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The process of creating complex shapes using proengineer, focusing on the use of splines, variable section sweep, and ribs. Sketching with splines, sweeping to create solids, and adding extrusions and full rounds. It also touches upon the use of projection curves and creating thin walls with shell.
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By D Cheshire^ When modeling any part you are likely to be working to certain parameterswhich can be used to create construction geometry in your model. In thecase of this remote control unit let’s assume that the design specificationstates^ the^ part^ should^ be^ no^ longer
than^ 150.^ Now^ let’s^ use^ that information^ to^ define^ two^ datum^
planes.^ Choose^ INSERT^ >^ MODEL DATUM > PLANE and click on the RIGHT datum in the graphics window.The Offset option is set automatically in the dialog box so type in a valueof 150. In the Properties tab type a name of ENDLINE and click OK.Repeat this making a similar datum called MIDLINE at a distance of 75.That has set up the reference geometry for us to use.We are now going to design the outside shape of the remote. As you cansee from the picture this is a complex shape and the simple EXTRUDEand REVOLVE commands would be totally inadequate. We are going touse^ a^ command^ we^ have^ already
introduced^ VARIABLE^ SECTION
to edit the curve by dragging any of the control points.^ Figure 1 : First control Spline
Once you have got the hang of drawing with splines draw the curve shownin Figure 1. Note it has 5 control points and the first and last points lie onthe references and are horizontally inline. Exit sketcher.Repeat the previous command and draw a second, separate curve. Thisone is just a simple horizontal line aligned to all references as shown inFigure 2.^ Figure 2 : Second Control Curve - Straight Line These first two curves define the shape of the remote when viewed fromthe front. Now we will draw two curves to control the shape when viewedfrom above. Draw another datum curve using the TOP datum as thesketch plane aligning the ends of the curve as shown in Figure 3.^ Figure 3 : First Top Spline The fourth and final curve is identical to the last one so simply click on thelast curve in the browser window then choose EDIT > MIRROR and pickthe FRONT datum as the mirror plane. You should now have 4 curves andare ready to create the solid.^ Figure 4 : Four Curves Defined
By D Cheshire^
where you will draw the cross- section of the sweep. You should see two references passing through theend of the origin curve and if you look carefully a reference has beenadded to the end of each of the four curves – shown as small crosses.Draw the section shown in Figure 5 locking on to these references.^ Figure 5 : Sweep Cross Section After leaving the sketcher you should see a prediction of the final shape inthe graphics window – if you don’t you have done something wrong.Check you have selected the curves in the correct order and drawn thecorrect section. Finish the sweep feature by pressing the green tick icon^.^ Figure 6 : The Sweep
By D Cheshire^
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Now it is time to hollow out the remote control using the INSERT > SHELLfunction. Choose a thickness of 1. Which surfaces should be removedfrom the shell? Obviously the large flat surface on the top of the remotebut the holes also need to be open. Select the circular surfaces at thebottom of both holes too (hold the CTRL key to select several surfaces).^ Figure 12 : Shell Creation The surfaces of the holes look a little fragile – they need some supports toensure they don’t get broken off. We will add a thin web of materialbetween the hole surface and the outside wall of the shell. You might thinkthis is a simple extruded protrusion but it is easy to make an invalid modelif you do that. The correct term is a non-manifold model because theextrusion just touches the hole surface tangentially – it does not mate withthe surface correctly – and there is a gap.^ Figure 13 : Invalid Extrusion
ProEngineer has a special function to avoid this problem. It is like anintelligent^ extrusion^ command^ that
automatically^ mates^ to^ adjoining surfaces correctly – it’s called a rib.^ Figure 14 : Surfaces for Intersection Before^ making^ the^ rib^ we^ need^
to^ prepare^ some^ geometry.^ The^
rib command requires you to draw a shape to enclose the material to beadded. So we need a line which touches the outside of the hole surfacesand also touches the inside of the shell. The hole surfaces have a ‘true’silhouette so you can easily create a reference for that and draw to thatreference. But the ‘problem’ is the inside of the shell – since that is afreeform surface it does not have a silhouette – we need to make one. Theline we need to reference is a curve along the intersection between theHOLES datum and the inside of the shell. To create this curve select oninternal surface of shell shown in Figure 14. The first time you pick thissurface you actually select the whole shell feature – we only want onesurface of the shell. Pick again in the same place and Pro Engineer will‘look inside’ the shell and find the surface (depending on how you drew theoriginal section curve for the body - Figure 5 - you will either select thewhole internal surface or just half of it). Next with the CTRL key held pickthe HOLES datum plane. The geometry is selected so now choose EDIT >INTERSECTION. You should see the intersection curve created.Now we are ready to create the rib feature. The command is INSERT >RIB – try it now.^ Figure 15 : The Rib Dashboard Gap between two surfaces. Non manifold model. Surfacetouches a cylinder tangentially.
By D Cheshire^ Go into sketch mode (REFERENCES > DEFINE) picking the HOLESdatum you created earlier as the sketching plane. The curve you justcreated can be picked as a reference curve along with external surface ofthe holes. Draw a line between these two curves. Because the ends of thisline a locked onto the references which themselves are locked onto theunderlying surfaces the rib will correctly join to these surfaces.^ Figure 16 : The Sketch Curve and Rib Close the sketch. Check that the arrow drawn on the curve points towardsthe material which you want added – if it doesn’t use the FLIP option in thereferences^ menu^ to^ change^ it.^ Type
a^ thickness^ of^2 and^ end^ the dashboard with^ the^ green^ tick.^ Create
a^ second rib (mirror?)^ on^ the opposite side.^ Figure 17 : Battery Holder
to^ demonstrate^ full^ rounds!). Choose INSERT > ROUND as before and select the two edges shown in NOTE : This command canFigure 18 using the CTRL key. By default you will get edge rounds onsometimes fail dependantthese selected edges. Click on the SETS tab in the dashboard and you willon the exact shape of thesee a button called Full Round – this button is only active if you haveoutside surface.exactly two edges selected. Click on this to change the type of round andyou should see the round created.^ Figure 18 : Full Round Now we want a round on the other slot to. Since for a full round you canonly have two edges selected we can’t select any more edges. You couldclose the dashboard and repeat the procedure above but there is analternative that allows you to group similar rounds together. In the Sets
By D Cheshire^ on^ this^ and^ choose^ EDIT^ DEFINITION.
This^ takes^ you^ back^ to^ the dashboard with all the options set. Reverse the side of the cut to removematerial by pressing the second^
icon. Close the dashboard and you should have the battery cover. Here are some pictures to help you finishthe model. Your dimensions may vary a little from those stated – feel freeto use a bit of creativity.REVOLVERemove material for afinger grip.Sketch^ on^ FRONTand^ choose^360 degree option. ROUNDAdd 4 round SHELLRemove 2 faces andchoose 1 thickness. EXTRUSIONSketch on TOP. Mirrorto make second side.Use Extrude To Nextoption. EXTRUSIONMake a new datum 8away from front faceof^ cover.^ Sketch^ onthis^ datum.^ Mirror^ tomake^ second^ side.Use Extrude To Nextoption.