NX TRAINING WORK BOOK

102 

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PRACTICAL APPLICATIONS

OF UNIGRAPHICS

WORKBOOK

September 2002

MT10050 - Unigraphics NX

EDS Inc.

U

NIGRAPHICS

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Proprietary & Restricted Rights Notices

Copyright

Proprietary right of Unigraphics Solutions Inc., its subcontractors, or its suppliers are included in this software, in the data, documentation, or firmware related thereto, and in information disclosed therein. Neither this software, regardless of the form in which it exists, nor such data, information, or firmware may be used or disclosed to others for any purpose except as specifically authorized in writing by Unigraphics Solutions Inc. Recipient by accepting this document or utilizing this software agrees that neither this document nor the information disclosed herein nor any part thereof shall be reproduced or transferred to other documents or used or disclosed to others for manufacturing or any other purpose except as specifically authorized in writing by Unigraphics Solutions Inc.

E2002 Electronic Data Systems Corporation. All rights reserved. Restricted Rights Legend

The commercial computer software and related documentation are provided with restricted rights. Use, duplication or disclosure by the U.S. Government is subject to the protections and restrictions as set forth in the Unigraphics Solutions Inc. commercial license for the software and/or documentation as prescribed in DOD FAR 227-7202-3(a), or for Civilian Agencies, in FAR 27.404(b)(2)(i), and any successor or similar regulation, as applicable. Unigraphics Solutions Inc., 10824 Hope Street, Cypress, CA 90630.

Warranties and Liabilities

All warranties and limitations thereof given by Unigraphics Solutions Inc. are set forth in the license agreement under which the software and/or documentation were provided. Nothing contained within or implied by the language of this document shall be considered to be a modification of such warranties. The information and the software that are the subject of this document are subject to change without notice and should not be considered commitments by Unigraphics Solutions Inc.. Unigraphics Solutions Inc. assumes no responsibility for any errors that may be contained within this document. The software discussed within this document is furnished under separate license agreement and is subject to use only in accordance with the licensing terms and conditions contained therein.

Trademarks

EDS, the EDS logo, UNIGRAPHICS SOLUTIONSR, UNIGRAPHICSR, GRIPR, PARASOLIDR, UGR, UG/...R, UG SOLUTIONSR, iMANR are trademarks or registered trademarks of Electronic Data Systems Corporation or its subsidiaries. All other logos or trademarks used herein are the property of their respective owners.

Practical Applications of Unigraphics Workbook Publication History: Version 15.0 . . . February 1999 Version 16.0 . . . January 2000 Version 17.0 . . . December 2000 Version 18.0 . . . September 2001 Unigraphics NX . . . September 2002

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Project Description

Project Description

Toy Radio Controlled Car

The objective of this workbook is to provide you with an an ongoing indication of your comprehension of the course material. The workbook will lead you through a modeling project with high level prompts. Detailed steps will not be present as they are in the student manual. However, feel free to reference the student manual as needed.

In this project you will model some of the component parts of a toy car and add them to an assembly. Some of the parts have already been modeled but need to be added to the assembly in the proper orientation. Other parts will require the documentation of a drawing.

This project will reinforce your Unigraphics skills of capturing design intent, modeling, assemblies, and drafting.

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Project Description

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Rear Differential Modeling

Rear Differential Modeling

Section 1

The first part to be built for the toy car assembly is the rear differential. This activity will show how a primitive may be used to start the model, then new features may be used to add detail to the part.

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Rear Differential Modeling

The design intent of the rear differential is to hold the rear drive gear and the rear axle. The bosses that protrude from the sides to support the axle need to be centered on the central square section, and should act as one feature should the part change. The rear differential also must have the ability to rotate to a certain degree, allowing the rear wheels to travel over uneven surfaces. The bosses used to mount the differential therefore are required to be aligned. The walls of the central square section should be of uniform thickness. The rear drive gear will protrude from the top of the differential so that it can mesh with the drive gear from the power source. This means that the bottom of the central square section must accommodate the rear drive gear passing

through it. The hole that allows the rear axle to pass through the part should be centered in the bosses that are provided to support it.

Step 1 Open pau_seedpart_mm save it as ***_rear_diff_1 where *** represent your initials.

Step 2 Start with a primitive as shown below. Be sure to enter the entire expression as the value in the length fields (i.e. BLLG=27.50). Locate the block at WCS origin 0,0,0. The expression names will help in referencing the values later.

Unigraphics builds the block and locates it in the location specified. Note the orientation of the block with respect to the WCS. Expressions are also stored for the three equations that were keyed in. These expressions store the

parameters for the block and allow future editing to change the values defining the block if desired.

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Rear Differential Modeling

Step 3 Use the Hollow operation to remove material from the center of the block. Remove the top face and leave the other faces a thickness of 1.

Step 4 On each of the 27.5 x 17.5 faces (front and back) create a Boss feature 17.5 in diameter by 21 high. When

positioning the first boss use the values BLLG/2 and BLHT/2 to place the bosses in the center of the face. BLLG and BLHT are expression names that were created in step 2.

Expressions are case sensitive. Referring to these expression names links the values to the expressions, so that when the value for the expression changes the feature location updates accordingly.

When creating the second boss, link its diameter and height to those of the first boss by using the expression names (p values) that were stored during creation of the first boss.

Locate the second boss relative to the first boss to assure that they move together.

Step 5 Create edge blends with a radius of 4 along the bottom two long inside edges.

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Rear Differential Modeling

Step 6 Create edge blends with a radius of 5 along the bottom two long outside edges.

Step 7 Use a Pocket feature to create a Rectangular opening 18 long by 12 wide in the bottom of the part for gear

clearance. A depth of 5 for the pocket should accomplish what is required. Center the pocket in the part using previously created expressions.

It is important to think of what is to be accomplished while using the various tools. A rectangular pocket created from the outside bottom face of the part will take away material upward as desired to create the clearance opening for the gear. Note that the pocket takes material from the blended faces and the bottom. A rectangular pocket created from the inside bottom face would not remove the material from the inside blended faces. They are above the placement face.

Step 8 Place the 5.5 diameter axle clearance Hole through the part. Be sure that the clearance hole is centered in the boss features.

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Rear Differential Modeling

Step 9 Create Single Offset Chamfers with a value of 1 on the outer edges of the hole.

Step 10 Create the mounting bosses.

- Create the two 5 diameter by 6.5 high mounting Bosses

centered on the 18 x 17.5 faces. Apply design intent during creation as was done earlier.

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Rear Differential Modeling

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Rear Differential Assembly

Rear Differential Assembly

Section 2

Assemblies

The purpose of this section is to begin the assembly of the toy car. This assembly will be revisited throughout the course.

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Rear Differential Assembly

Step 1 Open pau_seedpart_mm save it as ***_assembly_1 where *** represent your initials.

Step 2 Add the pau_chassis_pan_1 to the assembly using the BODY reference set.

Step 3 Add the pau_rear_diff_1 to the assembly using the BODY reference set.

The pau_rear_diff_1 part is owned by another user and is write protected. It may not be modified and saved, however the assembly file is owned by you and may be modified and saved.

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Rear Differential Assembly

Step 4 Reposition the pau_rear_diff_1 as required to locate the arc center at the end of front mounting boss with the arc center at the front of the cradle provided.

Arc Center

Arc Center

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Rear Differential Assembly

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Rear Differential Drafting

Rear Differential Drafting

Section 3

The next step in the rear differential process is to create a drawing of the rear differential in the master model assembly.

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Rear Differential Drafting

In this section you will create a discipline specific single part assembly for drafting purposes.

Because of the associative nature of Unigraphics assemblies, changes to the solid model will update its depiction in the discipline specific single part assemblies.

The downstream application that will be used in this example is Drafting. Other discipline specific assemblies could be created to support analysis,

manufacturing, etc..

Step 1 Open pau_seedpart_mm save it as ***_rear_diff_1_dwg where *** represent your initials.

Step 2 Add the pau_rear_diff_1 part from the parts directory to the assembly using the BODY reference set.

This will ensure that the solid model and all of its construction tools remain segregated onto individual layers.

This completes the first step in the creation of a drawing for the rear differential of the car assembly.

Step 3 Save the part.

Step 4 Enter the Drafting Application and edit the drawing such that the units are metric, the scale is 2/1, the drawing size is A3, and the drawing name is DWG1.

The current drawing, created when the drafting application was entered, is changed as specified to better suit the rear differential part file.

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Rear Differential Drafting

Step 5 Add the views to the drawing as shown below. Remember to use Orthographic views once the original view is placed to assure proper alignment. Add the views with the Create Centerline option toggled on.

Step 6 Save the part.

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Rear Differential Drafting

Step 7 Dimension the part as shown below. Remember that this part is metric. Try using the Inferred dimension type first. If need be, use the Horizontal, Vertical, Hole, and Radius NOT to center types of dimensions.

If time permits, additional drafting activities may be found in Appendix B. Step 8 Save and close the part.

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Rear Axle Modeling, Assembly, and Drafting

Rear Axle Modeling, Assembly, and Drafting

Section 4

The rear axle is meant to be driven by the rear drive gear. It has a flat area on a cylindrical body. The rear drive gear and the rear axle are made of a material that allows the drive gear to be pressed onto the axle until its mating flat locks it into the rear axle. The rear wheels are simply pressed onto the rear axle and held in place by friction. The rear drive gear should always remain centered along the length of the axle.

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Rear Axle Modeling, Assembly, and Drafting

The second part to be built for the toy car assembly is the rear axle. This activity will reinforce the use of reference features.

Step 1 Open pau_seedpart_mm save it as ***_rear_axle_1 where *** represent your initials.

Step 2 Create a Cylinder along the +XC axis with a diameter of 5 and a length of 30.

The rear axle has a notch centered along its length with the purpose of keeping the rear drive gear from slipping. A rectangular pocket will be used to create this notch, but first reference features must be created to aid in the placement of the pocket.

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Rear Axle Modeling, Assembly, and Drafting

Step 3 Make layer 61 the Work Layer.

Step 4 Create the first reference feature through the cylindrical face of the part.

Step 5 Create the second reference feature through the axis of the cylindrical face and at an angle to the newly created datum plane of 905.

This reference feature will be used to locate the notch in the axle in the center of the cylinder width.

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Rear Axle Modeling, Assembly, and Drafting

Step 6 Create the third reference feature parallel to the original datum plane and tangent to the top of the cylindrical face. This reference feature will be used as the planar placement face for a rectangular pocket.

Step 7 Create the final reference feature halfway between the two planar faces on the ends of the cylinder.

This reference feature will be used to position the pocket in the center of the part regardless of changes in length.

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Rear Axle Modeling, Assembly, and Drafting

Step 8 On the datum plane that is tangent to the cylindrical face, create a Rectangular Pocket feature with a value of 10 along the length of the cylinder, a value of 5 across its width, and a depth of .5. Position it so that the centerlines of the pocket are collinear with the two centering datum planes.

Step 9 Add chamfers with an offset of 1 to each end of the cylinder.

Step 10 Make layer 1 the Work Layer and make layer 61 Invisible.

Step 11 Save and Close the part.

Now that some of the component parts have been created for the toy car it is time to start the assembly.

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Rear Axle Modeling, Assembly, and Drafting

Step 12 Open ***_assembly_1.

Step 13 Add the ***_rear_axle_1 to the assembly using the BODY reference set.

Step 14 Reposition the ***_rear_axle_1 so that its notch is centered in pau_rear_diff_1.

TIP

Analysis→Distance may be helpful in determining how to locate the rear axle.

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Rear Axle Modeling, Assembly, and Drafting

In the rear differential part the Master Model technique was used to facilitate concurrent engineering when the designer is not the drafter. Should these tasks fall to the same individual there may be no advantage to using the Master Model technique. In this case the drawing may be created in the same file as the model.

Step 16 Change the displayed part to ***_rear_axle_1.

Step 17 Enter the Drafting application and edit the drawing to meet the following specifications:

- the drawing units are in System International. - the drawing size is A4.

- the drawing scale is 2/1. - the drawing name is DWG1.

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Rear Axle Modeling, Assembly, and Drafting

Step 18 Add the views, utility symbols, and dimensions as shown below.

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Power Pack Sketching

Power Pack Sketching

Section 5

The power pack is actually the housing for the electronics and radio receiver. This housing also contains gear sets that would connect the electric motor to the drive wheels. The power pack should be compact and yet accommodate the gear sets and rack spur gear.

This section will reinforce your freehand sketching and constraining skills. In this activity you will create two profiles that represent the shape of the power pack.

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Power Pack Sketching

Step 1 Open pau_seedpart_mm save it as ***_power_pack_1 where *** represent your initials.

Step 2 On layer 21 create a sketch named, s21_top, on the XCĆYC.

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Power Pack Sketching

Step 4 On layer 1 extrude the profile up a distance of 60. Step 5 Move the reference features to layer 61.

Step 6 On layer 22 create a sketch named, s22_front. Define the attachment face and horizontal reference as shown below.

Attachment Face

Select the horizontal reference here.

Step 7 Make layers 1 and 21 invisible.

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Power Pack Sketching

Step 9 Save the part file.

Step 10 Activate the sketch named S21_TOP and apply the

dimensional and geometric constraints as shown below as required.

There are 4 horizontal constraints. There are 2 vertical constraints. There are 2 pairs of horizontal lines that have a equal length constraint. The sketch is located in space by applying a collinear constraint on a vertical line and a datum axis and a horizontal line and a datum axis.

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Power Pack Sketching

Step 11 Activate the sketch named S22_FRONT and apply

collinear constraints to locate the sketch as shown below.

The right side of the sketch is aligned with the right side of the solid body and the bottom of the sketch is aligned with the bottom of the solid body.

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Power Pack Sketching

Step 12 Apply the dimensional and geometric constraints as shown below as required.

This should be the name of the expression that controls the extrusion (=60). The name of your expression may be different.

This should be the name of the expression that controls the over all length in the S21_TOP sketch. See the illustration on page 6-4. The name of your expression may be different. There are 4 horizontal constraints.

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Power Pack Sketching

Step 13 Extrude the FRONT sketch across the solid body (+YC). Apply a parametric value so that if the solid body changes the extrusion will update with it. Use the intersect

boolean type to get a resultant shape that is the shared area of the extrusions.

Step 14 Hollow the part to a thickness of 2 removing the 3 faces shown below.

Remove these faces with the Hollow operation

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Power Pack Sketching

Step 15 Create a hole through both side flanges with a diameter of 15 with its center located .06 above the bottom edge and set back from the front of the part a distance of 20.

Step 16 Create a hole through both side flanges with a diameter of 2.5 with its center located a distance of 17 up from the bottom edge and set back from the front of the part a distance of 27.

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Power Pack Sketching

Step 17 Create a hole through both side flanges with a diameter of 2.5 with its center located a distance of 29.5 up from the bottom edge and set back from the front of the part a distance of 40.

Step 18 Create a hole through both side flanges with a diameter of 2.5 with its center located a distance of 17 up from the bottom edge and set back from the front of the part a distance of 62.5.

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Power Pack Sketching

Step 19 Create a hole through the back side with a diameter of 6 with its center located a distance of 21 up from the bottom edge and centered in the rear face.

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Left Pinion Modeling, Assembly, and Drafting

Left Pinion Modeling, Assembly, and Drafting

Section 6

The next part to build for the toy car assembly is the left pinion. This activity will reinforce the use of swept features.

The left pinion is used to mount and steer the left front wheel. The right and left pinions are attached to the chassis pan by snapping into place.

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Left Pinion Modeling, Assembly, and Drafting

NOTE: Consider the use of reference features to aid in the creation and/or positioning methods.

Step 1 Open pau_seedpart_mm save it as ***_left_pinion_1 where *** represent your initials.

Step 2 Create a block 25 long by 10 high by 7.5 deep.

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Left Pinion Modeling, Assembly, and Drafting

Step 4 Create a Boss on the top face of the block with a diameter of 7.5 and a height of 5. Position it so that it is centered along the width of the block and tangent to the end as shown.

Step 5 Create another Boss on the top face of the previously created boss. The boss is to have a diameter of 5 and a height of 10. Constrain it to be concentric with the last boss.

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Left Pinion Modeling, Assembly, and Drafting

Step 6 Create another Boss on the top face of the block 27.5 high by 7.5 in diameter and constrain it so that the axis of the cylinder falls on the right edge of the block and is

centered in the width of the block. This boss will be used to hold the front spring.

Step 7 Extrude the lower edges of the newly created boss down 12.5 to finish the cylindrical mounting feature. This boss/extrusion combination is associative in that the mounting feature is dependant on the boss' diameter for size purposes.

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Left Pinion Modeling, Assembly, and Drafting

Step 8 Using the center datum plane create a boss with a diameter of 5 and a height of 30. Locate the boss a

distance of 5 from the bottom of the block, and so that the boss stays centered on the axis of the mounting/spring feature.

Mounting spring feature

Step 9 Create another boss using the planar face of the last boss as the placement face. This last boss should be 7.5 in diameter by 7.5 high. Locate this boss concentric with the last one.

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Left Pinion Modeling, Assembly, and Drafting

Step 10 Create an edge blend on the placement face edge of the last boss with a radius of 2.

This blend will allow ease of front wheel operation.

Step 11 Create an edge blend on the other end of the last boss with a radius of 3.75.

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Left Pinion Modeling, Assembly, and Drafting

Step 12 Move the datum plane to layer 61.

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Left Pinion Modeling, Assembly, and Drafting

Update the assembly to reflect the new parts.

Step 14 Open ***_assembly_1 where *** represent your initials. Step 15 Add the pau_left_pinion_1 to the assembly using the

BODY reference set.

Step 16 Add the pau_right_pinion_1 to the assembly using the BODY reference set.

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Left Pinion Modeling, Assembly, and Drafting

Step 17 Reposition both pinions as required to locate the arc center where the bottom of the block intersects with the extrusion coincident with the respective arc centers in the opening in the chassis pan.

Reference Arc Center

Destination Arc Center

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Left Pinion Modeling, Assembly, and Drafting

Step 18 Save and close the part.

Step 19 Create a Master Model assembly called ***_left_pinion_dwg.

Add the ***_left_pinion_1 part to the assembly. Create a drawing to the following specifications: Drawing units are System International

Drawing size is A3 size The scale is 2/1.

Create the utility symbols and dimensions as shown below.

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Rear Drive Gear Modeling

Rear Drive Gear Modeling

Section 7

The rear drive gear takes the power from the power pack and applies it to the rear axle so that the wheels turn. As mentioned in the rear axle activity, the two parts have matching flats to keep the gear from spinning on the axle. Each of the gear teeth should be the same profile, and the spacing between the gear teeth should be equal.

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Rear Drive Gear Modeling

The next part to be built for the toy car assembly is the rear drive gear. In this section you will start the construction of the rear drive gear by creating

reference features, the center hole, and a sketch to define the tooth profile.

Step 1 Open pau_seedpart_mm save it as ***_rear_drive_gear_1 where *** represent your initials.

Step 2 Create a Cylinder with a diameter of 24 and a height of 10.

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Rear Drive Gear Modeling

Step 3 On layer 61, create a Datum Plane Through face axis of the cylindrical face.

This datum plane will be used to locate a central gear tooth.

Step 4 Create a second Datum Plane Through face axis and at an Angle to plane of 905.

Step 5 Create a third Datum Plane with an offset of 2 above the second datum plane.

This plane will be the planar placement face for a rectangular pad that will form the flat to match the one on the rear axle.

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Rear Drive Gear Modeling

Step 6 Create a hole through the center of the cylinder with a diameter of 5.

Step 7 Create a sketch named tooth on layer 21. Define the attachment face and horizontal reference direction as shown below.

Attachment face

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Rear Drive Gear Modeling

Step 8 Create the sketch geometry and constraints as shown below.

Step 9 Sweep and Subtract the triangular shape from the cylinder to create a groove.

This groove is the side of two gear teeth. Step 10 Save and close the part file.

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Rear Drive Gear Modeling

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Part and Assembly Editing

Part and Assembly Editing

Section 8

The assembly process quite often will show problems with the design. In this case the rear axle was found to be too short to serve its purpose. Parametric modeling allows for parts to be easily modified.

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Part and Assembly Editing

Step 1 Open ***_rear_axle_1.

Step 2 Change the length of the cylinder feature from 30 to 195.

Step 3 Save the part.

Step 4 Enter the Drafting application and update the views. Step 5 Edit the drawing size from A4 to A3.

Step 6 Move the views as required.

Step 7 Change the origin of the dimensions and notes as required.

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Part and Assembly Editing

Step 8 Save and Close the part.

Since the size of the axle has changed, you will now realign the axle in the assembly so that it is positioned correctly.

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Part and Assembly Editing

Step 9 Open ***_assembly_1.

Step 10 Reposition the ***_rear_axle_1 so that its notch is centered in pau_rear_diff_1.

TIP

Analysis→Distance may be helpful in determining how to locate the rear axle.

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Rear Drive Gear Completion

Rear Drive Gear Completion

Section 9

Use your newly acquired modeling techniques to complete the solid model of the rear drive gear.

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Rear Drive Gear Completion

In this section you will create a pad and apply an instance feature to create the teeth of the gear.

Step 1 Open the ***_rear_drive_gear_1 where *** represent your initials.

Step 2 Create a 5 x 10 x 1 rectangular pad on top of the offset plane and center it in the part to form the flat.

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Rear Drive Gear Completion

Step 3 On layer 61, create a relative Datum Axis through the center of the cylinder.

Step 4 Create 24 copies of the extrusion around the Datum Axis at an angle of 360/24.

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Rear Drive Gear Completion

Step 5 Create edge blends at the top and bottom of all of the teeth with a radius of .25.

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Assembly Completion

Assembly Completion

Section 10

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Assembly Completion

Step 1 Open ***_assembly_1 where *** represent your initials. Step 2 Add the pau_rear_drive_gear_1 to the assembly using the

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Assembly Completion

Step 3 Reposition the rear drive gear as required to locate the arc center of the hole in the gear with the corresponding arc center at the end of the flat on the rear axle.

Reference Arc Center

Destination Arc Center

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Assembly Completion

Step 5 Reposition the pau_rack_1 as required to locate the arc center where the hole pierces the bottom of the rack coincident with the respective arc centers on the pinions.

Reference Arc Centers

Destination Arc Centers

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Assembly Completion

Step 6 Add the pau_power_pack_1 to the assembly using the BODY reference set.

Step 7 Reposition the power pack as required to locate the bottom left corner of the power pack with the upper left corner of the battery enclosure on the chassis pan.

Reference End Point Destination

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Assembly Completion

Step 8 Add the pau_rack_spur_gear_1 to the assembly the BODY reference set.

Step 9 Reposition the rack spur gear as required to locate the arc center on the end of the rack spur gear shaft with the arc center of the power pack.

Reference Arc Center Destination

Arc Center

Step 10 Use Analysis"Distance to find the distance that the rack spur gear must move to match with the steering rack and move it into position.

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Assembly Completion

Step 11 Add the pau_rear_wheel_1 to the assembly using the BODY reference set.

Step 12 Reposition the rear wheel as required to locate the arc center on the inside of the hub coincident with the arc center at the end of the axle.

Reference Arc Center Destination

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Assembly Completion

Step 13 Repeat the process to add the second rear wheel to the other end of the axle.

Step 14 Add the pau_front_spring_1 to the assembly twice using the BODY reference set. Use the arc centers shown below as the origin points when placing the parts.

Origin Arc Centers

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Assembly Completion

Step 15 Add the pau_front_wheel_1 to the assembly using the BODY reference set.

Step 16 Reposition the front wheel to the left pinion so that the arc center at the end of the mounting hole is coincident with the arc center at the end of the wheel mounting shaft.

Reference Arc Center

Destination Arc Center

Step 17 Repeat the process to add the second front wheel to the right pinion.

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Assembly Completion

Step 18 Add the pau_gear_set_1 to the assembly using the BODY reference set. Reposition the gear set so that the two arc centers shown below are coincident.

Reference Arc Center

Destination Arc Center

Step 19 Add the pau_gear_set_2 to the assembly using the BODY reference set. Reposition the gear set so that the two arc centers shown below are coincident.

Reference Arc Center

Destination Arc Center

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Assembly Completion

Step 20 Add the pau_gear_set_3 to the assembly using the BODY reference set. Reposition the gear set so that the two arc centers shown below are coincident.

Reference Arc Center

Destination Arc Center

The graphic below shows the car from the rear with the three gear sets in place.

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Assembly Completion

Step 21 Add the pau_frt_spoiler_1 to the assembly using the BODY reference set.

Step 22 Reposition the frt spoiler so that the end points shown below are coincident.

Reference End Point

Destination End Point

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Assembly Completion

Step 23 Add the pau_body_1 to the assembly using the BODY reference set.

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Assembly Completion

Step 24 Reposition the body so that the arc centers shown below are coincident.

Destination Arc Center Reference

Arc Center

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Additional Modeling Projects

Additional Modeling Projects

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Additional Modeling Projects

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Additional Modeling Projects

Activity 1 - The Steering Rack

This activity will reinforce the application of a rectangular instance array.

Step 1 Open pau_seedpart_mm save it as ***_rack_1 where *** represent your initials.

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Additional Modeling Projects

Step 3 On layer 61, create a Center Datum Plane halfway along the length of the block.

This datum plane will be used to locate the central gear tooth.

Step 4 Create rounds with a radius of 5 at the four edges of the part to completely round off the edge along the edge that is 10 long.

Step 5 Create holes with a diameter of 5 through the part and concentric with the rounded ends.

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Additional Modeling Projects

Step 6 Create a rectangular pad across the 10 width 2.5 high and 2.5 wide, use a 12 degree taper from the bottom of the pad, and center it on the part.

Step 7 Create 9 instances of the pad along the top face in each direction (total 17), 4.5 apart.

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Additional Modeling Projects

Step 8 Create .75 radius rounds and fillets on the long edges of each copy (all instances) of the pad.

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Additional Modeling Projects

Activity 2 - The Steering Rack Spur Gear

To create this part you will have to apply the following functionality: cylinder, boss, reference features, pocket, sketching, swept body, and instance array.

Step 1 Open pau_seedpart_mm save it as ***_rack_spur_gear_1 where *** represent your initials.

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Additional Modeling Projects

Step 3 On layer 61, create a Datum Plane Through the face axis of the cylindrical face.

This datum plane will be used as the placement face to create the notch on the end of the shaft.

Step 4 Create a second datum plane through the axis of the cylinder and at an angle of 905 to the first datum plane. This plane will be used to center the notch.

Step 5 Create a 5 x 5 x 5 rectangular pocket on the top of the datum plane to make a 5 unit long notch halfway through the cylinder.

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Additional Modeling Projects

Step 6 Create a boss with a diameter of 15 and a height of 10 on the opposite end of the cylinder from the notch and make it concentric with the cylinder.

Step 7 Create a sketch named tooth on layer 21. Define the attachment face and horizontal reference direction as shown below.

Attachment face

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Additional Modeling Projects

Step 8 Create the sketch geometry and constraints as shown below.

Step 9 Extrude and Subtract the triangular shape to create a groove.

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Additional Modeling Projects

Step 10 Create a relative Datum Axis through the center of the cylinder.

Step 11 Create 10 copies of the extrusion around the Datum Axis at an angle of 360/10.

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Additional Modeling Projects

Step 12 Create fillets and rounds at the top and bottom of all of the teeth with a radius of .75.

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Additional Modeling Projects

Activity 3 - Rear Wheel

This activity will challenge you to select and apply the appropriate functionality to create a parametric solid body of the rear wheel.

Step 1 Open pau_seedpart_mm save it as ***_rear_wheel_1 where *** represent your initials.

Step 2 Create a model of the rear wheel based on the drawing attached.

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Additional Drafting Projects

Additional Drafting Projects

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Additional Drafting Projects

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Additional Drafting Projects

Step 1 Create a Master Model assembly called

***_rear_drive_gear_dwg to facilitate drafting of the pau_rear_drive_gear_1 part as shown below. The drawing is A3 size, the scale is 4/1.

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Additional Drafting Projects

Activity 2 - Steering Rack

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Additional Drafting Projects

Step 1 Create a Master Model assembly called ***_rack_dwg to facilitate drafting of the pau_rack_1 part as shown below. The drawing is A3 size, the scale is 2/1.

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Additional Drafting Projects

Activity 3 - Spur Gear

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Additional Drafting Projects

Step 1 Create a Master Model assembly called

***_rack_spur_gear_dwg to facilitate drafting of the pau_rack_spur_gear_1 part as shown below. The drawing is A3 size, the scale is 2/1.

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Additional Drafting Projects

Activity 4 - The Power Pack

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Additional Drafting Projects

Step 1 Create a Master Model assembly called

***_power_pack_dwg to facilitate drafting of the

pau_power_pack_1 part as shown below. The drawing is A3 size, the scale is 1/1.

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Additional Drafting Projects

Activity 5 - Rear Wheel

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Additional Drafting Projects

Step 1 Create a Master Model assembly called

***_rear_wheel_1_dwg to facilitate drafting of the pau_rear_wheel_1 part as shown on the next page. The drawing is A3 size, the scale is 1/1.

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Additional Drafting Projects

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Figure

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References

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