.

Figure 10:12: Drawing View/Sections menu completed for a half section view similar to thatin figure 10:11

Display Centerlines Add centerlines to the drawing.

Select VIEW → Show/Erase or ( ) to open the SHOW/ERASE window.

Select the axis icon and Show All, confirm ‘Are you sure that you want to show all?’ andthen Accept All

Drawing Dimensions Add the basic dimensions the drawing using the ‘Show and

Erase’function ( ) as above. Select show ( ) and dimension ( ) →

ShowAll → Accept All.

5.2 Sectioned Views As ProEngineeer is a solid modeller it can be used toautomatically generate cross-sections. To change an existing view to a cross section

• Drawing View Select the view you wish to change and use RMB → properties tostart the DRAWING VIEW menu.

• Sections Selecting the menu option Sections will open the SECTION Optionssub-menu.

• 2D Section Selecting the option 2D cross-section and then pressing the add iconactivates the section table. Selecting create opens the XSEC CREATE menu.

Accept the defaults (Planar, Single and Done).

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• Section Name At the prompt enter the name for the section, normally a singleletter, e.g. X.

N.B. Parts started with the CUED new part function will have sections A,Band C predefined and the system will by default choose the most appropriate. Ais defined on the FRONT plane, B - MID and C - TOP

• Section plane The system now prompts the user for the plane of section via theSETUP PLANE menu. Using the default option Plane select the plane of sectionyou require. Normally a datum plane in an adjacent projected view, this is from easeof selecting and stability of the drawing should an associated dimension be changedin the model.

• Section Area The system offers a number of standard sectioning techniques, Full,Half, Local, Full (Unfold) Full (Aligned) (Only the Full, Half,and local optionsare considered here). Each require various amounts of additional information to becompleted. Details of the options required are:

1. Reference and Boundary These options are only used for the Half and Localsection options.

In the Half section option the Reference is used to define the plane at which thesection begins, the boundary option defines which side of the line is sectioned.

The Local section option allows small areas to be sectioned, see Section 5.6. TheReference is used to define a point near the center of the area to be setionedand the Boundary defines the extent of the section using a user defined spline.

2. Arrow Display (Available for use with all sections) This option allows the userto place arrows on another view to indicate the line of the section. (NB This isthe last column in the table and may require the table to be scrolled). Select theappropriate table cell and then the view required. The length and position ofthe arrows can be adjusted by selecting and dragging.

Thus to produce a half section similar to that in Figure 10:11 select a referenceplane through the middle of the pulley and then the area to be sectioned. Selectthe view on which to show the arrows, see figure 10:12.

• Apply/OK Selecting Apply at any stage will cause the system to try and action therequested section. OK closes the DRAWING VIEW menu.

• Hatching Properties The system tries to make an intelligent guess at the requiredhatching spacing however it is a common requirement to modify this to match aparticular material type or fit a detail. The spacing etc can be modified by selectingthe hatching and then RMB → properties opens the MOD XHATCH menu.Selecting Spacing or Angle from this menu open sub-menus which allow thehatching to be changed by factors of two or to predfined values, see figure 10:13.

5.3 Tidy Drawing The position of symbols and text can be moved using theLMB to select a item which can then be dragged to the required position. MMB to stop,LMB to exit move.

A large number of functions are available via the RMB context sensitive menus, seeFigure 10:14, and from the INSERT and FORMAT menus. (See FORMAT → DecimalPlaces.. to change default number display and therefore implied accuracy)

63

Figure 10:13: (a) General Hatching modifcation menu (b) Spacing specific options (c) Anglespecific options.

(a) (b) (c)

Figure 10:14: Examples of context sensitive Pull out Menus, (a) On background (b) Onselection of 1 dimension (c) Multiple dimension selection

Use the functions, details about some are given below, to tidy the dimensioning etc. (Alsosee Figure 10:15)

• Cleanup Dimensions: Multiple selection → RMB automatically aligns dimensions ona user definable spacing.

• Move Item to View: Single or Multiple selection allows dimension etc to be switchedbetween views.

• Flip Arrows: Single or Multiple selection allows dimension arrows to be realigned

• Text Style: Change text in multiple dimensions etc.

• Properties : Gives access to the DRAWING VIEW menu

5.4 Isometric View The advantage of CAD is that it is relatively easy to addadditional views. It is often useful to add an Isometric view to aid visualisation. To add ageneral view select RMB → Insert General View or ( )

Set specific view properties from the DRAWING VIEW menu, e.g. Scale, Figure 10:16.

64

Figure 10:15: Detail of a dimensioned drawing of the Pulley

Figure 10:16: Example of a view specific scaled general view the pulley

5.5 Printing a Drawing N.B. By default the system prints the drawing thatis visible on the screen, To print the whole drawing either select VIEW→

ORIENTATION → View Refit or use LMB + CTRL to zoom to the required view.

• Select the printer icon or Print from the File pull down menu.

• Select Generic Postscript

• Enter printer command lp -dxxxx, where xxxx is the printer name, e.g. ljmr1 for theprinter at CUED.

65

Partially completed drawing of the shaft.

5.6 Shaft Drawing Complete a basic dimensioned drawing of the shaft and thenadd additional views to generate a drawing as shown above.


66

Exercise 11


DRAWING COURSE

Introduction

This task builds on the experience gained in Tasks 8 -10, to build the tensioner unit as anassembly and produce an assembly drawing. Modifying the pulley allows a single assembly(+ associated drawings) to be used for two configurations.

Problem

Using Proengineer first create a sub-assembly of the shaft and then place this sub-assemblyinto a given housing and bearings. Finally generate two assembly drawings showing twoarrangements of the tensioner.

1. Shaft Sub-Assembly

• Shaft .

• Keeper Plate

• Bolt

• Woodruff Key

• Pulley

• Nut

• Check Interferences (Modify if required)

2. Bearing Assembly

• Assemble Shaft

• Check Interferences

• Insert Sub-Assembly

• Check Interferences

3. Drawing

• Generate Drawing

4. Modify Pulley (Optional)

• Generate Drawing

• Update Drawing

N.B. Save your work at regular intervals and print out your work after each item hasbeen competed to avoid clogging the printer at the end of the session.

67

M12 Bolt

KeeperShaft Roller Bearing

Woodruff Key Pulley

M18 Nut

Figure 11:1: Shaft Sub-Assembly

1 Additional Parts

To complete the following exercise you will require a number of additional components andassemblies, these should be found in your directory ‘ex8 11’. To ensure correct operationFILE → Set Working Directory (or hotkey cd) to ex8 11, i.e. change directory to/ProE/ex8 11.

2 Sub-Assembly

2.1 Start Assembly using the (New Assy) function (icon in CUED area) calledshaftassy xxx123 (xxx123 = userid)

Placement Menu

2.2 Initial Component Insert the shaft as the initial component by using

INSERT → Component → Assemble or ( ) (from the right icon bar) then

68

• Component Selection Select shaft xxx123.prt from the list of files. (If your versionis missing use shaft mast.prt)

N.B. You can limit the list of files to just parts by selecting TYPE part at thebottom of the window.

• Placement By default the system will try and automatically place the shaft in themain drawing window. To specifically place the shaft restraining constraints in threeplanes need to be added.

It is normal with the first component in an assembly to constrain it via it’s basecoordinate system, this can be done by either

placing the shaft using the ‘Assemble component at default location’ tool ( )

or

1. CONSTRAINT TYPE → Coord Sys

2. Select the Component Reference CSO, (picked from the window)

3. Assembly reference A-CSO, (picked from the window or MODEL TREE)

N.B. To aid the selection of constraint references it is often useful to toggle thedisplay of datum planes/axis/points/coordinate systems to simplify the view.These can be switched on/off via the icon bar or hotkey sequences (ed - Datumplanes, ec - Cordinate systems, ea - Axis, ep - datum Points).

2.3 Exit If the references have been selected correctly the placement status shouldshow ‘Fully Constrained’, references can be re-picked by selecting the associated arrow inthe menu and reselecting in the window. Accept the placement with ‘OK’ ( ).

Mate

Align

Keeper Plate Placement Constraints

2.4 Keeper Plate To assemble the Keeper Plate use the same basic command

structure as with the shaft, i.e. ( ) or INSERT → Component → Assemble, but thenselect your keeper plate from the previous session, keeper xxx123.prt (or a master copykeeper mast.prt).

N.B. To manipulate the component being assembled use <CTRL><ALT> + mousebuttons

• Align constraint using the axis of the shaft and the plate as references. Thisconstrains the keeper in the two dimensions perpendicular to the axis of the shaft.

N.B. It is often useful to use the RMB select option in conjunction with theSMART selection tool to ‘drill’ to the selection of references

69

• Mate To restrict motion along the shaft add a second constraint, TYPE Mate andchoose the side of the keeper and the end of the shaft as the references.

If the system prompts for an offset dimension, enter 0 mm.

The keeper plate should now snap to the correct position and the Placement Statusindicate ‘Fully Constrained’. (Leave the Allow Assumptions box ticked)

• Review ( ) If you are not satisfied with the placement re-edit the

constraints/references, then click OK ( ) to accept the placement.

N.B. In many cases the Automatic alignment function, i.e. allowing the system toguess the type of alignment, is successful. It can be aided by choosing the drivingfeature first, e.g the major axis on an assembly, the system will then look for anotheraxis + alignment as the preferred option

Mate

Align

Bolt Placement Constraints

2.5 M12 Bolt Assemble the bolt (m12 bolt.prt) in a similar manner to the KeeperPlate aligning the axis with the Shaft axis and mating the undersurface of the bolt headwith the outer side of the Keeper Plate.

2.6 Simplification To improve the response of the system and to remove screenclutter temporarily suppress or hide the keeper/bolt.

Select the keeper and bolt from the screen or MODEL TREE and then RMB → Suppressor Hide.

• ‘Hide’ removes the items from the screen

• ‘Suppress’removes the items from the display and reduces regeneration calculationsbut keeps the assembly definitions.

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Mate

Align

Roller Bearing Placement Constraint

2.7 Roller Bearing Assemble the roller bearing, again using the same basiccommand structure, but at the opposite end of the shaft. Use

• Component roll bearing25x62.prt

• Constraints

1. align the bearing axis with the axis of the shaft and the bearing as references

2. Mate the side of the bearing with the location shoulder on the shaft.

• Check and Exit ( , ).

Align AxisAlign Offset

(Surfaces/Datum Planes)

AlignPlanes

Woodruff Key Placement Constraints

2.8 Woodruff Key The placement of the key ( woodruff xxx123.prt orwoodruff 16mm.prt) requires, depending on the method of construction, two or three

constraints :-

71

• Constraints

1. Align the central-axis of the key with the axis of the circular cut used togenerate the key slot.

2. Constrain the third dimension by aligning the central plane of the key with thecentre plane of the shaft.

3. In some constructions the key will appear inverted. Correct this by addinganother constraint, Align + Oriented or Mate Oriented, using thesurfaces/datums perpendicular to the center planes.

N.B. Normally the system will prompt for an offset distance, even if theplanes are not aligned. Accept the default values and then change theoffset column to read oriented using the pulldown menu in the table cell.

• Preview/Check ( ) the placement status, redefine if required and accept

with OK ( ).

2.9 Pulley Assemble the pulley ( pulley xxx123.prt or pulley mast.=prt) in a similarmaner to the keeper plate and bolt, i.e. align with the central axis and mate the side ofthe pulley with the outer face of the roller bearing.

Check the relative orientation of the key/keyslots in the shaft and pulley. If incorrect addan additional align or mate constraint based on the datum planes or flat surfacesassociated with the slots/key.

2.10 Nut Assemble the nut M18 nut.prt using align to central axis and mate tothe outer surface of the pulley.

Shaft Interference Analysis

2.11 Analysis The system has numerous checking and analysis routine, one that isuseful on the completion of a (sub-)assembly is Global Interference to check that theparts are correctly defined/assembled.

72

• Model Analysis From the ANALYSIS pull down menu select Model Analysis. Inthe new menu select analysis TYPE → Global Interference. Accept the defaultsetting by selecting Compute. After a few seconds the system will return withinformation about any interferences in the lower scrollable window.

• Correction Depending on the construction/errors made in the assembly there arelikely to be one interference shown, the Woodruff Key with the associated volume ofinterference in mm3.

To correct this interference it is neccessary to understand the error and modify theparts or assembly settings.

Checking the parts should show that the keyway slot is 3.5 mm wide and the Key 4mm. Modify the slot width in the shaft to be 4 mm wide.

N.B. Modification of parts can be carried out by reloading the individual partfile or from the assembly itself. (Select SETTINGS (above model tree) → TreeFilters → Display Features (‘tick’) → OK will allow individual features to beaccessed from the assembly MODEL TREE.) The box by the component’sname allows the feature information to be expanded/contracted.

• Re-check Return to the assembly window, (reactivate if required) and re-run theanalysis to confirm the interference has been eliminated.

2.12 Resume To return the components hidden/suppressed earlier,(bearing/keeper/bolt), select RMB → unhide or EDIT → Resume → All.

Print Arrange the assembly on the screen, ensure that the MODEL TREE menu isvisible, and print using Print Scrn.

Save Save the assembly

Assemble Shaft assembly into the housing Cut away model of the basic Tensioner

3 Main Assembly

The basis of the main assembly is given as a predefined file:

73

3.1 Tensioner Load the partially completed file of the total assembly, filenametensioner assy.asm. DO NOT assemble the tensioner assembly into the shaft!

N.B. The view looks partially complete as there is an active assembly cut, removingthe front half of the housing to aid the location of the shaft sub-assembly.

3.2 Sub-Assembly. Locate the shaft sub-assembly into the Tensioner, using asimilar manner to that used to align the keeper/bearing/pulley etc. Mate the inner surfaceof the Roller Bearing with the locating step in the left end of the housing, i.e. opposite endfrom the circlip/roller bearing. Align the central axis of the housing with that of the shaft.

N.B. The order of the choice of assembly references. If the axis alignment is chosenfirst the shaft will snap to the centre of the housing making the selection of themating surface more difficult. An alternative method of assembly keeps thecomponent in a separate window, see ‘separate window’ tick box, prior to acceptingthe placement.

When fully constrained Preview (redefine if required) and accept OK.

3.3 Analysis Rerun the model analysis to check the Global Interferences

This should show one interference between the shaft and the ballbearing. This is a result ofthe mate constrain of the keeper on the end of the shaft leaving only 16 mm for a 17 mmbearing and not allowing for a clamping force. This can be modified by either defining theball bearing as part of the shaft sub-assembly and using stacked mate constraints. Or byadjusting the keeper placement by 1 mm.

• Correction Switch the active window to the shaft assembly. Select the keeper platefrom the window or MODEL TREE and then RMB → Edit Definition. When theplacement window appears select the mate constraint and set the Offset to 1 mmaccept the placement.

N.B. The placement of the bolt is automatically updated as it is a ‘child’ of thekeeper

• Reload Return to the Tensioner assembly window. (Remember to reactivate thewindow from the WINDOW pulldown menu or CTRL-A)

• Check Rerun the global interference analysis and confirm that the interference hasbeen removed.

Print Arrange the assembly on the screen, ensure that the MODEL TREE menu isvisible, and print using Print Screen.

N.B. The assembly can be slow to orient in shaded mode, to speed up placementzoom out reorient as a small item on the screen and then zoom in to the requiredmagnification. The amount of information transfer required to update the screen issignificantly reduced thus increasing the update speed especially on slow graphicscards or on remote displays.

Save Save the assembly

74

Figure 11:2: General Assembly Drawing of Tensioner

3.4 Remove Cut

• Display Features Ensure that the MODEL TREE display option to show featureshas been actioned. (Select SETTINGS (above model tree) → Tree Filters →

Display Features (‘tick’) → OK)

• Suppress Cut Select the assembly feature HOUSING CUT from the MODELTREE, the RMB → Suppress.

N.B. HOUSING CUT is a standard extruded cut but the feature has beenrenamed (RMB→ Rename) to make it easier to identify in the model tree. Thistechnique is often used in parts/assemblies with a large number of features.

3.5 Transparency ProE allows colours to be changed and textures/lighting andtransparency etc to be modified. As an example select VIEW (pulldown) → DisplaySettings → Model Display → SHADE (menu tab) → toggle Transparency /Apply.

N.B. The transparency can be accessed through the hotkeys et Enable Transparencyand te Transparency disEnable

4 Drawing

4.1 Load Drawing Open the drawing file tensioner drawing.dwg whichcontains an end view of the assembly.

4.2 Datum Planes Select the datum planes on ( ) and repaint the screen ( ).

75

4.3 Section View Add a side view of the tensioner and section the view on thecenterline using similar techniques that were used to section a part(See Figure 11:2), e.g.

• Select the existing view and RMB→Insert Projection View

• Select the new view RMB→Properties

• Select the Sections option in the DRAWING VIEW menu, and complete the optionsfor a full section

N.B. The drawing table, above the information box has been updated to containinformation on all the parts now in the drawing

4.4 BOM Ballons Display the Bill Of Material ballons by selecting from theTABLE pull down menu

• Select BOM Balloon → Set Region → Simple from the menus and then selectthe table of parts just above the title block, i.e. the Region to be used to define theballoons. Finish with Done.

• Select Create Balloon from the BOM BALLOON menu and then the cross sectionview to place the balloons.

4.5 Additional View Add an additional isometric view and set the individualview scale to 0.5.

Print Arrange the windows on the screen, ensure that the MODEL TREE menu isvisible, and print using Print Screen.

Save Save the updated drawing

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5 Modified Pulley (Optional)

Modified Pulley

In some applications a cooling fan is added to the pulley end of the tensioner, to updatethe pulley to allow for this reload the pulley and add the following features

• Thicken the outer flange of the pulley

• Create a radial threaded hole

• Pattern the hole on a 70mm PCD

5.1 Load or reactivate the pulley window

Base Auxiliary Drive Section - Revolved Protrusion10

Ø36

32

Section Dimensions Finished protrusion

5.2 Thicken Flange Create a revolved protrusion, centred on the axis of thepulley with dimensions as shown above, i.e. thickness 10 mm, ID 36 mm and OD 100 mm.(If the sketch align options are used it is possible to draw the addition with only 1 (10mm)dimension.)

N.B. If there is no preview option available it is likely that the axis of revolution hasbeen obmitted, re-edit the section or select the axis via PLACEMENT→Axis

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5.3 Mounting Holes Use the Hole Tool ( ) to model one tapped (threaded)hole for a M5 bolt.

Hole Type

Select a Standard Hole, ISO, M5 x 0.8 , Tapped Hole (N.B.Deselect the ‘Add Countersink’ option)

Hole Dimensions Leave as defaults, i.e. Hole Depth 12.6 mm (and ThreadedDepth 10.1mm)

Hole Placement

1. Select a point on the outer surface of the new protru-sion.

2. Select Placement Type Radial

3. Highlight the second reference field and select the axisof the pulley unit as the Axial Reference

4. Set the Radius, (PCD/2) to 35 mm

5. Using <CTRL> and LMB, select a datum plane (typ-ically FRONT or TOP) as the angular reference andset the angle to 45o.

5.4 Patterned Holes The previous section (5.3) defined a tapped hole on a PCDoffset at an angle (45o) from a datum. This angle can now be used to duplicate the holes.

Select hole feature from the model tree or from the main drawing window and then usingRMB → Pattern (or EDIT → pattern) activate the Pattern dashboard.

1. In response to the request to ‘Select dimensions to vary in the first direction’ selectthe offset angle of 45o. (It may be necessary to rotate the model around to see thisdimension clearly.)

2. A prompt will now appear requesting the dimension increment, enter 45.

3. At the Number of Pattern Members (1) field (second from left) enter 8

Exit the dashboard ( ) and after a few seconds the pattern should appear on the partand in the MODEL TREE.

6 Drawing 2 (Optional)

Reselect the window containing the drawing, and see that the drawing has been updated.

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Print Tidy up the drawing, arrange the windows on the screen and print using PrintScreen.

Use Move to rearrange the position of the balloons. Use Edit Attachment to change theend location of the balloon leaders.

Save Save the updated drawing

6.1 Suppress Re-activate the pulley and select the additional revolved protrusionfrom the screen (or the model tree) and then RMB → Suppress. As the Holes are a childof the protrusion you are prompted to confirm that you wish to suppress all the highlightedfeatures, select OK. (N.B. Suppressed features are indicated in the model tree with a blacksquare)

Note that the pulley is now represented on the screen and on the screen in it’s originalform, however the information about the modifications is still available should bothalternatives are required.

N.B. If the feature is not visible in the MODEL TREE Select SETTINGS (abovemodel tree) → Tree Filters → Display Suppressed (‘tick’) → OK.


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80

Exercise 12


DRAWING COURSE

Introduction

This task builds on the experience in the previous CAD exercises to assemble the tensioneryou constructed in task 11 on to an engine block and produce an Assembly drawing and3D views.

Problem Complete tasks 1, 2 3 and 4 below

1. Tensioner If you did not complete question 11, do so such that you have a completetensioner assembly.

2. Engine Assembly Load the blank assembly called, ‘engine-assy’ and assemble thefollowing items (see Figure 12:1) using the constraints indicated below.

Engine block Coordinate System Representation of a 4 cylinder en-gine block

Alternator Mate, Align (axis)

M12 bolt Mate, Align (axis)

(pattern) Ref Pattern Pattern the Alternator fixing boltsusing the reference pattern used togenerate the location holes.

Belt Align (Axis & Plane) Use the main crankshaft axis andthe predefined belt location plane

Tensioner Assy Align(axis) & Mate Align pivot axis and mate to themounting lug, and then locate inposition using the axis on the belt.

Tensioner Bolts Mate, Align (axis) Locate Tensioner bolt NB allowstensioner to pivot.

3. CAD Drawings

(a) Load the predefined assembly drawing file called eng assembly and insert 3orthogonal views. Print Screen

(b) Arrange the view on the screen to shown the area around the tensioner, usesuppress/resume to expose the components of the tensioner. Print screen of thedetailed view.

4. Drawing Updates

• Ensure the additional boss on the pulley is resumed and then add the fan +bolts

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• Update the drawing

• Using VIEW → Model Setup → color and appearances change the colour ofparts and surfaces in the assembly to make it more understandable

• Add an additional detailed view to the 2D drawing showing the tensioner indetail, see Figure 12:2. (Use INSERT → Drawing View → Detailed).

Figure 12:1: Completed Engine Assembly

Figure 12:2: 2D drawing of the Engine Assembly showing the Detailed View


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Exercise 13


DRAWING COURSE

Introduction

This task builds on the experience gained in previous CAD exercises in the design of partsbut introduces more flexibility in the design process.

Problem

The A3 drawing shows an air compressor with the piston and crankshaft removed.

Using ProE design a piston and crankshaft for the compressor shown in the drawing. Tohelp the interpretation of the drawing bring up the compressor assembly in ProE beforeyou begin the process.

Design Considerations

1. PISTON

The flap valve on the top of the piston is spot welded in position. Details of the flapvalve are shown on the drawing provided. The piston seal is an ‘O’ ring of φ 2mmcross section diameter. Details of the connecting rod are shown on the drawingprovided.

2. CRANKSHAFT

To be machined from a one piece casting. The main gear to be bonded to thecrankshaft with suitable adhesive. The counterbalance shape to be similar to thedrawing provided. A circlip 0.2 mm thick should be used on the smallest diameter toprohibit axial movement of the shaft.

CAD Drawings

After modelling the two parts produce orthogonal drawings of them showing front and sideelevations only. Show all necessary manufacturing dimensions.

N.B. Save your work at regular intervals and print out your work after each item hasbeen competed to avoid clogging the printer at the end of the session.

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84

86

Exercise 14


DRAWING COURSE

Introduction

Using the experience gained in the previous exercises to produce an assembly andanimation including the parts completed in question 13. (i.e. the piston and crankshaft)plus the library parts available in your shared directory.

Problem

1. To assemble the piston and crankshaft you have produced into a complete compressorassembly (compressor v2) and to produce and detail an othogographic drawing with3 views, including one cross section, and an exploded isometric view.

2. Finally animate the moving parts of the assembly

Method

1. Assemble the piston and crankshaft you produced in exercise 12. It is recommendedthat a series of sub-assemblies are first produced with all items arranged in the topdead centre position including :-

(a) Piston sub-assembly - containing Piston, Flap valve, ‘O’ ring and gudgeon pin

(b) Con-rod sub-assembly - containing Con-rod with Big End bearing.

(c) Crankshaft sub-assembly - containing Crankshaft, large gear and circlip.

(d) Moving parts sub-assembly - items 1,2 & 3 above

(e) Add ‘Moving Parts’ sub-assembly to the given compressor

(f) Produce an assembly drawing, (use the A3 Assy Drw icon to start thedrawing)

2. Animate the model using both manually (using the ‘drag’ option ) and automaticallyusing the analysis and servo drivers.

Colour the parts introduced to give a contrast to existing parts.

N.B. Save your work at regular intervals and print out your work, using the PRINTSCREEN function, after each item has been competed to avoid clogging the printerat the end of the session.

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X

X 45° X 1.0

SECTION X-X10

.0

ø14.0

ø19.5

ø16.5

2.5

20.0 15.5

ø4.

0

6.0

ø3.05.0

45° X 0.5ø

4.0

8.0

7.5

10.0 16.0 9.0

5.0

0.2

7.0

ø 8.0

ø 7.0

ø 4.0

ø3.

5

CRANKSHAFT

PISTON

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Complete Compressor

1 Dynamic Analysis

To define a mechanism within ProEngineer location connections are added to a assembly ina very similar way to normal fixed assembly constraints. Although it is possible to modifyan existing assembly to allow motion it is often easier to restart. Thus in your completedassembly delete or suppress the piston, conrod subassemblies and the crankshaft.Although, as with other parts of Proengineer, it is possible to assemble the moving parts ina number of different ways it is suggested that you follow the procedure below. Once youhave completed it you may experiment with the assembly options/funtionality to discoverwhat other features are available. There is further information on the how to use themotion options within ProEngineer Wildfire to be found on the web, see the help pages atwww.eng.cam.ac.uk/DesignOffice, in particular the link relating to Design Dynamics.

There are 7 standard joint types available (+ user defined joint), see below, that can becombined in a similar method to that found with fixed constraints to achieve the particulartype of motion required. In many cases it is useful to think of the 6 Degrees of Freedom(DOF) available (3 Translation + 3 Rotation) and confirm the the choice of constraintslimits the motion to only the DOF’s you require.

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Joint Type Constraints Required DOF Real Life Joint

Ball Point alignment to point 3xR Idealised Ball joint

Bearing Point alignment to edge oraxis

3xR, 1xT Sliding idealised ball joint

Cylinder Axis alignment 1xR, 1xT Cylinder, plain bearing

Pin Axis alignment, Planarmate/align

1xR Bearing with no axial move-ment, e.g. Roller bearing

Planar Plane alignment 2xT 2-D sliding, e.g. plate-plate.

Slider Axis alignment, Planarmate/align

1xT Slot

Weld Coordinate system align-ment

Welded/bolted/glued joint

Rigid One or more constraints Specialised user definedjoint

2 Dynamic Model Assembly

Crankshaft Placement Constraints

2.1 Crankshaft Sub-Assembly As noted above the joint that actuallysimulates a plain bearing best is a ‘Cylinder’, however it is often easier to use a ‘Pin’ jointthat allows rotation and also restricts axial displacements in one constraint. Thus the firstcomponent, the crankshaft, is assembled using a Pin joint.

Start the assembly procedure as for a fixed constraint, i.e. using INSERT → Component→ Assemble or ( ) (from the right icon bar)

Select the connections option, which will cause a new set of options to be available. Add aPIN connection and use

1. The axis of the crankshaft and the axis of the small bush to complete the axisalignment.

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2. The step in the shaft and the edge of a bush to give an axial translational placement.

select OK when the PLACEMENT STATUS indicates Connection Definition Complete.N.B. The crankshaft is now displayed in the model tree with a small white square,indicating that the component is not fully constrained.

2.2 Piston Sub-Assembly The piston can be assembled in a number of ways,but it is most convienent to use the cylinder option. Use the central axis of the piston andthe cylinder to align the subassembly. N.B. The flip option can be used to reorientate thepiston if it appears in the model upside down.

To simplify the assembly of the conrod use <CTRL><ALT> to move the pistonsubassembly into the approximately correct position.

Connections displayed on the assembly and details of the conrod definitions

2.3 Conrod Sub-Assembly Assembly of the Con-Rod completes themechanism and is assembled using a combination of a ‘Pin’ connection to locate the littleend bearing in the middle of the gudgeon pin and a cylinder connection to locate thebig-end bearing on the crankshaft.

N.B. In some situations the system can lock into the secondary stable positions, e.g. withthe piston below the unit and the conrod passing through the piston assembly. (There is nocollision checking at this stage of the assembly process) In these situations place the conrodsubassembly into the approximately correct position using <CTRL><ALT> and mousemovements, and then redefine the piston position. This will force the piston into position.

3 Manipulation of Dynamic Assembly

Once assembled with connections the mechanism can be manipulated either manually orautomatically with one or more predefined motions. A limited amount of analysis of thesystem is also available at this point. To activate this mode select APPLICATIONS →

Mechanism. The change of mode is indicated by the appearance of a new set of icons inthe right menu and a new set of features in the model tree.

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3.1 Manual Movement The mechanism can be manipulated ‘by hand’ using thedrag function, ( ) or MECHANISM → drag. This will highlight the connections andprompt the user to select a component. Selecting a movable item, e.g. the crankshaftbalanceweight, results in a small white circle appearing on the component at which pointthe mouse can be used to move the item as though it was being dragged/pushed. Anyconnecting parts also move as defined by the connections.

3.2 Automatic/Driven

Servo Motor Definition Menus

The system allows a number of different analyses to be undertaken, However in all cases‘drivers’ need to pre-set. To setup a ‘servomotor’, select ( ) or MECHANISM →

servomotors. In the new window select NEW and enter a name of your choice (or acceptthe default) in the SERVO MOTOR DEFINITION window. Select the crankshaft axis (theyellow highlighted joint) as the Driven Entity and selecting the PROFILE submenudefine the servo motor to have a profile of specification of Position, Magnitude Rampwith position values of A=0 and B=360. Accept the Servo Motor definition and return tothe main screen.

Analysis Definition Menus

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Select ( ) or Mechanism → Analyses followed by New, choose a RepeatedAssembly TYPE and enter

1. START TIME = 0

2. Length and Rate type

3. END TIME = 1

4. FRAME RATE = 20

5. MINIMUM INTERVAL = 0.05

Selecting Motors choose the motor definition entered previously. Selecting Run from theANALYSIS DEFINITION menu will run the basic analysis and store the results. Returnto the main screen using OK and Close.

3.3 Results Display Select ( ) (MECHANISM → Playback or Playbacksfrom the model tree). Accepting the defaults select the small playback arrow at the top ofthe menu and then use the cassette recorder like controls to display the motion.

If you are using your own piston/crankshaft you might like to check for inteferences.Selecting the Global Interference option on the PLAYBACKS menu will set going ananalysis of the interferences thoughout the motion. Any collision volumes are shown in redwireframe, c.f. the interference between the motor shaft and the small gear.

Trace Curve Menu

Another interesting and often useful facility is to trace the position of a component/part ofa component thoroughout a cycle. Although very simple in this instance, this functionalitycan be demonstrated by selecting Trace Curve from the MECHANISM menu and thenselecting the Trace curve pnt on the con rod. This will automatically select the PaperPart entry and by selecting Preview the trajectory is displayed as a purple line in themain screen. (N.B. It may be neccessary to select the display datum point icon on the topmenu bar to make the point visible.)

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94

Exercise 15


DRAWING COURSE

Introduction

This exercise extends your experience in animating mechanisms using a IDP robot as thebasic model. The task is to complete a static assembly and associated 2-D assemblydrawing and then using the techniques learnt in Exercise 14 to convert the lifting systeminto a mechanism and to update the Assembly drawing to show the extremities of travel.

N.B. The components required for this excercise can be found in your subdirectory/ProE/ex15 16. Do not forget to set your working directory before starting to work.

Problem

1. Add the castors and cable support to an existing model and generate an assemblydrawing.

2. Complete the ‘static’ model, adding the lift mechanism, drive units, controller etcand update the drawing

3. Modify the lifting system to be a mechanism

4. Add the new lift sub-assembly to the model and produce a drawing showing theextremities of the motion.


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1 Key


Font Used Item





Abbreviation Action





Model Manipulation

Key/Mouse Action





2 Getting Started






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Top view of Robot Underneath view of Robot

3 Task 1 - Static Assembly 1

1. Load the partially completed assembly robot1

2. Assemble the two castors, (castor.asm).

3. Assemble cable support, (support supply.prt).Hint: use the tangent constrain to locate the support

4. Generate a A3 Assembly drawing

5. Print drawing

4 Task 2 - Static Assembly 2

1. Assemble the pre-defined, lift static.asm, lifting mechanism onto the robotHint: Think how the unit would be assembled in real life

2. Assemble the drive units, drive unit.asm (motor/wheels/supports).Suggestion: Use second assembly window, or suppress a constrain if you findaligning the axes confusing.

3. Update the drawing and print

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Lift Mechanism

5 Task 3 - Dynamic Assembly of lift mechanism

1. Load the static lift mechanism, lift static, and save a copy lift dynamic

2. Load lift dynamic

Hint: Select Mechanism application temporarily to show any existing dynamicconstraints

3. Modify the pivot points etc. to allow rotationHint: You should only need to change 4 joint definitions. Start redefining theconstraints from the bottom of the model tree to remove problems associatedwith parent-child rconstraints

4. Check the motion by using drag and the predefined motion of the pnuematic cylinder.Hint: Be careful not to drag the mechanism beyond its normal limits. Runanalysis and use the predefined servo-motor, set analysis type toRepeated Assembly

6 Task 4 - GA drawing 2

1. Assemble the new lift sub-assembly into the existing main assembly, robot1. Hint:Suppress the static assembly to aid visualisation. See how defining a usefulCSO can aid assembly

2. Arrange the mechanism at the end of its travel

3. Update the drawing to show the mechanism at the extremities of its motion Hint:Use the static assembly.


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Exercise 16


DRAWING COURSE

Introduction

This exercise builds on your experience of Pro/Engineer and introduces a new module’Sheetmetal’ that enables a designer to generate development drawings of sheetmetalconstructions.

Complete the sub-tasks listed below, items 1 & 2 use a number of the standard functions inthe sheetmetal module to produce a support bracket. Items 3 & 4 are based around achassis for an Part IB Intergrated Design Project robot used in Qu 15. The emphasis is oncompleting well laid out dimensioned 2-D drawings suitable for design acceptance in thisproject.

The additional items 5 - 7 give experience in using more of the sheetmetal functionality.

Problem

1. Construct a support bracket

2. Add a flat ‘wall’ to [1] and produce a 2-D development drawing

3. Construct the outline of an example IDP robot chassis in solid, convert to sheetmetal.

4. Add ‘edge rips’ and ‘flat pattern’ features to the model. Generate a drawingcontaining 2 sheets showing the isometric + development of the chassis.

5. Construct a simple metal tab to the chassis

6. Copy existing tab

7. Add Wall extensions to [1]


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1 Key


Font Used Item





Abbreviation Action





Model Manipulation

Key/Mouse Action





2 Getting Started






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3 Sheetmetal Fundamentals

The user interface employed by the ‘sheetmetal’ module of Pro/Engineer is very similar tothe default solid modelling part. The same principles hold, select the type of feature togenerate, sketch/pick&place the feature completing all the elements required and thenpreview/accept.

4 Task 1 - Extruded Bracket

In this section we use a standard technique in the sheetmetal module to produce material,an extruded section. This is similar to the extrude function in the solid module, but onlyone side of the section needs to be drawn as the sheetmetal thickness is defined.

Figure 16:1: Basic Bracket

Start a new part, bracket userid, invoke the ‘Sheetmetal’ option from theAPPLICATIONS menu and start to create a one-sided ‘Unattached Extruded Wall’ ( )feature, (in the flyout menu on the fourth icon down or INSERT → Sheetmetal Wall →Unattached → Extrude). Once in the sketcher draw the general bridge outline of the partwith the dimensions shown in the figure above.

Ensure that the ‘bridge’ is centred about the MID datum plane.

Hint: If a centreline is placed on the desired mid plane, the ‘symmetric about acentreline’, constraint can be used. Select the centreline followed by the two verticesto be made symmetric

Whilst in the sketcher mode, select the thicken function (RMB → Thicken) and thenchoose the direction to retain the internal dimensions, e.g. internal radii 1.5 mm (SeeFigure 16:1). Enter a material thickness of 1.5 mm.

Exit the sketcher, accept the default direction and enter a blind depth of 60 mm.

Preview and accept.

Create a Flat Pattern feature, using the bottom icon on the side icon bar, selecting the topof the bracket as the plane to remain fixed.

N.B. Once created the Flat Pattern feature will automatically remain the lastfeature. To return to the folded state suppress the feature.

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Print an image of the bracket

Use the ANALYSIS → measure function to manually check the calculated value for thebend allowance and compare it with a hand calculated figure. Add the calculation, andcomments about any differences, to the printout.

5 Task 2 - Adding an additional Wall 1

Additional flaps etc can be added to a part by using the various attached wall features,here the Create Flat Wall feature is used.

5.1 Flat wall Select the ‘Create Flat’ ( ) feature, (second icon down or INSERT→ Sheetmetal Wall → Flat), which opens the associated dashboard (Figure 16:2)

Figure 16:2: Standard setting for the Flat Wall dashboard

Accepting the default settings and selecting an attachment edge immediately generates anadditional wall.

Figure 16:3: Initial Display of the flatwall, having chosen an attachment edge

A Flat wall is simply additional material attached to an existing piece of sheetmetal work.It can be an arbitary shape and attached at a user defined angle, see the first twodashboard items. The default Rectangle shape can be modified in the SHAPE dashboardpulldown menu, see Figure 16:4.

If a different shape, e.g. Trapezoid, L, T is chosen from the wall shape selection both theshape display and the model automatically change. An arbitary shape can be defined in asketcher window by selecting the User Defined option or selecting sketch from theSHAPE menu.

Hint: Although it is additional work it is often useful to use the User defined optioneven to define a rectangular wall, when the dimensions can be constrained by anexisting feature/dimension.

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Figure 16:4: Screenshot showing both the interactive SHAPE menu and the pulldown menuallowing the selection of predefined shapes

5.2 2-D drawing Start a new A4 part drawing (using the a4 part.frm format),named bracket1, and place an edge view and a plan view of the bracket development fullydimensioned.

Reminder: To change the scale double click on the value at the bottom left of thescreen

In many cases it is useful to also display one or more views of the finished folded item.This can be done on another drawing or second sheet of the same drawing. Alternativelythe concept of a ’family table’ combined with the ability of the system to include drawingsof more than one item on one drawing can be used.

Add itemAdd row

Figure 16:5: Typical layout of a ‘Family Table’

The family table allows a series of similar ‘instances’ of one model each differing by one ormore dimensions/features, the details of which are contained in a table.

In this situation a family table needs to be produced with two instances differing by theinclusion/exclusion of the flat pattern feature.

To set up a Family table for the bracket, return to the part window, ensure that thebracket has the Flat Pattern feature resumed and then select Family Tab from theTOOLS menu. Following the instructions in the Family Table window first add the FlatPattern feature as column to the table. (Add item → feature → Select the feature →

OK). Add a second instance, using the add row icon, and set the Instance Name toBracket1 folded and the feature setting to N (Use the pulldown options.), see Figure 16:5.

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When you have complete the table, exit using OK.

N.B.: A suppressed feature cannot be selected. Also, it is often useful to add threeinstances, generic, folded and flat. This allows drawings and models to remaincorrect even if the flat pattern status is changed in the generic mode

Figure 16:6: Dimensioned Drawing

To add views of the folded bracket to the drawing, the folded instance of the part needs tobe made active by, selecting RMB → Properties → Dwg Models → Add Model.Select Bracket1 userid and then Bracket1 folded → Open in the SELECTINSTANCE menu. To select the folded model as the current model select Set Model →Folded bracket → Done/Return.

Add a general view as shown in the figure above.

Update any dimensions required in the 2-D drawing and print. Although the show alloption can be used from the show and erase menu this often produces a large number ofawkward dimensions. It is often better to manually insert dimensions using theINSERT→Dimensions →New references or ( )

6 Task 3 - Robot Chassis

A powerful facility within Pro/Engineer and a number of the other large CAD packages isto be able to construct a model in solid and then finally shell it, c.f. the cylinderintersection problem, and then generate the development. The next two tasks are examplesof this process being used to produce drawings, and therefore possible CNC codes, for themanufacture of a typical IDP robot chassis.

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15

300

80

200

16 24

General view of the final assembled robot Overall dimensions of the chassis

6.1 Solid Model of chassis Construct a new part names chassisshell,constructed using a solid one-sided extrusion to the dimensions shown in the figure above.

Hint. While the cross-section of the extrusion can be sketched on any plane it isoften useful to arrange for them to be named correctly to aid with future assemblies,i.e. sketch the section on the ‘yellow’ side of the top plane and orientated with thefront of the vehicle aligned with the yellow side of the FRONT plane

6.2 Conversion of chassis to sheetmetal In essence this is very similar toa standard shell operation, but the system recognises the resulting shell as a sheetmetalobject.

While the solid chassis window is still active select APPLICATIONS → Sheetmetal →shell. Then select the surfaces to be removed, the base + four surfaces in the slots. Onceselected, complete the feature definition with Done → Done Refs and enter the materialthickness, 1.6 mm.

An indication that the model is now in sheetmetal mode is that this shelling results in anew ’First Wall’ feature.

7 Task 4 - ‘Ripping’ the 3-D model

Inserting a flat pattern feature at this point indicates that only the flap at the centre of thefront is available for automatically bending.

7.1 Insert ‘rips’ Although the chassis part is recognised as a sheetmetal elementthe system does not automatically choose cut lines. These are normally added by using the‘Conversion’ feature.

Select the ‘Create Conversion’ feature ( )and select to define (from the SMT Conversionmenu), Edge Rip. Add the four outer corner edges of the chassis together with the outerreturn edges by the notches at the front of the chassis, then Done Sel → Done Sets,Preview/Redefine/Accept.

Hint. If the material is thick there can be problems with too much material in thecorners of bends. The problem can be eleviated by adding ‘Corner Relief’ eitherwhen defining the conversion or afterwards using the Create Corner Relief feature.

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7.2 Second Drawing Sheet + Development To fully describe an objector assembly it is often neccessary to produce a number of drawings. These can be separatedrawings, however it is often useful to have sub-sheets with different aspects of the itemdescribed. In the case of the chassis it may be useful to have one sheet with theorthographic views and a second with the development.

Use the technique described in 2 to generate folded and unfolded instances of the chassis.Produce a A4 drawing of the folded chassis and then add a dimensioned developmentdrawing on the second sheet.

To add a second sheet to a drawing select INSERT → Sheet. The sheets can be switchedusing VIEW → Go To Sheet or use the sheet selection icon ( ).

Print the two sheets.( Note any differences to the length of the sides of the chassis andpropose a reason(s).)

8 Task 5 - Adding Tabs to the Chassis

It is often required to increase the torsional stiffness of a chassis (or other sheetmetalobject) by adding tabs at corners, which are subsequently attached with bolting, rivetingor spot-welding. The simplest method to add tabs is to use the ‘Create Flat Wall’ featureused in task 2.

8.1 ’Flat Wall’ Tab Select the ‘Create Flat’ ( ) icon and when the dashboardhas loaded select an edge of one of the exisiting chassis walls. Although a rectangular tabcan be used it often useful to choose a Trapezoid shape with a shallow angle to allow forvariations in bending, see Figure 16:7 for typical dimensions. Use the first flip option, onthe dashboard, to orientate the tab if required. If the tab is coincident with the second walluse the ‘offset’ pulldown options to automatically realign the bend.

8.2 Bend relief In the corner where the tab,top and walls meet there is an area ofhigh deformation. By default, Wildfire defines a rip in the material, see Figure 16:8. Inmanufacture it is better to control the deformation by the removal of material in this area,which can be done automatically with a predefined relief option, e.g. Obround, seeFigure 16:9. Before this form of relief can be used the tab needs to be reduced in size.

Select/redefine the Flat Wall feature used to define the tab and reduce the size by 2mm.Then insert a default Obround feature at the corner end of the tab, N.B. Inserting a relief

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Figure 16:7: Placement/Shape/Dimensions of a tab at the corner of the chassis

(a) (b)

Figure 16:8: Rendered images of (a) ‘Rip’ (b) ‘Obround’ relief

at the open end will cause a simply recoverable error.

8.3 Drawing Update Add a detail scrap view of the tab/relief to the existing 2Ddrawing of the flat chassis.

9 Task 6 - Copying Tabs

Experiment with the Feature → Copy feature to generate a second ‘dependant’ tab onanother corner.

Hint: This functionality can be used to copy features in both Solid and Sheetmetalparts.

Select the tab completed in section 8 and then using the EDIT→Copy (or <CTRL> C)and

EDIT→Paste Special add the same wall definition to another corner. When the pasteSpecial option is selected choose the option make copies dependent on dimensions oforiginals. This ensures that changes to the master tab are propagated to all copies, thiscan subsequently be disabled by selecting the feature and RMB→Make Sec indep.

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(a) (b)

Figure 16:9: (a) Adjustment of Tab size (b)‘Obround’ relief default definition

Pasting a copied object initates the normal dashboard, but ony requires the placementreferences to be picked from the model, here an external edge at another corner, before thefeature is defined and the dashboard can be exited.

Figure 16:10: Example of Extended Wall

10 Task 7 - Predefined wall extensions

It is often useful to add small extensions to walls to close a box for instance, seeFigure 16:10. While it is possible to manually add wall extensions, there is an automaticfeature.

Reload/re-Activate the bracket and then choose the Create Extended Wall feature ( )and then select the outer edge of the tab and the side of the existing bracket to extend thetab.

Update the 2-D drawing and print


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Sheet metal Conversion

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Sheet metal Cut

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Pro/Engineer Wildfire 2 Sheet metal Menus & Bend Al lowance Calculation

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CUED Part 1A Drawing

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