Section1 Manual
Section1 Manual
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NOTICE OR R IGHTS
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ACKNOWLEDGEMENTS
Getting Started
Solid Modeling in Industry and the Classroom
This manual has been created to introduce students to the same world
of product development as our customers. The purpose of this manual
is to provide a guide for workshops and in-class curriculum which
prepares students to plan and create effective 3D solid models. Each
year volunteers from PTC and their customers help provide hands-on
workshops using this manual to students all over the world. We hope
that the instruction given in this manual will help make your experience
in product modeling successful.
Case Study
Industry
WHirlpool
SOLID M OD E LING TR A NSFOR ME D TH E D ESIG N OF NE W PR OD UC TS
Whirlpool is considered the worlds #1 major appliance company. Its annual revenue is
close to $20 billion, and it employs around 70,000 employees worldwide. Whirlpool
creates its products with global design teams and provides products and services in
over 170 countries. Whirlpool faces stiff competition and holds itself to high standards
in producing and offering products to its customers across the globe.
Whirlpool has been a PTC customer since 1986. It implemented the new solid modeling
technology that PTC had developed and offered in its Pro/Engineer CAD software
(Now PTC Creo). Whirlpools ability to design new products and deliver them to
market was dramatically
improved. Today,
Whirlpool has standardized
on the complete array of
PTC product and service
advantage software to
support their entire range
of products and services.
Through the Whirlpool
Constellation program all
of their product data is
managed throughout the
product lifecycle.
Whirlpool engineers use solid modeling to create concepts, detailed product models,
and production and assembly plans. Solid modeling has led to shorter product
development cycles and therefore better products.
Case Study
Academe
Students today are immersed in a 3D world of video games and computer animation that
transforms their ability to think and visualize in the real world. Ryan Daley, a teacher at
Hudson High School has embraced this strength by introducing solid modeling into the
classroom. He introduces design challenges and robotics which require that the students
learn and become proficient in PTC Creo.
High School students begin to use their 3D visualization skills to conceptualize
and design new robots that solve specific challenges.
Section
Solid Modeling
UNDER STANDING HOW TO CR EATE MODELS OF PAR TS AND PR ODUCTS
One of the greatest developments evolving out of the computer age is the development
of 3-dimensional modeling of parts and products. Computer technologies have enabled
the representation of 3D parts and facilitated the viewing and rendering of these models
so that it is easier to create and present product concepts and bring those concepts to
market. In order to fully understand this exciting field it is important to understand
some important fundamentals.
3D solid models are mathematical models of real or virtual parts & products.
3D solid models are mathematical models of real or virtual parts and products. In this
chapter, we will look at the anatomy or elements of solid models, how solid models are
organized, and we will also introduce you to the solid modeling tool PTC Creo.
Effective 3D solid models require careful planning. Good practices translate into
models that can be used again and again to launch successful products.
Before you begin to develop a model plan, it is important to understand what 3D solid
models consist of and how they are constructed.
Characteristics of a SolidModel
3D solid models are constructed by adding and subtracting geometric shapes to create the final
shape of a part or product. This use of sums of geometry has become a language for
representing ideas for new parts and products. So lets begin by exploring the anatomy or
elements of a solid model.
Model Anatomy
A solid model is really a sophisticated mathematical set of equations represented in software;
however, you hardly ever have to work with those equations. You are able to create and modify
solid models simply by working with two representations of the model; a procedural
representation and a graphical representation.
The procedural representation is like a list of instructions which when followed will produce
the solid model. It is called a Model Tree. It doesnt look much like a tree in this view because
it is just a list. However, we can look at it in a different way that makes it look very much like a
tree.
Notice that there are three sections to the
model tree. The tree begins at the top with
coordinate systems that are important to the
model. Next is the list of all the parts in the
model. It is sort of like a big sum of all the
parts. Finally there is the insert location
which is the place where a new part can be
added. It turns out that the order in which
things are added is important.
The graphical representation is what the
solid model looks like. That is easy to
understand. You will use both of these
representations when building or modifying
solid models.
Coordinate System
All geometry is built in reference to a global coordinate system. It is
usually referred as the origin. This is simply a point in space that is
recognized as the starting point or (0,0,0) location. This point is usually
represented by three crossing lines as shown. Product models may have
several origins, one for each part in the assembly.
There are also other types of references that are
used in solid models such as planes, axes, and
points. All of these references are called Datums
and are typical referred to specifically as datum
planes, points, and axes.
A default set of datums includes the origin
coordinate system, and the three coordinate planes
(FRONT: X-Z, RIGHT: Y-Z, TOP: X-Y). Axes can be
defined at the intersection of any of two of these
planes.
Carefully selecting what datums you use as references for creating geometry will make sure
that your model is robust (doesnt break or fail) and helps insure that you will be able to create
all the different aspects of your model as easily as possible. Well show you how to plan these
datums and references later and also show you how to create them in PTC Creo.
Sum of Parts
Most of the model tree consists of a list of parts. These parts can be single parts or sub-
assemblies of parts (sort of a model inside of a model). This means that there are relationships
between the parts in the list. All of the
parts in a model are the children of that
model. The top-level model is the
parent. These relationships are referred
to as Parent-Child relationships and just
represent which models own what
parts.
It is these types of relationships that
turn the model tree from a list into a
tree. Look what happens when we draw
a hierarchical representation of the
parent-child relationships in our model.
These relationships will become
important to you as you build your
model and we will explain how to
create them later on.
Sum of Features
So far we have talked about how assembly models are made up from a collection of parts. What
about the model of a single part? It isnt a collection of parts; instead it is a collection of
geometric features.
Geometric features are chunks of
geometry that make up the model of the
part. If we look at the model tree of a part
model we will see these features.
Part models are different from assemblies
or models of products (collections of
parts). Part models can have positive and
negative features. The features or chunks
of geometry can add solid material or can
subtract solid geometry.
Review
So lets review, there are two types of solid models; an assembly model which is a collection of
part models for modeling products, and part models which are collections of positive and
negative chunks of geometry called features.
There are two types of representations for these models; procedural (model tree) and graphical.
We will use both in creating and modifying these models.
Finally, there are references used in the creation of the models called datums. These consist of
coordinate systems, datum points, datum planes, and datum axes.
Exercise 1:
In this exercise we are going to open PTC Creo and explore the different elements of a solid
model. Lets start by exploring a relatively simple model of a next generation bike.
First of all lets find each of the parts in the Model tree for the assembly and then well
open a part and look at the features in the model tree of the part.
Find in the Appendix Exercise 1: The Model Tree and follow the
instructions to complete the exercise.
The Art of SolidModeling
PTC Creo is a software tool that helps you build part models and assembly models. It is like a
virtual art studio where you can build 3D solid models. There are many different modes where
different functions can be completed. Within each of the modes the tool sets are different.
Moving from one mode to another is important part of PTC Creo.
For creating parts and assemblies we will stay primarily in the 3D Part Modeling room and in
the 2D Sketch room. Later on we will explore some of the other rooms.
The other unique aspect of PTC Creo is the amount of user interaction that is required in
creating geometry. When you think
about how you would use your
hands, fingers, and all types of tools
if you were creating or sculpting in
an art studio, you can understand
why it requires so much user
interaction in creating geometry.
Because PTC Creo is software, the only means of user interaction is through the buttons and
motion of the mouse and keyboard. You will find that you will use more buttons and button
combinations in interacting with PTC Creo than any other program you have used.
The Creo Parametric user interface is the now familiar Windows Ribbon environment.
The Windows Ribbon makes it easy to navigate functions arranged in toolbars and
menus. Take some time to familiarize yourself with the various menus as these will be
used throughout this modeling activity.
This was a brief introduction to the PTC Creo user Interface. As you progress through this
activity you will explore and use many more functions within PTC Creo.
SolidModeling Operations
As discussed previously, part models are collections of positive and negative features. Lets talk
about features and how they are constructed. Features are chunks of geometry that can be
positive or negative. They are often referred to as volumes. When constructing the model of a
part, volumes are added or subtracted to create the final shape. This is much like using Venn
diagrams to create set theoretic sums.
The sets in our solid modeling context are collections of points within a volume. Each volume
represents a different set of points and these volumes can be unioned, differenced, or
intersected. But first we must construct the volumes and then we can apply the set theoretic
operations of union and difference.
2D sketches must be closed, meaning that there are no openings in the sketch
2D sketches should not have any dangling edges or free floating geometry.
Lets look at each of these cases.
Once we have a good 2D cross section, we can do four different operations to extend them into
3D.
Four Operations
There are four basic operations that are used to create volumes or features.
1. Extrude is taking a cross-section and extending it in a straight line into 3D as shown.
2. Revolve is taking the cross-section and revolving it about an axis as shown.
4. Blend is taking two or more cross-sections and blending between them along a
curve.
Using these four operations it is possible to construct a significant number of 3D models. There
are other additional operations, but since these four can represent almost all types of 3D parts,
we will work with these.
Boolean Addition and Subtraction
Once you have created a volume, you can then create a second volume and add or subtract it
from the first one to create a new shape. This can continue volume after volume until you have
created the final shape of the part you desire. For example, here is a sphere and a rectangular
cube. In the first situation they are added together. In the second the rectangular cube is
subtracted from the sphere.
Therefore, using the four operations for creating volumes and then adding or
subtracting them allows for a great deal of diversity in the 3D models.
Now lets explore a new assembly model and discover how each of the parts in the
model were made using the different solid modeling operations we have learned about.
This assembly model is of a robot and is made of three parts (the arms are one model
used twice).
Assembly Operations
When constructing a 3D assembly of parts, we use a different set of operations to construct the
product model. For example, we dont use Boolean adds or subtracts since we dont want to
subtract parts in the assembly. Instead we use assembly constraints that determine how parts
relate one to another. There are many different types of constraints, we will present a few.
When creating an assembly the first part must be grounded or placed in reference to the default
coordinate system. This is usually done with a default constraint.
When the next part is brought into the assembly, it must be placed in reference to the first part.
In this example the neck is placed within the neck hole in the body part using a coincident
constraint to align the axes and then another coincident constraint to identify where along the
axis the neck must rest.
Each additional part must be assembled using constraints that locate it with respect to the
existing parts until the entire assembly is finished.
There are other types of constraints that allow parts to move with respect to each other. We call
these types of constraints Kinematic constraints. In order for the arms and legs of this
wooden man to move with respect to each other, we must use kinematic constraints.
Once we have our product model assembled, we can analyze the characteristics of the model.
For example, we can calculate its total weight, volume, size, etc. We can also cause the parts to
move and expose them to virtual forces.
To finish this chapter, lets explore an assembly model and find all the different elements that
we have talked about. This model is of Davincis Ornithopter design.
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APPENDIX
Exercise 1: The Model Tree
Open Creo Parametric 2.0 and
click the icon called Select
Working Directory to set the
folder in which you will be
working.
A revolve is coming
Right click on
EVE_BODY.PRT and click
Activate.
Zoom
Rotate
Pan
Click OK.
Now click OK
Now select both of the measures
you created using the CTRL key
and left clicking. Then click on the
Result Set: Wing_Flapping.
This exercise is based on a model of Leonardo da Vinci's Ornithopter by Pathfinders Design from his
Codex Atlanticus notebook in about 1488. Leonardo drew many designs of flying machines and this
model is based on both those drawings, and his drawing of a bevel gear in one of his other notebooks
around the same time. Many of Leonardo's machine drawings were designed to convert rotational
movement into reciprocating motion, and in modern industry and manufacturing we continue to do
the same!
Used by permission from Da Vinci Ornithopter model Pathfinders Design and Technology, 2011. Visit
www.pathfindersdesign.net for more about Leonardo's designs.