WF4 Surfacing Sample

Introduction to Surface Modeling

Using Pro/ENGINEER Training Manual

Wildfire 4.0 Rev A

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PRINTING HISTORY

Document Date Description

Rev A 1/5/2010 Initial Printing.

Introduction to Surface Modeling Using Pro/ENGINEER

Training Course Agenda

Day One

Introduction to Surface Modeling

Getting Started With Surfaces

Surface Manipulation

Creating Solid Geometry From Surfaces

Curves for Complex Modeling

Creating Surfaces From Boundary Curves

Introduction to Surfacing Modeling Using Pro/ENGINEER Wildfire 4.0

TABLE OF CONTENTS

INTRODUCTION TO SURFACE MODELING 1-1 SURFACES 1-3

What Are Surfaces? ............................................................................ 1-3 Typical Usage .................................................................................... 1-6

GENERAL CONSTRUCTION APPROACHES 1-10 Complex Features .............................................................................1-10 Overbuild.........................................................................................1-10 Explicit Boundary Definition ................................................................1-11 EXERCISE 1: SURFACING PRIMER .......................................................1-12

GETTING STARTED WITH SURFACES 2-1 BASIC SURFACE CREATION 2-3

Extrude Tool...................................................................................... 2-3 Revolve Tool ..................................................................................... 2-3 Swept Surfaces.................................................................................. 2-4 Parallel Blend Surfaces........................................................................ 2-6 Fill Tool ............................................................................................ 2-9 Rounds............................................................................................. 2-9 Chamfers .........................................................................................2-10 Draft ...............................................................................................2-10

COMBINING SURFACES 2-11 EXERCISE 1: MODELING GEOMETRY WITH SURFACES............................2-12 EXERCISE 2: CONVERTING A SOLID TO A SURFACE...............................2-20

SURFACE MANIPULATION 3-1 SURFACE MANIPULATION 3-3

Extend Tool....................................................................................... 3-3 Trim Tool .......................................................................................... 3-7 Copy Tool ........................................................................................3-10 Offset Tool .......................................................................................3-12 Mirror Tool .......................................................................................3-14

SURFACE SELECTION METHODS 3-14 Individual ........................................................................................3-14 Loop ...............................................................................................3-14 Seed & Bound...................................................................................3-15 Solid Surfs .......................................................................................3-16 EXERCISE 1: COPYING AND MOVING SURFACES ...................................3-17 EXERCISE 2: OFFSETTING AND EXTENDING .........................................3-25 EXERCISE 3: TRIMMING SURFACES .....................................................3-37 EXERCISE 4: FIXING THE CONTAINER..................................................3-44

CREATING SOLID GEOMETRY FROM SURFACES 4-1 CREATING SOLID GEOMETRY 4-3

Terminating Solid Features .................................................................. 4-3

Solidify............................................................................................. 4-4 Thicken ............................................................................................ 4-6 Offset............................................................................................... 4-6 EXERCISE 1: FEATURE TERMINATION ................................................... 4-9 EXERCISE 2: OFFSET REPLACE ...........................................................4-12 EXERCISE 3: OFFSET EXPAND ............................................................4-18

CURVES FOR COMPLEX MODELING 5-1 CURVES 5-3

Sketches........................................................................................... 5-3 Project Tool....................................................................................... 5-3 Wrap Tool ......................................................................................... 5-4 Intersect Tool .................................................................................... 5-4 Thru Points ....................................................................................... 5-5 Curve From Equation .......................................................................... 5-9 Examples.........................................................................................5-11 EXERCISE 1: INTERSECT CURVES .......................................................5-15 EXERCISE 2: CREATING A CURVE NETWORK.........................................5-19 EXERCISE 3: ADDITIONAL CURVE NETWORKS ......................................5-32 EXERCISE 4: CURVE AND SURFACE MANIPULATION...............................5-39 EXERCISE 5: CURVE FROM POINT FILE ................................................5-45

THE BOUNDARY BLEND SURFACE 6-1 BLENDED SURFACES 6-3

FiRst Direction Curves......................................................................... 6-3 CURVATURE 6-7

Surface Continuity.............................................................................. 6-7 N-SIDED SURFACES 6-8

EXERCISE 1: FIRST DIRECTION BOUNDARY BLEND SURFACES................6-10 EXERCISE 2: TWO DIRECTION BOUNDARY BLEND .................................6-17 EXERCISE 3: ELIMINATING SURFACE PATCHES .....................................6-25 EXERCISE 4: CREATING AN N-SIDED SURFACE .....................................6-30

CHAPTER

11

INTRODUCTION TO SURFACE MODELING

Introduction To Surface Modeling

Chapter 1 Page 3 of 17

SURFACES WHAT ARE SURFACES?

Surfaces can be thought of as three-dimensional “construction” geometry. Surfaces are infinitely thin, do not have mass and by default, do not impact interference calculations. In most cases, the surfaces will be used at a later time to create a solid feature.

Figure 1

TERMINOLOGY

There are several surface related terms that are fairly similar in name, yet mean different things:

• Surface Patch: The smaller portions of a surface feature that are generated from the vertices of your sketch.

Figure 2



• Quilt: A single surface that is created by combining two surface features.

Figure 3

APPEARANCE

When a surface is not shaded, the feature may be displayed with two colors:

• Pink Edges: Indicates a single-sided edge. This means that the pink edge is not “stitched” to the adjacent edge.

• Purple Edges: Indicates a double-sided edge. This means that the system will consider the two adjacent patches as one quilt. Tangencies and silhouette edges of surfaces are examples of double-sided edges.

Surfaces can be shaded and colors can be assigned to each side of a surface and to the different patches. Figure 4 shows a surface feature that has different colors assignes to each side of the surface patches.

Figure 4



The configuration file option, “hlr_for_quilts”, determines if surfaces are considered during Hidden Line Removal computations.

Figure 5

LAYERING

Surfaces can be associated to Layers and hidden to aid visualization of the geometry. Also, solid geometry can be layered and hidden to reveal only the surfaces.



TYPICAL USAGE

Surfaces can be used to:

• Develop Complex Geometry. Some geometry is so complex it can not be modeled using traditional solid features. It will need to be “stick built” using points, curves, surfaces and finally turned into solid geometry.

Figure 6

• Model difficult Rounds. There will be cases where you will not be able to model the needed round geometry using a Round feature. When this happens, the next choice is to build the Round using surfaces.

Figure 7



• Efficiently duplicate geometry. Patterning many features can be difficult, even when using a Reference Pattern. Surfacing provides a “Seed & Boundary” method to easily copy geometry and duplicate it. Not only is it easy to accomplish, it is fast to regenerate and robust to maintain over the life of the part.

Figure 8

• Perform Top Down Design tasks. In the example below, the top and bottom cover of the design must share the same profile and several cutouts must be aligned. This can be accomplished using a Skeleton Part or a Master Model that contains surface geometry that is passed into the top and bottom cover parts. When the Skeleton/Master part is changed, the top and bottom cover parts will automatically update.

Figure 9



• Develop Map Parts. A “map part” is a technique in Pro/ENGINEER where geometry from key components is copied into one part, the Map Part. This part is the first component assembled into a sub-assembly and it allows work such as top level cable routing to be performed at the sub-assembly level, instead of at the top leve assembly.

Figure 10

It is a good way to allow several people to perform top level work at the same time. Also, it improves performance when working with large data sets.

• Develop Envelopes for use in Large Assembly Management. Entire sub-assemblies can be represented by an Envelope model. These are also referred to as space claim models. These differ from shrink wrap geometry in that they are manually constructed by copying surfaces from models on the “outside” of the subassembly to produce one part that is very small and clean in comparison to the original sub-assembly.

Figure 11



• Solving Data Import Problems. Importing geometry into Pro/ENGINEER from another CAD program will not always result in a usable solid model. Boundaries between surface patches can be ripped open, tangencies removed and edges warped. To correct this, surface modeling techniques can be used with the Import Data Doctor to repair the data and develop a solid model.

Figure 12



GENERAL CONSTRUCTION APPROACHES COMPLEX FEATURES

One approach to surface modeling is to use Pro|ENGINEER’s complex features to develop the exact geometry you desire. The feature added to the model shown in Figure 13 is an Offset With Draft feature with Tangency enabled. Developing this geometry using other methods would be a fairly involved process.

Figure 13

OVERBUILD

You can develop surfaces that extend beyond their intersections and let the system automatically trim away any excess material when they are combined into one quilt.

Figure 14



EXPLICIT BOUNDARY DEFINITION

You can also develop a surface by defining the boundaries of the surface. Typically, a network of Datum Curves is constructed and a surface created that passes through them. If more control over the shape is desired, internal curves can be added to the network.

Figure 15



EXERCISE 1: SURFACING PRIMER

In this exercise, you will use several simple surface modeling techniques to develop a trajectory

for a complex sweep.

Task 1. Create a new part.

1. Create a new part named: SGI-logo

2. Your model should begin with three default planes at a minimum.

Task 2. Extrude a box shape as a Surface instead of a Solid feature.

1. Launch the Extrude Tool .

2. On the Dashboard, set the feature to be a Surface.

Figure 16

3. Press RMB > Define Internal Sketch and pick the FRONT plane as the Sketching Plane.

4. Sketch a 2 x 2 rectangle and exit Sketcher.

Figure 17

5. On the Dashboard:

o Set the Depth to 2.00.

o Click Options and check the box for Capped Ends.

o Complete the feature.

Click Here To Build A Surface



6. When shaded, the geometry appears solid. When viewed in Wireframe, you notice the purple edges, indicating the geometry is a surface.

Task 3. Add a Chamfer on the model.

1. Launch the Chamfer Tool .

2. Pick the 6 edges shown.

Figure 18

3. Set the size to .350.

Task 4. Add Rounds to the part.

1. Launch the Round Tool .

2. Pick the 6 edges shown.

Figure 19



3. Set the Radius to .200.

Task 5. Add two more Rounds to finish the construction geometry.

1. Create .500 radius Round and select the three edges shown in Figure 20.

Figure 20

2. Repeat this and create another Round on the three edges on the opposite corner.

Figure 21

3. Save the part.

Task 6. Create a Solid Sweep feature to sweep a “tube” around the tangent edges of the surface.

1. Click Insert > Sweep > Protrusion.

2. Click Select Traj and then Tangent Chain from the menu.

Pick this edge for the Sweep Trajectory



3. Pick the edge shown in Figure 21 for the sweep trajectory.

4. Click Done > Accept > Okay.

5. Sketch a .250 diameter circle on the cross-hairs, as shown in Figure 22.

Figure 22

6. Exit sketcher and complete the feature.

Figure 23

Task 7. Hide the Surface geometry.

1. In the Model Tree, select the first feature and press RMB > Hide.



Figure 24

2. After reviewing the geometry, unhide the surface.

Task 8. Assign the surface a different color and also make the surface transparent.

1. Click View > Color and Appearance.

2. Click + to create a new, custom color.

Figure 25

3. A new color is created by copying the default “white” color. Click the Color box and change the R-G-B sliders to create a color of your liking.

Figure 26

4. When the desired color is achieved, click Close.

Click Here

Click Here



5. In the Assignment area, click the drop down and select Quilts from the list.

Figure 27

6. Pick anywhere on the Extruded surface. Click OK to finish selecting Quilts and click Both to color both sides of the quilt. Click Apply.

7. Make the color transparent. Click the Advanced tab. Drag the Opaque slider to the right until the desired transparency level is achieved.

Figure 28

8. Click Close in the Appearance Editor.

Figure 29

9. Save the part and close the window.

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