wf2 Tutorial PDF
wf2 Tutorial PDF
Introduction
ASSEMBLY
ProEngineer Wildfire2 is a computer aided design (CAD) program that is
used to create models on a computer in three-dimensions. Since three
dimensions are used the models mimic real parts in the way that they are
constructed. The models are sometimes referred to as virtual parts since
at the design stage they only exist within the computer. Most of the models SUB
made in ProEngineer Wildfire2 are termed solid models which implies that PART PART ASSEMBLY
the computer has a full understanding of the solidity of the part i.e. the
computer knows where there is material and where there is empty space.
Solid modelers use commands to construct models that reflect
manufacturing techniques, such as extrude and cut, combining these to PART PART
make complex shapes. FEATURE FEATURE FEATURES
Extrude Extrude
ProEngineer Wildfire2 is a fully parametric CAD program. This means that Block Holes
when a part is designed and modeled dimensions are assigned which FEATURE FEATURE
define the part. If, at a later time, these dimensions are found to be Extrude Extrude
Slot Hole
unsuitable they can be easily changed and the modification will filter FEATURES FEATURES
through the system wherever the part appears. This is particularly helpful
when dealing with collection of parts (known as an assembly) since if a
modification is made to a single part, the modification is carried throughout
the assembly. A designer can also define relationships between parts. For Figure 1 : The Structure of Models
example, in an engine, if the diameter of the piston is increased or
decreased, the corresponding engine block can be defined such that it is Creating a Part
automatically modified to match the specifications of the modified piston.
In this tutorial we will introduce you to some basic modeling concepts
Using any CAD system complex models need to be built by combining including creating parts, creating basic features, sketching and saving
simpler shapes. In ProEngineer Wildfire2 these simpler shapes are called information. Before starting to work through this tutorial you need to be
features. Several features are combined to form a part. Using Figure 1 as sitting in front of a computer which has access to ProEngineer Wildfire2
an example the part shown diagrammatically is made up of four features and be logged on. You tutor should have advised you of how to log in
as follows:- already.
1. A rectangular block of material is created.
2. Removing material from the block creates a slot. Start ProEngineer Wildfire2 by double clicking on the icon on your
3. Finally material is removed to form a large hole. desktop or from the START menu. The main application window should
4. Material is again removed to make four small holes. appear shortly.
Later tutorials will explain how several parts can be combined to form
assemblies as shown in Figure 1.
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Introduction To Modeling
After choosing the new command a dialog box will appear as shown in
Figure 3. Notice that the Part option is already checked and type in
calculator as the name of this part (Note : ProEngineer does not allow
spaces and other special characters in names).
A second dialog will appear offering different options for parts in
particular different units of measurement. Choose mmns_part_solid which
means the units of length will be millimetres and units of mass will be
Newtons and click on the OK button.
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Introduction To Modeling
Extrusions
Choose INSERT > EXTRUDE from the menu. Note the icon for this
command which also appears to the right of the screen it is a very
commonly used command. You should see a new toolbar appear like the
one in Figure 7. This is called the dashboard and contains all of the
options for the type of feature you are creating. Figure 8 : Outline Sketch
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Introduction To Modeling
that you drew the original rectangle. You will also notice that constraints
have been created. These are indicated by the small symbols next to each
Enter Select line. V stands for vertical and H stands for horizontal.
Draw Lines Now to set the size of the rectangle to the correct value, choose the
Draw Rectangles selection tool and double click on each dimension and type in the
Draw Lines required value from Figure 8.
The dimensions will now be in yellow indicating that they have changed
Draw Arcs
and the shape will change to the sizes entered. To end sketching press
Draw Fillets
the icon. To complete this first feature type 12 into the numeric field
Draw Curves of the dashboard (See Figure 7) and click the green tick to finish.
Draw Points To see this block in all its glory choose the command VIEW >
Use Edges as ORIENTATION > STANDARD ORIENTATION and try the different display
Add Dimensions option icons . You can also look around your design press
the middle mouse button and move the mouse to spin the model around.
Drag Geometry Middle mouse button and SHIFT key moves the model around the screen.
Constraints Middle mouse button and CTRL key zooms into the model you can use
Draw Text the mouse wheel for this too.
Trim
Mirror Objects
Leave Sketcher
Quit Sketcher
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Introduction To Modeling
Lets make a another extrusion on top of the first. Choose the command
VIEW > ORIENTATION > STANDARD ORIENTATION to make sure you
are viewing the model correctly then choose INSERT > EXTRUDE from
the menu. Start to draw a new sketch as before by clicking PLACEMENT
then DEFINE. The sketch plane option in the Shape dialog option is
highlighted in pale yellow awaiting your input. The sketch plane for this
feature is the large flat surface of the first extrusion (see Figure 11a) so
click on this surface in the graphics window. Now click on the SKETCH
button.
We need to define some extra references in the sketcher. References are
used to locate dimensions but they also allow you to lock your drawings
onto existing edges. Whilst the references dialog is open click on the four
edges of the original extrusion you may just see some dotted lines
appear on them (see Figure 11b). Now close the references dialog and
draw the rectangle shown in Figure 11c you should notice the cursor
locking onto the edges. Change the dimension to 55 and exit sketcher by
clicking on .
Figure 12 : Second Feature
You should be getting the hang of extrusions by now but we will come
back to them later there is more to learn.
Rounds
The calculator looks like a brick lets improve its appearance by
smoothing off some of the edges. To do this we will use the INSERT >
ROUND command. The dashboard for the round command will appear as
shown in Figure 13.
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Introduction To Modeling
the surface you want to offset the edges of in this case it happens to be
the one highlighted in red in Figure 16. Type an offset distance of -5 the
negative value is needed to go the opposite way to the direction arrow. A
series of lines is created offset from the edge of the surface. Exit sketcher
with the tick icon .
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Introduction To Modeling
goes round the whole model because all the edges are tangential Now for the clever bit! We will make multiple copies of this first button
(smoothly joined). using the PATTERN command. You need to select what you are going to
pattern first so click on the button in the graphics window it should turn
Also add a 2 round all around the top edge of the screen. Again you will
red. Now choose EDIT > PATTERN. The dashboard for the pattern
need two picks because of the sharp corner.
command will be displayed.
Thats the main part of the calculator completed. Now it is time to add First lets make 4 copies of the button along the phone. Click on the 20
some details. We will start by creating the buttons. You may be thinking dimension. An edit box appears into which you should type the increment
that these are just circular extrusions and you would be right but rather for the dimension after each copy is made. Type in 8 in other words
than drawing each one individually will make use of some of the repetition there will be 8 between each button along the phone. You must press the
features in CAD. The golden rule of CAD is dont draw anything twice if Enter button on the keyboard for your entry to be properly recognised. We
you can avoid it! said we wanted 4 buttons in this direction so type 4 into the second input
box from the left in the dashboard again you must press Enter.
We will start by drawing just one of the buttons. It is an extrusion of a
circle. The sketching plane is shown in red in Figure 18a and the If you ended pattern definition now you would get four buttons copied
dimensions are shown in Figure 18b. The height of the extrusion is 1.5. along the phone. We want buttons along AND across the phone. If you
look at the dashboard you will see the 4th and 5th input boxes are identical
nd rd th th
to the 2 and 3 which you have already filled in. The 4 and 5 input
boxes are for the second direction of copies.
To start to define the second direction click in the 5th (last) input box which
currently says Click here to add item. Now click on the 15 dimension and
type in -10 as the increment and press Enter. A negative value is required
because the 15 dimension needs to decrease each time a copy is made.
Type 4 into the 4th input box and press Enter to make 4 copies. You have
now completed the input and can end by clicking on the green tick. If you
have got it right you should see a rectangular array of 16 buttons.
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Introduction To Modeling
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Introduction To Modeling
suitable dimension to use. So this time change the left-most option to EXTRUSION command then PLACEMENT and DEFINE and choose the
DIRECTION. This option simply copies the feature a number of times in a sketching plane shown in red in Figure 18a. Now draw three concentric
given direction. To define the direction click on the datum DTM1. The circles as seen in Figure 26a then draw three horizontal lines that cross
copies will be made in the direction perpendicular to this datum. (Note : right over the circles as shown in Figure 26b (Note the top line passes
you dont have to use datums to define direction you can also use through the centre of the circles).
surfaces, edges or axes etc.). Now click in the third option pane and type 5
If the dimensions arent exactly in Figure 26 new dimensions can be
(to make 5 copies) and in the fourth option pane and type 2 to set the
distance between the copies as shown in Figure 24. (Note : The icon added. Use the dimension tool then click with the left mouse button
can be used if the copies go in the wrong direction). on the geometry you want to dimension and then click with the middle
button to add and position the dimension. Any weak (grey) dimensions
made redundant by this new dimension will be automatically removed. If
ProEngineer is unable to delete dimensions because they are strong it
Figure 24 : The Direction Pattern Dashboard will warn you and ask you which dimension or constraint you want to
remove.
No second direction input is required so just press the green tick to make
the pattern.
the tool for the job. Locate the trim icon on the toolbar. When this
tool is selected and you move the cursor over a line part of the line (until it
crosses another line) highlights. Clicking on it deletes that PART of the
line. Go round now deleting parts of lines until you are left with the sketch
shown in Figure 27. Exit sketcher if you get an error message you have
not trimmed back all of the lines correctly and extrude a cut 1mm deep
into the model.
Figure 25 : Speaker Pattern
This trimming technique is one useful way of drawing more complex
Complex Sketcher Tools shapes. There are related tool icons in the panel next to the trim icon
including one which extends two lines/arcs to their intersection.
Finally we will add an extrusion to represent the microphone for the
Speak-&-Tell calculator. This is a simple extrusion again but we can use it
as a means of introducing some new sketcher tools. Start the INSERT >
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Introduction To Modeling
Review
So what should you have learnt?
Note the gaps here How to create a new part
How to create extrusions to add and remove material.
How to sketch basic shapes.
How to create edge rounds.
How to create simple patterns.
Any problems with these? Then you should go back through the tutorial
perhaps several times until you can complete it without any help.
Next have a go at modelling the shapes below then move on to Tutorial 2
where you will attempt another model which uses different feature types.
Conclusion
That is our model completed. This is a simple representation model as it
doesnt have all of the parts defined correctly there are no internals and
the keys are stuck on rather than being a separate keypad sticking
through from the inside. In later tutorials you will see how you could model
this more accurately.
To make the calculator more interesting you could have a go at modelling Figure 28 : Some Sample Models Estimate the Dimensions
some numbers/symbols on each key. Choose the top of the key as a
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Intermediate Modeling
Not all shapes are made from extrusions so this second tutorial introduces
some new types of features. These include revolved features where a
curve is spun around a central axis (like working on a lathe or potters Figure 2 : The Revolve Dashboard
wheel) and simple sweeps where a cross-section curve is swept along a
centre line (ideal for making pipes). We will also return to the subject of Just like extrusions revolved features use sketches that are created in the
patterns and rounds showing some more options for these commands. same manner. Enter sketcher (PLACEMENT > DEFINE) choosing FRONT
as the sketching plane. Draw the two lines and the arc shown in Figure 3a.
The subject of this modeling exercise is a pair of headphones. Once again If you try to exit sketcher now you will get an error message No axis of
this will be a representation model made as a single part. In reality revolution. All revolved features must have and axis of revolution a
headphones are made from many pieces assembled together and this is centre line around which the curve is revolved. This is drawn using the
the way you should use ProEngineer if you were going to manufacture the
headphones. As a designer looking at the overall finished product it is Centreline tool found by clicking the small arrow next to the normal
often easier to model the complete design until a final decision to
manufacture is made then return to break the design down into individual line tool . Select this tool now and draw a centreline on top of the
detailed parts later. horizontal line you have already drawn it should lock onto the reference
line.
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Intermediate Modeling
We need a new datum plane to draw this trajectory curve on. Choose
BLIND you type in a value as the INSERT > MODEL DATUM > PLANE then click on the RIGHT datum
depth of the extrusion.
plane then whilst holding the CTRL key click on the axis through the centre
SYMETRIC the extrusion goes
of the last extrusion. The Datum plane dialog should now contain two
both sides of the sketch plane. references and next to the RIGHT datum reference it will say Offset - click
on this and choose parallel.
THRU NEXT the extrusion stops
at the next surface.
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Intermediate Modeling
Now to create the 3D geometry. Choose INSERT > VARIABLE SECTION
Align points or Move a point to Make two lines SWEEP. The SWEEP dashboard should appear.
lines to vertical the middle of a perpendicular.
or horizontal. line.
Figure 8 : The Datum Sketch SECTION SWEEP then click on the first icon to make a solid. Now, in
the main graphics window click on the circular edge of the phone half of
After exiting sketcher you will see the sketched datum in the main graphics the circle is selected in red. Now hold the SHIFT key down and click on the
window.
other half to select it as part of the same curve. Enter sketch mode
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Intermediate Modeling
and draw a 10 circle centered on the automatic references. Exit sketcher Now to add the 3D geometry. Choose INSERT > VARIABLE SECTION
and end the feature definition.
SWEEP then click on the first icon to make a solid. Now, in the main
graphics window click on the curve you have just drawn. Enter sketch
added using the icons. Add a vertical constraint between the top end of Figure 13 : Head Strap
the arc and the centre of the arc using the icon. Now this is quite To tidy up the strap add a double sided extrusion of a diameter 6 circle
tricky till you get the hang of it! - the left hand end of the arc is aligned with that is 35 long around the join of the strap to the wire.
centre of the wire by using the icon and repeatedly RIGHT clicking
near the centre of the wire until the END:CURVE symbol highlights.
Exit sketcher.
Figure 14 : Extrusion
More Patterns
In the introductory modelling tutorial you were introduced to patterns
multiple copies of features. Those simple patterns were rectangular or
linear patterns. Here we will introduce polar patterns (based on angles)
and rather clever Fill patterns unique to ProEngineer.
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Intermediate Modeling
Fill Patterns leave that copy out of the pattern. Close the Dashboard with the green
tick.
Fill patterns are very easy and impressive! Like all patterns you first have
to create something to pattern. So lets make a cut into the earpiece for the
sound to get out. Make a 1 diameter extruded cut 0.5 deep at the centre of
the flat face of the earpiece.
Polar Patterns
The fill pattern is very versatile and can be used in many situations but you
should be aware of other ways of making patterns. So here are some
examples of patterns based on angles polar patterns.
First we will make a cut into the back of the phone. Choose INSERT >
Figure 15 : Initial Cut for the Pattern
EXTRUDE and enter sketch mode choosing DTM1 as the sketch plane.
Now to make multiple copies of this cut. Right click on the cut you have The sketch you need to draw is shown in Figure 18.
just made in the model tree then choose EDIT > PATTERN. The default
type of pattern is to define by Dimensions as shown by the first list box.
Change this first list box to the Fill option and the appearance of the
dashboard should change to that shown in Figure 16.
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Intermediate Modeling
NOTE : If you have used an earlier version of ProEngineer you may be
surprised that this sketch does not have an angle dimension. A new
pattern option makes this type of pattern extremely easy so you dont need
this complication.
Ready for the pattern? Right click on the cut (not the round) feature you There is one more polar cut to add a series of holes through the head
have just made in the model tree then choose EDIT > PATTERN. The strap. These are created in the same way as the last AXIS pattern. Before
default type of pattern is to define by Dimensions as shown by the first list you make the feature and pattern lets prepare by making an axis around
box but we want an AXIS pattern so change the first list box now and see which the copies will take place. Choose INSERT > MODEL DATUM >
the dashboard change to the one shown in Figure 20. AXIS. Pick the inside cylindrical surface of the head strap make sure you
pick the surface and not an edge. An Axis will be created through the
centre of the strap. Close the axis dialog.
As always we need to draw the cut which will later be patterned. Choose
Figure 20 : The Axis Pattern Dashboard INSERT > EXTRUDE. Enter Sketcher choosing the TOP datum as the
The first step in this pattern is to choose an axis around which the pattern sketching plane. Now choose the end of the headphone as a reference
and draw the simple sketch shown in Figure 22. Exit sketcher. Make sure
will be made (the centre of rotation). Make sure axes are displayed the options for removing material entirely through the head strap is set
then pick on the axis at the centre of the earpiece. This may be a little before closing the dashboard.
tricky as there are lots of axes for the other holes here the one you want
will have a low number probably A2. Now click on the third list box and
change the 4 to 8 as the number of copies. Click on the fourth list box and
type in an increment of 45. There is no second copy direction in this case
so close the dashboard with the green tick. You should see 8 cuts around
the phone. Right click on the round feature then choose EDIT >
PATTERN. The fillet is automatically propagated around each of the cuts
because the original cut to which this round belonged was itself
patterned!
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Intermediate Modeling
To complete simply RIGHT click on the cut in the browser on the left and MIRROR pick the flat end of the head strap as the mirror plane. The
choose PATTERN. Choose the AXIS option and pick the axis you created headphones should be complete!
Mirroring
Finally to create the other half of the headphones click on the name
HEADPHONES.PRT at the top of the browser window then choose EDIT >
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Advanced Modeling
Once you have got the hang of drawing with splines draw the curve shown
When modeling any part you are likely to be working to certain parameters
in Figure 1. Note it has 5 control points and the first and last points lie on
which can be used to create construction geometry in your model. In the
the references and are horizontally inline. Exit sketcher.
case of this remote control unit lets assume that the design specification
states the part should be no longer than 150. Now lets use that Repeat the previous command and draw a second, separate curve. This
information to define two datum planes. Choose INSERT > MODEL one is just a simple horizontal line aligned to all references as shown in
DATUM > PLANE and click on the RIGHT datum in the graphics window. Figure 2.
The Offset option is set automatically in the dialog box so type in a value
of 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 can
see from the picture this is a complex shape and the simple EXTRUDE
and REVOLVE commands would be totally inadequate. We are going to
use a command we have already introduced VARIABLE SECTION Figure 2 : Second Control Curve - Straight Line
SWEEP but use it to its full capabilities. These first two curves define the shape of the remote when viewed from
the front. Now we will draw two curves to control the shape when viewed
Sketching with Splines from above. Draw another datum curve using the TOP datum as the
You may remember this command relies on existing curves so we need to sketch plane aligning the ends of the curve as shown in Figure 3.
draw some curves now. Like many complex shapes, lines and arcs arent
suitable for the shapes we want we will use a free form curve known as
a spline.
Choose INSERT > MODEL DATUM > SKETCH and choose FRONT as
the sketch plane. On entering sketch mode click on the ENDLINE datum
as an additional datum. The is used to create splines. Choose it now
and have a practice it takes a little getting used to. Each click of the Figure 3 : First Top Spline
mouse defines a point on the curve and ProEngineer smoothly interpolates
The fourth and final curve is identical to the last one so simply click on the
between these points. Click the mouse button to finish drawing a spline.
last curve in the browser window then choose EDIT > MIRROR and pick
You can then use the selection tool to edit the curve by dragging any the FRONT datum as the mirror plane. You should now have 4 curves and
of the control points. are ready to create the solid.
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Advanced Modeling
Sweeping To make the flat ends of the sweep more interesting we will use and
extrusion to cut them. You will need to create two separate extruded cuts
To make the solid choose INSERT > VARIABLE SECTION SWEEP and using the TOP datum as the sketch plane. The sketches for these are
click on the straight line curve FIRST (it will be called origin) then whilst shown in Figure 7. They must be drawn as two separate cuts.
holding the CTRL key the other three curves. Choose the Sweep As Solid
icon then enter sketch mode where you will draw the cross-
section of the sweep. You should see two references passing through the
end of the origin curve and if you look carefully a reference has been
added 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.
Blending
Dont try this now but this is not the only way of creating such a shape. An
alternative which might be more appropriate in some circumstances is
blending. With blending you draw (or select) several cross section curves
then create (using INSERT > BLEND) a solid which morphs between
Figure 6 : The Sweep these.
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Advanced Modeling
> SAVE A COPY and type the name BatteryCover in the New Name field
you will have a copy of the current model saved. Later we can go back to
this second model and EDIT DEFINTION on the last feature (the cut) and
reverse its direction to start to define the battery cover in the sure
knowledge that they will exactly match each other. Two models for the
price of one!
Figure 8 : A Blend
Try this in your own time in a different part file.
Cut Reversal
Figure 10 : Reversing a Cut
The next step is to add a battery compartment. Although this is a simple
Now we will make two screw holes at the opposite end to the battery
shape we will use it to illustrate a useful technique. Start the extrusion like
compartment to join the parts of the remote together. First create a new
all others selecting FRONT as the sketch plane and drawing the simple
datum plane Offset from the RIGHT datum by 30 and call it HOLES. Make
shape in Figure 9. Notice the extra reference that has been added to the
a revolve feature then draw the sketch in Figure 11 on this datum. Exit
bottom edge of the sweep. Exit sketcher.
sketcher and choose the Remove material icon to make the first hole.
The second hole is identical so choose EDIT > MIRROR then select the
cut feature and pick the FRONT plane to make a copy on the opposite
side of FRONT datum. Finish the mirror feature by pressing the green tick
icon .
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Advanced Modeling
Now it is time to hollow out the remote control using the INSERT > SHELL ProEngineer has a special function to avoid this problem. It is like an
function. Choose a thickness of 1. Which surfaces should be removed intelligent extrusion command that automatically mates to adjoining
from the shell? Obviously the large flat surface on the top of the remote surfaces correctly its called a rib.
but the holes also need to be open. Select the circular surfaces at the
bottom of both holes too (hold the CTRL key to select several surfaces).
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Advanced Modeling
Go into sketch mode (REFERENCES > DEFINE) picking the HOLES The next step is the battery holder. This is not complicated it is made up of
datum you created earlier as the sketching plane. The curve you just two extrusions and a cut. The cut is sketched onto the side of battery
created can be picked as a reference curve along with external surface of holder. Rather than making a second cut on the other side you can use
the holes. Draw a line between these two curves. Because the ends of this the EDIT > MIRROR command to make a copy.
line a locked onto the references which themselves are locked onto the
underlying surfaces the rib will correctly join to these surfaces. Full Round
Here is a chance to demonstrate a new type of round. Up till now all
rounds have been edge rounds rounds applied to an existing edge.
There are other options for rounds in ProEngineer for example the FULL
ROUND. We can use this to add a round to the end of slots (Note : this
could have been added by drawing the correct shape for the initial cut but
then we wouldnt have had an excuse to demonstrate full rounds!).
Choose INSERT > ROUND as before and select the two edges shown in
NOTE : This command can
Figure 18 using the CTRL key. By default you will get edge rounds on
sometimes fail dependant
on the exact shape of the these selected edges. Click on the SETS tab in the dashboard and you will
outside surface. see a button called Full Round this button is only active if you have
exactly two edges selected. Click on this to change the type of round and
Figure 16 : The Sketch Curve and Rib you should see the round created.
Close the sketch. Check that the arrow drawn on the curve points towards
the material which you want added if it doesnt use the FLIP option in the
references 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.
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Advanced Modeling
menu you should see the name Set1 and below this the words NEW SET Using Offset Curves
click on this and Set2 will be created and you can now select the two
edges on the other slot creating two rounds in one command. To finish this part we will add a cut to the top edge to make a dust seal
when this part is assembled with the keypad. As always there are several
ways of approaching this we will use a simple extrusion.
Using Projection Curves
Choose INSERT > EXTRUDE and pick the TOP datum as the sketching
Now we will add a simple logo to the remote. This is a letter S surrounded
plane. We will use a command to make the curve we need which was
by a circle. If the surface was flat this would be a simple matter of drawing
introduced in the Introduction To Modelling Tutorial. The edges of the seal
a circle and two arcs for the S then using the SWEEP command to cut
will follow the outside edges of the remote. Chose the command SKETCH
away material. But the surface isnt flat so how do we draw a curve onto a
non flat surface? The answer is we cant! But we can project curves onto a > EDGE > OFFSET and in the Type dialog choose CHAIN. Now pick
surface. Choose INSERT > MODEL DATUM > SKETCH and pick the TOP on an outside edge of the remote one edge highlights. Now pick on an
datum as the sketching plane. Draw a circle and two arcs to make the S adjacent edge the whole loop around the remote highlights and you
logo. Exit sketcher. choose ACCEPT in the side menu. Enter an offset distance of 0.5 a
negative value may be needed to go the opposite way to the direction
Now click on the curve in the browser panel and choose EDIT > arrow. A series of lines is created offset from the edge of the surface. Exit
PROJECT. In the project dashboard pick the External surface of the sketcher.
remote (depending on how you drew the original section curve for the
body - Figure 5 - you will may need to select twice using the CTRL key to Choose the options to remove 1 material into the remote and thats it the
get the whole surface). Close the dashboard. A copy of the curve will now
be sitting on the surface. model is finished. Remember, you can use the second icon to
change the material side to be removed.
Now you have the curves you can use the INSERT > VARIABLE
SECTION SWEEP command using these curves and a circular cross-
section to cut the grooves in the surface. You will have to do a separate
sweep for each of the two curves. If you need reminding how to do these
simple sweeps refer to the section Sweep Features in the Intermediate
Modelling Tutorial.
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Advanced Modeling
on this and choose EDIT DEFINITION. This takes you back to the ROUND
dashboard with all the options set. Reverse the side of the cut to remove
Make a FULL ROUND
material by pressing the second icon. Close the dashboard and you on the end of both
sliders.
should have the battery cover. Here are some pictures to help you finish
the model. Your dimensions may vary a little from those stated feel free
to use a bit of creativity.
REVOLVE
Thats the both halves of the model completed. In a later tutorial you will
Remove material for a learn how to assemble these two pieces together.
finger grip.
Sketch on FRONT
and choose 360
degree option.
ROUND
Add 4 round
SHELL
Remove 2 faces and
choose 1 thickness.
EXTRUSION
Figure 21 : The Completed Battery Cover
Sketch on TOP. Mirror
to make second side.
Use Extrude To Next Review
option.
So what should you have learnt?
How to create complex surfaces.
EXTRUSION
How to make thin walls with shell.
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Drawing Layout
choosing the A0 option is not sensible since by the time the page is shrunk
Creation of drawings from PRO/Engineer models is a straightforward task.
to fit on an A4 sheet the text will be unreadable. For student work it is
Completing a drawing can be broken down into two stages:-
acceptable to choose an A3 format and plot this onto an A4 sheet as this
1. Drawing Layout - Elements making up a drawing are brought gives more room for dimensions to be shown. Another way of specifying
together. These include selecting a drawing sheet, positioning the size is to choose a Template or a Format. This is like starting with a
views of your model on the sheet, adding cross-section or scaled pre-printed drawing sheet with boxes for drawing title and other
views, etc. information but we will show you how to add this in later. For this model
2. Drawing Detail - Adding information such as dimensions, choose Empty, Landscape and select the A3 standard size.
geometric tolerances and drawing notes to your drawing.
This document covers the first of these stages, drawing layout, the second
stage is covered in a companion document ProTutor05.
This drawing layout tutorial covers the following procedures
Creating a drawing sheet and assigning a model to the drawing.
Positioning drawing views onto the drawing sheet. The position of
the first view of the specified model is important since it
determines the layout of other views. Subsequent views are
placed as projections of this view and PRO/Engineer automatically
determines the view orientation based on the projection mode.
Additional views can be placed which are not projections. For
example it is often useful to add a 3D view (an isometric
projection) to the drawing as this can aid visualisation of the part.
Cross-sections are also a useful tool for communicating ideas. Figure 1: Creating a new Drawing
Cross-sections, either planar or dog legged, can be added and A new window will be displayed in which your drawing will be created with
numbered quite easily in PRO/Engineer. the file extension .DRW. If you have chosen one of the standard sheet
The drawing tutorial is based on the main housing of a valve. The model sizes a rectangle will be displayed indicating the extents of the drawing
for this part can be found at the location where you found this document. sheet. All drawing should take place inside this rectangle. Figure 2 shows
Copy the model called valve_housing to your directory before you start. the new drawing sheet, as it should appear on your screen.
Creating a Drawing
A new drawing is created using FILE > NEW choosing the type as
DRAWING and giving a suitable name (valve_housing suggested). At this
point the drawing format definition dialog appears, as shown in Figure 1.
The default model will be set to none (unless you already have a model
open). Use the browse button to locate the model you want to create a
drawing of in this case valve_housing.
Also from this dialog box the size of the drawing can be specified. When
you are choosing the size bear in mind the size of printer or plotter that is
available for the final output. If only an A4 printer is available then
Figure 2: A Drawing Sheet
By D Cheshire Page 1 of 4
Drawing Layout
To position the first view of your model choose INSERT > DRAWING
VIEW > GENERAL (if by mistake you left the model name as none in the
original dialog box you will be asked to enter the name of the model that
you want to detail - choose valve_housing). After the system has located
the model you are asked to indicate the position of the view within the
drawing. Click inside the drawing in the lower right-hand quadrant (see
Figure 3) and a default view of the housing model will be shown.
Next the DRAWING VIEW dialog will appear. This dialog offers all of the
options for setting up views.
Figure 3 : The First View is Placed and Awaiting Orientation using the ORIENT tab in the VIEW > VIEW MANAGER dialog.
Although the view is located on the drawing it is not correctly orientated. The drawing should now look like Figure 5. If any of the views are incorrect
The VIEW ORIENTATION section of the dialog allows you to change this. click on the view to highlight it with a red outline then choose EDIT >
If you click on GEOMETRY REFERENCES this works in the same way as DELETE. You will be asked to confirm removal then you can add it again.
orientating the display and setting up sketch planes. Choose TOP in
reference 1 and click on DTM2, then choose LEFT in reference 2 and click
on DTM3. The view should be orientated to show a side view as in Figure
4. Choose OK in the DRAWING VIEW dialog.
The projections from this first view can now be created. Choose INSERT >
DRAWING VIEW > PROJECTION and click to the left of the first view.
The view is projected from the currently selected view so click on the first
view you created (a red box should highlight around the view) then repeat
the process to add a third view this time clicking above the first view. You
should now have three projected views on the drawing.
By D Cheshire Page 2 of 4
Drawing Layout
The views are positioned but they can be moved if you wish. You may The view is not sectioned yet so select it and choose EDIT >
decide for example that an extra view is needed showing a cross-section. PROPERTIES (or double click on the view). The DRAWING VIEW dialog
To accommodate this, the first view you placed needs to be moved to the should appear. On the left of this dialog click on SECTIONS then click on
left. The movement of views is probably locked check the icon on 2D CROSS-SECTION and finally the icon. An old-fashioned style
the toolbar is NOT pressed. Now click on the bottom right view (the one menu will appear on which you should accept the defaults of a PLANNAR |
you placed first). A dotted box will be drawn around it with grab handles SINGLE cross-section. After choosing DONE you will need to enter a
at the corners (if you dont get the grab handles you need to press the name for the section. This is usually a single capital letter such as Z. Next
choose DTM1 to indicate where the model is to be cut to create the
icon). Now click and drag the view to the left. Note that the view section. Choose APPLY in the DRAWING VIEW dialog to see the section
above it also moves because it is a projection from the view that was and if it is correct choose CLOSE.
moved. The first view placed can be moved freely. Projected views can If you feel the cross-section lines are not suitable, for example the spacing
only be moved along the projection. If you tried to move the top view to the between the lines is too wide, then click on the cross hatching to select it
left or right it would not move, it could only be moved up or down. Try it and choose EDIT > PROPERTIES (or just double click on the hatching).
and see. On the old-fashioned style menu to the right choose SPACING and
OVERALL | HALF.
You may have noticed that hidden details (the lines showing what is going
on inside the model) are shown on all views. It is not normal practice to
show these lines on isometric or sectioned views. So to finally tidy up the
drawing the cross-section (bottom right) and general view (top left) need to
have hidden detail lines removed. Select one of these two views by
clicking on it then choose EDIT > PROPERTIES. The familiar DRAWING
VIEW dialog appears you need to choose the VIEW DISPLAY option on
the left. In the DISPLAY STYLE list box choose NO HIDDEN. APPLY and
CLOSE the dialog. The finished drawing layout is shown in Figure 7.
By D Cheshire Page 3 of 4
Drawing Layout
To fit the views onto the sheet Pro Engineer has chosen an overall scale. The format has boxes where you can fill in your name and other
The text in the bottom left of the graphics window tells you what the scale information. To do this choose INSERT > NOTE choose the options from
is (probably 1.00 in this case). You can change this to increase or the menu and then choose MAKE NOTE and click to position your text
decrease the size of all of the views giving you more or less room for then type in the text you want to appear. Press RETURN twice to end text
dimensions to be added. Simply double click on the scale text at the entry.
bottom left and type in a new value try 0.5 in this case to make the views
smaller.
What Next?
You need to experiment with creating drawings of your own parts perhaps
investigating how to do scaled views.
Now you know how to layout the drawing it would be good to move on to
annotating the drawing with dimensions and other information. This is
covered in the next tutorial.
By D Cheshire Page 4 of 4
Drawing Detailing
Creation of drawings from ProEngineer models is a straightforward task.
Completing a drawing can be broken down into two stages:-
1. Drawing Layout elements making up a drawing are brought
together. These include selecting a drawing sheet, positioning
views of your model on the sheet, adding cross-section or scaled
views.
2. Drawing Detail Adding annotation information such as
dimensions, geometric tolerances and drawing notes to your
drawing.
The companion document Drawing Layout covers the first stage of the
process and should be worked through first, the second stage is covered
here.
Since the model has already been built all of the dimensions to fully define
the model have already been entered it would be stupid to have to enter all
of these dimensions again on the drawing. ProEngineer is not stupid and
does not expect you to be either! So the first stage of the detailing process
alows you to show the existing dimensions on the views. Having done this Figure 1 : Show and Erase Dialog
you will probably find that the position of the dimensions on the drawing
needs changing to make the drawing easier to read. Certain dimensions In the dialog box which appears click on the button with a picture of a
may not be displayed on the most suitable view so this can be changed
too. Finally certain cosmetic features may not be to your liking so minor dimension and then press SHOW ALL and confirm your action.
changes can be made to dimensions for example the arrow heads can be The confirmation step is required because with a big drawing showing all
flipped around. of the dimensions can create a very confusing jumble. You dont always
have to crack a nut with a sledge hammer there are other choices
Showing Dimensions available to you as you can see from the dialog. In this case the drawing is
not too complex so this is probably the easiest way however it would be
You should already have completed the companion tutorial so you should usefull for you to investigate the other options. After showing the
have a drawing called valve_housing which can be retreived using FILE > dimensions you are left in preview mode where you have the choice of
OPEN. Having retreived the drawing lets take the sledge hammer picking dimensions to erase or as we require in this case simply pressing
approach and show on this drawing ALL of the dimensions which were the OK menu option to keep all the dimensions shown. The result of this
used to create the model. Choose VIEW > SHOW AND ERASE and you command is shown below. The drawing clearly needs tidying up!
should see the dialog in Figure 1.
By D Cheshire Page 1 of 5
Drawing Detailing
Although this is better there is still work to do. The 28, 14 and 25
dimensions all refer to the boss and its central holes. Is this the best place
to show these dimensions? This feature can be seen much better on the
sectioned view. Why not add the dimensions here instead? You will have
to zoom out a bit before you can do this so that you can see the section
view as well. Use the selection tool and select these three dimensions
now (hold the CTRL key to select multiple dimensions). Choose EDIT >
MOVE ITEM TO VIEW and point to the view that you want them to be
moved to in this case the sectioned view.
Take a closer look at the section view and you will see that the switched
dimensions need tidying again. Rather than moving them individually there
is an automated way of tidying up the dimensions. You will need to ensure
the three dimensions you just moved are selected then choose EDIT >
CLEANUP > DIMENSIONS. Set the two tabs in the dialog box to the
values shown in Figure 4 and then APPLY to see the changes.
Positioning Dimensions
To see how to tidy up the drawing lets concentrate on the view in the top
middle. Zoom in to this view to see it better. The dimensions are all
overlapping the drawing so the first thing to do is to position them better.
Use the selection tool and move each dimension in turn. Click on the
dimension to select it, to start moving click again, drag the dimension then
when the dimension is positioned better click a third time. Work on this
part of the drawing now until the appearance is as shown in Figure 3.
By D Cheshire Page 2 of 5
Drawing Detailing
these names, go back to the properties dialog for dimension we were
button with a picture of a dimension is pressed and then select editing earlier. Edit the note replacing the 8 with &d50 and adding on
the 120o dimension and finally OK and the dimension will disappear. &d49 PCD to the end (PCD stands for Pitch Circle Diameter meaning the
CLOSE the dialog. holes are equally spaced around a circle). DO NOT FORGET TO
PRECEED THE NAMES WITH &. The note should now be correct and will
Now some of the dimensions have been moved or erased there is more be automatically updated if any changes are made to the model. The
room in this view so try to position the dimensions better. You will probably
original dimensions 8 and 38 can be ERASED to avoid duplication.
find that as you move the 5 dimension the text stays on the wrong side
of the leader line. You will notice that when a dimension is selected small Continue to use the techniques you have learnt to tidy up the remaining
square boxes are drawn on key points of the dimension. These can be views. Be prepared to switch dimensions to other views as you feel
moved individually. The one on the end of the text allows you to move the necessary. Make sure to use the handles on the end of the dimension
text to the other side of the leader. Also whilst moving a dimension the extension lines to move them so that they do not overlap the model.
right mouse button can be pressed to flip the arrows to a new position.
Dimension Parameters
The 5 holes are probably going to be drilled together and so it is good
practice to keep all of the information for these holes together as a single
note. The actual text of a dimension can be changed too. Select the 5-
diameter dimension and from the drop down menus use the command
EDIT > PROPERTIES. This will bring up the properties dialog. On the
DIMENSION TEXT tab there is a simple editor to modify the text of the
dimension. You will see some unusual characters like @D. These make
up the existing dimension text a diameter symbol followed by the value
of the dimension represented by @D. Dont change these in any way but
add your note to them as follows Dimension d50 Dimension d49
3 holes @D x 8 deep.
This solution looks correct but really it is incomplete. The number 8 is the
depth of the hole which appears elsewhere as a dimension. The beauty of
Pro Engineer is that all occurrences of a model are linked or associated.
You will see later that it is possible to change a dimension in a drawing
and the model will be updated to reflect the change and vice-versa. Since
the depth of the hole in this note is not a dimension, its just a text note, it
will not be updated automatically. A better solution would be to include a
reference to the actual dimension in the text note. Here is how to do that.
In Figure 5 you will notice that the highlighted 8 depth and the 38 both
relate to the 3 holes. If you hover your cursor over each of these in turn
you will notice that in the information line at the bottom of the screen it will Figure 5 Adding Parameters to Dimension Notes
say d49:F21(HOLE) and d50:F21(HOLE). The reference d49 and d50
are the names that Pro Engineer uses for the dimensions. Take a note of
the name of these i.e. 8 is called d50 and 38 is called d49. Having noted
By D Cheshire Page 3 of 5
Drawing Detailing
Modifying Dimension Values These are available from Pro Engineer and you should refer to the Help
system under Detailing for more information.
Earlier in the tutorial it was mentioned that the links between models and
drawings allows dimensional modifications to be made from within the
drawing. You have no doubt already seen how modifications can be made
Review
within a model. The process from within a drawing is very similar. Just So what should you have learnt?
click on a dimension to select it THEN double click on it to edit it (NOTE: If
you just double click with out first selecting you will get the Properties How to show and erase dimensions.
dialog you met earlier). How to reposition dimensions.
How to maintain dimension parametrics.
Try this now on the 49 for the central bore. Select, double click then type
in a new value for this, say 55 and press RETURN. The colour of the Any problems with these? Then you should go back through the tutorial
dimension will change to show that it has been modified but the model will perhaps several times until you can complete it without any help.
not change until you choose EDIT > REGENERATE > MODEL. The
before and after of this exercise is shown in Figure 6.
Printing a Drawing
Printing a drawing is straightforward using FILE > PRINT. One point worth
noting is how do you print an A3 drawing on an A4 printer? Simple in the
Print dialog choose Configure in the Page tab choose Size as A4 then in
the Model tab choose Plot as FULL PLOT. The entire drawing should now
be scaled to fit onto an A4 sheet.
This completes the drawing tutorial. The completed drawing is shown in
Figure 7 at the end of the tutorial.
There are other additions that more advanced users may wish to include in
their drawing such as geometric tolerances, machining and other symbols.
By D Cheshire Page 4 of 5
Drawing Detailing
By D Cheshire Page 5 of 5
Modifying Models
Often when creating features in a model other features, created earlier,
are referenced. These references are called parent child relationships. For
example a hole cut into a block clearly references the block! The block is
the parent the hole is the child. The child cannot exist without the parent. If
the parent is removed the child must go too, or else another parent must
adopt the child. It is important to understand the hierarchy that is being
created in this way, as with a little thought it can be used to help your
design and not hinder it. This is particularly true when the design requires
modifying.
Relationships are created all the time within Pro Engineer. It is often
possible to design a feature in several ways, with apparently the same
result, but creating different parent child relationships. Some of these
methods will capture the design intent better than others. As an example a
hole may be created in another circular feature, a boss. The hole could be
dimensioned independently of the first feature. If the boss is moved the
hole will not move as well since there are no parent child relationships to
the first feature. If however the hole is made concentric to the boss a
relationship is built in that describes the design intent the hole and boss
are intended to always be concentric. Now the hole moves with the boss to
maintain the concentric relationship. Figure 1 : The Base Protrusion
What parent child relationships have been created in this feature if any?
Parent Child Relationships As previously stated some dimensions (usually location dimensions)
This tutorial is designed to show that solid modelling in a parametric create relations. Which of the dimensions you entered have created a
system need not be a rigorous fully structured procedure. Good technique relationship? Which dimensions referenced other features for location?
can allow flexibility in the design process. It is assumed that the reader has The 100 and 150 dimensions control the position of the box relative to the
already completed the previous modelling tutorials and is competent at FRONT and RIGHT datums so a parent child relationship exists there. Is
creating models. there any relationship to the TOP datum? You chose the TOP datum as
the sketching plane (and the FRONT datum as a bottom plane) which also
Start by creating a new part called COVER using the mmns_part_solid creates a relationship. So your block is related to all of the previous
template. Next create an extruded protrusion as shown in Figure 1. The features! None of the datum planes could be deleted without deleting the
protrusion should use the TOP datum as the sketching plane and the block. You can prove this by choosing from the pull down menu INFO >
FRONT datum as the BOTTOM reference and be created to a depth of PARENT/CHILD and picking on the block. A window appears as shown in
100. Figure 2 which states that the block has no children but its parents are the
TOP, RIGHT and FRONT datums.
By D Cheshire Page 1 of 6
Modifying Models
Reordering Features
Since this part is going to be a cover the centre needs hollowing out. A cut
Figure 2 : Information On Parent Child Relationship
could be used for this but Pro Engineer has a special feature for this
You may be already aware that the dimensions assigned to any feature purpose. It is called a shell feature you may have met it before. Use
are not fixed. Their value can be changed at any time by using the EDIT or INSERT > SHELL and pick on the bottom most surface in Figure 3 enter a
command in the pop up menu. As a reminder right click on the protrusion shell thickness of 10. The surface you picked will be removed and all of
in the feature tree and choose EDIT. All of the dimensions used to define the remaining surfaces will be offset by 10 to make the shell.
the block will be displayed. Double clicking on these dimensions will let
you change the value. The modified value will be displayed in green
indicating the change. The modification will not affect the 3D model until
you choose EDIT > REGENERATE. Try this now by changing the 100
thickness of the block to 200. Regenerate to see the change and then
change it back to 100.
Next create a second protrusion for a flange. The flange should use the
TOP datum as the sketching plane and FRONT as the BOTTOM reference
and should be created in the same direction as the first protrusion
maintaining the overall height of 100. The sketch for the flange (Figure 3)
should be created by using the offset edge icon . The LOOP option
and click on the top surface of the first block allows all four sides to be
offset in one go choose and offset of 10. Finish the sketch and choose
the BLIND option with a length of 10.
This is an example of another type of parent child relationship. The use
Figure 4 : The Shell
edge and offset edge both reference existing geometry and so a parent
child relationship is formed.
By D Cheshire Page 2 of 6
Modifying Models
The cover is full of sharp corners so add rounds (INSERT > ROUND).
There are eight edges to be rounded all around the outside of the cover.
There are four around the top and the four vertical sides so you will need
to hold the CTRL key whilst selecting them. Enter a radius of 25 for all
rounds.
Drag the round
above the shell
None
constant
wall thickness
By D Cheshire Page 3 of 6
Modifying Models
Here reference in the model tree to the end of the list. The model will be the boss and is not the obvious way to do it, its not even the correct way
regenerated with the boss before the shell maintaining a constant wall of doing it but it illustrates a point!
thickness.
By D Cheshire Page 4 of 6
Modifying Models
The hole hasnt moved because it was dimensioned independently of the
boss. No parent/child relationship was established even though this would
be good practice in this case. You could just modify the dimensions of the
hole as well but lets change the model to capture the design intent.
First modify the (now) 60 back to its original 80 and EDIT >
REGENERATE so the boss is back to its original position. The hole needs
the dimensioning scheme changing. To do this, right click on the hole in
the feature tree (the cut) and choose EDIT DEFINITION. Enter the sketch
mode with PLACEMENT> DEFINE and delete the circle. Create a new
circle this time using the concentric option . Choose the icon click on
the circle around the boss and click again to place the circle. You will
notice that no linear (positional) dimensions are created because the
circular hole is aligned to the boss thereby creating a parent/child
relationship. End the sketch and the definition. Now try making the Figure 11 : Draft References
modification again and the hole should move with the boss.
By D Cheshire Page 5 of 6
Modifying Models
What Next?
You may wish to experiment yourself with these techniques whilst
modelling the shape below. Scale or estimate all dimensions. Notice that
most faces are angled to aid moulding so you will need to use Draft
Features or other techniques.
By D Cheshire Page 6 of 6
Assembly
diagrammatically in Figure 2. It may be interesting to work out what
An assembly is a collection of parts oriented and positioned together. As
degrees of freedom are constrained by each.
such it is the highest level of data that can be manipulated within
ProEngineer as shown in Figure 1.
By D Cheshire Page 1 of 8
Assembly
Creating a Sub Assembly The second part can now be placed using INSERT > COMPONENT >
ASSEMBLE as before. Choose the name of the second component
If you have not already been given them, the parts for the valve assembly valve_cover. The part will appear at some random position in the
used in this tutorial can be found in the same directory on the Web as this assembly and the Component Placement Dialog box is shown ready to
document (http://www.staffs.ac.uk/~entdgc/tutorials.html). All 5 parts add the first constraint.
should be copied to your local system before you start.
A sub assembly is a small collection of parts which are assembled first
then later they are added to the main assembly. As an example a car
engine would be completely assembled first before it is added as a single
unit to the car on the main assembly line. Pro Engineer can treat any
assembly as a sub assembly.
Create a new assembly component using NEW from the FILE drop down
menu choosing the Assembly option and giving a suitable name - in this
case valve_sub. Choose the empty template and click OK. A new window
contain default assembly datums will be displayed into which parts will be
assembled.
The first part in the assembly is known as the base component. It is
usually obvious which part in your assembly should be considered as the
base part since other parts are attached to it. Choose the command
INSERT > COMPONENT > ASSEMBLE or icon and pick the base
part called valve_shaft from the file list. The base part will now be shown in
the assembly window. Since this is the first component it is automatically
located at the default position. (If you had used a template which
contained some datums then this would not have been the first component
and you would have had to locate the part using the techniques you are
about to learn).
Figure 4 : The Component Placement Dialog
It is now time to apply constraints to the valve_cover. As each constraint is
applied the window updates to show the constraint and states whether the
component is sufficiently constrained to be placed. The valve_cover needs
to have (at least) two constraints. You will see that under Constraints Type
in the dialog there is a drop down list. This list contains the constraint
types. It also has the option of Automatic. If Automatic is selected (the
default) ProEngineer will decide on the type of constraint based on the
type of geometry you choose. Leave the choice as Automatic and pick on
the central hole in the cover. Now pick on the shaft on the 14mm dia. near
where the keyway is located (see Figure 5). This adds the first constraint,
which is reported in the component placement dialog box. Since you have
chosen 2 cylindrical surfaces ProEngineer assumes you want an Insert
Figure 3 : The shaft in default position constraint.
By D Cheshire Page 2 of 8
Assembly
Pick Here
Pick Here
By D Cheshire Page 3 of 8
Assembly
The first stage of this assembly is now complete as shown in Figure 11.
Dont forget to save the assembly using FILE > SAVE.
Pick Here
Figure 10 : Arm Orientation Constraint. 1. VALVE_SUB (the sub assembly you made earlier) with three
constraints. Pick the shaft on the 14mm dia. and the hole in the
By D Cheshire Page 4 of 8
Assembly
top of the housing. This will be reported as an Insert type. Now 2. VALVE_BUTTERFLY with three constraints. Pick one small hole
pick bottom face of the cover in the sub-assembly and the top of in the butterfly and one hole in the shaft to make an Insert type.
Pick the other small hole and the other hole in the shaft to make
boss in the housing. If necessary change orientation using to
and Insert type. Pick one of the flat faces of the butterfly with the
make a Mate type. Add another constraint using and pick
flat on the shaft. If necessary change orientation using to
one of the 3 holes in the cover with the matching hole in the
make a Mate type.
housing. This will be an Insert type.
By D Cheshire Page 5 of 8
Assembly
Modifying Assemblies Exploding Assemblies
Choosing EDIT > DEFINITION and picking one of the components allows Sounds exciting! Bang! Actually an exploded assembly is nothing more
modification of the constraints you have applied (Alternatively you can than the parts shown separated from each other. This can be achieved in
right click on the component name in the feature tree on the left then ProEngineer using a simple command VIEW > EXPLODE > EXPLODE
choose EDIT DEFINITION). The familiar Component Placement dialog VIEW try it in the valve assembly. ProEngineer will make certain
box will appear showing the placements already applied. Clicking on one assumptions based on the type of constraints applied and guess at a
of the constraints makes it current. As each constraint is made current the suitable exploded state. As you can see from Figure 15 this is rarely
references (the surfaces you selected to define the constraint) on the perfect but it is a good starting point.
assembly and the component are highlighted. The current constraint can
be deleted and/or an additional constraint can be added.
It is also possible to modify component dimensions of parts from within the
assembly. First you need to select one of the features in one of the parts.
At the very bottom of the Pro Engineer window you will see the selection
list. This controls what will be selected when you click on an object in the
graphics window. This will probably be set to SMART so that ProEngineer
tries to guess what to select for you. Change this option to FEATURES.
Now when you move the cursor over a part in the graphics window the
individual features are highlighted and selected if you left click on them.
Select a feature then press and hold the right mouse button. A popup
menu will appear and you can choose Edit the dimensions of the
selected feature will appear and you can change them by double clicking
on them. To see the changes you will need to choose EDIT >
REGENERATE. Dont forget to reset the selection list to smart.
By D Cheshire Page 6 of 8
Assembly
the valve_cover and valve_arm will need to be moved up as well. It may CTRL key whilst picking (pick the valve_butterfly, valve_shaft, valve_cover
also look better if the valve_butterfly is moved forward. and valve_arm) and click OK. You can now click and drag to move the
parts. You may also decide to move the butterfly forward a little. To
To make sure these modifications are permanently saved choose VIEW >
maintain a true explosion this part should only be moved in a direction at
VIEW MANAGER. To show the view manager dialog in Figure 16. In the
right angles to the flat on the shaft. Click on the arrow button in the motion
Explode tab choose EDIT > REDEFINE > POSITION to reposition the
reference field and click on the flat face of the butterfly. This now sets the
parts. The explode position dialog will be shown as in Figure 16.
movement direction correctly and the butterfly can be moved as before.
Choose OK to save these modifications.
By D Cheshire Page 7 of 8
Assembly
for each part. Also subassemblies may be recorded as either a single part
or they may be broken down as well to show their make-up. These would
normally be indented in the list to show they are part of a subassembly.
The bill of materials list is a good example of the way in which a CAD
system can form the core data for more general data retrieval system. The
bill of materials information is needed for stock control and order
processing systems.
To create a simple Bill of Materials report from an assembly choose INFO
> BILL OF MATERIALS. A dialog box appears as shown in Figure 18.
Review
So what should you have learnt?
How to create assemblies.
How to assemble components using insert, align and mate.
How to edit features in an assembly.
How to explode an assembly.
How to create simple parts lists.
Figure 18 : BOM Dialog Box Any problems with these? Then you should go back through the tutorial
The default options are probably fine so just click on OK and a window will perhaps several times until you can complete it without any help.
appear showing the details of the assembly. You can see from this that the
VALVE Assembly contains 2 parts and one sub-assembly. The sub- What Next?
assembly itself contains 3 parts. The valve assembly contains a total of 5 You need to experiment with other assemblies of your own as there are
parts. This listing appears on the screen and is also written to the disk as a more constraints which we have not covered here.
text file under the name valve.bom.1. You could add this text to a drawing
(not an assembly) by choosing INSERT > NOTE then FILE MAKE Also assemblies are the starting point for mechanism analysis so take a
NOTE locate the notes position and type in the filename valve.bom.1. look at the mechanism tutorials.
By D Cheshire Page 8 of 8
Working With Tolerances
determined whilst in the sketcher by SKETCH > OPTIONS on the
Most CAD systems have functionality to allow the user to add tolerance
PARAMETERS tab under NUM DIGITS. The default values, shown above,
information to dimensions. This allows drawings to reflect design or
can also be changed choosing ANNOTATION in the selection filter at the
manufacturing intent but since the tolerances are nothing more than an
bottom of the screen and double clicking on the tolerance value. Any
additional text note applied to the dimension no additional functionality can
modifications you make to these default tolerances apply only to
be gained from the tolerance value. These unintelligent tolerances can
dimensions subsequently created. Previous dimensions will have the
serve no benefit for analysing such things as tolerance build up problems
default tolerances active when they were created. If, for example, you
and volume/weight variations.
normally work with a general tolerance of +/- 0.3 on all unspecified
Pro Engineer builds three-dimensional models and allows the defining dimensions, you could change all of the linear values to 0.3 and then
dimensions to have tolerances applied to them. These tolerances can be assign suitable tolerances to individual dimensions as required later.
displayed in the three-dimensional model window as well as appearing on
the subsequent drawing derived from the model. Since these tolerances Assigning Tolerances To Part Dimensions
are inherent in the defining dimensions of the part they can be used in a
much more intelligent way for analysing the parts performance in an The two components shown in Figure 1 and Figure 2 are simple parts
assembly as will be shown in the following scenario. which are intended to fit together as part of an assembly. They are to be
constructed as two separate Pro Engineer parts called tol1 and tol2. Using
your existing knowledge of Pro Engineer create these two separate parts
Tolerance Overview now using mmns_part_solid template. The L shaped block in tol1 can be
All Pro Engineer components are built with nominal values. The nominal created as an extruded protrusion and the three pegs are a second
values represent the ideal sizes that are intended by the designer. extruded protrusion created by sketching three circles onto the top face.
However manufacturing practice dictates that no dimension can be ENSURE YOU DIMENSION THE PARTS EXACTLY AS SHOWN.
guaranteed exactly. All manufacturing processes require a dimensional
tolerance range within which the size can be guaranteed. The smaller the
tolerance range required the more expensive the manufacturing process
required is likely to be. Assigning very narrow tolerances to every
dimension causes a component to be more expensive than is necessary to
achieve the function intended. It is the designers role to analyse the
product and decide which dimensions are critical to achieving the product
function.
All dimensions entered in Pro Engineer are given a default tolerance
value. To see these values make sure that the option DIMENSION
TOLERANCES is checked in the TOOLS > ENVIRONMENT dialog. Every
dimension for a feature will now be displayed with tolerances shown. Also
the part window will display the default tolerances as follows
X.X +- 0.1
X.XX +-0.01
X.XXX +-0.001
ANG +-0.5
This shows that the default tolerance varies according to the number of
decimal places assigned to a dimension. The number of decimal places is Figure 1 : An Engineering Component Called tol1
By D Cheshire Page 1 of 5
Working With Tolerances
As an example of what tolerances can be used for at a part level the
volume of material in a component could be calculated. Clearly since the
dimensions have a tolerance the volume would also have a tolerance. To
find out the volume range we need to calculate mass properties at
maximum and minimum material conditions. The part dimensions are set
to an extreme value by EDIT > SETUP > DIM BOUND > SET ALL >
UPPER > DONE. Notice that SET ALL can be used for tol1 since
maximum material conditions are when all dimensions are at the upper
limit. If the part had a hole the dimensions for the hole feature would need
to be set to the lower limit for maximum material. The volume can now be
calculated using ANALYSIS > MODEL ANALYSIS and choosing the Type
as Model Mass Properties and Compute. The density can be set to 1. Note
the volume is calculated as 76 495 mm3. The calculation can now be
repeated after first setting the dimensions to minimum material condition
using EDIT > SETUP > DIM BOUND > SET ALL > LOWER > DONE. Note
the volume is calculated as 75 863 mm3 a total variation of 632 mm3. Use
Figure 2 : A Second Engineering Component Called tol2
EDIT > SETUP > DIM BOUND > SET ALL > NOMINAL > DONE to reset
Having created the two parts it would be interesting to see what tolerance the bounds to their normal state.
has been applied to each dimension. Open part tol1 now. First make sure
that the DIMENSION TOLERANCES is checked in TOOLS
> ENVIRONMENT. The default number of decimal places in sketcher is 2.
If you have not changed this or the default tolerance values the tolerance
on all dimensions with two decimal places X.XX should be reported in the
graphics window as +/- 0.01. Confirm the tolerances are as you expected
by right clicking on a feature in the model tree on the left of the screen and
choosing EDIT. The dimensions should now be shown with their upper
and lower limit values as you can see in Figure 3.
By D Cheshire Page 2 of 5
Working With Tolerances
Showing Tolerances on Drawings Choose LIMITS or PLUS-MINUS to display tolerances. Notice that you can
also adjust the value of the dimension and the tolerance from here.
To show dimensions on a drawing is a simple matter so long as the
system has been set-up correctly. The following paragraph describes how
to set up the system. You should be working in a drawing for these
commands to work. Refer to Tutorials 4 and 5 for creating drawings and
adding dimensions. Create a drawing of part tol1 now positioning the
dimensions as shown in Figure 5
By D Cheshire Page 3 of 5
Working With Tolerances
Analysing Assemblies with Tolerances each other. In the assembly tolass issue the command ANALYSIS >
MODEL ANALYSIS and choose the type of analysis as PAIRS
The holes and pins in parts tol1 and tol2 are intended to assemble CLEARANCE. Pick the two parts in the assembly and Compute. At this
together with a clearance fit of H9e9 as designated by BS4500. Reference stage ProEngineer should report a zero clearance. Of course since the two
to this standard shows that the tolerance for a 12mm shaft of this parts are designed to touch along two faces this is what you would expect.
specification is 0.032 to 0.075. The matching hole would be +0.000 to What is the clearance between the pins and their holes? To find this use
+0.043. Change the tolerance of these two features now. In the tol1 part the command ANALYSIS > MODEL ANALYSIS and choose the type of
right click on the feature for the pins in the model tree and choose EDIT. analysis as PAIRS CLEARANCE but this time choose SURFACE as the
Since you just set the tolerance mode for the diameter dimension to Limits From and To option. Pick on the cylindrical surface of one pin then right
two diameter values (12.01 and 11.99) should be displayed. Double click click until you pick the cylindrical surface of the corresponding hole.
on the lower diameter dimension value for the pins (11.99) and type in the ProEngineer should report a clearance of 0. 0.0529799mm and a red
new value of 11.880. Double Click on the upper dimension value (12.01) marker will be displayed at one of the points of minimum clearance. Why is
and type in the new value of 11.950. In tol2 you will need to Edit the there this clearance value? Because the calculations are currently being
feature then click on the diameter dimension and choose EDIT > performed on the parts at nominal sizes. The calculation is
PROPERTIES so that you can set this to Tolerance Mode Limits. Then
repeat the changes setting the lower dimension to 12.000 and the upper to Pins at (11.88+11.95)/2=11.9150mm diameter.
12.043.
Holes at (12.043+12.000)/2=12.0215mm diameter.
To illustrate these concepts create a new empty assembly called tolass
Clearance of (12.0215-11.915)/2=0.053mm.
and assemble the two parts, tol1 and tol2, together. Use tol1 as the first
component. Apply three constraints as tol2 is placed as shown in Figure 8. If you do not get this value make sure you have set the dimension bounds
Make sure that the first mate constraint references the end from which the to nominal (EDIT > SETUP > DIM BOUND > SET ALL > NOMINAL > pick
15 dimensions is taken on tol2. part > DONE for each part).
The question remains that if the parts are at their worst extremes of
tolerance will the parts still assemble? What are the worst extremes? This
clearly occurs when the pins are at there biggest and the holes are at
there smallest. Also if the distance between the pins is at a minimum and
the distance between the holes is a maximum (or vice versa) a worst case
scenario exists. To achieve this condition in ProEngineer we need to set
up the dimension bounds as we did before but in the assembly. Use EDIT
> SETUP > DIM BOUND > SET SELECTED > LOWER and pick the part
tol1 on one of the pins. The dimensions for this feature will be displayed
and you can now pick each spacing dimension in turn (i.e. 15mm, 20mm
and 20mm) followed by DONE. These will be displayed in white indicating
they are set to lower. Now using the similar command set the diameter of
the pins to the UPPER tolerance. This time the dimension will be displayed
in grey indicating an upper tolerance. Repeat this procedure for the holes
Figure 8 : The Assembly Constraints in tol2 (use right click until you pick on the holes). This time the spacing
Once the assembly is complete analysis can take place. One problem that needs to be set to UPPER and hole diameters to LOWER.
often occurs with tolerances is that assembled components will not work The assembly is now set to one extreme of tolerance. If the interference
correctly when the parts in an assembly are all at one extreme of size. analysis between the two parts is performed again interference will be
ProEngineer can calculate whether two parts in an assembly interfere with
By D Cheshire Page 4 of 5
Working With Tolerances
reported the red areas where the parts overlap is highlighted. The
assembly will NOT work as intended with the current tolerances. To make
it work the tolerances on the spacing of the holes could be reduced but
this is likely to increase the cost of the component. Is there an alternative?
Figure 9 : Interference You may like to return to the parts tol1 and tol2 and EDIT DEFINITION on
the features so that the dimensions for the holes and pins reflect the
If you look at the previous interference analysis you can see that the baseline scheme. If you perform the analysis again you will find there is no
interference occurs on the last two pins, why? The problem is called interference and the assembly will work as intended.
tolerance stack up. Consider Figure 10 which shows two alternative
dimensioning schemes. Review
The two schemes apparently are no different until you consider tolerances. So what should you have learnt?
If a tolerance of +/- 0.01 is applied to each dimension what is the overall
distance to the centre of the right most circle. Using the chain- How to define tolerances on part dimensions.
dimensioning scheme the tolerances are cumulative so the answer is 55
+/- 0.03. Using the baseline dimensioning scheme the dimension is How to show tolerances on drawings.
specifically stated so the tolerances do not add up and the answer is 55 How to use tolerances for analysis.
+/- 0.01. An improvement in accuracy has been achieved with no
tightening of tolerances and no extra cost. In general baseline Any problems with these? Then you should go back through the tutorial
dimensioning is more accurate and should always be used except when perhaps several times until you can complete it without any help.
chain dimensioning better reflects the critical dimensions.
By D Cheshire Page 5 of 5
Basic Moulding
Having created a model of your part it is often necessary, dependant on The first step in the process of creating moulds from a model is to create a
the manufacturing technique, to develop a mould system for injection new file in which to work. Choose FILE > NEW and in the subsequent
moulding or casting. This document introduces the process of producing dialog box choose the options for MANUFACTURING and MOLD CAVITY
moulds covering the creation of mould halves from the defined part. It and type in the name mould. Choose the mmns_mfg_mold template. This
does not cover other aspects of mould creation such as adding mould creates a new assembly ready for the definition of the mould.
filling channels, ejection pins etc.
The tutorial starts by assuming you already have a part designed and this
is suitable for moulding. You should use the standard part provided for this
tutorial. This part can be downloaded from the internet and can be found at
http://www.staffs.ac.uk/~entdgc/WildfireDocs under the Casing link in the
Basic Moulding section. Save this part to your working directory.
PREPARING TO MOULD
Before we start to create the mould it would be good to check out the part
to be moulded. Choose FILE > OPEN and choose the name casing.prt to
load the part we are to mould.
Figure 2 : Creating a Mould Manufacturing Part
By D Cheshire Page 1 of 4
Basic Moulding
SPLITTING THE MOULD
We now have the part to be moulded and the material from which the
mould is to be made positioned correctly together. The next stage is to
prepare to split the material block into two halves to make the mould. To
do this we need to define another feature that will act as the knife to cut
If this section is blank then the material in two halves. This feature defines the split-line in this case a
the mould library has not flat plane. You could do this using the command PARTING SURF >
been installed on your CREATE but we will use the automated icons provided. First choose the
computer. You will have to
define the workpiece icon and simply click OK in the following dialog as all options are
manualy - your on your
own. correctly defined automatically. You should see red lines appearing in the
model as shown in Figure 5. These lines indicate where the casing will be
split to create the mold. You may be thinking how does Pro Engineer know
where to split it? The answer is simple it infers much of the information
from the location of the original coordinate system which is why when we
defined the first coordinate system in the casing model the location was
important as this defined the position of the split and also the orientation
was important as the Z axis defines the direction of the split.
By D Cheshire Page 2 of 4
Basic Moulding
will be created inside the material (Figure 6) which we will now use to cut
the mould into two parts.
EXTRACT or the icon and choosing all of the parts with from
the dialog box and OK. This operation has created two separate parts
(mold_vol_1.prt and mold_vol_1.prt), that can be retrieved individually and
used (e.g. machined).
By D Cheshire Page 3 of 4
Basic Moulding
In this dialog click on the name MOULD_WRK below visible components
and press BLANK at the bottom of the dialog. Now press
and blank the parting surface. Close the dialog. This leaves just the two
mould halves and the casing visible but with the mould in the closed
position. The open position of the mould is defined by the command
MOLD OPENING or the icon. Now choose DEFINE STEP > DEFINE
MOVE and pick the top half of the mould. To define the move direction
click on one of the vertical edges of the mould and type in a distance of
100 Done. Repeat this for the lower half moving it down by -100. The drop
down menu command VIEW > EXPLODE > EXPLODE VIEW controls the
movement of the model between its open and closed state.
Review
So what should you have learnt?
How to define coordinate systems for moulds.
How to create and locate basic mould components.
How to split into mould halves.
How to show mould components in the open position.
Any problems with these? Then you should go back through the tutorial
perhaps several times until you can complete it without any help.
By D Cheshire Page 4 of 4
Introduction To Plastic Advisor
can be used to analyse the moulding process and increase confidence in
Introduction to Injection Moulding the design before significant costs are incurred in mould manufacture.
One of the main problems with injection moulding is the set up cost; this Pro Plastic Advisor will now open. To show the part to be analysed choose
includes the mould design and the tooling required. This makes it suitable WINDWO > CASING. Holding down the left mouse button and moving the
for high volume production where the cost of moulds can be amortised mouse will rotate the view of the part. The middle mouse button zooms
over a large number of products. To help to reduce the cost of setting up in/out and the right button pans. You can also use the arrow keys to rotate
this process ProEngineer has designed a package called Pro Plastic the view.
Advisor. This is an optional package there is no guarantee any system
(outside of Staffordshire University) will include the software. This package
By D Cheshire Page 1 of 5
Introduction To Plastic Advisor
To select the polymer injection location, click the polymer injection location
icon that can be found at the top of the screen then click in the centre
of the model. An arrow will appear as shown in Figure 4. Is this a good
location from a design perspective? Injection locations will leave marks on
the product so you would normally choose to inject on the inside of a
product.
Material Definition
The next step is to define a suitable polymer. ProPlasticAdvisor has a built
in polymer materials database with over 4000 polymers to choose from.
When selecting a polymer for a product the physical and mechanical
properties such as strength, stiffness, hardness, etc. must be considered.
The diagram in Figure 5 shows a generalised performance spectrum of
plastic materials.
Injection Location
The first step in defining and analysis is to position the injection location
where the polymer will enter the mould. Consideration must be taken to
find the best place to inject the polymer. In the first exercise we will inject
the polymer from the top of the model. Orientate the part as shown in
Figure 4.
By D Cheshire Page 2 of 5
Introduction To Plastic Advisor
We are now ready to analyse the model. This process is started by Close the results summary box. The main graphics display will have
changed to show confidence of fill which is entirely green indicating the
ADVISER > ANALYSIS SELECTION or by clicking on icon. The
dialog box displayed allows you to choose the type of analysis required. part should fill correctly. Click on the Weld line Locations button . This
Choose plastic flow analysis and START. will show red lines on the model where weld lines may form. Weld lines
are where two separate flows of material within the mould meet and weld
together. They can cause weaknesses in the final product and so should
be minimised or avoided.
Click on the Air Traps Location button . This will show blue dots
around the bottom edge of the model. This is the location where air may
get trapped in the moulding process. Air pockets can result in incomplete
filling of the mould causing weaknesses or poor surface finish in the final
product and so should be minimised or avoided.
By D Cheshire Page 3 of 5
Introduction To Plastic Advisor
Remember it is rare to achieve a perfect mould analysis and good mould
can be achieved even when nominal problems are reported. This analysis button . This will play a small animation showing the module filling with
for example may well achieve a good mould even with these reported polymer and also gives the fill time on the right hand side of the screen.
problems.
Generating Reports
To improve your understanding of the analysis you can choose ADVISER
> ADVISER or the icon. This displays a dialog with two tabs choose Pro Plastic Advisor can produce a web based data sheet showing all the
the Quality Prediction tab. Areas of the model are shown in yellow showing information on the products progress. This is achieved by clicking on the
problems exist. Report button . A wizard will appear asking for information about the
product and allowing you to choose what analysis elements you want to
include. You will now need to select a location where you wish to save the
report. Since the report will contain many files it is a good idea to keep
them all together by creating a new directory. The program will generate a
report in web page format and save all the information in the chosen
directory. The web page will load up in the analysis software. If this does
not happen or you wish to view the page at a later date then in Windows
open the directory and double click on file index.htm.
You may have noticed that both the weld lines and the low quality area Review
occur around the screw holes. One of the design goals for plastic injected
parts is to maintain constant wall thickness. The material is much thicker in So what should you have learnt?
this area could this be a source of the problem? Could a design changes
How to start a mould flow analysis.
in the part help?
How to position injection points and select materials.
The software also gives the user access to additional information on the How to perform analyses.
RESULTS > SHOW menu. This menu will display the confidence of fill, fill How to understand results.
time, pressure drop, injection pressure and flow front temp. Lets look at fill How to generate reports.
time. Choose RESULTS > SHOW > FILL TIME. When any time based
result is displayed the video control buttons are active at the top of the Any problems with these? Then you should go back through the tutorial
window. These let you view the results over time. Click the play results perhaps several times until you can complete it without any help.
By D Cheshire Page 4 of 5
Introduction To Plastic Advisor
What Next?
Now you have a general idea of how to operate the software you may
want to try a correctly structured analysis either on this or another part of
your own. The table below shows the sequence of steps you should
undertake to correctly perform a full analysis and generate all possible
feedback.
By D Cheshire Page 5 of 5
Mechanism Design
Mechanism design in Pro Engineer is very comprehensive. You can
assemble components of the mechanism together using joints which
accurately reflect their movements, you can animate the movement
creating movie files which can be displayed on any PC and you can ask
Pro Engineer to calculate the forces and movements of a mechanism to
enable you to determine the suitability of the mechanism.
Degrees of Freedom
! " " "
Understanding degrees of freedom is critical to selecting the appropriate "
joints for your mechanism. In mechanical systems, the number of degrees
of freedom (DOF) represents the number of independent parameters
required to specify the position or motion of every body in the system. A
completely unconstrained body has six degrees of freedom, three
translational and three rotational. Joint connections act as constraints, or
restrictions, on the motion of bodies relative to each other, reducing the # $% & & " & % !
total possible degrees of freedom of the system. If you apply a pin joint to
a body, you restrict the body's movement to rotation around the pin joint,
and the degrees of freedom for the body reduce from six to one. Below is
a table describing the joint connections you can create in Mechanism
Design and the degrees of freedom corresponding to each joint.
( ! "
'
( ! " !" " "
Mechanism Design
It will be valuable if you already understand the assembly process in Pro
Engineer and have completed the assembly tutorial. We will use the pair of
mole grips as a basis for explaining how to assemble mechanisms
together. Mole grips are like a pair of pliers with one additional function.
They have an over centre mechanism so that when they are squeezed to
By D Cheshire Page 1 of 6
Mechanism Design
grip a bar they stay locked until they are released by the user. To achieve
this they must be correctly adjusted to the size of the bar using the
adjuster screw on the end of the handle.
By D Cheshire Page 2 of 6
Mechanism Design
This will align the axes of the two holes and the jaws will move to make The joint definition is identical to the previous PIN joint so choose the
this alignment however you have not yet constrained the position of the correct two holes and DTM3 in the handle and jaws. IMPORTANT NOTE:
jaws along this axis. You should notice that the Component placement All of the defining surfaces for a joint must come from the same pair of
dialog has moved on to Translation and is waiting for you to make further components since the holes were in the handle part and the jaw part the
selections. To be correctly positioned the jaws must be in the centre of the two datums must be in these parts to. You could not for example pick
mole_main part in other words datum plane DTM3 on the jaws should be DTM3 in the mole_main part. Close the dialog and perhaps try dragging
aligned with datum plane DTM3 of the mole_main part. Click on these two
the mechanism.
datums now and the joint should be made (Cant see any datums? Then
choose TOOLS > ENVIRONMENT and tick next to Datum Planes). This is
the only joint we need so click OK to finalise the placement of the jaws.
By D Cheshire Page 3 of 6
Mechanism Design
Drag the parts so the strut is in a more realistic position (See Figure 10).
The final part in the mechanism is mole_screw. This is the adjuster screw.
As you turn the screw it moves in and out. The strut touches the end of the
screw so that as the screw moves it has the effect of altering the distance
between the jaws. Lets try and simulate this now so that you can
understand it better.
Choose INSERT > COMPONENT > ASSEMBLE to assemble the
mole_screw. Dont forget to click on the CONNECTION tab (see Figure 4).
We need a different type of joint this time called a SLIDER so choose this
now below the word TYPE. A slider joint allows movement along an axis
so that we can move the screw in and out (we wont bother simulating the Figure 11 : Cylinder Joint
screw rotation). The joint definition is similar to the previous PIN joint. First
we need two axes to align so choose the hole in the end of the mole_main As you are dragging parts in this mechanism you may notice that when
part and the cylindrical surface of the mole_screw. A slider also requires dragging the handle the screw moves in and out. In real mole grips the
two planar surfaces to stop rotation pick DTM3 in mole_screw and DTM3 screw position would not change when moving the handle. How can we
in mole_main (of course strictly speaking our screw does rotate but it does make this work correctly?
not matter). DO NOT close the Component Placement dialog yet! Go to APPLICATIONS > MECHANISMS and MECHANISM > DRAG and
notice the DRAG dialog box. This has a tab called Constraints. Click on it
now and then click on the body-body lock constraint icon . This allows
you to restrict movement of a joint. Click on the mole_main part then click
on the mole_screw part and choose OK. These two parts will be locked in
their current position. You should now be able to drag the handle without
the screw moving. You can remove this lock by removing the tick next to
the body-body lock in the constraints tab. The screw is then free to move
again and can then be locked again in a new position by adding the tick.
By D Cheshire Page 4 of 6
Mechanism Design
Mechanism Animation
You have seen how by dragging you can move the mechanism through its
range of movement. This can be used to generate a sequence of
movements for the mechanism that can be replayed within Pro Engineer
whilst modifying some design parameters or can be saved as a video in
one of the standard Windows video formats then replayed outside of Pro
Engineer in Windows Media player or similar.
To define an animation choose APPLICATION > ANIMATION. The screen
will change with the important addition of an area below the main graphics
window. This is where the timeline editor will appear. A timeline defines
what events happen and at what they start/stop. But what are these events
and how do we define them? In simple terms an event is a mechanism
position. The model can be dragged to different positions and a snapshot
taken of the model in that position. Here is how
First lets set the mechanism up correctly. The command ANIMATION >
By D Cheshire Page 5 of 6
Mechanism Design
Review
So what should you have learnt?
How to assemble mechanisms using different joint types.
How to drag mechanisms.
How to create and save animations.
Any problems with these? Then you should go back through the tutorial
perhaps several times until you can complete it without any help.
By D Cheshire Page 6 of 6
Advanced Mechanisms
Part for assembly References
Joint
This tutorial builds on the experience of working with mechanisms
provided in the MECHANISMS tutorial. It is essential that you have Reference 1 Reference 2
None None
completed and fully understand that tutorial before you progress on these
more advanced functions.
None
Two new functional areas are covered here. First the concept of using
gears and drivers to power mechanisms is covered. Secondly a novel use
for mechanism in preparing assembly instructions is demonstrated. The Bracket.prt
whole tutorial is based around the mechanism shown in Figure 1 which is Mate face surface of Align washer axis A_3 to
washer to face surface of bracket axis A_8
a simple wash/wipe assembly for the rear window of a hatchback car. bracket
Assembly only
Washer.prt
Axis alignment Translation base of
gearwheel A_2 with gearwheel with top of
washer A_3 washer
Pin Joint
Gearwheel.prt
Assembly Only
Figure 1 : Wash/Wipe Mechanism
Mechanism Review
Gearshaft.prt
By way of review we will go through the process of assembling the Align motor axis Mate face
mechanism. This uses the techniques already shown in the A_2 to bracket surface of and align
axis A_6 motor to motor axis A_5 to
MECHANISMS tutorial and so instructions will be brief. If you need to, bracket axis A_8
underside of
refer back to the earlier tutorial.
Assembly Only
bracket
By D Cheshire Page 1 of 8
Advanced Mechanisms
Axis alignment pinion Translation top of pinion Align nut7mm axis A_2 to Mate base surface of
A_2 with motor A_2 with top of motor shaft arm axis A_10 nut7mm to top of arm
Assembly Only
Pin Joint
Pinnion.prt Nut7mm.prt
Align nut3mm axis A_2 to Mate base surface of Axis alignment longarm Translation bottom of
motor axis A_5 nut3mm to underside of A_5 with gearwheel A_46 longarm with top of step on
motor bracket gearwheel
Assembly Only
Pin Joint
Nut3mm.prt Longarm.prt
Align axle axis A_2 to Mate base surface of axle Axis alignment longarm
bracket axis A_7 to top of bracket A_6 with arm A_6
Assembly Only
Cylinder Joint
Create a second joint in the same part
Assembly Only
Assembly Only
Nut7mm.prt
Nut7mm.prt Align nut7mm axis A_2 to Mate base of nut7mm with
Axis alignment arm Translation base of axle arm axis A_6. top surface of arm with 2.5
A_10 with axle A_2 with top of step on axle offset.
shaft
Assembly Only
Pin Joint
Nut7mm.prt
Arm.prt
By D Cheshire Page 2 of 8
Advanced Mechanisms
Align wiper axis A_3 to Mate inside surface of
arm axis A_11. wiper with top surface of
arm.
Assembly Only
Wiper.prt
Align blade axis A_8 to Mate front datum plane of
wiper axis A_9. blade with front datum
plane of wiper.
Assembly Only
Blade.prt
Align pin axis A_2 to Mate front surface of pin
wiper axis A_9. with end surface of wiper. Figure 2 : Gears Dialog
You now have to define the two gears. First pick the joint axis the yellow
Assembly Only
arrow symbol at the centre of the large gearwheel. Click on the Gear2
tab and pick the joint axis for the pinion gear. On the properties tab change
the Gear Ratio to user defined. The gearwheel (Gear1) has 42 teeth and
the pinion (Gear2) has 12 teeth so enter these values in the boxes.
Exit the dialog and try dragging the mechanism to check that the gears
Pin.prt now mesh correctly.
If you have assembled the mechanism correctly you should now be able to
enter mechanism mode (APPLICATION > MECHANISM) and drag the Drivers
wiper blade to flex the mechanism using the MECHANISM > DRAG . If Of course with a real wiper you dont move it by dragging the wiper! You
the mechanism does not flex you will need to check each of the assembly turn on the motor. The equivalent in Mechanism is to define a driver to turn
steps for accuracy particularly check that you have selected the axis of the gear on the motor. One type of driver called a servo motor - can be
the correct body at each stage. created using MECHANISM > SERVO MOTORS and pressing the NEW
button. The dialog in Figure 3 will be shown.
Gears Like gears you first have to select the axis of the motor so pick the yellow
You may notice as you drag the mechanism that the pinion gear on the arrow at the centre of the pinion. On the profile tab you can define how
motor does not move. There is no connection between the two gears. A quickly the motor turns. Change the specification from position to velocity
connection can be created using MECHANISM > GEARS and pressing and enter a value into the A pane below Magnitude. This value specifies
the NEW button. The dialog in Figure 2 will be shown. the speed of rotation of the motor in degrees per sec. This motor turns at
120rpm or 2 rev per second or 720 deg per sec so enter 720 as the value.
This means each wipe takes 3.75/2 or just under 2 secs.
By D Cheshire Page 3 of 8
Advanced Mechanisms
the mechanism simulation. So to start open the wipermechanism
assembly and choose FILE > SAVE AS and enter a new name such as
wiperassembly. You will notice that the file that is open in front of you now
is still wipermechanism so choose FILE > CLOSE WINDOW then FILE >
OPEN and locate the newly created wiperassembly file. This is of course
currently identical to the original assembly file.
Now we need to modify this file to simulate the assembly. Basically each
part in the assembly needs to be defined by a joint which allows the part to
move along the direction it will be assembled.
Figure 3 : Servo Motor Dialog For example the second part in the assembly is the washer. Originally this
To see the motor in operation it is necessary to define an Analysis using was assembled without a joint at all. It now needs to be assembled with a
MECHANISM > ANALYSES and creating a New analysis. First define the joint that allows the washer to move along the axis of the washer this
graphical display parameters. Enter the values shown in Figure 4. Also type of joint is called a cylinder (you could also use a slider but that also
restricts rotation which is not necessary). This modification (using EDIT
click on the Motors tab and press the or button to add the motor DEFINITION) is shown in Figure 5.
definition to the analysis. When this is done you should be able to press
the RUN button at which point the motor will run and the mechanism will Step 1. Delete the
be flexed through its full range of movement you should see the MATE constraint
movement on the screen. using . Step 3. Hold CTRL
and ALT and drag
the part to its
Step 2. Convert
position before
constraint into a joint
assembly.
by clicking on
Connections arrow.
Assembly Simulation
One novel use of mechanisms is to simulate the steps undertaken in the
process of assembling the components together. To achieve this is a Figure 6 : Modifying the Gearwheel
different set of joints would be needed than those used in the mechanism
so it is necessary to save the assembly simulation as a different file from
By D Cheshire Page 4 of 8
Advanced Mechanisms
So to prepare the current model into an assembly simulation you need to Pinion.prt Convert PIN joint to CYLINDER.
go through each part in turn, right click on the name in the feature tree and Move to starting position.
choose EDIT DEFINITION then create or change the joint type. Finally,
drag the part to a position away from the assembly in the position where
it would start the assembly process. Close the assembly dialog and move
on to the next part. The following table describes the joints for each part.
Motor.prt Delete the MATE constraint. Arm.prt Convert PIN joint to CYLINDER.
Convert to CYLINDER joint. Move to starting position.
Move to starting position.
By D Cheshire Page 5 of 8
Advanced Mechanisms
Nut7mm.prt Delete the MATE constraint. Wiper.prt Delete the MATE constraint.
Convert to CYLINDER joint. Convert to CYLINDER joint.
Move to starting position. Move to starting position.
By D Cheshire Page 6 of 8
Advanced Mechanisms
The assembly should now have all the joints defined and the parts in their We now have to create a snapshot with each component in its assembled
starting positions. Now we have to create an animation. You did this in the position. You could use the drag icon to position each part in its
MECHANISM tutorial but we will review and introduce some new functions assembled position but there are some more accurate functions we can
now. use.
Creating an Animation The CONSTRAINTS tab provides functions to control the position of
components. There are functions similar to assembly functions such as
To define an animation choose APPLICATION > ANIMATION. (You may MATE and ALIGN but these are temporary constraints only. Choose the
get a warning message about invalid servo motors because the servo
motor defined earlier is no longer valid this can be ignored) The screen MATE icon now and pick the top surface of the bracket and the bottom
will change with the important addition of an area below the main graphics surface of the washer. The washer should snap to the correct assembled
window. This is where the timeline editor will appear. A timeline defines position. You may find that some of the other parts move as well due to
what events happen and at what time they start/stop. But what are these the internal relationships. You can use the drag icon to reposition these
events and how do we define them? In simple terms an event is a other parts to their original position at which point you can use the camera
mechanism position. The model can be dragged to different positions and
a snapshot taken of the model in that position. Here is how icon again to take another snapshot of the mechanism after the
washer is assembled. This will be called Snapshot2.
Choose the icon or the ANIMATION > SNAPSHOT command. The This basic procedure needs to be repeated for every part if the assembly.
Drag Dialog shown in Figure 6 will appear.
Some of the parts (the Blade) may require MATE and/or ALIGN
functions to correctly position them. Dont forget after each position is
defined to take a snapshot. When the mechanism is fully assembled you
should have 17 snapshots or events defined that need to be turned into an
animation. Close the Drag dialog.
You can use the camera icon at the top of the dialog to take snapshots
of the mechanism in its current position. Do this now to save a snapshot
of the mechanism in its starting position. This will be saved under the
name Snapshot1.
By D Cheshire Page 7 of 8
Advanced Mechanisms
Press the icon or choose ANIMATION > KEY FRAME SEQUENCE. However you may wish to change the view during the animation this is
Choose NEW and the Keyframe Sequence Editor dialog appears (see possible using the ANIMATION > VIEW @ TIME or icon. First though
Figure 7). Type Assembly in the name field. Below Keyframe Snapshot1 you have to define the views that you want using the VIEW > VIEW
should be listed and time 0.000. In the dialog press to add this ORIENTATION > REORIENT command (use the mouse to get the view
Snapshot1 to the animation. Then select Snapshot2 from the list and you want then press type in a meaningful name then press SAVE).
change the time to 1 and press again (The time of 1 sec could be set Create two views now one called CLOSEUP which is zoomed into the
to the actual time that this part of the assembly takes). Repeat this process motor end of the bracket and one called FAR which shows the whole
fro each of the 17 snapshots defined. Press OK. You should see the assembly. Now you have the views you need choose ANIMATION > VIEW
Assembly animation appearing in the timeline. You can right click on the
timescale at the bottom of the screen and choose EDIT TIME DOMAIN to @ TIME or icon. Choose CLOSEUP as the name and a time of 0 then
change the overall time (to 16 secs) and frame rate of the animation press the apply button. Choose CLOSEUP again and a time of 12 then
period. press the apply button. Choose FAR and a time of 14 then press the apply
button. Close the dialog. In the timeline at the bottom of the screen a
Now in the animation toolbar press or ANIMATION > START to second line should have appeared with the view names. Now in the
generate all the intermediate frames between the snapshots. Once animation toolbar press or ANIMATION > START to generate all the
generated you can press or ANIMATION > PLAYBACK to play the intermediate frames between the snapshots and then or ANIMATION >
sequence using the Animate dialog which has controls like a video PLAYBACK to play the sequence. The animation should start with a close-
recorder. up then after 12 secs zoom out.
Review
So what should you have learnt?
How to assemble mechanisms using different joint types.
How to create gears and motors
How to simulate the assembly process.
How to create and save animations.
How to change the view during an animation.
Any problems with these? Then you should go back through the tutorial
perhaps several times until you can complete it without any help.
By D Cheshire Page 8 of 8
Dynamic Mechanism Design
It is essential that you have completed the previous two tutorials on Joint Definitions
mechanisms from this series before starting this one. The part and As you drag this mechanism you will probably have noticed that the
assembly files for this model can downloaded from the internet and can be damper joint moves too far. The parts can actually move so they pass
found at http://www.staffs.ac.uk/~entdgc/ProeDocs in the Dynamics through each other. This means the suspension travel is much too large.
section. Save all 7 parts and 1 assembly to your working directory. Any joint in Pro Engineer can have it movements restricted heres how.
Open the assembly and you will see that the mountain bike has already
First use the DRAG tool to position the mechanism such that the
been assembled for you and operates correctly as a mechanism. Check
damper is near one extreme of its travel as shown in Figure 2 (you may
this out now by using the DRAG command. Some points worth noting
are:- want to switch to hidden line display to see this). Then choose
MECHANISM > JOINT AXIS SETTINGS and pick the SLIDER joint to
1. The method used to model the frame of the bicycle. define its settings. Press the MAKE ZERO button to define the current
2. The front wheel is the first part assembled and is effectively locked position as the zero location. Next click on the Properties tab in this dialog
to ground so it doesnt move. and tick Enable Limits and enter the values for maximum and minimum
travel. This damper has a range of 50mm and the travel is in the opposite
3. The rear wheel is assembled using a planar joint so it is free to direction to the joint so the maximum value will be 0 and the minimum -50.
move backward and forward as the suspension flexes since the
wheelbase will change. The SLIDER joint
Springs
Although the bike moves correctly there are some elements of the bike
Figure 1 : The Bike suspension that are missing. The first of these is the spring. It is possible
Review all these features now and ensure you understand how they were to model a spring using the HELICAL SWEEP command and this would
achieved by referring to the earlier mechanism tutorials. You may even look like a spring. For the analysis of mechanisms we need a spring that
prefer to create your own assembly file and assemble your own cycle to reacts correctly like a spring applying forces as it is compressed. This type
ensure you fully understand the process. of spring can be defined in mechanisms. Make sure you are in
mechanism analysis mode (APPLICATION > MECHANISM) then choose
By D Cheshire Page 1 of 5
Dynamic Mechanism Design
MECHANISM > SPRINGS and create a NEW spring. From the dialog box different rates for compression and bump). Enter a value of 1.1 for the
which appears (Figure 3) you will see there are two ways of defining the damping constant C. Choose OK to finish the definition.
spring on a joint axis or point-to-point. We will use the point-to-point
option so choose this then pick the 2 points that have already been
created in the model called SHOCKTOP_POINT and
SHOCKBOTTOM_POINT. One of the advantages of using point-to-point is
that Pro Engineer will create a visual representation of the spring untick
the Default option for the icon and type a diameter of 36.
Finally we have to define the dynamic properties of the spring. The force
created by a spring is directly related to the compression of the spring (Pro
Engineer has no facility for variable rate springs). Most springs start of with
some pre-compression so the actual force from a spring is given by the
formula Force=k*(x-U) where K is the spring stiffness (N/mm) and U is the
free length of the spring (mm). Enter values of 190 for k and 125 for U.
Choose OK to see the spring icon which may not be perfect but it is a
reasonable representation
Figure 4 : Damper Settings
Materials
Closely related to the gravity settings are the material properties. The
3
default density assigned by Pro Engineer is 1 tonne/mm which means
parts will be extremely and have very high inertia they will be difficult to
move! To set the correct density values choose MECHANISM > MASS
PROPERTIES.
Dampers
The second missing element is the damping action which is created in a
similar manner. Choose MECHANISM > DAMPERS and create a NEW
damper. From the dialog box which appears (Figure 3) you will see there
are three ways of defining the damper. Though it is less important in this
case we will be consistent and use the point-to-point option so choose this
then pick the same two points SHOCKTOP_POINT and
SHOCKBOTTOM_POINT. The damping force created by a damper is
related to the velocity of movement of the damper multiplied by a damping
constant C (Pro Engineer has no facility for variable rate dampers or Figure 5 : Material Density
By D Cheshire Page 2 of 5
Dynamic Mechanism Design
Pick one of the parts in the mechanism (say the frame) and change the
Define Properties by to Density. The DENSITY field should now be
3
editable and you can type in a value in tonne/mm . (Aluminium 2.7936e-9,
Steel 7.82708e-09, Nylon 1.20014e-09). Change the value to aluminium
for ALL the parts in this assembly. Dont forget to do all the parts otherwise
the later calculations will not work correctly.
Gravity Forces
If the mechanism is to react correctly gravity must be specified. This is
easily set using MECHANISM > GRAVITY. Note the units required in this Figure 7 : Setting an Initial Condition
dialog mm/sec2 so the normal (earth) value is 9810. The direction for this Whilst you are here drag the mechanism so that the damper is fully
model is -1 in Y. extended and create a second snapshot called DamperMax. Then create
a second NEW condition called EXTENDED and select the second
snapshot you have just saved. Click OK to finish.
Static Analyses
Now we are ready to start to analyse the model. The first type of analysis
we will investigate is called a static analysis. This type of analysis will take
into account all of the forces on the mechanism and find the equilibrium
position. Lets start with a simple situation the bike is standing still with
no rider seated just supporting its own weight. In this situation you would
expect that if the suspension is designed correctly the damper would be
Figure 6 : Gravity stretched to its maximum limit. Lets see how we can prove this.
Initial Conditions Choose MECHANISM > ANALYSES and create a NEW analysis. Change
the settings in the dialog to reflect those in Error! Reference source not
We are soon going to start to analyse this mechanism soon. To do this it is found.. You will need to change the Name, Type, Initial Configuration and
useful to have a known starting position called an Initial Condition in Pro Tick Enable Gravity in the Ext Loads tab.
Engineer. Initial conditions can specify the start position, velocity and
acceleration of a mechanism. We are only interested in the start position
which is defined by a snapshot. Drag the mechanism so that the damper s
fully compressed and save this as a snapshot called DamperMin as
described in the earlier Basic Mechanisms tutorial (hint : use the icon
in the DRAG dialog). Now choose MECHANISM > INITIAL CONDITIONS
to define the start conditions. Create a NEW condition and the dialog in
Figure 7 will be displayed. Call the condition COMPRESSED and select
the snapshot you have just saved.
By D Cheshire Page 3 of 5
Dynamic Mechanism Design
If you press RUN now you should see the model gradually changing the
position as the program iterates the equilibrium position. The graph that
appears also reflects the program homing on the correct position if the
final point is plotted at a Y axis value of zero you know the model has
found the equilibrium. If you look carefully at the damper you should see
that it has stretched to its maximum length as you would expect. Press OK
to finish this analysis.
Loads
Lets use a similar analysis to find out how much the damper would
compress when a rider sits on the seat. The rider weighs 12
stone/168lbs/76Kg so the force which will be applied to the seat will be
750N. This load can be created using MECHANISM > FORCE/TORQUE Figure 10 : Forces in a Static Analysis
and creating a NEW force.
Just like the last analysis the model should home in on the equilibrium
position but you would now expect the damper to be just a little
compressed zoom in to the damper to see this is the case.
Dynamic Analyses
A second type of analysis will also be useful in designing this bike. If the
rider goes over a large jump a correctly designed suspension should
compress but not reach its full travel or bottom out. Lets test this using a
dynamic analysis. The parameters for this test are that a force of 8 times
the riders weight will be applied for 0.02 sec and then a constant load
equal to the riders weight will be applied.
By D Cheshire Page 4 of 5
Dynamic Mechanism Design
To prepare for this analysis create a second force called JUMP which is 8 Review
times the RIDER load (6000N).
So what should you have learnt?
Now create a new analysis called JUMP. Change the type to DYNAMIC
and the duration to 0.1 then switch to the EXT LOADS tab and add both How to define joint limits, springs, dampers and forces.
the RIDER load and the JUMP load over the durations shown in Figure 11. How to create static and dynamic analyses.
How to create measures.
Run the analysis and you should see the damper compresses to near its
full extent then bounces back before settling back to normal riding position. Any problems with these? Then you should go back through the tutorial
perhaps several times until you can complete it without any help.
Measures
Watching the action on the screen is not very accurate. You may need to
know more precisely some value from the mechanism such as how the
damper length varies over the duration of the dynamic analysis. This is
known in Pro Engineer as a measure. Measure are available for lots of
things such as velocity, acceleration, forces as well as distance.
To create a measure choose MECHANISM > MEASURES. In the dialog
choose to create a new measure. Type a name of DAMPERLENGTH
and a type of SEPERATION picking the SHOCKTOP_POINT and
SHOCKBOTTOM_POINT. Click OK on the Measure Definition dialog. Now
highlight the DAMPERLENGTH measure and the JUMP result set and the
small graph icon at the top of the dialog should activate. Press this icon
to see the results.
By D Cheshire Page 5 of 5
Warp Modeling
Warp features are a fairly new addition to Pro Engineer Wildfire that allows
global modifications to be made to a solid model. It is like having the ability
to turn your solid model into a lump of plasticine and then bend twist and
stretch the whole model into shape. These techniques allow you to make
some very complex shapes which you could not make by any other
method within a solid modeller. The tools you have for the control of these
shapes are fairly versatile (if a little tricky to use at first) but due to the
global nature of the modifications the control may not be as precise as with
other functions you are used to in Pro Engineer Wildfire. That said, as you
can see from Figure 1 you can make some very unusual shapes.
Figure 2 : Initial Extrusion
Now its time to warp this simple shape into something more interesting.
Choose INSERT > WARP and you will see the warp dashboard displayed
at the bottom of the screen. This has several for the different warp
functions and a series of menus which hide functions which are very
useful.
By D Cheshire Page 1 of 5
Warp Modeling
Your First Warp So how do you use this to add a taper? The drop down list box on the
warp dashboard will probably be set to OPPOSITE change this to
We will introduce the warp functions by working on the hex bar we have CENTRE. Now drag the arrow handle highlighted in Figure 7 to create a
just created to make it taper along its length. If you have just issued the tapered bar.
INSERT > WARP command Pro Engineer should be waiting for you to
select the solid to be warped so pick the extruded hex bar and click on OK Use this handle
in the select dialog on the right of the screen. You will immediately be to add a taper.
asked to pick a reference for the warping so pick the coordinate systems
PRT_CSYS_DEF. The warp tools should now be active in the dashboard -
press on the second button . The bar should now be surrounded by a
box (known as a marquee) with square grab handles with which you can
drag the model. Try dragging the model now to see what effect each of the
drag handle has when you click on a corner you will get additional drag
arrows to play with
Figure 7 : Warp taper
As you drag a handle you get visual feedback of the changing shape.
There is also a numeric value that you can change which appears in the
OPTIONS menu. The higher this number the greater the effect of the warp
command and the more the shape tapers change this value to 6. If you
tick the adjacent box the value can be changed later using the EDIT
command like any other dimension. Press the green tick to finish the
warp feature creation.
Figure 5 : Warp Drag Handles
The Twist Warp
When you have played with the drag handles your model may well be
distorted. We need to restore its shape this is no problem because the You should now have a tapered hexagonal bar. Lets twist it around its
warp function has its own history under the LIST menu. Click on this menu length. Choose INSERT > WARP again and pick the extruded hex bar and
click on OK in the select dialog on the right of the screen. You will
now and use the delete icon to delete all of your modifications except immediately be asked to pick a reference for the warping so pick the
the first WARP : REFERENCE function. The dialog should look like Figure coordinate systems PRT_CSYS_DEF. The warp tools should now be
6.
active in the dashboard - press on the sixth button . A numeric input
window should appear in the dashboard into which you can type a twist
value in degrees. Type a value of 360 and tick the adjacent box to export
the value as an editable value. After entering this value the shape on the
screen will be unrecognisable! This is because it is twisting around the
wrong axis. Press the to cycle through the 3 axis until the shape is
correct. The icon changes the direction of the twist.
By D Cheshire Page 2 of 5
Warp Modeling
To complete this part go back (move the insert here icon) and add an
extruded hole for the electric wires to go through (Extrude 3) and a lug to
aid assembly.
By D Cheshire Page 3 of 5
Warp Modeling
the shape by modifying an edge curve. Pick any one of the edges of the
rounds as the control curve and click on OK in the select dialog on the
right of the screen.
By D Cheshire Page 4 of 5
Warp Modeling
We havent finished so DONT press the green tick yet. Next we will twist
the lampshade so click on sixth button and type a twist angle of 60
degrees. Press the icon twice to cycle through the 3 axis until the
shape is correct (refer back to The Twist Warp as a reminder).
Review
So what should you have learnt?
How to create individual warps
How to combine warps into a single feature.
Figure 17 : Warp History
Understand the limitations of using warp features
Press the green tick to finish the warp feature creation. All these Any problems with these? Then you should go back through the tutorial
warps appear as a single feature in the feature tree. perhaps several times until you can complete it without any help.
Finish the lampshade design off by adding rounds, a shell, a full round and The Transform, Stretch and Sculpt Warps have not been discussed here.
an extruded cut. Experiment with these on your own models.
By D Cheshire Page 5 of 5
Extra, Extra, Read all about it!
Here are some answers to questions that are often asked. The
explanations are brief as you are expected to be a competent user of
ProEngineer.
Underlay
It is a common technique to use a photograph as an underlay or guide
when sketching in a CAD model. Though not an explicit function of Pro
Engineer his can be achieved with a little work as follows.
Before you start you will need one or more orthographic digital pictures of
Figure 2 : Filled Surface
a product (photographs of a real object or scanned sketches of your own
design). Now we need to associate a picture with this surface. Choose View >
Color and Appearance to show the materials palette. In this dialog choose
Create a new part using the mmns_part_solid template. Insert a new
MATERIAL > NEW and change the name of the material to
sketch (INSERT > MODEL DATUM > SKETCH ) and draw a simple FrontPicture . Click on the MAP tab and click on the square button
rectangle on the FRONT datum. Adjust the size of this rectangle to be the next to DECAL . At the top of the dialog choose TEXTURE > ADD
overall size of part to be modelled. and using the dialog that appears to locate the texture. This can be any of
the common picture file formats (bmp, jpg etc) but you are strongly
advised to copy the picture file to the same directory as the model before
you apply it. After loading the picture click on its name to apply it to the
surface and CLOSE the Appearance Placement dialog. In the
Advanced tab of the Appearance dialog you may wish to adjust the
Transparency to say 80% so the texture is see through. Finally below
Assignment choose Surfaces and pick the fill surface choose OK and
BOTH. You can now use this picture as an underlay when drawing. You
can visually sketch on it but you cannot lock the points onto the picture.
By D Cheshire Page 1 of 3
Extra, Extra, Read all about it!
You may want to repeat this procedure for the other datum planes adding Method 1 Multiple 2D tubes
pictures of the model from other directions.
The first method recognises that many 3D tubes can be made up of
several planar tubes connected at their ends. Think of a traditional racing
bicycle handle bars. These can be made up of two planar curves as shown
in Figure 4. This shows two curves being drawn on separate datum
planes. The ends of these curves meet and they are tangent. The tube
was made using the Variable Section sweep tool and the References >
Details button was used to add both curves to the Origin chain.
Tubes
Figure 5 : Adding Datum Points
Creation of planar (2D) tubes in ProEngineer is easy using the Variable
Section sweep tool. What is not so obvious is how to create tubes that You can now use these points to create a datum curve using INSERT >
bend in all 3 dimensions. Here are two methods MODEL DATUM > CURVE (not SKETCH). Choose THRU POINTS |
DONE then pick one of the points (since they are a group they will all be
selected). Choose DONE and OK in the Dialog box to create the curve.
By D Cheshire Page 2 of 3
Extra, Extra, Read all about it!
Figure 6 shows the difference between the curve type options. Now use If you change the length of the spring now by editing the 80 dimension to
the Variable Section sweep tool to create a tube from this curve. say 100 you will see that an extra coil is added. The spring hasnt
stretched as you might expect. To make the spring act more realistically
you can build in some relationships. Choose TOOLS > RELATIONS to see
the dialog in Figure 8. Click on the spring in the main window and choose
to show ALL dimensions. The dimension names not their values will be
shown. Notice that the pitch of the spring is d2 and the length is d0 (if
yours are different use your values. Enter the formula shown in into the
dialog. Click OK and now when you change the length of the spring the
coils should stretch just like the real thing. Can you work out what this
formula is doing? (Hint there are 4 coils in this spring)
Figure 6 : Curve Types (Spline, Single Rad, Multiple Rad)
Springs
There is a special function for creating springs in ProEngineer. Choose
INSERT > HELICAL SWEEP > PROTRUSION. From the side menu
choose the parameters you want for the spring CONSTANT | THRU AXIS |
RIGHT HANDED | DONE. Next choose a sketching plane such as the
FRONT datum then OK and DEFAULT. You should now be in sketcher.
Draw a line representing the outside shape of the spring. In the case of the
80 dimension represents the length of the spring and the 20 is half the
diameter of the spring. You will also need to draw a centre line for the
spring. After leaving sketcher you will be asked for the pitch of the spring
type in 20. You will now be back in sketcher this time to draw the cross-
section of the wire from which the spring is made draw a 5 circle on the
end of the line. Exit sketcher and choose DONE to see the spring.
Figure 7 : Springs
By D Cheshire Page 3 of 3
Turning
This tutorial introduces the concept of machining of turned parts using a
CNC lathe. A sample model of a turned part is provided for you to work
with in this tutorial. There is a link to it next to this tutorial at
http://www.staffs.ac.uk/~entdgc/WildfireDocs/tutorials.htm and it is called
turnedpart.prt. This part should be downloaded to your working directory
before starting the tutorial.
Machining Setup
To start the tutorial, create a new file for the machining data using FILE >
NEW. Select MANUFACTURING and NC ASSEMBLY as shown in Figure
1 and type in a name such as turnedpart. In the New File Options dialog
that follows choose EMPTY.
Figure 2 : The Mould Part to Be Machined
As an aid to visualising the machining process it is beneficial (though not
essential) that the stock material from which this part will be machined is
defined. To do this choose MFG MODEL CREATE WORKPIECE
and type in the name turnedpart_work. Now choose PROTRUSION
EXTRUDE | SOLID | DONE to enter the extrude dashboard. If you have
completed the modelling tutorials you will be familiar with this function.
Enter the sketcher by choosing PLACEMENT and DEFINE from the
dashboard. Choose the RIGHT datum as the sketching plane then the
TOP datum as the reference plane. In the sketcher choose the FRONT
and TOP datums as references. Draw a 50mm diameter circle to represent
the bar from which this part is turned.
By D Cheshire Page 1 of 11
Turning
Exit sketcher and type a length of 75mm for the extrusion. A cylindrical It is ESSENTIAL that the Z axis is correctly oriented if the turning operation
block of material the same size as the original bar from which the part is to is to be correct. The Z axis defines the rotation of the work in the lathe
be turned will be shown. After pressing to exit the dashboard the chuck. If the Z axis is incorrectly oriented then Pro Engineer will try and
material should be shown in transparent green. machine from the wrong direction. Click OK to close the dialog and ACS0
should appear in the model tree.
It is also useful to define the location of the position that the tool will return
to before/after each cut is taken. To specify this point we will define a
datum point with INSERT > MODEL DATUM > POINT > OFFSET
CORDINATE SYSTEM... As a reference point, choose the coordinate
system ACS0. Type a name of HOME and add a value of 30 in the X
column and 5 in the Z. Click OK to close the dialog and create this point.
By D Cheshire Page 2 of 11
Turning
Defining the First Cut
We can now start the machining process. It would be good at this stage to
plan the sequence of events for machining. For this shape we will first
remove the mass of material around the finished part with a large tool,
leaving some material to be removed by a second finer cut. Later we will
machine the grooves and other features.
Now we start to define the first cut into the material. Choose MACHINING
NC SEQUENCE MACHINING | AREA | DONE. A series of
parameters is offered. Ensure that Name, Tool, Parameters, Start and End
are checked and then choose DONE. Type the name as RoughCut. Enter
the tool values as shown in Figure 7a and APPLY OK.
Negative Z
then here
Pick here
Figure 7 : Roughing Tool and Manufacturing Parameters
From the MFG Params menu choose SET and enter the values as shown Positive Z
in Figure 7b then File > Exit and DONE. Now define the position of the tool
at the start by picking the HOME datum point created earlier then pick the
same HOME datum point a second time to define the position of the tool at Figure 9 : Defining a Profile by Section
the end of the machining sequence. This has defined the profile which the tool will follow but the shape
Next you will see the CUSTOMIZE dialog. This dialog allows you to define includes the grooves around the part and the hole in the end. These
the geometry that will be machined. Press INSERT to define a new cut should not be included so they need to be removed. In the CURVE: TURN
then choose CREATE PROFILE. There are lots of ways of creating the PROFILE dialog double-click on ADJUST TURN PROFILE to show the
profile which is going to be machined. We will start of by using the ADJUST PROFILE dialog. In this dialog click ADD to create a new
SECTION | DONE option. adjustment then pick the points in Figure 10. Press PREVIEW to see that
By D Cheshire Page 3 of 11
Turning
the machine profile now misses out the groove the two points you chose Defining the Second Cut
are joined by a straight line. Add a similar adjustment to the other groove.
Click OK in the ADJUST PROFILE dialog and OK in the CURVE: TURN Have you pressed DONE SEQ. IF YOU DONT DO THIS YOU WILL
PROFILE dialog. ProEngineer next offers the opportunity to extend the LOOSE THE DEFINITION OF THIS TOOLPATH!
profile at each end to ensure a clean cut choose the options NEGATIVE Having completed the roughing toolpath we can now define a second
Z | DONE for the first end and POSITIVE Z | DONE for the second end as toolpath for the finishing cut. Choose NC SEQUENCE NEW
shown in Figure 9b. Then choose DONE CUT and the toolpath will be SEQUENCE MACHINING | PROFILE | DONE. Again a series of
previewed. Choose OK in the CUSTOMIZE dialog to finish the definition of parameters is offered. Ensure that Name, Parameters, Start and End are
this cut. checked then choose DONE. (Note : We havent chosen the Tool option
this time so the same tool as the previous cut will be used which is fine in
this case)
Pick here
then here Type the Name as FinishCut. At the MFG Params menu choose SET and
enter the values as shown in Figure 12 and FILE > EXIT and DONE.
By D Cheshire Page 4 of 11
Turning
uses software called Vericut to simulate the machining process. A Defining the Groove Cuts
graphical representation of the part should appear on the screen after a
few moments. You can use the buttons in the bottom right of the screen to Have you pressed DONE SEQ. IF YOU DONT DO THIS YOU WILL
LOOSE THE DEFINITION OF THIS TOOLPATH!
play the toolpath . Use the solid green arrow to Having completed the roughing toolpath we can now define a second
play the path now.
toolpath for the finishing cut. Choose NC SEQUENCE NEW
SEQUENCE MACHINING | GROOVE | DONE. Again a series of
parameters is offered. Ensure that Name, Tool, Parameters, Start and End
are checked then choose DONE.
Type the Name as GrooveCut1 and in the Tool Setup dialog define a new
tool as shown in Figure 14 finishing with APPLY and OK.
By D Cheshire Page 5 of 11
Turning
Having completed all of the machining steps you may want to check the
whole machining process by viewing in Vericut. To join all the steps
together you need to create an intermediate file containing all of the
toolpaths. CL DATA > OUTPUT > SELECT ONE > OPERATION then pick
the operation name TURNING > FILE > DONE and accept the name
turning.ncl for the filename. This has created a .ncl file in your working
directory. Choose DONE OUTPUT > NC CHECK > CL FILE and select the
file you just created. Choosing a final DONE will take you to Vericut where
you can view the whole machining process seeing the results in Figure 17.
Axial Drilling
All lathes have the option of using a drill s a tool to cut holes axially along
the centreline of the work. Some lathes (like the Beaver Turning Centre at
Staffordshire University) can have live tooling drills which a powered by
the tool post and so can cut holes off the axis of rotation. This section
Figure 16 : First Groove describes how to program such movements.
Have you pressed DONE SEQ. IF YOU DONT DO THIS YOU WILL The model you have been working on has holes designed in it. These are
LOOSE THE DEFINITION OF THIS TOOLPATH! currently suppressed so they are invisible. To resume them so you can
see them follow the following steps illustrated in Figure 18
Repeat the process creating a new sequence for the second groove. The
step on the end of the part should also be machined as a groove. You can Expand the model tree under TURNEDPART.PRT
also use grooves to define parting off operations. 1. Click on SETTINGS at the top of the model tree
2. Choose TREE FILTERS to display the dialog.
NOTE : You have been shown two ways of creating the geometry to be 3. Tick Suppressed Objects and OK
machined SECTION and SELECT PROFILE. The most flexible method 4. Two patterns of holes will be shown in the model tree. The black
is SKETCH which allows you to draw the profile in sketcher. This method dot next to the name shows they are suppressed.
is not covered here but it is intuitive if you are familiar with sketcher. 5. Right click on each pattern and choose RESUME.
By D Cheshire Page 6 of 11
Turning
2
By D Cheshire Page 7 of 11
Turning
The rest of the process is basically the same as for Axial Drilling so
perform the following steps while referring to Axial Drilling for more detail
1. Create a new NC Sequence.
2. Select a SEQ TYPE of Mill.
3. Choose HoleMaking and 5Axis (dont forget this!!).
4. Select Name, Tool, Parameters, Retract, Holes, Start and End.
Figure 22 : Axial Drilling Toolpath 5. Enter Name, Tool, Parameters as before.
6. For retract choose Along Z axis with a distance of 0.
7. For holes choose Axes tab, Pattern then choose Add. Now pick
Radial Drilling any of the axes for the four holes. All four holes will be selected
Have you pressed DONE SEQ. IF YOU DONT DO THIS YOU WILL then OK and DONE/RETURN.
LOOSE THE DEFINITION OF THIS TOOLPATH! 8. Define the Start and End points as normal.
To drill the final set of radial holes requires a machine type where the tool Screen play the toolpath to see the results.
moves along the X axis rather than the Z on a normal lathe. This type of
machine is known as a mill/turn as it combines the functions of both a
milling machine and a lathe. Since Pro/Engineer does not allow you to
change an existing machine type once you have created sequences for it
we need to create a complete new machine. Do this with MACHINING
OPERATION (from the MANUFACTURE menu) and you will see the
Operation dialog from Figure 23. Choose FILE > New in this dialog to
create a new operation. Type in an Operation Name of MillTurn. Press
to go to the machine Tool Dialog and choose FILE > New in this
dialog. Type in a machine name of CNCMiller, choose a Machine Type of
Mill/Turn, 3 Axis and tick Head 1 for Milling Capability then press OK to Figure 24 : Radial Drilling Toolpath
return to Operation Setup. Next click on next to Machine Zero and pick
on the coordinate system ACS0. Close the dialog with OK. Post Processing
Post Processing is the act of converting the toolpaths from a standard
language called a cutter location file (.ncl) to the language of your specific
CNC machines controller. The resultant file in Pro/Engineer is known as a
tape file (.tap) which contains all the G codes to control the CNC
machine. The post processor is a program that performs the translation
process. Even though Pro/Engineer comes with some general post
processors you must have the correct post processor for your specific
machine controller otherwise breakages may occur.
You were instructed how to create a CL file in the previous section. This
same file can be used to produce the CNC instructions via post
processing. To use this file choose CL DATA > POST PROCESS and then
select the filename turning.ncl followed by DONE. Pro/Engineer should
Figure 23 : Operation and Machine Tool Setup Dialogs
By D Cheshire Page 8 of 11
Turning
now generate a list of the post processors available on your system.
These have names from UNCX01.1 to UNCX01.99 (milling) and APPENDIX
UNCL01.1 to UNCL01.99 (lathe). As you move the cursor over these
names a description of the post processor will be shown at the bottom of
File Structure
the main window. To use the Beavor Turning Centre at Staffordshire
University choose UNCL01.99 as the post processor. On completion an The machining operation in Pro/Engineer brings together data from
information window will be displayed and the file turning.tap will have been several places. This requires several files to be associated to the
created in your working directory. This file should be uploaded to the CNC manufacturing process. It is important to understand the structure of these
machine and checked by the operator before running. files because if one of these required files is deleted by mistake the whole
manufacturing process may be lost. Figure 25 shows this file structure.
Review
Turnedpart_temp.tph Turnedpart.mfg Turning.ncl
So what should you have learnt?
How to create a coordinate system. Turnedpart.asm Turning.tap
How to define stock material. To CNC
machine
How to define an operation.
How to define a cut area, profile groove and holemaking.
How to post process a file. Turnedpart.prt Turnedpart_work.prt
Any problems with these? Then you should go back through the tutorial Turnedpart.mfg Stores all manufacturing parameters
perhaps several times until you can complete it without any help.
Turnedpart.asm Assembles model and work parts together
Turnedpart.prt The part to be machined
By D Cheshire Page 9 of 11
Turning
Important Manufacturing Parameters Calculating Speeds And Feeds For Turning
ProEngineer provides an enormous amount of parameters to control each
Most tooling manufacturers catalogues will give formulas or tables for
machining sequence. These are set for any sequence through SEQ
calculating the most efficient speed of rotation (rev/minute) of the work
SETUP PARAMETERS | DONE SET | DONE. A table of parameters
(known as SPINDLE_SPEED in ProEngineer) and feed rate (m/sec) of the
will be displayed (See Figure 7, Figure 12 and Error! Reference source
tool along the work (known as CUT_FEED in ProEngineer). The
not found.). The ADVANCED button at the top of the table will show all of
manufacturers values should be used if available but if you do not have
the manufacturing parameters. There follows and explanation of the most
access to this information this simple method of calculating speeds and
important ones
feeds can be used.
To calculate the lathe spindle speed (N rpm)
Parameter Explanation Typical Setting
1000S
OUTPUT_POINT The position on the tool which is CENTER the centre N=
programmed. Should match the tooling of any radius on the D
offset on the machine you are using. tool tip is output.
where :
GOUGE_AVOID_TYPE Checks whether the tool will incorrectly TIP_&_SIDES
cut into the part. D= Diameter of workpiece (mm). Diameter of the finished piece
STOCK_ALLOW Amount of material to be left on the Operator choice
is usually used although blank diameter or mean diameter
part for a finishing cut. can also be used.
CUT_FEED The feed rate of the tool along the Use Figure 28 S= Recommended surface cutting speed (m/min) from the
work. See CUT_UNITS. following table
CUT_UNITS The units for CUT_FEED either MMPR
mm/rev or mm/min.
SPINDLE_SPEED The rotational speed of the work. See Use Figure 27. Material Surface Cutting Speed (m/min)
SPEED_CONTROL.
SPEED_CONTROL The units for SPINDLE_SPEED either CONST_SMM Rough Cuts Finish Cuts
rev/min or constant surface speed.
Machine Steel 27 30
START_MOTION How the tool approaches the work. Z_FIRST
Normally the tool should position along Tool Steel 21 27
the work axis Z before plunging into
the work along X. Cast Iron 18 24
END_MOTION How the tool leaves the work. Z_LAST Bronze 27 30
Normally the tool should leave along X
before being position along the work Aluminium 61 93
axis Z.
Figure 27 : Surface Cutting Speed
Figure 26 : Important Sequence Parameters
Alternatively, you can enter the surface cutting speed directly into
Pro/Engineer. In the advanced parameters of the Param Tree dialog
change the Speed Control from CONST_RPM to CONST_SMM (constant
surface speed in m/min). The values from the table above can now be
entered as the spindle speed.
By D Cheshire Page 10 of 11
Turning
Tooling Available At Staffordshire University
A typical federate can be found from the following table
No Type Parameters Diagram
Material Feed Rate mm/rev 1 Axial Cutter Dia = 5 Side Angle = -
Mill/Drill Length = 10 No Teeth = 2
Rough Cuts Finish Cuts Corner Rad = -
Machine Steel 0.25-0.50 0.075-0.25 2 Not
Tool Steel 0.25-0.50 0.075-0.25 Defined
8 Not
Defined
9 Turning Length = 125 Side Angle = 92
Tool Width = 29.5 End Angle = 30
Nose Rad = 0.4 Side Width = 30
RIGHTHAND
By D Cheshire Page 11 of 11
Milling
This tutorial introduces the concept of machining of freeform surfaces
using a 3 Axis CNC miller. A sample model of a mould half is provided for
you to work with in this tutorial. It can be found at
http://www.staffs.ac.uk/~entdgc/WildfireDocs/tutorials.htm and is called
mould.prt. This part should be downloaded to your working directory
before starting the tutorial.
Machining Setup
To start the tutorial, create a new file for the machining data using FILE >
NEW. Select MANUFACTURING and NC ASSEMBLY as shown in Figure
1 and type in a name such as mould. Figure 2 : The Mould Part to Be Machined
To enable visualisation of the machining process it is beneficial (though
not essential) that the stock material from which this part will be machined
is defined. To do this choose MFG MODEL CREATE WORKPIECE
and type in the name mould_work. Now choose PROTRUSION
EXTRUDE | SOLID | DONE and create a rectangular block of material the
same size as the mould. (Hint : Pick the top surface of the mould as the
sketch plane. In sketcher pick and pick the top surface again and
ACCEPT to make a rectangle the same size as the mould. For extrude
By D Cheshire Page 1 of 6
Milling
When machining it is essential that you know where to consider the origin with a large tool, leaving some material to be removed by a second finer
(0,0,0) for machining to be. It is common to define one corner of the top cut with a smaller tool.
surface of the material as zero. This is done in Pro Engineer with a
An operation is the term Pro Engineer uses to define the type of machine
coordinate system. It would be useful to create one now. Choose INSERT
that will be used for a sequence of cuts. Since all our machining is taking
> MODEL DATUM > COORDINATE SYSTEM. The coordinate system
place on a single milling machine we only need a single operation.
dialog is displayed. This is an intelligent dialog it will try and make
sense of what you select. Click on the 3 sides of the block now in the order Choose the command MACHINING from the side menu and a dialog
shown in Figure 4. appears in which you define the Operation. A series of options are
Pick 1
Pick 2
By D Cheshire Page 2 of 6
Milling
On the Define Wind menu Choose Create Wind and type in a name of
cavity. Now Choose SELECT TANGNT CHAIN and pick on the top
edge of the cavity DONE and OK. A curve will be shown projected onto
the retraction plane which you defined earlier being 5 from the top surface.
This curve is a boundary within which the tool will be constrained. It will
machine all of the surfaces it can inside this boundary.
By D Cheshire Page 3 of 6
Milling
Having completed the roughing toolpath we can now define a second
toolpath for the finishing cut. Choose NC SEQUENCE NEW
SEQUENCE MACHINING | SURFACE MILL | DONE. Again a series of
parameters is offered. Ensure that Name, Comments, Tool, Parameters
and Window are checked but NOT Define Cut and then choose DONE.
Type the Name as FinishCut. Enter the values as shown in Figure 10 and
also on the settings tab choose tool number 2 APPLY then OK.
If your options are
different to these
you chose the
wrong type of
toolpath. Quit this
sequence and
create a new one
ensuring you
choose the
SURFACE MILL
option.
By D Cheshire Page 4 of 6
Milling
University choose UNCX01.99 as the post processor. On completion an
information window will be displayed and the file milling.tap will have been
created in your working directory. This file should be uploaded to the CNC
machine and checked by the operator before running
FILE STRUCTURE
The machining operation in Pro/Engineer brings together data from
several places. This requires several files to be associated to the
manufacturing process. It is important to understand the structure of these
files because if one of these required files is deleted by mistake the whole
Figure 12 : Cut Verification for Rough and Finish Cuts manufacturing process may be lost. Figure 13 shows this file structure.
Having completed all of the machining steps you may want to check the
whole machining process by viewing in Vericut. To join all the steps Turnedpart_temp.tph Mould.mfg Milling.ncl
together you need to create an intermediate file containing all of the
toolpaths. CL DATA > OUTPUT > SELECT ONE > OPERATION then pick Mould.asm Milling.tap
the operation name MILLING > FILE > DONE and accept the name To CNC
machine
milling.ncl for the filename. This has created a .ncl file in your working
directory. Choose DONE OUTPUT > NC CHECK > CL FILE and select the
file you just created. Choosing a final DONE will take you to Vericut where Mould.prt Mould_work.prt
you can view the whole machining process.
Mould.mfg Stores all manufacturing parameters
POST PROCESSING
Mould.asm Assembles model and work parts together
Post Processing is the act of converting the toolpaths from a standard
language called a cutter location file (.ncl) to the language of your specific Mould.prt The part to be machined
CNC machines controller. The resultant file in Pro/Engineer is known as a
tape file (.tap) which contains all the G codes to control the CNC Mould_work.prt The model of the stock material
machine. The post processor is a program that performs the translation
process. Even though Pro/Engineer comes with some general post Mould_temp.tph Temporary geometry of all toolpaths
processors you must have the correct post processor for your specific
Milling.ncl Cutter location (CL) file
machine controller otherwise breakages may occur.
You were instructed how to create a CL file in the previous section. This Millning.tap Post processed file which is sent to CNC machine
same file can be used to produce the CNC instructions via post
Cgtpro1.* Temporary files to interface with Vericut
processing. To use this file choose CL DATA > POST PROCESS and then
select the filename milling.ncl followed by DONE. Pro/Engineer should *.acl, *.lst, *.mbx, *.tl Temporary files associated with creation of .tap file
now generate a list of the post processors available on your system.
These have names from UNCX01.1 to UNCX01.99 (milling) and Vericut.log Temporary log file for Vericut
UNCL01.1 to UNCL01.99 (lathe). As you move the cursor over these
names a description of the post processor will be shown at the bottom of Figure 13 : Manufacturing File Structure
the main window. To use the Kryle Machining Centre at Staffordshire
By D Cheshire Page 5 of 6
Milling
The first part of the filenames will vary with your naming convention. The D= Diameter of tool (mm).
grey boxes or ticked rows in the table must be kept to avoid loss of data.
S= Recommended surface cutting speed (m/min) from the
The white files or crossed rows are not essential and can be deleted as
following table
they will be recreated if required.
Material S for Rough S for Finish
EXERCISE Cuts Cuts
As an exercise you might want to create a second finishing cut in exactly Machine Steel 27 30
the same way as before however change the value for CUT_ANGLE from
Tool Steel 21 27
0 to 90 (You can see this value in Figure 11). This value specifies the
angle of the cut relative to the X axis a value of 0 means cut along the X Cast Iron 18 24
axis a value of 90 means cut across the X axis. Two finishing cuts are
sometimes used like this to improve surface finish. Bronze 27 30
Aluminium 61 93
REVIEW To calculate the feed rate (m/min)
So what should you have learnt?
NkT
How to create a coordinate system. F=
How to define stock material.
1000
How to define an operation. N = Tool speed (rpm)
How to define a cut using volume mill.
k = Machine Constant (use 0.17 for Kryle)
Any problems with these? Then you should go back through the tutorial
T= Number of teeth on tool
perhaps several times until you can complete it without any help.
APPENDIX
By D Cheshire Page 6 of 6
Introduction To Finite Element Analysis
Creating a Part
In this part of the tutorial we will introduce you to some basic modelling
concepts. If you are already familiar with modelling in Pro Engineer you
will find this section very easy. Before starting to work through this tutorial
you need to be sitting in front of a computer terminal which has access to
Pro Engineer and be logged on. You tutor should have advised you of how
to log in already.
By D Cheshire Page 1 of 7
Introduction To Finite Element Analysis
Now lets start modelling. Models are made from a series of building 100 into the depth field of the dashboard (See Figure 4) and click the
blocks called features. This model is so simple it will have only one feature green tick to finish.
called an extrusion. Second click about
here on the screen
Choose INSERT > EXTRUDE from the menu. You should see a new
toolbar appear like the one in Figure 4. This is called the dashboard and
contains all of the options for the type of feature you are creating.
You are now ready to use sketcher. Choose the circle tool or SKETCH
> CIRCLE > CENTER AND POINT and draw the circle with two clicks as
shown in Figure 5.
Your window should now look like Figure 5 but the diameter of the circle
will be different. If the dimension isnt positioned exactly as in Figure 5
dont worry, just choose the select tool and click and drag the
dimension text to a new position. Now to set the size of the circle to the Figure 6 : First Feature
correct value, choose the selection tool and double click on the This is all the modelling you will need to do for this very simple part. You
dimension and type in the required value of 20. To end sketching choose are referred to the other modelling tutorials at
http://www.staffs.ac.uk/~entdgc/WildfireDocs if you want to learn more.
and click OK in the Section dialog. To complete this first feature type
By D Cheshire Page 2 of 7
Introduction To Finite Element Analysis
Starting an Analysis
You are now ready to start the analysis process. We can try several
different load cases on this simple bar and you can compare these with
manual calculations.
ProEngineer has two ways of running analyses. You can run the
ProMechanica software completely independently or you can run it in
integrated mode from within ProEngineer this has some small limitations
but is much more streamlined. We will use integrated mode. Choose
APPLICATIONS > MECHANICA now to take your model into analysis.
Click OK on the box notifying you of the units of your model.
The MODEL TYPE dialog should appear. If the FEM Mode option is ticked
you are running on a machine that does not have a licence for
ProMechanica. You will not be able to continue with this tutorial. If this is
not ticked accept the default STUCTURE mode and click OK. Figure 7 : The Constraint Dialog
ProMechanica can undertake different types of analysis. These are
Make sure the References option is set to SURFACE(S) then click on
Motion Analysis of mechanisms and assemblies. Only available below. Now pick one end of the bar then click OK in the small SELECT
when in an assembly file. dialog below the constraint dialog. You have picked one surface to
Structure Static loading of parts to calculate stresses. Also constrain and the & symbols show what movements are restricted
calculates vibrations. they all are, so this surface is fully constrained. Every model to be
analysed must be constrained at some point in all six degrees of freedom.
Thermal Applying thermal gradients to calculate heat Click OK in the constraint dialog to finish.
distribution.
This tutorial covers the structural analysis only. Make sure the MODE
option is set to STRUCTURE and click OK.
Defining Constraints
The first step for this model is to define the constraints. Constraints
determine where and how the model is held or fixed in position. We are
going to apply a tensile (pulling) force to the bar so one end needs to be
fixed.
Choose INSERT > DISPLACEMENT (or you could just pick the icon).
The constraint dialog will appear.
By D Cheshire Page 3 of 7
Introduction To Finite Element Analysis
Defining Loads If you look carefully at the graphics window you should see a symbol
Definition of loads is similar to constraints. Choose INSERT > displaying the X, Y and Z directions (if you cant see it make sure the
icon is clicked at the top of the window). This shows that for a tensile load
FORCE/MOMENT LOAD or pick the icon to apply a load over a to be applied along the bar we need to apply a load in the Y direction. So
surface. The Force/Moment Load dialog will appear. type a value of 100000 in the Y field below FORCE. Press PREVIEW if
the arrows point into the bar rather than out type -100000 instead. Click
OK in the Force/Moment Load dialog to finish.
Defining Materials
Figure 9 : Force/Moment dialog
The final definition for this analysis is to determine the material for the bar.
Make sure the References option is set to SURFACE(S) then click on
below. Pick the OTHER end of the bar (spin the view with the middle Choose PROPERTIES > MATERIALS and the MATERIALS dialog
mouse button if you need to) then OK in the small SELECT dialog below will appear. Scroll down the MATERIALS IN LIBRARY to find STEEL and
the constraint dialog. double click on it to transfer it to this model. If you choose EDIT you will
see the material parameters defined for steel the most important ones
are Youngs Modulus and Poissons ratio. Press ASSIGN > PART and
click on the bar and OK to assign the material. CLOSE the material dialog.
By D Cheshire Page 4 of 7
Introduction To Finite Element Analysis
Running an Analysis
Thats it you are ready to run an analysis. Choose ANALYSIS >
MECHANICA ANALYSES/STUDIES and the dialog in Figure 13
appears. From this dialog choose FILE > NEW STATIC and type the name
BAR. Notice the METHOD is single pass adaptive. This method is used for
quick checks to ensure everything is defined correctly and to get rough
results quickly. For more accurate results you would change this to multi
pass adaptive. Leave it as it is for now and OK. Choose the icon to run
this analysis choosing yes for error detection. Press to watch the
report of the analysis as it runs. After a few seconds (longer on a slower
machine!) the report should state RUN COMPLETED. Close the REPORT
dialog and the ANALYSES dialog. Figure 14 : Results Definition
The resultant plot shows the stress distribution over the whole bar where
the colours show the stress ranges and the values are shown on the scale
to the right. The unexpected variation of stress at one end is due to being
local to a constraint which can affect the result. Choose INFO > DYNAMIC
QUERY to get more feedback on actual values. Now as you move the
cursor over the model you will get the actual value at the cursor reported in
the dialog box. You will see that the majority of the model is at about 3.18
N/mm2 (notice the units are reported at the top left of main window). Is this
value correct? For tension stress is calculated by load/area. The cross-
2 2
sectional area of this bar is x20 /4 or 314mm . The load we applied was
2
100000N so the stress should be 100000/314 or 318 N/mm . Spot on -
even though this was only a quick single pass adaptive check!
What else can we show? Choose EDIT > RESULT WINDOW to bring
Figure 13 : Analyses and Design Studies Dialog back the dialog in Figure 14. Below QUANTITY change STRESS to
DISPLACEMENT then OK AND SHOW. Again a coloured plot appears
Seeing the Results with the colours relating to the amount of displacement. One end is blue
with a displacement of 0 because it was constrained. The other end has
Results are handled in a separate though integrated module of Pro stretched as the load is applied so this is shown in red with a displacement
Engineer. Choose ANALYSIS > RESULTS (Note : this icon was value of 0.00158mm.
available in the Analyses dialog as well). The main graphics window will go We can combine the display of displacement with stress in a very
blank and the menus and icons will all change. Choose INSERT >
RESULT WINDOW or the icon. In the RESULT WINDOW interesting and informative way. Choose EDIT > RESULT WINDOW
to bring back the dialog in Figure 14. Below QUANTITY change
DEFINITION dialog that appears press and click (not double click) on DISPLACEMENT back to STRESS then on the DISPLAY OPTIONS tab
the folder which is the same name as the analysis that is BAR. Make sure tick DEFORMED and ANIMATE. OK AND SHOW should now show the
all the options are the same as in Figure 14 then click OK AND SHOW. original stress plot on a model that is stretching as the load is applied. You
By D Cheshire Page 5 of 7
Introduction To Finite Element Analysis
can control the animation with the icons at the top of the window the percent convergence parameter and increase the maximum
polynomial order. Of course you would have to re run the analysis if you
. Close the results window with FILE >
EXIT RESULTS then NO. change these parameters.
By D Cheshire Page 6 of 7
Introduction To Finite Element Analysis
From Blevins'"Formulas for Natural Frequency and Mode Shape", the
natural frequency of a clamped-free beam is:
2 2
F=( (EI/M)) /(2 L )
where: = 1.875 for first mode
L= length of cantilever (m)
E= modulus of elasticity (N/m2)
4
I= area moment of inertia (m )
m= mass per unit length of beam (kg/m)
Figure 17 : Torsional Moment Which calculates the first natural frequency as 1420 Hz.
Re-run the analysis and view the results for maximum shear stress. Note
the value of the maximum stress. What should this value be (Torsional Review
Stress = Tr/J)?
So what should you have learnt?
By D Cheshire Page 7 of 7
Thermal Finite Element Analysis
Structure Static loading of parts to calculate stresses. Also
It is anticipated that before starting this tutorial that you have completed
calculates vibrations.
the tutorial Introduction to Finite Element Analysis. You should therefore
be familiar with the process of defining constraints, loads, materials and Thermal Applying thermal gradients to calculate heat
running analyses. If you are familiar with these techniques then the distribution.
transition to performing thermal analyses will be straight forward as there
is a direct correlation between stress and thermal analysis. This tutorial covers the structural analysis only. Make sure the MODE
option is set to THERMAL and click OK.
In a stress analysis loads (N) are applied to the model in thermal
analysis the equivalent is a thermal load measured in Watts. In a stress Defining Thermal Loads
analysis boundary conditions are applied (known as constraints) which
restrict the movement of the model in thermal analysis the equivalent The first step is to define the thermal loads on this saucepan. Thermal
boundary constraints are either temperature (C) or convection coefficient loads are heat sources applied to the model. In this case the heat source
is the gas flame or an electric element which applies heat to the base of
the pan. Choose INSERT > HEAT LOAD then pick SURFACE from the
A sample model of a saucepan is provided for you to work with in this
tutorial. There is a link to it next to this tutorial at side menu or choose the icon. Select the base of the saucepan as the
http://www.staffs.ac.uk/~entdgc/WildfireDocs/tutorials.htm and it is called heat source and fill in the name as HeatSource and enter a heat load
saucepan.prt. This part should be downloaded to your working directory value Q of 3500000mW as shown in Figure 1.
before starting the tutorial.
By D Cheshire Page 1 of 4
Thermal Finite Element Analysis
Ambient and enter a convection coefficient of 0.03 and a Bulk Running an Analysis
Temperature (the temperature of the ambient air) as shown in Figure 2.
Thats it you are ready to run an analysis. Choose ANALYSIS >
MECHANICA ANALYSES/STUDIES and the dialog in Figure 4
appears. From this dialog choose FILE > NEW STEADY STATE
THERMAL and type the name SAUCEPAN. Notice the METHOD is single
pass adaptive. This method is used for quick checks to ensure everything
is defined correctly and to get rough results quickly. For more accurate
results you would change this to multi pass adaptive. Leave it as it is for
now and OK. Choose the icon to run this analysis choosing yes for
error detection. Press to watch the report of the analysis as it runs.
After a few seconds (longer on a slower machine!) the report should state
RUN COMPLETED. Close the REPORT dialog and the ANALYSES
dialog.
Defining Materials
The final definition for this analysis is to determine the material for the
saucepan. Choose PROPERTIES > MATERIALS and the
MATERIALS dialog will appear. Scroll down the MATERIALS IN LIBRARY
to find AL2014 and double click on it to transfer it to this model. If you
choose EDIT you will see the material parameters defined for aluminium
the most important ones are Specific Heat Capacity and Thermal
Conductivity. Press ASSIGN > PART and click on the saucepan and OK to
assign the material. CLOSE the material dialog. Figure 4 : Analyses and Design Studies Dialog
DEFINITION dialog that appears press and click (not double click) on
the folder which is the same name as the analysis that is SAUCEPAN.
Figure 3 : Materials Dialog
By D Cheshire Page 2 of 4
Thermal Finite Element Analysis
Make sure all the options are the same as in Figure 5 then click OK AND The inside surface of the aluminium saucepan is coated in a non-
SHOW. stick material which reduces the convection coefficient to 0.02.
What is the effect on the handle temperature? (Hint: You will need
to define a second CONVECTION CONDITION for these surfaces
with a different h value. Make sure you remove these surfaces
from the original convection condition.
Combining Analyses
One of the consequences of heating things up is that they expand. This
expansion is directly related to the temperature rise and can be calculated
using the coefficient of expansion for that material. ProMechanica knows
about this to so it can calculate the expansion for you. This is done using a
structure analysis. Here is how but you should have covered structural
Figure 5 : Results Definition analyses in the Introduction to Mechanica tutorial so the instructions will
The resultant plot shows the temperature distribution over the saucepan be brief.
where the colours show the temperature ranges and the values are shown From the Mechanica modeling window change to structural analysis by
on the scale to the right. Choose INFO > DYNAMIC QUERY to get more choosing EDIT > MECHANICA MODEL TYPE. Like all structural analyses
feedback on actual values. Now as you move the cursor over the model the model must be constrained. Lets assume the cook has picked up this
you will get the actual value at the cursor reported in the dialog box. You saucepan (using an oven glove if necessary!) so to (roughly) simulate this
will see that the end of the handle is at around 40-50C. Is this too hot to INSERT > DISPLACEMENT constraint to the SURFACE at the very end of
hold? the handle. Fix movement in all directions.
Additional Analysis
You have now learnt the basics of thermal analysis. By returning to the
modelling window and changing certain parameters you could answer
various questions related to this design. Try to answer the following
questions now
What is the effect on the handle temperature if the material is
changed to STEEL? (Hint : PROPERTIES > MATERIALS )
To accommodate the change to steel the main part of the
saucepan must be increased in thickness to 4mm thick. What is
Figure 6 : Displacement Constraint
the effect on the handle temperature? (Hint: You will need to
return to APPLICATION STANDARD and EDIT the first revolve The second thing required for a structural analysis is a load. In this case
feature to change its thickness) the load is due to the expansion caused by the temperatures already
calculated in the Saucepan thermal analysis. These can be applied using
How high can the heat load be increased before an aluminium INSERT > TEMPERATURE LOAD > MEC/TThe Design Study and
saucepan would melt at 600C? (Hint: Locate HeatSource in the Analysis should already be set to Saucepan in the MECT Temperature
Model Tree window and EDIT DEFINTION. Increase Q value and
analyse again. Repeat until max temperature exceeds 600C)
By D Cheshire Page 3 of 4
Thermal Finite Element Analysis
dialog. This means that the temperatures previously calculated will be In this plot the colours denote the internal stresses due to expansion and
applied over the whole model causing differential amounts of expansion. the shape is the exaggerated shape due to expansion. (Note temperature
loads can be combined with any other structural load so you could for
The final thing required for a structural analysis is a material but you have
example add a gravity load to the saucepan and see the stresses due to
already assigned that as part of the thermal analysis so there is no need to
gravity as well though they would be small compared to thermal
do that here.
expansion.)
Choose ANALYSIS > MECHANICA ANALYSES/STUDIES . From this
dialog choose FILE > NEW STATIC and type the name EXPANSION and
Review
OK. Choose the icon to run this analysis choosing yes for error So what should you have learnt?
detection. If you get an error message about model having changed since How to start analysis.
thermal analysis was run simply choose EDIT > MECHANICA MODEL How to define thermal loads, boundary conditions and materials.
TYPE to change to thermal mode run the analysis again return to
How to run an analysis.
structure mode and run this analysis). Press to watch the report of the How to show results of a thermal analysis.
analysis as it runs. After a few seconds (longer on a slower machine!) the How to use temperature loads in structural analyses.
report should state RUN COMPLETED. Close the REPORT dialog and the
ANALYSES dialog. Any problems with these? Then you should go back through the tutorial
perhaps several times until you can complete it without any help.
To see the results choose ANALYSIS > RESULTS (Note : this icon
was available in the Analyses dialog as well). The main graphics window
will go blank and the menus and icons will all change. Choose INSERT >
RESULT WINDOW or the icon. In the RESULT WINDOW
DEFINITION dialog that appears press and click (not double click) on
the folder which is the same name as the analysis that is EXPANSION.
Make sure all the options are the same as in Figure 7 and also that
DEFORMED is ticked in the Display Options tab then click OK AND
SHOW.
By D Cheshire Page 4 of 4
Shell Modeling and Analysis
You have probably already realised that the initial model is very important Shell Modelling
and can affect both the result accuracy and the time taken to perform the
analysis. For example analysis is often undertaken on models where the
majority of radii and other small features which have no significance on the
results have been removed of suppressed this can reduce analysis time
tremendously. Of course it is down to skill of the operator to decide which
features can be suppressed without affecting the results.
A particular area where correct modelling can improve analysis speed is in
parts which have lots of thin walls of constant thickness. Examples of
these include sheet metal parts (simple brackets or complex car bodies)
and even moulded parts (since good moulding practice requires constant
wall thicknesses wherever possible). The modelling technique used for
these parts is called shell modelling. Here the designer will model the
centreline of a feature then assign a thickness to the feature. Pro Engineer Figure 1 : The Chair Base
combines the information to generate a solid model which looks identical
to one made from normal modelling techniques. When analysing the The part we are going to analyses is the injection moulded base to a
model the shell information can be used to reduce the analysis time swivel chair as shown in Figure 1. The first thing you should notice about
experience has shown that this can be by as much as 100 times in such a part is that it has 5 identical legs. This should immediately show
extreme cases. you that you can save both modelling and analysis time by only looking at
one of the five legs. Even more time can be saved if you recognise that
Here is an example of the techniques involved. The tutorial uses a realistic each leg has a plane of symmetry along its length (see Figure 2) so even
part so the process is quite complex. Pay careful attention as you read more modelling and analysis time can be saved.
especially if you have not completed all of the modelling exercises in this
series.
Even if you dont intend to use shell modelling the tutorial is worth
completing as it introduces other techniques related to analysis. If you find
the modelling instructions difficult to follow then have you completed the
modelling tutorials? If you havent you might find it helpful to do so.
By D Cheshire Page 1 of 7
Shell Modeling and Analysis
Next create an extrusion (INSERT > EXTRUDE). From the dashboard
choose the SKETCH icon then pick the datum plane TOP by clicking on it
in the graphics window or in the browser then click on the SKETCH button.
Draw the sketch in Figure 3. Exit sketcher and type in the extrusion
Figure 5 : A Round
Add a 13mm round (INSERT > ROUND) to the edge around the top of the
Figure 3 : First Feature Sketch leg it should automatically propagate all around as the edges are all
tangent.
Next create an revolution (INSERT > REVOLVE). From the dashboard
choose the SKETCH icon then pick the datum plane FRONT by clicking on
it in the graphics window or in the browser then click on the SKETCH
button.
Draw the sketch in Figure 4 notice that the top line is inline with the top
of the first feature. Draw a centreline on top of the RIGHT datumFigure 3.
Exit sketcher and type in the revolve angle of 36. Finish the feature
with .
By D Cheshire Page 2 of 7
Shell Modeling and Analysis
Now click on the thicken sketch button . This button takes the single
line sketch you have drawn and adds material to the thickness typed in the
box next to the button 4. Also the second button decides which side
of the sketch to add material click it till the material is outside of the arc.
By D Cheshire Page 3 of 7
Shell Modeling and Analysis
click on it to transfer it to this model. Press ASSIGN > PART and click on
the chair leg and OK to assign the material. CLOSE the material dialog.
Thats it you are ready to run an analysis. Choose ANALYSIS >
MECHANICA ANALYSES/STUDIES . From this dialog choose FILE >
NEW STATIC and type the name leg and OK. Choose the icon to run
this analysis choosing yes for error detection. Press to watch the
report of the analysis as it runs. Note how many elements are used in this
analysis and the elapsed time to complete the analysis. Close the
REPORT dialog and the ANALYSES dialog.
The analysis should complete correctly and you could review these results
if you wanted. This has performed a normal analysis it has not used any
Figure 10 : Constraint Surface information about shells at all. So how do we use shell information? The
easiest way to do this is to use the automated INSERT > MIDSURFACES
Definition of loads is similar to constraints. Choose INSERT >
then choose AUTO DETECT. This takes any shelled surfaces or thickened
FORCE/MOMENT LOAD or pick the icon to apply a load over a protrusions and automatically generates thin shells from them. After this
surface. Click on below Surface(s) then pick the surface in Figure 11 command you can see the shells by choosing COMPRESS > SHELLS
then OK to return to the Force/Moment dialog. Type a value of 300 in the ONLY > SHOWCOMPRESS.
correct field for a vertical load on the leg (probably the Y direction). This
will be half the total load applied to a single leg as we are only modelling
half the leg. Press PREVIEW to check the arrows point in the correct
direction. Click OK in the Force/Moment dialog to finish.
By D Cheshire Page 4 of 7
Shell Modeling and Analysis
type of constraint could be used Since we are only analysing half a leg we
cannot use this automated method we will have to replicate this using
displacement constraints.
This time the constraint is not along the normal X, Y or Z axes. We need to
make a new definition for the direction of X, Y and Z. This is done in Pro
Engineer with a coordinate system. We need to create one now. Choose
INSERT > MODEL DATUM > COORDINATE SYSTEM. The coordinate
system dialog is displayed. This is an intelligent dialog it will try and
make sense of what you select. Click on the 3 surfaces/datums now in the
order shown in Figure 15. Notice the new yellow coordinate system icon
the X direction is at right angles to the FIRST surface you picked and this
Figure 13 : Analysis Using Shells is the direction which we will constrain. In the properties tab type the name
ANGLED. Click OK to close the dialog and ANGLED should appear in the
There is a problem with the analysis! Look carefully at the leg and you will model tree under Simulation Features.
see that as it is loaded it twists. This wouldnt happen in real life because
we would have a full leg not just half. We can correctly simulate the other
half of the leg without having to model it by correct use of constraints.
Choose INSERT > SYMETRY CONSTRAINT and the symmetry
constraint dialog will appear. Pick the edges in Figure 14 then OK to return Pick 2
to the constraint dialog and OK again to finish.
NOTE: edges are selected rather than the central surface because the
surface disappears when the model is collapsed into shells.
Pick 3
Pick 1
By D Cheshire Page 5 of 7
Shell Modeling and Analysis
have drawn and adds material to the thickness typed in the box next to the
button 4. Also the second button decides which side of the sketch to
add material click it till the material is on the correct side. Finish the
feature with .
Figure 18) and exit sketcher . On the dashboard choose the up to next
surface option and use the button to make sure the extrusion is going
the correct direction towards the inside of the leg. Now click on the
thicken sketch button . This button takes the single line sketch you
By D Cheshire Page 6 of 7
Shell Modeling and Analysis
Review
So what should you have learnt?
How to create variable thickness shells.
How to create thin extrusions.
How to create symmetry constraints.
How to use coordinate systems in analysis.
Any problems with these? Then you should go back through the tutorial
perhaps several times until you can complete it without any help.
By D Cheshire Page 7 of 7
Joint Analysis
pick the back surface of the bracket then OK to return to the constraint
This tutorial looks at different ways of analysing bolted joints within Pro
Mechanica. This is an important technique as correct analysis may have dialog. You have picked one surface to constrain and the &
significant effects on the results for the whole part being analysed. The symbols show what movements are restricted they all are so this surface
tutorial uses a simple bracket which can be downloaded from is fully constrained. Click OK to finish.
http://www.staffs.ac.uk/~entdgc/WildfireDocs/tutorials.htm under the
bracket link.
Bonded Analysis
As a base point for our comparison of different methods of simulating
joints we will analyse the bracket as though it was bonded (glued) to the
wall (if you did the Introduction to Mechanica tutorial you should already
have done this as a further exercise). Even this is a simplification and if
you wanted to correctly analyse a bonded joint you would approach it
differently to account for bond flexibility and other factors.
You are now ready to start the analysis process so load the part into Pro Figure 2 : Constraint Surface
Engineer.
Next define the load on the bracket. Choose INSERT > FORCE/MOMENT
LOAD or pick the icon to apply a load over a surface. Click on
below Surface(s) in the Force/Moment dialog then pick the surface
highlighted in Figure 3 then OK to return to the Force/Moment dialog. Type
a value of -10000 in the Y field below Force. Press PREVIEW the arrows
should point the same way as in Figure 3. Click OK in the Force/Moment
dialog to finish.
By D Cheshire Page 1 of 6
Joint Analysis
on it to transfer it to this model. Press ASSIGN > PART and click on the should see a new toolbar appear like the one in Figure 5. This is called the
bracket and OK to assign the material. CLOSE the material dialog. dashboard and contains all of the options for the type of feature you are
creating.
Thats it you are ready to run an analysis. Choose ANALYSIS >
MECHANICA ANALYSES/STUDIES and in the dialog that appears
choose FILE > NEW STATIC and type the name BONDED and press OK.
Choose the icon to run this analysis choosing yes for error detection.
Figure 5 : The Extrude Dashboard
Press to watch the report of the analysis as it runs. After a few
seconds (longer on a slower machine!) the report should state RUN To start creating this feature choose PLACEMENT > DEFINE in the
COMPLETED. Close the REPORT dialog and the ANALYSES dialog. dashboard and the Section dialog appears. Notice that this dialog has
many fields but the sketch plane option is highlighted in pale yellow
After the analysis completes choose ANALYSIS > RESULTS menu. awaiting your input. The sketch plane is a flat surface onto which you will
The main graphics window will go blank and the menus and icons will all draw your shape. Choose the back surface of the bracket (the one you
change. Choose INSERT > RESULT WINDOW or the icon. In the constrained in Figure 2) by clicking on it in the graphics window. The other
fields in the Shape dialog are filled in automatically so you dont need to
RESULT WINDOW DEFINITION dialog that appears press and click worry about them at the moment just click on the SKETCH button.
(not double click) on the folder which is the same name as the analysis
The graphics screen will change to a black background looking directly on
that is BONDED. Make sure all the options are the same as in Figure 4
to the sketch plane, and the drawing icons described will appear. You can
then click OK AND SHOW.
CLOSE the References dialog.
You are now ready to use sketcher. Choose SKETCH > CIRCLE >
CONCENTRIC and draw the circles with two clicks the first click on the
radius in the corner of the bracket, the second click to determine the size
as shown in Figure 6 press the middle mouse to finish drawing each
circle. You should be able to get all four circles to lock on to the same size
and showing an R1 symbol.
By D Cheshire Page 2 of 6
Joint Analysis
The new constraints have been defined. They are stored in a separate set
the selection tool and double click on the dimension and type in the
from the original constraint. You are ready to run an analysis. Choose
required value of 12. To end sketching choose and click OK in the
ANALYSIS > MECHANICA ANALYSES/STUDIES and in the dialog
Section dialog. To complete this first feature at the dashboard choose the
choose EDIT > COPY and press OK. You now have two analyses which
thru all option and to remove (rather than add) material if the are currently identical except for their name. Choose EDIT >
ANALYSIS/STUDY to edit the copy. Change the name of the analysis to
extrusion is going in the wrong direction press (see Figure 6b). Click EDGES. Below CONSTRAINTS choose CONSTRAINTSET2 so that the
the green tick to finish. You should have four bolt holes. analysis will use only the edge constraints just defined then click OK.
Choose the icon to run this new analysis choosing yes for error
Edge Constraint
detection. Press to watch the report of the analysis as it runs. After a
Now we have to modify the analysis to take account of these holes. The few seconds (longer on a slower machine!) the report should state RUN
load and material will stay the same but the constraints will alter. COMPLETED. Close the REPORT dialog and the ANALYSES dialog.
Choose APPLICATION > MECHANICA now to take your model back into After the analysis completes choose ANALYSIS > RESULTS menu.
analysis. From the MODEL TYPE dialog choose STRUCTURE and OK. The main graphics window will go blank and the menus and icons will all
We are going to simulate a bolted joint by just holding the edges of the change. Choose INSERT > RESULT WINDOW or the icon. In the
holes in position. We could delete the surface constraint we applied earlier
and a new one but we can learn another technique. Choose INSERT > RESULT WINDOW DEFINITION dialog that appears press and click
(not double click) on the folder which is the same name as the analysis
DISPLACEMENT (or you could just pick the icon). On the dialog there that is BONDED. Make sure all the options are the same as in Figure 8
is a NEW button next to the MEMBER OF SET FIELD. Click on this button then click OK AND SHOW.
to create a new set of constraints by default called CONSTRAINTSET2.
Click OK to return to the CONSTRAINT dialog. Below the word
REFERENCES it will say SURFACE(S) change this to
EDGES(S)/CURVE(S) then click on below then pick the back edges of
the holes in the bracket holding the CTRL key. When you have picked all 8
edges click OK to return to the constraint dialog. Click OK to finish defining
this constraint.
By D Cheshire Page 3 of 6
Joint Analysis
accurate comparison we can show the two analyses side by side with the Choose ANALYSIS > MECHANICA ANALYSES/STUDIES and EDIT
same legend values. >COPY a new analysis called SURFACES which uses
CONSTRAINTSET3. Run the analysis and show the results of the three
Choose INSERT > RESULT WINDOW or the icon. In the RESULTS analyses side by side with the same legend values.
WINDOW DEFINITION dialog that appears press and click (not
double click) on the folder for the BONDED analysis then click OK AND
SHOW. You will see the two analyses together. Click on each window in
turn then choose FORMAT > LEGEND. Type 2 as the minimum value and
20 as the maximum value so that you can get a fair comparison.
Figure 11 : Comparison 3
By D Cheshire Page 4 of 6
Joint Analysis
STEEL. Press the MORE button next to SECTION. Choose NEW then set
the type to SOLID CIRCLE with a radius of 6 (this represents the size of
the bolt shank). Click all the OK buttons to finish defining this beam.
Repeat it for all four holes (you wont need to define material or section as
they are now the defaults).
By D Cheshire Page 5 of 6
Joint Analysis
Finally, all that is needed is to correctly constrain the model. Create a new Review
DISPLACEMENT CONSTARINT in a new constraint set. Change the
reference type to POINT and pick all four datum points on the back of the So what should you have learnt?
bracket. You should now be able to analyse this model creating a new How to create various types of constraints.
analysis called SPIDER which use the correct constraint set. (It is called a How to define volume regions.
spider connection for historical reasons). How to define rigid connections.
Compare the results of all four analyses. How to compare results of an analysis.
Any problems with these? Then you should go back through the tutorial
perhaps several times until you can complete it without any help.
Figure 16 : Comparison 4
By D Cheshire Page 6 of 6