Precision Modelling 006

006
Introduction
This guide was created to assist Artists and Engineers, to learn the basics of mesh modelling of non deformable objects with 'Blender'. It uses a structured approach to introducing Blenders tools and wor !methods. "ollowing the guide should enable #ou to become familiar with blender and create models from the simplest of parts to comple$ accurate engineering assemblies and designs. The guide focuses solel# on Blenders %esh %odelling capabilities, it ignores the m#riad of animation, te$turing and photo!realistic rendering tools and concentrates solel# on getting started and producing accurate models suited for both artistic and engineering purposes. The guide was originall# made as a series of web pages that documented the design ideas and Blender methods used do design a few of the components I will be ma ing for a rebuild of m# &'& router. It has been ported to this .pdf boo from the web pages, so some references in the guide will still onl# relate to the on!line (ersion.
The )mall *rint

This guide is pro(ided as a free reference to new and e$isting Blender users. The contents of the guide are cop#right +obert Bur e , -00., but permission is granted for #ou to store a cop# on #our computer or print a hard cop# for personal use onl#. /ou ma# not use this guide for an# commercial purposes without written permission. (I have donated my time and knowledge
free to produce the guide, I don't expect people to make money from it)
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Blender ! *recision %odelling 1uide B#: +obert Bur e
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&ontents
*age 'o Introduction &ontents 1etting )tarted 4(er(iew of &ontrols Blender 2nits and *recision %odelling in Blender %odelling a 60@ Bearing *art !? *art A -. *art A ; *art A < *art A = *art A 6 *art A . *art A @ *art A > *art A ?0 *art A ?? +eference 1eometr# The Inner and 4uter +ace Adding the Ball Bearings %odelling the Bearing &age 3etailing the &age )ecuring &lasp %odelling the 3ust )hield %odelling the &irclip The 9ow *ol#gon Bearing %aterials and +endering &onstructing a *age 9a#out The )cale 3rawing 9a#out ?; -? ;0 ;= <6 =? => 66@ .; .> ; < = > ??
%odelling a 1uide +oller *art A ? *art A *art A ; *art A < 3esigning a &asting *art A ? *art A *art A ; *art A < *ositioning the &omponents The Initial 9a#out +oller 'ut %ounting Brac ets &ompleting the &asting ?;0 ?;6 ?<?<@ %odelling the '5' +oller The 1uide +oller A$le 3etailed Thread *rofile 9a#ing out the &omponent 3rawing @> >@ ?0> ??>
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)tarting Blender
There is a wealth of information a(ailable on the Internet in the form of manuals, guides and tutorials that co(er the full potential of this program. This 1uide is intended as a starter for people interested in the creation of mesh models and more specificall#, dimensionall# accurate mesh models. Appendi$ ? gi(es a short list of useful Internet lin s. Obtaining and loading Blender The 4pen )ource and freel# a(ailable creati(e pac age Blender can be downloaded from www.blender.org. 4nce on the site, clic the download lin to open the download page. &hoose the file to suit #our operating s#stem and follow the simple installation instructions at the bottom of the download page to install the program. What you see when the program starts
7hen #ou run blender for the first time #ou are presented with the default screen. It contains the user preferenceBs window at the top of the screen. The main ;3 wor area in the centre of the screen and the buttons window at the bottom of the screen.
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!uic" Overview of the controlls#

Relevant sections of the program 7hen #ou first start modelling, the main two screens are alread# open, the ;3 wor space and the Buttons window. A cube object C?D is in the centre of the ;3 (iew and the window is orientated so #ou are loo ing down onto the top of the cube. There is also a 9amp C-D to illuminate the cube and a &amera C;D to output a -3 bitmap of the cube. 3D View: Header Bar At the bottom of the ;3 (iew is blenders 5iew 0eader Bar. The purpose of each section within the (iew header is detailed below.
?D 7indow T#pe &lic on the window t#pe button and a menu will appear showing all the different window t#pes. Each window has a function within the process of ;3 modelling, image creation or animation. 0owe(er our initial interest lies just with the following windows: ;3 5iew: Buttons 7indow: This contains Blenders control buttons. 4utliner: A structured (iew of objects within the ;3 scene and there relationships to each other. )cript 7indow: To run useful add on scripts.
-D *ull up menu A conte$t sensiti(e menu showing the operations that can be carried out and the e#board shortcut for the operation.
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;D %ode: The operating mode for the window, initiall# we will onl# be using 4bject mode and Edit mode. 4bject mode is where assemblies of components are constructed. Edit mode is where the indi(idual components are modelled. <D 3raw t#pe This is the wa# the model is displa#ed on screen. The two useful t#pes we are interested in for modelling are 7ireframe and )olid.
=D *i(ot *oint This gi(es a choice of centre points for rotating and scaling the ;3 models.
6D 7idget control &lic the hand icon to de!select this. It should show a light gre# bac ground .D 9a#ers These allow #ou to organise components in big assemblies, onl# showing those that are needed.
Buttons Window Header Bar
&onte$t Buttons: These change the control button options in conte$t with the operation #ou are performing.
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@D %aterial &onte$t Button Brings up a choice of material te$turing and lighting options. >D Editing Button Brings up the modelling tools. ?0D +ender Button &ontrols the output to a -3!bitmap image. ??D %aterial )ub!conte$t Each conte$t button has sub conte$t options. $nderstanding 3D co%ordinates and Blenders 3D views 7hen #ou first run blender #ou are presented with a (iew of the wor space loo ing directl# down from abo(e. The screen in this position represents the 8 and /!a$is. The E!a$is is coming awa# from the screen directl# towards #ou. /ou can change the (iew direction b# either clic ing and holding the middle mouse button whilst dragging the mouse to rotate the (iew around a point in ;3 space, or using one of the pre!set (iews accessed (ia the number buttons on the right of the e#board. C'um *ad ButtonsD 7hen modelling in blender #ou draw parallel to the surface of the (iew at the depth of the ;3 &ursor Csmall cross hair positioned b# clic ing the 9eft %ouse ButtonD, so the (iew rotation and position of the cursor is important to the desired outcome.
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Blender uses the right hand co!ordinate s#stem with the E!a$is pointing upwards. This is in common with the co!ordinate s#stems used b# most common ;3 &A3 pac ages. Its worth noting though, that some programs use a co!ordinate s#stem where the / a$is points up and it ma# be necessar# to rotate the model if e$porting #our model into a program with this configuration. Blender displa#s the co!ordinate as: 38 0.0000 3/ 0.0000 3E 0.0000 C0.0000D 7hen mo(ing or e$truding a (erte$ the brac eted figure denotes the distance from the start point and 38, 3/, 3E will change relati(e to the distance along the a$is relati(e to the start point. &artesian &o!ordinates In object mode The Transform *roperties pane, accessed b# pressing the ' e#, displa#s the objects position, relati(e to the global co!ordinates. It also gi(es details of its rotation, scale and bounding bo$ siFe. The object centre co!ordinates of the blue cube in the &artesian co!ordinates diagram are displa#ed in the Transform properties window.
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Blender units and precision In order to ma e blender units represent a real world unit it is necessar# to assign a dimension siFe to the blender unit. 7hen Blender first opens #ou are presented with the default cube measuring - blender units wide b# - blender units deep b# - blender units high. 7hen importing a 5+%9 or )T9 file into a rapid protot#ping machine it is necessar# to tell the software what dimension the units represent. )o in order to manufacture an accurate ;3 model in Blender and e$port it to a ;3 printer or &'& machine, #ou need to now what the blender unit represents as a real world measurement. The ;3 world within Blender isnBt an unlimited space and there are restrictions as to how big a model can be. )iFe is limited b# the a(ailable power and fall! off distance of the lights, the ma$imum clipping distance of the (iew camera and the ma$imum clipping distance of the render CoutputD camera. &omple$it# of a model is limited b# the amount of (ertices #our s#stem can handle. The more powerful a machine #ou ha(e the more (ertices #ou will be able to handle before the computer starts to lag behind the speed #ou can model at. )o how big should I ma e a blender unitG If #ou were considering modelling a precision component or assembl#, being able to model down to sub micron accurac# would be a distinct ad(antage. )o if we consider one blender unit to eHual one millimetre how accurate can we getG Blender allows #ou to numericall# input the distance of (ertices to the precision of < decimal places C0.0000D. )a# #ou e$trude a (erte$ 0.000?mm along the 8!a$is #ou ha(e set its position ?I?0th of a micron from the original. *rett# darn accurate and gi(en that the best &'& machining centres can position to an accurac# of plus or minus ; microns, #ou can model to a much greater accurac# than #ou could e(er manufacture to. The draw bac to this is #our (iewable wor space will be limited to a cube with ?0 metre sides. This is due to the clipping limit of the (iew camera, but unless #ou are designing a gantr# mill to cut the wing spars for an Air!Bus A;@0 this shouldn't present a problem.
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*utting )iFe into *erspecti(e The human hair is around .6 microns thic . %ost general purpose machine tools in s illed hands would be able to wor within two thousands of an inch C=0 micronsD The best &'& machining centres can position to an accurac# of plus or minus ; micron, with repeatabilit# of plus or minus ? micron. A ?00mm!iron bar will e$pand 0.0?-mm with a rise in temperature of ?0 degrees &
4ther scales could be chosen for precision wor such as ? blender unit J ?0mm gi(ing a wor area of ?00 cubic metres, howe(er this confuses the process and #ou constantl# need to be aware of where the decimal point goes when #ou are entering e$trude lengths etc. "or architectural designs it is common to use a scale of ? blender unit J ? metre allowing a (iewable design space of ?0 cubic ilometres and an accurac# of 0.?mm
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%odelling in Blender 7hen blender first opens the (iew has a cube object in the centre. This is one of se(eral primiti(e shapes a(ailable to #ou that can be altered to form #our component. In 4bject %ode the shape appears as a solid cube and #ou are limited to being able to mo(e its position within the global space, rotate it about a chosen point or scale the whole model. B# pressing the Tab e# #ou enter Edit %ode and the corners of the cube now ha(e a #ellow dot on them, connected b# #ellow edges. The #ellow denotes the (ertices are selected. In edit mode #ou can mo(e the position of an# selected (ertices, add, join or delete (ertices, fill the area between an# three or four (ertices with a face and much more to construct #our model. Ob&ect 'ode % (olid View &ube C?D is selected with focus. If #ou press Tab this cube will become a(ailable to edit in edit mode. &ube C-D is selected. &ube C;D is not selected Ob&ect 'ode % Wire View &ube C?D is selected with focus. &ube C-D Is selected. &ube C;D is not selected. )dit 'ode % (olid View &ube C?D All (ertices selected. &ube C-D 'o (ertices selected. &ube C;D 4ne (erte$ selected. 'ote the edges fade from #ellow selected end to blac deselected end. )dit 'ode % Wire View &ube C?D All (ertices selected. &ube C-D 'o (ertices selected. &ube C;D 4ne (erte$ selected
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Blender has a wealth of tools that allow #ou to model almost an#thing and these will be described in the following tutorials. If #ou are new to ;3, wor through the tutorials in seHuenceK drawing methods and the use of tools are introduced and described as the tutorials progress getting less detailed as #our e$perience progresses. If #ou get stuc , simpl# go bac through the tutorials to where the tool or method #ou are struggling with was introduced. The initial description of the process will be the most detailed and helpful. %odelling a 60@ Bearing *art ? ! 9a#ing out the reference geometr#. *art - ! 3etailing the bearing +ace cross section. *art ; ! Adding the Ball Bearings. *art < ! %odelling the Bearing &age. *art = ! 3etailing the Bearing &age )ecuring &lasp. *art 6 ! Adding the 3ust )hield. *art . ! %odelling the &ir&lip *art @ ! 9ow (ertices (ersion bearing. *art > ! +endering the Bearing. *art ?0 ! &reating a *age Template. *art ?? ! 9a#ing out scale drawings 7ith the e$perience of modelling the Bearing its time to put the Bearings to use. The ne$t tutorial constructs a 5!roller and A$le that will be used to run on the 1uides of m# &'& machine. Building A 5!+oller 1uide Assembl# *art ? ! %odelling the 5!+oller. *art - ! &onstructing the a$le, washer and nut. *art ; ! *roducing 3etailed Threads. *art < ! 9a#ing out the Assembl# 3rawing
If #ou ha(e completed in seHuence all the tutorials abo(e #ou should now be comfortable with Blenders wa# of modelling. This ne$t part loo s at positioning the 5!roller's alongside other components and designing a casting around them. The casting will form the 8!a$is of m# &'& router. Design (teps for a *asting *art ? ! 9a#ing out the components *art - ! Initial casting design *art ; ! )upport Brac ets *art < ! &ompleting the casting
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%odelling a 60@ Bearing *art!? +eference 1eometr# To introduce #ou to Blenders modelling tools I will wal through the process of designing a 60@ Bearing, the t#pe used in s ateboards and in!line s ates. The geometr# from the bearings will later be used in the design of the other components and castings. I will use this tutorial to introduce some of the basic modelling techniHues that can be used to build components accuratel#. Two bearings will be co(ered in the tutorial, a detailed model with a large number of (ertices and a low detailed one with substantiall# fewer (ertices for use on slower computers or for use in large assemblies. The low detailed model will still be dimensionall# accurate. "irst of all, I thin a brief description of what we are about to model and how we will go about it is in order. Its alwa#s better to plan what #ou are doing before #ou start, rather than lea(ing it to chance as #ou wor through #our ideas. This model won't be used to manufacture the bearings so I am onl# concerned with the internal diameter, e$ternal diameter and width of the bearing being accurate, the rest is open to some artistic interpretation. The method to create the shell of the bearing will be to draw a cross section of the inner and outer race relati(e to the centre of the bearing and then spin this through ;60 degrees. 7e will wor to a scale of one blender unit eHuals one millimetre. 'othing has to be set in blender to achie(e this, just alwa#s remember for this tutorial e(er# dimension #ou input is in millimetres. Le#board and mouse actions will be shown in bold t#pe 4pen blender, #ou will be presented with the default top (iew loo ing down onto the top of a cube object. In the bottom left corner the co!ordinates arrows show the directions of the a$is. *ress and hold the ''B Cmiddle mouse buttonD and drag the mouse around to rotate the (iewing direction, the other sides of the cube will then be seen. /ou can pan the (iew b# holding down the (hift e# whilst pressing the ''B and mo(ing the mouse The top (iew can be reset at an# time b# pressing +um,ad%- CTop 5iewD. If #ou loose #our cube from the (iew #ou can retrie(e it b# pressing the Home e#. 7hen we draw our bearing we need to orientate the model so the front face of the bearing is shown when we press the front (iew. The first part of the
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process is to draw a section through the bearing perpendicular to the front face, therefore we need to draw on the side (iew. *ress +um,ad%3 C)ide 5iewD. The position of the cameras and light will change in the (iew and the co!ordinate arrows will change to reflect the different a$es positions.
If #ou press + on the e#board the Transform *roperties window will open. This gi(es details of the location of the object within the ;3 co!ordinates, the rotation around its centre point, an# scale applied to the object and the siFe of its bounding bo$ Cbo$ that encloses the objectD.
The red green and blue arrows in the centre of the cube object can get in the wa# when precision modelling. *ress the hand icon on the Transform *roperties panel of the (iew header. The options in the Transform *roperties panel will change and the hand icon will turn white. The arrows will be remo(ed from the (iew. 7e need an object to build our model on but the cube isn't (er# useful for the bearing so we will delete it. *ress the . e# to bring up the delete menu and accept the pop up menu option. The cube will be remo(ed from the screen lea(ing the cursor in the centre of the global co!ordinates. &ursor position 80.0000, /0.0000, E0.0000 In order to draw our bearing we need an object with at least one (erte$. "or this we will insert a *lane. %a e sure #ou are still in side (iew +um,ad 3 then press the (pace Bar to bring up the Toolbo$, as we are adding a mesh object, mo(e the mouse o(er 6Add6 a sub menu appears, mo(e the mouse o(er 6%esh6, another list of options will appear, clic on 6*lane6. A *lane will be created, centred on the cursor and the (iew will ha(e switched to Edit %ode to allow #ou to edit the plane.
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As we need to wor from one (erte$ centred on the cursor, press the e# to de!select all the (ertices which will turn them gre# and the edges blac . 0old the (H/01 e# to multiple select three (ertices with the R'B Cright mouse buttonD.
*ress the . e# to bring up the delete menu. In edit mode, there are more options a(ailable than object mode. )elect 65ertices6 and the three selected (ertices will be remo(ed from the (iew along with the face and edges of the plane. A single (erte$ will remain in the (iew and the *lanes object centre will remain centred on the cursor. In Edit %ode #ou can undo an# changes #ou ma e b# pressing *trl%2 7ith the R'B clic on the remaining (erte$ to select it, it will now turn #ellow. 7e need to snap this (erte$ to the cursor position *ress (H/01%( together to bring up the snap menu and select, )electionM&ursor. The (erte$ will now snap to the cursor position, howe(er it can't be seen as the object centre hides it. A 60@ bearing has an inside diameter of @mm therefore if the object centre is on the centre a$is of the bearing we need to position the inner race <mm from the object centre. *ress ) to e$trude the (erte$ then press 2 to constrain the mo(ement of the (erte$ to the E! a$is then press 3 the (erte$ will e$trude <mm along the a$is. *ress )nter to accept the mo(e. An edge has now appeared coming from the object centre to the mid point of the inner race.
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The width of a 60@ bearing is .mm so from the centre point we need to e$trude an edge ;.=mm along the /!a$is. *ress ) to e$trude, 4 to constrain it to the a$is, %;#5 to set the position ;.=mm along the negati(e /!a$is and )nter to accept. The second edge will now ha(e appeared.
+epeat the e$trude process for the other sides of the bearing. The dimension between the inner and outer race is .mm so: *ress ) to e$trude, 2 to constrain - to position and )nter to accept. E$trude the outer diameter .mm along the / a$is. E$trude the other side of the bearing !.mm along the E a$is. /ou should now ha(e the shape opposite in #our (iew.
7ith the R'B )elect the (erte$ under the cursor and then (H/01%R'B the (erte$ directl# abo(e, so both are selected. These are no longer needed so press . and delete 5ertices
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)elect the two bottom (ertices (hift%R'B and press 0 CfaceD to add an edge between them
7e ha(e now created the reference geometr# to construct the detailed cross section of the inner and outer race relati(e to the centre a$is. Blender has the abilit# to show the length of an# selected edge. To acti(ate it go to the buttons window at the bottom of the screen. &lic the Editing &onte$t button C?D to bring up the edit buttons. In Edit mode the buttons panels below will become a(ailable spread horiFontall# along the bottom of the screen. It ma# be necessar# to drag the button panels to the left to see all the options. *ressing the ''B and dragging can do this. In the %esh Tools ? panel C-D select Edge 9ength and the (iew will displa# the length of an# selected edge.
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The bearing has a 0.6mm fillet on the edge of the inner and outer race. As Blender is not primaril# a &A3 program it doesn't #et ha(e a dedicated fillet tool. 0owe(er it is both Huic and simple to add a fillet using the )pin function C;D in the %esh Tools *anel "irst we need to add a (erte$ at the start point of the fillet and also at the centre of the fillet. The spin tool wor s in the cloc wise direction so it is important to ta e this into account when positioning the first (erte$. )tarting in the bottom left corner, select R'B the corner (erte$. *ress ) to e$trude, 4 to constrain to the /!a$is, 6#7 for the length and )nter to accept. This has created the fillet start (erte$. 7ith the new (erte$ still selected, E$trude ), &onstrain 2, and length 6#7 and accept )nter. The fillet centre has been created. +epeat this seHuence in the other corners. )elect R'B the top left (erte$, ), 2, %6#7 and Enter. Then ), 4, 6#7 and )nter. )elect R'B the top right (erte$, ), 4, %6#7 and )nter. Then ), 2, %6#7 and )nter. )elect R'B the bottom +ight (erte$, ), 2, 6#7 and )nter. Then ), 4, %6#7 and )nter. /our (iew should now loo li e the image opposite.
)tarting in the bottom left corner select R'B the (erte$ on the centre point of the fillet *ress (hift % ( to open the )nap menu and select &ursor !M )election. The cursor will be positioned on the fillet centre.
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'ow select R'B the (erte$ that will be spun to form the fillet.
In the %esh Tools panel ma e sure in the te$t bo$ below the spin button 3egr: >0 is displa#ed. &hange the )teps: > to )teps: . as we don't need that man# (ertices to scribe the fillet. &lic ing on the small arrow either side of the N)teps:O te$t bo$, or pressing (hift and clic ing o(er the number with the 8'B Cleft mouse buttonD can alter the number. /ou can then use the e#board to enter the number.
*ress the )pin button and the first fillet will be created.
+epeat the process on the other corners )elect R'B centre (erte$. (hift%( cursor! M)election. )elect R'B the (erte$ to spin. *ress )pin in %esh Tools panel. The (ertices of the fillets are the first part of the bearing section that we will eepK the other edges are onl# there as drawing aides and will be remo(ed later.
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7e now ha(e the Inner diameter, outer diameter and width of the bearing cross section positioned accuratel# abo(e the centre a$is, together with the corner fillets. The four corner (ertices and edges we ha(e created are onl# reference points, which we will use to position the detail needed for the inner and outer race. This is a good time to sa(e #our wor . Blender handles this slightl# different to other programs, a good description of the process can be found on the Blender 7i i. "or now though press "ile ! )a(e As. The ;3 (iew will change to the "ile window. &hoose the folder where #ou want to sa(e #our file and name it as 60@!Bearing.blend &lic )a(e "ile and the screen will change bac to the ;3 7indow. 7hen #ou first use blender it ma# seem this is a slow and cumbersome wa# of drawing, but as #ou get used to the concept and the e#board short!cuts become instincti(e it is e$tremel# fast. I ha(e timed m#self and from clic ing the Blender icon on m# des top to load blender, to reaching this stage ta es less than two minuteBs. This is about the same amount of time it ta es just to load the &A3 pac age on m# wor s &A3 machine.
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%odelling a 60@ Bearing *art!- Inner and 4uter +ace
7ith the corner fillets in place it's now time to define the inner and outer race. The thic ness of each race is ?.>-mm, so we need to di(ide the cross section accordingl#. C/ou should now now the e#board commands to select, e$trude and constrain (ertices to a set a$is, so from now on I will onl# include the commands for these operations occasionall#.D )elect the bottom left (erte$ and )$trude it on the 2!a$is 9#:;mm. Then e$trude this (erte$ .mm in the / a$is. )elect the top left (erte$ and e$trude it !?.>-mm in the E!a$is. Then e$trude this .mm in the /!a$is. The thic ness of the Inner and outer race is now defined.
The ne$t stage is to form the groo(es that the ball bearings will run in. To do this we must spin a circle from the centre point of the two bearing races. 0old (hift and )elect R'B the four (ertices that are on the ends of the two edges that we ha(e just created to define the thic ness of the inner and outer race. *ress (hift%( and snap the cursor to the selection. Because we ha(e selected more than one (erte$ the cursor will snap to the centre of all the (ertices.
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7e now need to snap a (erte$ to the cursor. To insert a (erte$, ensure nothing is selected and holding the *trl e# clic 8'B an#where near the cursor. A new (erte$ will be created. )nap the (erte$ to the cursor. (hift%(, )election!M&ursor. The Ball Bearings ha(e a diameter of ;.>=mm so we need to spin a radius of ?.>.=mm. E$trude the (erte$ !?,>.= on the /!a$is.
In the %esh Tools panel set 3egr: to ;60 as we are going to spin a complete circle. )et )tep: to 6<. This will gi(e us a sufficientl# detailed circle. Its worth noting that if possible #ou should alwa#s choose a number of steps that will gi(e a (erte$ on each of the circles Huadrants. 7ith the (erte$ we ha(e just e$truded still selected spin the circle. E$cluding the (ertices whose edges intersect the line defining the inner and outer race, the centre (ertices are no longer reHuired and can be deleted. +ather than )hift!+%B selecting all the (ertices Blender allows #ou to bo$ select a group of (ertices. To do this press the B e#, the mouse pointer will change to a cross hair. *osition it abo(e and to the left of the (ertices #ou need to delete. *ress and hold the 8'B and drag the cross hair to the lower right of the (ertices to be deleted, release the 8'B. The (ertices within the selection bo$ will now be selected. *ress . and 3elete the (ertices.
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2ntil now we ha(e been wor ing with the pi(ot set to %edian. This means that if #ou rotate or scale a group of (ertices the centre of the rotation or scale will be the centre of the selected (ertices. To align the end (ertices of the bearing groo(es we need to rotate indi(idual (ertices around the centre of the ball bearing. 4n the (iew header clic on the pi(ot button and choose ;3 &ursor. As the cursor is alread# positioned on the centre of the ball bearing we can rotate the end (ertices. Eoom in on one of the end (ertices b# rotating the (W Cscroll wheelD and panning b# pressing (hift and holding the ''B whilst mo(ing the mouse. To rotate the (erte$ press R and drag the (erte$ until it is o(er the line defining the inner portion of the bearing race. &lic the 8'B to accept the rotation. +epeat this on all four (ertices
The (ertices we ha(e just rotated will be close to the edge defining the inner surfaces of the bearing race but not e$actl# on it. To correct this we will position the cursor on the inner surface edge. )elect a (erte$ on the edge and (hift%( &ursor!M)election.
Then scale the two (ertices onto the edge. *ress ( to scale 2 to constrain the mo(ement to the E! a$is and 6 to position the (ertices in line with the cursor. +epeat this on the other edge.
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7e now ha(e enough detail to complete the inner race. )elect the 6 reference (ertices shown abo(e and . delete them
7e are left with the two corner fillets and the bearing groo(e.
To reconstruct the face of the bearings inside diameter select the inner most (ertices on the bottom fillets and press 0 to insert an edge.
)$trude the end (erte$ of the bearing groo(e and constrain to the /!a$is
To align this to the outer edge of the bearing snap the cursor to the top (erte$ of the fillet. +e!select the e$truded (erte$ and scale ( constrain to the 4!a$is and 6 to set its position in line with the cursor.
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The inner edge of the inner race has a 0.0=mm chamfer. To form this press < to grab the (erte$ Cmo(eD, 4 to constrain, 6#65 to set its position. 'ow e$trude this (erte$ !0.0= in the /!a$is then grab <, constrain 2, %6#65 to position. The chamfer is now formed. "inall# join the chamfer to the fillet with an edge. )elect the end (ertices on the chamfer and fillet and 0 to insert a new edge. +epeat this on the other end to complete the section of the inner race. The outer race is a little mode difficult as it contains a circlip groo(e and location for the dust shield. The creation of this form is fairl# straightforward. "rom the top left corner (erte$ simpl# e$trude and constrain the mo(ement to the E and /!a$is at the dimensions opposite. 4nce completed repeat this on the other end of the bearing. 4nce the edges are in place #ou can refine the cross section b# adding a 0.0-mm chamfer on each of the corners. This can be achie(ed b# deleting one edge, e$truding the end (ertices 0.0- in the direction of the deleted edge, reinserting the edge and then mo(ing the corner (ertices 0.0- in the perpendicular a$is. 3elete . the si$ (ertices used as reference points.
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The basic shape of the outer race is now constructed. )elect the (ertices both ends of a gap and press 0 to insert an edge. 3o this one edge at a time until the outer race is complete.
The section through the bearing is now complete and we are read# to spin this through ;60 degrees to form the ;3 model. 0owe(er the spin process rotates around the cursor and it is currentl# in the wrong position. 7hen we started to construct the section we wor ed from the 4bject &entre which defined the centre a$is of the bearing.
To snap the cursor to the object centre press 1ab to go into 4bject %ode. "rom here #ou can press (hift%( &ursor!M)election The selection point of an object is the object centre.
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1ab bac into Edit %ode and press all (ertices.
to select
As we want to spin the bearing in the front (iew press +um,ad 9 and the (iew will change with the (ertices lined up abo(e the cursor.
In the %esh Tools panel chec 3egr: is set to ;60 and )tep: is set to 6<. *ress spin. The bearings inner and outer race will be formed. The last set of (ertices created will now be selected but the# aren't #et connected to the first set of (ertices.
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To join these press twice to select all the (ertices then W to bring up the )pecials menu, from this select +emo(e 3oubles, which will merge an# (ertices that are sitting on top of each other.
That's it for modelling the inner and outer race. *ress 1ab to go into 4bject %ode and rotate the (iew with the ''B to see the ;3 (iew of the bearing from an# angle. /ou can pan the (iew with (hift%''B and mo(ing the mouse. If #ou loose #our model from the (iew #ou can retrie(e it b# pressing the Home e# /ou will notice howe(er that all the faces are flat with faceted edges to correct this in the (iew we will smooth the surfaces we need to appear round and retain edges we need to be sharp. 1ab bac into edit mode and select all 6)et )mooth6. . In the 9in and %aterials panel clic
If areas of blac appear on the surface of the bearing press *trl%+ and accept 6+ecalculate 'ormals 4utside6. This will allow Blender to now which side of the faces are pointing to the outside of the object and which are on the inside.
In the %odifiers panel press Add %odifier. "rom the pop up menu choose Edge )plit. In the Edge )plit modifier 6"rom %ar ed As )harp6 and 6"rom Edge Angle6 will alread# be selected. 9ea(e )plit Angle:;0. 7hich will smooth the join between an# faces with an angle of ;0 degrees or less. /ou will notice though that there is not a sharp edge between the bearing groo(e and the inner edges of the race because the angle is less than ;0 degrees. This can be corrected b# mar ing these edges for the Edge )plit modifier to recognise as sharp.
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)elect the edge loops on the outer edges of the bearing groo(e. This can be achie(ed b# first deselecting all (ertices and then selecting each loop (hift% lt%R'B
7ith the four loops selected press *trl%) to bring up the Edge )pecials menu. )elect 6%ar )harp6. This will tell the Edge )plit modifier that these edges should be (iewed as a sharp edge and it won't appl# an# smoothing to them.
Before we create the ne$t object we will gi(e this one a meaningful name. In the 9in s and %aterials *anel &lic in the 4B: *lane field
3elete plane and re name the object 60@!+ace
This is a good point to sa(e #our wor . *ress *trl % W and accept the sa(e menu.
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60@ Bearing *art!; Adding the Ball Bearings
In *arts ? and - we created the bearings inner and outer race, now we need to add some ball bearings. The 60@ bearing has . balls so we will create and position one ball and then use a similar spin process to position the other si$. This time though we will use 6)pin 3up6 to duplicate the selected (ertices of the first ball around the cursor at the reHuired step positions. In front (iew +um%,ad 9, go into edit mode 1ab, select wire frame 2, and de! select all (ertices . Before we insert a )phere to use as the ball bearing we need to position the cursor central to the bearing gro(es of the inner and outer race. To do this we will hide all the (ertices of the bearing race other than the perpendicular section directl# abo(e the cursor. *ress B CBo$ )electD and drag a selection bo$ to select all the (ertices to the right of the (ertical centre line. *ress B again and select all the (ertices to the left of the centre line. +epeat this again to select the remaining (ertices below the horiFontal centre line. If #ou select the wrong (ertices simpl# press *trl%2 to undo the selection. /ou should be left with onl# the (ertices directl# abo(e the bearing centre deselected. *ress the H e# to hide the selected (ertices. The (ertices ha(en't been deleted the# are hidden so the# don't clutter the (iew and cant be edited. /ou can retrie(e these (ertices at an# time b# pressing lt%H.
/ou will now ha(e one row of (ertices directl# abo(e the bearing centre.
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*ress +um,ad 3 to go into side (iew and select R'B the centre (erte$ of the inner race, bearing groo(e. 'ow add to the selection (hift%R'B the (erte$ directl# abo(e this on the outer race. The centre of these two (ertices is the centre point for the ball bearing. *ress (hift%( to bring up the snap menu and select &ursor!M)election. The cursor will be positioned at the insertion point for the first ball.
2n!hide the (ertices we hid to ma e positioning the cursor eas# b# pressing lt% H. &hange to front (iew +um,ad 9 and 1ab into 4bject %ode. /ou will see the cursor positioned between the bearing races directl# abo(e the 4bject &entre.
To form the ball we will use one of Blenders pre!set objects, the 25 )phere. The sphere is constructed from a series of latitudinal and longitudinal edges with poles at the top and bottom. 7e will be using the geometr# from the sphere to construct the bearing cage and it is important that it is oriented correctl#. 7hen we insert the sphere we need one of the poles to be pointing towards the bearing centre.
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To achie(e this it is necessar# to insert the sphere whilst in the top (iew, so press +um%,ad - for the top (iew and then press the (pace Bar to open the Toolbo$. select: Add M %esh M 25sphere.
Accept the default ;- segments and ;- rings, a 25 sphere will be inserted centred on the cursor with a diameter of -mm. The mode will ha(e switched to Edit %ode and all the (ertices will be selected. If #ou clic into front (iew +um,ad 9, /ou will see the bearing is hanging in space and too small for the race. To correct this we need to scale the bearing.
To obtain the correct scale factor, di(ide the reHuired siFe of the ball b# the inserted siFe of the 25 sphere. As the balls are ;.>=mm diameter and the 25 sphere is -mm then: ;.>= I - J ?.>.=. *ress ( for scale 9#:-5 for the amount and )nter to accept. The ball now correctl# fits the race.
Blender ;#33 $pdate 7hen #ou add a 25 sphere there is a new floating panel that allows #ou to specif# the radius, along with the segments and rings of the sphere. )o #ou no longer need to calculate the scale factor when imputing some of the mesh primiti(es. /ou can now simpl# hold down )hift and &lic 9%B o(er the radius figure and input the new radius of ?.>.= and clic 4L. The 25sphere will now be inserted at the correct siFe. Its still good to understand how to calculate a scale factor, as it will be needed in man# other modelling situations.
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The 4bject &entre for the ball is currentl# central to the 25 )phere and it would be much more useful if it was positioned central to the Bearing. To achie(e this 1ab into 4bject mode and select R'B the bearing race. *ress (hift%( to bring up the snap menu and select cursor!M)election. The cursor will be repositioned to the centre of the bearing. 'ow reselect R'B the Ball
In the %esh *anel there are three options for mo(ing the cursor. &entre: mo(es the object so it is centred o(er the 4bject &entre. &entre 'ew: %o(es the 4bject &entre to the centre of the object. &entre &ursor: mo(es the 4bject &entre to the cursor position, which is the option we reHuire. 7ith one ball in place we now need to create the other si$. As the cursor is on the bearing centre we can duplicate the first bearing . times around the race. To achie(e this 1ab into Edit %ode. In the %esh Tools panel set the 3eg: and )teps: as shown. *ress )pin 3up to duplicate the (ertices se(en times around the cursor. As with the spin command we ha(e just placed a cop# of the original ball o(er the top of the first one. To correct this select all (ertices , #ou will need to press it twice, once to de!select the last ball and then to select all. *ress W C)pecials %enuD and then select remo(e doubles.
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To change the appearance from the faceted surface of the 25sphere to a smooth surface, with all (ertices selected clic 6)et )mooth6 in the 9in s and %aterials panel. The balls are now created and positioned around the bearing. *ress 1ab to go into 4bject %ode, 2 for solid (iew and rotate the (iew with the ''B to see the bearing as a ;3 object.
In the 9in s and %aterials panel rename 4B:)phere to 4B:60@!Balls If #ou ha(en't alread# done so press *trl%W and sa(e #our wor . *art < modelling the cage becomes a little tric ier but as #ou get used to panning, rotating and Fooming the (iew, selection of (ertices and constructing models becomes a little easier to achie(e.
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60@ Bearing *art!< %odelling the Bearing &age
7hen we inserted the 25sphere that formed the ball bearings it was important to ensure that one of the poles pointed to the centre. B# doing this it has left us with the rings of the ball running perpendicular to the to the bearing centre a$is and this allows us to e$tract the geometr# from the surface of the 25sphere to form the inner profile of the bearing cage. This will become as little clearer as we wor through this part of the tutorial.
In front (iew select the balls, as the bearing race will get in the wa# of our (iew select local (iew +um,ad =. This will remo(e e(er#thing from (iew e$cept the selected objects. 7ith onl# the balls in (iew, Foom in and pan on to the top ball, (W Cscroll wheelD to Foom, (hift ''B to pan. 1ab into Edit %ode and go into solid (iew 2. 4n the (iew header select the 9imit selection to (isible button, so #ou onl# select (ertices from one side of the sphere. 7ithout this being chec ed #ou would also select the unseen (ertices from the bac of the sphere.
Bo$ select B @ rings of (ertices starting from the centre ring and mo(ing towards the bottom of the sphere. 7e will cop# these (ertices and turn them into a new object, the# will then form the inner part of the bearing cage.
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*ress (hift%D to cop# the (ertices, then press )sc so the# aren't mo(ed from their original position. A new set of (ertices has been created on top of the sphere. 7ith these still selected press , CpartD to separate them from the 60@! Balls object. A new object has now been created and remo(ed from the current Edit %ode selection.
Tab into 4bject mode and though not (isible the new cage object is on top of the top 25sphere. R'B clic o(er the cage and its outline will be highlighted. 1ab bac into Edit %ode.
&urrentl# the (ertices of the cage are sitting on the surface of the ball which would stop the bearing from turning, so we need to add some clearance. To achie(e this we will scale the cage from the centre of the top ball bearing. "irst we need to set the cursor at the centre of the top ball. 1ab into 4bject %ode and select the 60@!Balls 4bject. 1ab into Edit %ode and de!select all mo(e the mouse close to a (erte$ on the top ball and press 8 Clin selectD this will select all the (ertices directl# lin ed b# an edge to the (erte$ #ou are closest to. All the (ertices of the top ball will now be selected. (hift%( and snap &ursor!M)election, this will centre the cursor on the top ball. 1ab bac into 4bject %ode and select the &age and 1ab bac into Edit mode. %a e sure the *i(ot *oint is set to ;3 &ursor and scale ( the cage ?.0- This will gi(e #ou a clearance of 0.0;>= between the ball and the cage. CC3iameter P ?.0-D ! 3iameterD I -
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7e ha(e now got the inside profile of the cage but we need to add thic ness to it. 7e could simpl# E$trude a new set of (ertices and then scale them from the centre howe(er we would need to wor out a scale factor. Instead Blender has the abilit# to scale all faces in the direction of the face normals Csee Blender 7i i for e$planation of 'ormalsD. As we are scaling indi(idual (ertices then we onl# need to use the thic ness as the scale factor. 7ith all the (ertices selected e$trude ) select N+egionO from the sub menu and then press )sc so the new (ertices don't change position. *ress lt%( to scale along normals and %6#3 for the thic ness then press Enter. The cage is now 0.;mm thic As we ha(e created the thic ness of the cage b# scaling in the direction of the faces, the new end (ertices are no longer on the centreline of the bearing. 7ith the cursor still on the centre of the top ball and *i(ot set to ;3 cursor, select the new end (ertices C#ou will need to deselect the 69imit selection to (isible6 button or go into wire (iew ED (hift%R'B and scale ( in the 4 a$is to 6. It ma# be easier to select all the end (ertices of the cage as those that are alread# on the centreline won't mo(e. Bo$ )elect (ertices within the area outlined abo(e then with pi(ot in ;3 &ursor, )cale /!a$is to 0D 7e now ha(e the cage form that surrounds the bearing but if we )pin 3up this we will still be missing the section that bridges between this ball surrounds. Therefore before we )pin 3up this section we need to locate (ertices so the bridging section when formed is 0.;mm thic . In top (iew select the outer most (erte$ and e$trude it !0.; in the / a$is. This (erte$ will be the reference point to cut a new row of (ertices. )elect all and press > C nifeD a sub menu will open select Lnife CE$actD. The mouse icon will change to a nife. %o(e the nife close to the reference (erte$ and holding down *trl clic with the 8'B the cut line will be snapped to the reference 5erte$.
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3rag the line to the right and clic ''B this will constrain the cut to a line running horiFontall# along the (iew, which is the 8!a$is. 7ith the line passing all the edges of the left side of the cage clic 8'B to set the line and then )nter to cut new (ertices.
+epeat the cut on the other end of the cage, then delete 8 the reference (erte$. 7e now ha(e a row of (ertices running parallel with the bac face of the cage at 0.;mm. 7e will need to delete the faces and edges between this new row and the bac edge. To ma e selection easier go into Edge )elect. )elect (hift%R'B o(er the 6 edges indicated and delete . selecting Edges from the delete menu. +epeat this on the other end.
The cage profile should now ha(e a row of faces missing on either end. 7hen e$truded and joined to the ne$t cage profile, this will allow us to ha(e a continuous shell without an# faces or edges inside the model.
As the cage has been created from the 60@!Balls 4bject, its object centre is on the bearings centre a$is. 1ab into 4bject %ode and snap (hift%( the cursor!M)election to centre the cursor on the bearing a$is. 1ab bac into Edit %ode and select all (ertices . In the %esh Tools panel set 3egr: ;60 and )tep:. and )pin 3up the (ertices. )elect all (ertices and remo(e doubles W
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&lic bac into (erte$ select mode.
7e now ha(e . cage profiles that need to be joined together. Eoom in on the top profile and select the loop of (ertices around one of the open ends lt%R'B
In front (iew, e$trude the selection ) and accept 4nl# Edges from the sub menu. 3rag the e$truded (ertices towards the ne$t cage profile. 7e now need to merge the e$truded (ertices onto the ne$t cage profile.
To do this select one (erte$ on the e$truded edge C?D then )hift select the corresponding (erte$ on the ne$t cage profile C-D. *ress lt%' to open the %erge sub menu and select 6At 9ast6. This will join the (ertices at the position of the last selected (erte$.
+epeat this for all the (ertices around the loops to be joined.
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7e now ha(e two cage shells joined together with a connecting bridge all with a thic ness of 0.;mm. )oon we will mirror this cage to form the cage on the other side. But before this a little more geometr# is needed, as the two half cages are joined together with a folded tab o(er the outer circumference of the cage.
To create the (ertices that will e(entuall# form the joining tab, select all and cut through the bridging section > but this time accept Lnife C%ulticutD from the &ut %enu. A new sub menu will open allowing #ou to choose the number of cuts. Accept the default -.
Two new edge loops will be formed on the bridging section, but not in the position we reHuire them in.
To reposition the (ertices we will use Edge )lide to slide the loops of (ertices towards the cage sphere profiles. lt%R'B select one loop and turn on 6Edge 9ength6 in the %esh Tools ? panel.
*ress *trl%) to open the Edge )pecials menu and choose 6Edge )lide6. )lide the loop of (ertices until the top (ertices are 0.;mm from the cage sphere profile as shown abo(e. 7hilst mo(ing the loop #ou can press (hift to gi(e finer control of the mo(ement.
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7ith the two edge loops slid to a position 0.;mm from the cage spheres select the (ertices of the bridge section. CThe two edge slide loops and the two loops connecting the bridge to the sphere.
Ensure the cursor is still on the bearing centre a$is and )pin 3up the selected (ertices. 3egr: ;60, )tep:.. )elect all and remo(e doubles.
/ou ha(e now made the basic construction for one half of the cage. 7e will chamfer the edges of this but first we need to cop# and mirror this object to ma e the other half of the cage. In the 9in s and %aterials panel change the 4bjects name from 4B:60@!Balls.00? to 4B:60@! &ageA, the pre(ious name was automaticall# assigned b# Blender as cop# 00? of the 60@!Balls object, from which we copied the cage geometr#. If #ou ha(e not been doing so at freHuent inter(als press *trl%W and sa(e #our wor . In 4bject %ode go to the side (iew +um,ad%3 and cop# the cage (hift%D then press )sc so the position of the cop# does not mo(e. 7e now need to %irror this cop# on the /!a$is. Ensure the cursor is on the 4bject &entre Ccentre of the bearingD and press *trl%' C%irrorD This will bring up the %irror A$is sub menu choose 6/ 9ocal6. The cop# will flip o(er to be a mirror image of 4B:60@! &ageA with the name 4B:60@!&ageA.00?.
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In the 9in s and %aterials panel rename this object 4B:60@! &ageB. 4ur model now consists of four objects. To ma e selection easier blender has the abilit# to show an object la#out in the form of a tree structure. This is seen in the 4utliner window.
To enable this we first need to ma e room on our screen for a new window. %o(e the mouse o(er the join between the ;3 (iew and Buttons 7indows. The mouse pointer will change to a double arrow
R'B clic whilst the arrows are showing and a sub!menu will appear, 8'B clic on )plit Area. A split line will follow the mouse pointer. %o(e the mouse o(er the ;3 (iew.
8'B clic and a new ;3 (iew will be created.
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&lic on the 7indow t#pe button in the lower left corner of the new window, a 7indow t#pe menu will appear choose 4utliner. The (iew will now show a list of all the objects that are in our scene Cassembl# and ;3 spaceD. Together with the default 9amp and &amera. It ma# be necessar# to increase the width of the 4utliner window to see all the options. To do this mo(e the mouse pointer o(er the join between the ;3 (iew and 4utliner, the pointer will change to a double arrow. 0old down the 8'B and drag, the siFe of windows will change according to the mouse position.
B# clic ing on the objects name in the 4utliner, the object will become selected in the ;3 (iew. &lic ing on the e#e s#mbol will show or hide the object in the ;3 (iew. &lic ing on the arrow will loc the object so it cant be accidentall# edited. The sHuare camera icon stops the object being rendered to a bitmap image but still allows #ou to see it in the scene. 'ow we ha(e both sides to the bearing cage howe(er there is still one operation that needs to be performed on 4B:60@! &ageA. 'o mechanical parts ha(e a perfectl# sHuare edge especiall# pressed parts li e the bearing cage. )o we need to add a chamfer to the outer edges of the object. This process is greatl# simplified b# using one of the p#thon scripts, so we need to open a scripts window. As abo(e with the 4utliner, split the ;3 (iew but this time on the right hand side of the (iew. "rom the window t#pe menu choose scripts window. In the scripts window 8'B clic on )cripts go to mesh and choose Be(el &entre. This will be used to add a chamfer to the chosen edges.
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In the outliner window clic on 60@! &ageA to select it and then clic on the e#e icon for the other objects to remo(e them from (iew. /our screen will become Huite cluttered and with the need to open more and larger windows the ;3 (iew will become uncomfortabl# small, especiall# if #ou are using a small monitor. To ma e selecting and modeling easier #ou can force an# of the windows to full screen b# pressing *trl%Down rrow with the mouse pointer o(er the window, gi(ing a much better wor area, pressing *trl%Down rrow again will return the screen to the normal la#out. In Edit %ode Foom in on one of the cage spheres and set the selection to Edge )elect.
ItBs now a matter of selecting all the edges on the outer and inner circumference. (hift% lt%R'B select the edges indicated and wor #our wa# all around the circumference of the cage. &hec #ou ha(e four continuous loops selected. This chec ma# be easier in wire mode 2.
In the Be(el &entre (hift%8'B o(er the thic ness figure and change it to 0.0=. This will gi(e a 0.0=mm chamfer.
*ress Be(el and after a few seconds a chamfer will be created on the selected edges.
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To get a smooth appearance on our cage we will add an Edge )plit modifier. In (erte$ )elect, select all (ertices and in the %esh Tools panel press )et )mooth. In the %odifiers panel press Add %odifier, "rom the pop up menu choose Edge )plit. In the Edge )plit modifier 6"rom %ar ed As )harp6 and 6"rom Edge Angle6 will alread# be selected. 9ea(e )plit Angle:;0. 7hich will smooth the join between an# faces with an angle of ;0 degrees or less.
If blac patches appear on the surface this is because the computer doesn't now what side of the face is outside. To correct this press *trl%+ and recalculate normals outside. 4B:60@!&ageA is now complete. *ress *trl%W and sa(e #our wor . In part = we will add the clasp that joins the two half cages to 4B:60@!&ageB.
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60@ Bearing *art!= 3etailing the &age )ecuring &lasp
7ith 60@!&ageA now complete its time to go bac to &age B which we copied and mirrored from cage A before the chamfers were added. In the 4utliner clic on 60@!&ageB, select the E#e icon to bring it into (iew and close the e#e icon of 60@!&ageA. 7hen we originall# mirrored the cage from 60@!&ageA, we effecti(el# applied a scale factor of !? in the / a$is. *ress + to open the Transform *roperties window, /ou will see )cale8:!?.000. To clear this bac to )cale8:?.000 we need to appl# the scale to the object. To do this press *trl% and accept 6Appl# )cale and +otation6. If #ou had simpl# changed the number in the Transform *roperties window to ? the cage would ha(e flipped bac to the other side of the bearing In front (iew select the (ertices that ma e up the loops we cut in the bridging section between the ball cups. (hift% lt%R'B but lea(e the (ertices of the bottom bridging section deselected as these are parallel to the 8 a$is and the easiest to modif#. 7ith the (erte$ loops selected on all but the bottom section, press . to delete them
Eoom (W, pan (hift%''B and rotate the (iew ''B, until #ou obtain a good (iewing angle on the bottom face of the remaining bridging section. )elect the central bottom face. C(hift%R'B the < (ertices on the corner of the face.D
)witch to top (iew and go into wire (iew mode 2. #ou will see the selected edges are not sHuare because the# were cut from geometr# originall# created from the ball bearing's 25spheer, so we need to sHuare up the edges.
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)elect the face (erte$ on the outer surface of the cage and (hift%( snap &ursorIM)election. )elect the (erte$ on the opposite end of the edge and )cale ( constrain . to a scale point of 6. +epeat this on the other edge of the face. )elect one of the edges that cross the bottom face. 1o to side (iew and wire (iew mode. /ou will see that the edge is not aligned to the /!a$is, this is because of the same reasons the edge abo(e are not sHuare. E$trude ) C4nl# Edges from sub menuD a face from this edge constrained in the 2! a$is. The length of the face is not important. 7e will use this face to see what angle the edge is at.
In the mesh tools ? panel select edge angle and then select the four (ertices of the face. The angle of each face corner will be displa#ed. To form the clasp we need to spin the bottom face >-.;.6 degrees. )elect onl# the bottom two (ertices and delete them . as the# were there just to obtain the reHuired spin angle.
)elect one (erte$ on the inside edge of the bottom face and snap (hift%( &ursor!M)election to position the cursor to the centre of the spin radius. (hift%R'B )elect the other (ertices of the bottom face.
1o to side (iew +um,ad%3. In the %esh Tools panel set 3egr:>-.;.6 and )tep:. and press )pin. )elect all and remo(e doubles W as we ha(e also stac ed . (ertices on either end of the edge below the cursor.
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+e!select the newl# spun face and E$trude ) C+egion from sub menuD and 6#3 for the distance. 7hen #ou select region a new face will be e$truded constrained to an a$is perpendicular to the original face.
If the face e$trudes in the wrong direction press grab < constrain to 4 and distance %6#7 C!0.; to bring it bac to the cursor and !0.; for the correct positionD
)elect one (erte$ on the top edge of the new face and snap the &ursor to the (erte$. This sets the centre for the ne$t spin. Then select the remaining (ertices of the face. In the %esh Tools panel set 3egr:>0 and lea(e )tep:.. 1o to side (iew and press )pin. The ne$t section of the clasp will be formed. )elect all and remo(e doubles W to remo(e the (ertices stac ed under the cursor. +eselect the newl# created face and e$trude C+egionD 0.-mm 7ith the (ertices of the face still selected cut a new edge across the centre of the face. > Lnife C%idpointsD. Two new (ertices will be created. )elect the two new (ertices and delete . CEdgesD. The edge joining the two (ertices and both faces either side will be deleted. )elect one middle (erte$ and snap the cursor to it.
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)elect the two centre (ertices and the two on the left edge. 7e will spin these in front (iew to form the front radius of the clasp. In the %esh Tools panel set 3egr:?@0 and )pin:?<, go to front (iew and then press )pin. As before select all and remo(e doubles.
)elect the newl# formed clasp and the four edge loops that ma e up the bridging section.
7e are now going to )pin 3up the new bridging section with the clasp around the cage. Tab into 4bject %ode and snap the cursor to the object centre. Tab bac into Edit %ode. In the %esh Tools panel set 3egr:;60 and )pin:.. *ress )pin 3up to cop# the bridging section between the cage spheres.
)elect all and remo(e doubles.
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! <> !
Its now time to add the fillet around the edges of the cage. This time the outer edge loops will also follow around the clasp. "ollow the details in *art < to add the "illets but with Edge )elect acti(ated ma e sure #ou select continuous loops that also include the clasp. Add the 0.0=mm "illets with the be(el &entre script. Add the Edge )plit %odifier also detailed in *art <
This completes 4B:60@!&ageB *ress *trl%W and sa(e #our wor . In the ne$t section's we will add the dust shield and circlip to complete the detailed model of the 60@ bearing
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! =0 !
60@ Bearing *art!6 %odelling the 3ust )hield The dust shield will be formed in the same wa# as we made the bearing inner and outer race. 7e will create a section through the dust shield and spin this around the bearing centre to form the ;3 component. In the 4utliner set the 60@!+ace to (isible and hide all the other parts. In 4bject %ode snap the cursor to the 60@!+ace object to set the cursor in the centre of the bearing. 7e will start this object with a plane, so press the (pace Bar to open the Tools menu and AddM%eshM*lane. The plane opens in Edit %ode.
3rag the four (ertices of the plane and position them in the retaining gro(e of the outer race. )elect the bottom two (ertices and delete them . as we will start the dust shield using onl# the top two (ertices.
1rab < the end (erte$ and mo(e it along the 4%a$is 9#-5mm so the top edge measures 0.-=mm, the thic ness of the dust shield. E$trude ) C4nl# 5erticesD the two end (ertices in the 2 a$is %6#-5. 1rab < the inside bottom (erte$ and mo(e it in the 2 a$is a further %6#933mm to form an angle between the two (ertices of 60 degrees from the (ertical.
)et the cursor on the inside lower (erte$ and then e$trude this !?.=mm in the / a$is. +otate R this edge %36 degrees from the cursor. +epeat this for the outer edge.
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! =? !
The dust shield offsets 0.@=mm so e$trude two reference (ertices from the top corner. !0.6 then !0.-= in the / a$is
E$trude a face from these (ertices constrained to the E!a$is and position the new (ertices between the dust shield edges. E$trude another face along the E!a$is below the dust shield.
7e will use the reference edges to accuratel# cut the angled dust shield edges to length. )elect all (ertices CE$actD and open the nife menu >, select Lnife
&lic 8'B below the lower right reference (erte$, press *trl and mo(e the nife towards the bottom left (erte$ the cut line will snap to the (erte$ clic 8'B to set the line then mo(e to the (erte$ abo(e *trl%8'B this (erte$ to snap the cut line, then press Enter to accept the cut. +epeat this on the outer edge but start the cut line on the top left (erte$ and cut to the (erte$ below. 7e now ha(e two new (ertices setting the offset width of the dust shield.
7e no longer need the reference (ertices or the end (ertices of the dust shield edges. )elect these (ertices and delete them .
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! =- !
)elect the two end (ertices of the dust shield read# to e$trude them.
Before we e$trude them we need to set the cursor on the top of the inner bearing race. 1ab into 4bject mode and select 60@!+ace. 1ab bac into Edit %ode for this object. )elect a (erte$ from the top of the inner race R'B and snap the cursor to this, (hift%( &ursor!M)election. 1ab bac into 4bject %ode, select the *lane object Cdust shieldD and 1ab bac into Edit %ode for this object.
E$trude the two selected (ertices towards the inner race constrained in the E!a$is. 7e will now scale them onto the inner race. 7ith the pi(ot point still set to ;3 cursor press ( for scale 2 to constrain the mo(ement to the E!a$is and 6 to scale the lines le(el to the cursor. The (ertices are now touching the inner race so we need to bac them off a little to pro(ide some clearance.
%o(e the (ertices < CgrabD 2 constrain 6#6; for the clearance. The (ertices will now be clear of the inner race. To complete the basic shape of the dust shield press 0 to put an edge between the (ertices. 7e now ha(e the basic cross section of the dust shield positioned accuratel# against the bearing race. As we no longer need to reference the bearing race press +um%= to go into local (iew for the dust shield. The last thing to do to the cross section is add some fillet radii to the offset corners.
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! =; !
dding 0illets I will show two methods of accuratel# positioning the fillets, one using trigonometr# and one using reference geometr# that has no need for a calculator. "or both methods #ou will need to now the angle between the edges, the fillet radius and ha(e one edge aligned to a nown a$is.
0illets % 1rigonometry 'ethod "irst we need to now the angle between the edges we are going to fillet. If #ou ha(en't been planning the construction of #our model and placing lines arbitraril# #ou can find the angle b# forming a face from the three (ertices and using the edge angle button in the %esh Tools ? panel. Another reHuirement is for one of the edges to align with a nown a$is.
To wor out the centre point of the fillet we simpl# construct a right angle triangle with half angle A and the radius. The h#potenuse is the distance to the centre point at an angle of half A
Therefore:
)in ?I-A J +adiusI 0#potenuse 0#potenuse J +adiusI C)in CA I-DD
4nce #ou ha(e determined the h#potenuse simpl# e$trude ) this from the intersect along the nown a$is and rotate R it ?I- angle A
0illets % Reference <eometry 'ethod E$trude a (erte$ from the intersect ?.= times the radius. +otate this (erte$ ?I- angle A
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! =< !
"rom the intersect e$trude a (erte$ perpendicular to the edge on the nown a$is and the length of the fillet radius. E$trude another (ertices from this parallel to the edge on the nown a$is. 7here these two lines cross is the centre point for the fillet.
2sing the nife tool > snap a cut line *trl%8'B between the two reference (ertices parallel to the nown a$is line and cut a new (erte$ on the centre point of the fillet.
"rom the centre point e$trude a (erte$ perpendicular to the edge on the nown a$is at the length of the fillet radius.
)et the cursor on the centre point and spin the (erte$ on the end of the radius edge through an angle of ?@0Q ! Angle A
3elete the reference (ertices.
+e ma e the edges between the fillet and surrounding (ertices.
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1etting bac to the dust shield we will use the reference geometr# method to position the fillets with a small radius of 0.?mm and a large radius of 0.;=mm. The angle between the edges is ?-0 degrees. "rom the intersect on the inside of the angle e$trude ) a (erte$ along the 2 a$is 6#95mm, then rotate R the (erte$ !60 degrees.
Again from the intersect e$trude a (erte$ !0.? in the / a$is Cdistance of radiusD and then e$trude this abo(e the 60 degree edge. )elect all and then > Lnife CE$actD a (erte$ on the 60 degree angled line snapping the cut *trl%8'B to the edge set at the radius distance from the dust shield. )elect the new (erte$ which has been created on the fillet centre and snap the cursor to it. "rom the fillet centre e$trude a (erte$ 0.? on the / a$is for the front fillet then e$trude this 0.-= on the / a$is for the bac fillet. In the %esh Tools panel set 3egr:60 and )tep:. and spin the two (ertices.
In edge select mode press B twice to bring up the selection painter reduce the siFe of the selection circle 'W and select 8'B the edges between the fillets. 3elete . these edges.
+epeat this procedure to produce the bottom fillet.
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! =6 !
Bac in 5erte$ )elect mode, select the reference (ertices along with those on the original angle intersects and delete them. 7e are now left with the fillet's and top and bottom edges of the dust shield.
)elect a (erte$ either end of a missing edge and press 0 to insert a new edge. +epeat this for all the open sections.
7e are now left with a completed cross section through the dust shield read# to spin into the ;3 object, howe(er as before the cursor is in the wrong position. )elect all the (ertices and 1ab into 4bject %ode.
)nap the cursor onto the object centre. (hift%( &ursor!M)election. 1ab bac into Edit %ode and go to front (iew +um,ad%9. In the %esh Tools panel set 3egr:;60 and )tep:6< press spin to form the ;3 object. )elect all (ertices 3oubles W. and remo(e
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! =. !
The dust shield is now almost complete, but chamfers are reHuired on the corners. In edge select mode loop select the four edge loops indicated (hift% lt%R'B
2sing the Be(el &entre script detailed in *art!<, add a 0.0=mm chamfer. "inish the dust shield b# adding an Edge )plit modifier also detailed in *art!<.
A 3ust shield will also be reHuired on the other side of the bearing. +ather than repeating the modelling process we will duplicate this dust shield and %irror it across the bearing centre. 1ab into 4bject %ode and go to the side (iew +um,ad%3. &hec the cursor is still on the object centre. *ress (hift%D to duplicate the object then )sc to lea(e the duplicate on top of the original. *ress *trl%' to open the %irror sub menu and select 68 9ocal6.
Both 3ust shields ha(e now been created so it is time to gi(e them a meaningful name. )elect *lane in the outliner and then in the 9in s and %aterials panel change its name to 4B:60@!)hieldA. +epeat this for *lane.00? naming it 4B:60@!)hieldB. *ress *trl%W and sa(e #our wor . The final components for the bearing assembl# are the circlips that retain the dust shields in place. These are co(ered in the ne$t section.
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! =@ !
60@ Bearing *art!. %odelling the &irclip The circlip is possibl# the easiest of the parts to model. 7e will start b# inserting a *lane object to form the circlip.
7hilst in 4bject %ode go to the side (iew +um,ad%3 and with the cursor on the bearing centre insert a *lane C(pace to open the Toolbo$ then AddM%eshM*laneD.
%o(e the (ertices so the top right (erte$ is positioned in the circlip groo(e of the outer race. )elect the left (ertices, grab < and mo(e them ?.6 in the / a$is so the width becomes 0.<mm. )elect the bottom (ertices grab and mo(e them ?.-= in the E a$is so the hight becomes 0..=.
1o into front (iew +um,ad%9 and spin the (ertices around the bearing centre. In the %esh Tools panel )et 3egr:;60 )tep:6<. *ress spin to form the ;3 ring.
)elect two loops of (ertices through the ring and . delete them to form the opening in the circlip. %a e sure #ou ha(e selected the (ertices on the bac edge as well as those on the front.
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To allow the circlip to be prised out with a sharp tool the cut through the circlip is made at an angle. To form this select the four (ertices on the outer edge of the brea and rotate R them from the centre of the circlip.
+otate #our (iew and select the < (ertices on one of the open ends. *ress 0 to insert a face. 3o the same on the other open end. 1o into edge select mode and loop select the four edge loops forming the inner and outer edge (hift% lt%R'B. )elect all the edges of the ends. 2sing the be(el centre script detailed in part < add a 0.0=mm fillet. )elect all the (ertices press 6)et )mooth6. and in the %esh Tools panel
"inish the circlip b# adding an Edge )plit modifier with the default settings as detailed in part <
To finish off we will mirror this circlip onto the other side of the bearing. In object %ode go into side (iew. &op# the circlip (hift%D then )sc to lea(e it in the same position. 7ith the cursor still on the object centre *trl%' for mirror and select 68 9ocal6. The copied circlip will be mirrored onto the other side of the bearing.
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! 60 !
In the outliner select *lane and then in the 9in s and %aterials panel re name it 4B:60@!&irclipA. )elect *lane.00? and rename it 4B:60@!&irclipB That completes the modelling of the components for the detailed bearing. In the 4utliner open the e#e icon for all the parts to bring them into (iew. (If the components don't appear you may still be in local view, try pressing NumPad-/ to close local view) +otate the (iew to see #our wor . The 3ust )hields co(er most of the components so #ou ma# want to hide one of the dust shields (Outliner eye icon). *ress *trl%W and sa(e #our wor .
To recap: the commands and tools #ou ha(e co(ered in this tutorial include.
Short Cut 7 Top E Extrude 1 Front G Move (grab) 3 Right Side S Scale SW oo! "n#$ut (!ou%e Scroll Wheel) Shi&t'S Snap MM( Rotate )ie* (Middle Mou%e Button) +',' -on%train to .xe% Shi&t MM( /an )ie* Tab $b0ect#Edit Mode 1o!e -entre )ie* Space Toolbox Wire#Solid )ie* -trl' 2ndo 3M( Set /oint (Le&t Mou%e Button) Edge Split Sur&ace (Modi&ier) RM( Select Spin Spin vertice% around axi% Shi&t'RM( Select Multiple )ertice% Spin 4up -op5 )ertice% around axi% ( (ox Select Edge Split Modi&ier R Rotate W Re!ove double% (Special% !enu) 6 6ni&e -trl'7 Recalculate 7or!al% $ut%ide -trl'E Mar8 Sharp (Edge Special% !enu) .lt'RM( 3oop Select ('( /aint Selection Shi&t'.lt'RM( Multiple 3oop Select -trl'M Mirror -trl'4 4uplicate (cop5) .lt'S Scale along nor!al%
The completed bearing is ideal for producing (isualiFations or detailed drawings but with o(er -6,000 (ertices it will reHuire a lot of #ou computers resources if #ou ha(e man# of these in an assembl#. %# &'& machines assembl# model will reHuire 60 bearings and at this le(el of detail that gi(es o(er ?.= million (ertices far more than m# old *& can handle, so *art @ will show how to retain the precision of the design but with substantiall# fewer (ertices.
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! 6? !
60@ Bearing *art!@ The 9ow *ol#gon %odel 7ith the detailed model now complete its time to concentrate on the low (ertices model that will ha(e far less o(erhead on the computers resources when modelling large assemblies. 7e could start modelling from scratch repeating *art ? but with fewer (ertices on the fillets, howe(er its a simple process to import CAppendD the alread# created components into a new file and modif# them. 4pen a new file and delete . the default cube. Turn off the transform manipulator Chand iconD &lic "ile in the top left hand corner and select 6Append or 9in 6
'a(igate to the 60@! Bearing.blend and from the options choose 64bject6. The components will now be listed. R'B on the components highlighted.
The fi(e components will now be loaded in #our file. If the# are not (isible open the 4utliner and ma e sure the e#e icon is open. 7e need to join these components to ma e a single object.
In the outliner select the fi(e components and then with the mouse cursor o(er the ;3 window press *trl%?. The components will be joined into a single mesh. 1ab into Edit %ode and press (ertices. to select all the
7e onl# need a single cross section of (ertices abo(e the centre of the bearing. This cross section will be modified to reduce the number of (ertices and then spun around the centre to form the bearing.
Blender ! *recision %odelling 1uide B#: +obert Bur e www.rab;d.com ! 6- !
In front (iew press B twice to bring up paint select, reduce the siFe of the selection circle with the (W and pressing the ''B paint o(er the (ertices directl# abo(e the centre. The (ertices will become deselected. *ress . and delete all the remaining selected (ertices.
7ere now left with a cross section through the bearing but still with far to man# (ertices and a lot of unnecessar# internal detail. 7e will start stripping out the detail b# rema ing the corner fillets with a smaller )tep: (alue.
)elect the lowest (erte$ on the top left corner fillet and e$trude it 0.6mm on the /!a$is. This will gi(e us the fillet centre point.
)nap *trl%(, &ursor!M)election onto the fillet centre. select the e$isting internal fillet (ertices and delete them. )elect the original lowest fillet (erte$ and in the %esh Tools panel set 3egr:>0 and )tep:<. *ress )pin to create the fillet, this time with three fewer (ertices. 3elete . the (erte$ on the fillet centre. +epeat this on the bottom left fillet.
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! 6; !
7e now need to create a continuous e$ternal profile of the bearing, combining all the outer (ertices of the loose parts. &ut two new (ertices through the left circlip snapping the line to the edge of the circlip groo(e's chamfer. > Lnife E$act, snap the cut line *trl%8'B to the circlip groo(e chamfer's.
Add an edge between the groo(e and the circlip 0.
+epeat this and cut a new (erte$ on the dust shield with the snap line cut from the lower right chamfer of the circlip
The offset fillet's of the dust shield still ha(e more (ertices than are needed. "rom the top (erte$ of the top fillet e$trude an edge !0.? in the / a$is. )nap the cursor to this new (erte$ which is on the fillet centre. )elect the internal (ertices of the fillet and delete them.
)elect the top (erte$ from the original fillet and spin this to form the new fillet. In the %esh Tools panel set 3egr:60 )tep:< and press )pin.
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! 6< !
A new fillet has been created with three fewer (ertices.
%o(e to the lower dust shield fillet and repeat the abo(e process. This time e$trude the bottom (erte$ of the inner fillet 0.?mm on the / a$is to set the centre point. )nap the cursor to this. )elect the inner (ertices of the large outer fillet and delete them. )elect the bottom outer (erte$ of the original fillet and spin this 3egr:60 )tep:< The (ertices of the lower dust shield fillet ha(e been reduced. 3elete the fillet centre (erte$.
&ut a new (erte$ on the inner race from the dust shield bottom fillet. > Lnife E$act, *trl%8'B to snap the cut to the chamfer, MMB to con%train to the vertical
7e now ha(e a continuous outer edge of (ertices down the left hand side of the cross section, rather than repeating this on the right hand side we can delete all the other (ertices and mirror this line of (ertices onto the right hand side. Bo$ select B all the (ertices on the right hand side of the cross section including the bearing gro(es. 3elete these ..
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! 6= !
*aint )elect B%B the remaining inner (ertices and delete these.
1ab into 4bject %ode and snap the cursor to the object centre. (hift%s &ursor!M)election.
The cursor is now set on the bearing centre so we can mirror the left hand profile onto the right hand side of the bearing. 7ith the pi(ot point set to 6;3 &ursor6 1ab into Edit %ode and select all (ertices . 3uplicate Ccop#D the (ertices (hift%D then )sc to lea(e the cop# o(er the top of the original. *ress *trl%' to open the %irror menu and choose 68 9ocal6. The cop# will now be mirrored to the other side of the bearing.
+e!ma e the top and bottom edge b# selecting a (erte$ either side of the opening and pressing 0. )elect all and remo(e doubles W to merge an# doubled up (ertices.
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1o into front (iew +um,ad 9. In the %esh Tools panel set 3egr:;60 and )tep:;-. *ress )pin to form the ;3 Bearing. )elect all , remo(e doubles W and in the 9in and %aterials panel 6)et )mooth6. As the bearing was created from the original components, an Edge )plit modifier will still be acti(ated on this object.
In the 9in and %aterials panel rename the object 4B:60@!Bearing)mall. )a(e the .blend file as 60@!Bearing)mall. This (ersion of the bearing has --<0 (ertices, far fewer than the -6,000R (ertices of the detailed bearing. 7ith 60 of these bearings in the &'& assembl# it will still onl# reHuire the computer o(erheads for ?;<<00 (ertices. This completes the modelling of both (ersions of the bearing. In the ne$t part we will loo at adding basic materials to the bearing and rendering a ;3 (iew and an e$ploded (iew of the bearing.
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! 6. !
60@ Bearing *art!> %aterials and +endering At the introduction to this tutorial I said I would not co(er materials, te$tures or man# of the other (ast arra# of features a(ailable within Blender. 0owe(er to use #our model for (isualisation or design drawing purposes #ou do need to now a little about the process of appl#ing materials and rendering images to -3 bitmaps. 7e will use the detailed model for this section so open the 60@!Bearing.blend file. 7hen Blender opens it automaticall# inserts a &amera and 9amp object into #our scene C;3 wor spaceD, in the 4utliner select the &amera object
In top (iew mo(e the camera < and position it to the front and right of the bearing. +otate it R to point at the Bearing, also chec it points at the bearing in side (iew. In the Editing Buttons window the &amera panel gi(es options for the camera. The default lens is ;=mm, to wide an angle for a decent image so change this to ==mm which will gi(e a less distorted (iew. "or a full description of the camera controls see the Blender 7i i.
7ith the mouse pointer o(er the ;3 window press +um,ad 6 which will open the camera (iew. )elect the outer rectangle of the camera R'B and mo(e it < so it is centred on the bearing. If the bearing doesn't fit in the camera (iew signified b# the dotted rectangle truc the camera along its (iew a$is <%''B and mo(ing the mouse. 7hen the bearing is positioned in the cameraBs (iew select the bearing, then select the )hading button and the materials sub conte$t button.
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! 6@ !
This will open the 9in s and *ipeline panel, clic on add new to open a new material.
A range of material panels will become a(ailable to #ou.
In the %aterial tab change the +, 1, B sliders to .=60 to gi(e a dar er gre#.
&lic the te$ture sub conte$t and in the Te$ture panel clic NAdd 'ewO. )elect 6Image6 from the pop!up list n the Image panel load the shin#ballSref.jpg image. This can be downloaded from the Blender Te$ture 3is . A lin to the Te$ture 3is is a(ailable on the Blender 7eb )ite, on the resources page.
1o bac into the material sub conte$t buttons and in the N%ap InputO tab and clic +efl which will ma e the image affect the reflection (ectors C)ee Blender 7i iD.
In the N%ap ToO tab lea(e the default settings.
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! 6> !
&urrentl# the ;3 space has a dar blue bac ground and we need to change this to white. In the 7orld sub conte$t, 7orld panel change 0o+, 0o1 and 0oB to ?.00.
In top (iew +um,ad - select the 9amp R'B and mo(e < it to the left of the camera.
&op# the 9amp (hift%D and mo(e the cop# to the right of the camera. In front (iew, select both lamps (hift%R'B and mo(e them < abo(e the bearing. 9amp Buttons The 9amp panel gi(es the settings for Energ#, distance, colour etc. The default settings should be 4L for this render. In the conte$t buttons, clic on the scene and sub conte$t +ender button. In the "ormat *anel change the )iFe $ and )iFe / to @00 pi$els and change the image format from Tpeg to *'1. In the +ender panel de!select 6+a#6, as we don't need to use +a# Tracing. )et 64)A6 to ?6, so we get a good smooth edge to the render. *ress the +ender button, a new window will open and an image of the bearing will be created.
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! .0 !
To sa(e the image go to "ileM)a(e Image or *ress 03. The acti(e window will change to a file window allowing #ou to sa(e the image as a .png file.
This is a prett# basic gre# colour material and with a little time and e$perimentation with the material controls, a much more con(incing material could be obtained. +ead the blender documentation and loo at e$amples of materials posted b# other users to gain more e$perience in creating realistic materials.
As most of the parts we ha(e modelled are hidden within the dust shields it would impro(e a drawing la#out if we included an e$ploded (iew. This can be created b# simpl# mo(ing each of the components along the / a$is. 1o into top (iew +um,ad - and select the bac circlip mo(e it constrained to the / a$is awa# from the bearing. +epeat this for all the other components spreading them in order along the a$is. The# can easil# be reassembled b# snapping the cursor to the bearing race and then snapping the other components to the cursor.
+eposition the camera to get all the components in the (iew. 7ith all the parts being the same material it is a little confusing and difficult to separate the parts where the# o(erlap. To o(ercome this we can change the material of the bearing cage to a brass coloured material. )elect 60@!&ageA .
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In the 9in s and *ipeline panel after the material name is the number of objects using the material. &lic on the number and accept 6)ingle 2ser6. This will stop the following material changes affecting an# of the other objects. +ename this material BronFe. To change the colour of the cage clic on the colour sHuare in the %aterials tab. This will open the colour pic er. &hoose a bronFe colour. In the 6%irror Trans6 tab de!select +a# %irror and in the Te$ture tab clic on &lear to remo(e the reflection image. To add this material to the other half of the &age, select 60@!&ageB and in the lin s and *ipeline tab clic on %A:)teel. )elect Brass from the list. To output the picture of the e$ploded (iew select the +ender Buttons and in the +ender panel press the +ender Button. As before a window will open and the E$ploded 5iew will be produced. *ress 03 and sa(e the image. 7ith the two images created press *trl%W and sa(e #our .blend file. In the ne$t section we will create a page template for a scaled line drawing of the bearing.
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60@ Bearing *art!?0 &onstructing a *age 9a#out *amera Before we go into the process of la#ing out the drawing (iewBs, an understanding of Blenders camera is needed. ,erspective ,ro&ection The two images we ha(e created in *art > use the camera in perspecti(e projection mode and gi(es similar results, as #ou would get if an actual bearing had been photographed. The siFe and shape of the image on the image plane is a product of the focal length of the camera, distance of the object from the camera and the object siFe. This t#pe of camera will ne(er gi(e us the flat!scaled -3 drawing reHuired.
Orthographic ,ro&ection Blender includes an orthographic mode for the camera, which ta es a parallel slice, the siFe of the image!plane through the ;3 wor space. The siFe of the image plane can be set to suit the o(erall siFe of the drawing #ou need to output. ,rinter The ne$t thing we need to consider is the printer. "or engineering purposes we are most li el# wor ing to a scale of ? Blender unit eHuals ? millimetre and the output from the camera is li el# to be in >6 3*I Cdots per inchD The usual output from a printer will be ;00 3*I. )o how do we get a drawing to scale out accuratel# onto a printed pageG (etting up the (cale The wa# I find easiest is to set the camera scale at a multiple of -=.< and set the siFe 8 and )iFe / in the "ormat panel of the +ender Buttons to an eHui(alent multiple but this time of ;00. )o if #ou wanted to ha(e a ?:? scaled image fit onto an A< page of ??O b# @O #ou would need to set the camera scale to -=.< $ ?? J -.>.<, the "ormat panel )iFe 8: to @ $ ;00 J -<00 and )iFe /: to ?? $ ;00 J ;;00. There is one further reHuirement as the image is set to print at >6 3*I not ;00 3*I. This reHuires the use of an image!editing program such as the 1imp or *hoto )hop, to change the output siFe of the image to ;003*I.
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If #ou want to set #our page up to print at an e$act siFe and at a scale other than ?:? the correct &amera scale factor and output resolution become a little more difficult to set up. The eas# solution is to scale #our model once #ou ha(e set the camera to suit the page template. ,age 1emplate )a(e an#thing #ou currentl# ha(e open *trl W and open a new Blender file *trl .. 7e will start b# ma ing a page template to suit an @ $ ??inch page, in front (iew add a *lane (paceBar AddM%eshM*lane, select and grab the top two (ertices mo(ing them -...<mm ( !." # $$ inches % the original &lane si'e) in the E a$is. This sets the height of the page. 1rab the two right!hand (ertices and mo(e them -0?.-mm ( !." # ( inches % the original &lane si'e) in the 8 a$is, to set the width of the page. )elect all (ertices and delete . 4nl# "aces to remo(e the face. This rectangle becomes the page boundar# we need to wor within. In the 9in s and %aterials panel, rename 4B:*lane to 4B:A<pBoundar#. CA<p being page siFe A< *ortraitD 'e$t we will set the camera to (iew this rectangle at the print resolution. *ress + to open the Transform *roperties panel. &hange +ot8:, / and E as indicated. The &amera will now be parallel to the plane.
In the &amera panel CEditing &onte$t ButtonsD press 4rthographic. )et the scale to -.>.< C?? inches $ -=.<mmD
In the "ormat panel C+ender )ub &onte$t buttonsD set siFe8: -<0 C@ inches $ ;00 pi$elsD and )iFe/: ;;00 C?? inches $ ;00 pi$elsD
)elect the camera and in camera (iew +um,ad 6, mo(e < the camera so that the outer dotted line aligns with the A<pBoundar#.
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)elect the A<pBoundar# object R'B and cop# it (hift%D then press )sc to lea(e it in its original position. 1ab into Edit %ode and in edge select mode select each edge indi(iduall# and mo(e it < ?-mm towards the centre of the rectangle, constrained to the 8 or / a$is. This rectangle will form our page border, it could now be rendered as a wire object but the output will onl# be one pi$el wide, so we need to thic en the line. )elect the 9eft hand edge and e$trude it !0.=mm on the 8 a$is. E$trude the +ight hand edge 0.=mm on the 8 a$is. Bo$ select the three edges ma ing up the top of the border and e$trude these 0.=mm on the E a$is and repeat this on the bottom edge but !0.= on the E a$is. +ename this object A<pBorder
Tab into 4bject %ode and Add a new *lane (paceBar AddM%eshM*lane. This will be used to create the edge ruler's. %o(e the *lane to the bottom left corner of the A<pBorder and resiFe to 8 a$is 6mm and / a$is 0.=mm.
)elect all (ertices 96mm.
and cop# (hift%D the (ertices on the 2 a$is
This will form the mar s for a ruler that runs along the outer edge of the border. 1rab < the two 9eft (ertices and mo(e them on the . a$is ;mm. then select all the (ertices A.
In the %odifiers panel clic Add %odifier and select Arra# from the pop up menu. The Arra# modifier will cop# the selection b# the number set in the &ount: field and offset each cop#.
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)et &ount:?;, 3e select +elati(e 4ffset, select &onstant 4ffset and set /:-0. The selected lines will be copied up the side of the border. 1ab into 4bject %ode and select A<pBorder object. 1ab into Edit %ode for this object and select one of the long bottom edges. )nap the cursor to the edge (hift%( &ursorM)election. The cursor will be repositioned in the middle of the edge. 1ab bac into 4bject %ode. )elect the *lane object and cop# it (hift%D then press )sc so it does not mo(e position. )et the *i(ot *oint to &ursor select. %irror the copied edge ruler *trl%' and accept 68 9ocal6. The Border rules will now be mirrored onto the right hand edge. )elect both border rulers and cop# them (hift%D then rotate them >0 degrees R%:6. These will form the top and bottom rulers. )elect the A<pBorder object and snap the cursor to the object centre (hift%( &ursorM)election. )elect the bottom ruler and snap this to the cursor (hift%( )electionM&ursor. In the %odifier panel, reset the Arra# count to > +epeat this on the top edge but snap the cursor to the top left (erte$ of the A<pBorder object C)dit *odeD. It ma# be necessar# to adjust the position slightl# to ensure the rulers are touching the A<pBorder object. It doesn't matter that the rulers o(erlap the border slightl#, as we will be using a shadeless te$ture. 7ith the top ruler selected press Appl# in the Arra# %odifier panel. This will con(ert the Arra# into a mesh objects. +epeat this on the other three ruler's. (hift%R'B )elect all the rulers and the A<pBorder 4bject ensuring the A<pBorder was the last selection and join them into one mesh *trl%?#
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All that's left now is the Title Bo$. Add a *lane object and mo(e it just inside the lower right hand corner. +esiFe the plane to 0.=mm high b# around two thirds the width of the border. The e$act siFe will be dependent on the te$t fields #ou want to put in it. &op# the plane se(eral times in the E a$is at a height to suit #our te$t. I ha(e used .mm for the small te$t and ?0mm for the larger te$t. "orm a space for the title bo$ b# shortening one of the lines. &op# one of the lines (hift%D and Rotate it :6 degrees. *osition it on the right hand side of the Title Bo$ and adjust its length to suit the horiFontal lines.
&op# this edge to form the other (ertical edges and resiFe them as necessar#.
1ab into 4bject mode and with the Title Bo$ selected, (hift%R'B select the A<pBorder object and join the meshes *trl%?# The Border and Title Bo$ are now one object. 7e now need to add a colour for the border. In the %aterials tab of the %aterial sub conte$t buttons, I ha(e set +, 1, B to 0 for a Blac colour. )elect the shadeless button so the colour won't be affected b# an# lamps in the scene. In the lin s and *ipeline panel press the small button with the car on it. This will gi(e the %aterial an automatic name representati(e of the colour chosen. In this case Blac .
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7e now need to add some test to the Title Bo$. 8'B clic o(er the Title Bo$ to set the cursor position. *ress the )pace Bar to open the Toolbo$ and choose AddMTe$t, a te$t object will be placed on the (iew, but much to small to see. In the "ont panel of the Editing &onte$t Buttons change )iFe: to ?0. Bac"space to remo(e the word Te$t and t#pe in 76@ Bearing. )cale ( and mo(e < the te$t so it fits in the Title Bo$. To add the same Blac %aterial to the te$t in the 9in s and *ipeline tab, clic the Arrow bo$ to the left of Add 'ew and select Blac from the pop up menu. In the 9in and %aterials tab of the Editing buttons change the name from 4B:Te$t to 4B:A<pTe$t. Tab into 4bject %ode and cop# the te$t (hift% D to another area of the Title Bo$ and (cale it to fit. 1ab into Edit %ode and Bac"space to clear the te$t, then t#pe in the new te$t. +epeat this for all the fields of the Title Bo$ 4ne further useful addition is to cop# a te$t object outside the Boundar# object and t#pe in the camera scale, "ormat siFe $ and siFe / and the printer dpi. In the 4utliner #ou will now ha(e a grouped list of A<p objects that can be easil# appended into an# .blend file #ou are wor ing on The settings needed for the camera will be appended along with the Border All that is left for #ou to do now is ma e more templates in different page siFes. "inall# sa(e #our wor as *ageTemplate.blend
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60@ Bearing *art!?? The )cale 3rawing 9a#out
8ayers
2p to now e(er#thing has been produced on la#er one of the twent# a(ailable la#ers within Blender. B# organising #our wor onto different la#ers, Blender allows #ou to set different lighting and rendering parameters for objects on different la#ers. As we need to combine some of the objects rendered with the edge render facilit# of blender, together with others that do not use the edge setting we will need to organise our la#ers and render output. "irstl# we will set our scene. If #ou still ha(e a .blend file open, sa(e #our wor *trl%W and then open a new file *trl%.. )a(e the new file *trl%W as 660@!9a#out.blend6. Append all the A<p objects from the *ageTemplate.blend file produced in part ?0. (hift%09 to open the "ile Browser window in Append mode and from the 6*ageTemplate.blend6 file 8'B clic 4bject then R'B select all the A<p objects. &lic on 9oad 9ibrar# to bring them into the new file. The# will be placed on 9a#er one, as this was the la#er the# were created on. 'ow append all the parts of the 60@ Bearing into the file. In front (iew +um,ad 9 select all the components of the bearing and mo(e them < to the top left corner of the page template. As the bearing is onl# --mm across we will scale it -:?. 7ith all the components still selected press ( for scale then ; for the scale factor. The bearing will double in siFe. 4pen the 4utliner as detailed in *art!<. All the components of the Border and Bearing will be listed. &op# the bearing (all bearing components selected) *trl% D and mo(e the cop# on the .!a$is to the right hand side of the original. In top (iew +um,ad - Rotate the bearing :6 degrees. 1o bac into front (iew +um,ad -. 7e now ha(e a front and side (iew, within the page border.
7ith the side (iew still selected cop# the components and mo(e them below the original. This will be used to create a part section through the bearing.
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The "ront, )ide and *art )ection (iew of the bearing needs to be rendered using Blenders edge render facilit# and therefore needs to be rendered separatel# from the rest of the la#out. Bo$ select the three bearings and press ' which will open the 9a#er %o(e panel clic on la#er - and press 4L. The two bearings will disappear from (iew until la#er - is acti(ated. To bring the bearings bac into (iew, (hift%8'B on la#er - in the (iew headerBs la#ers panel. If #our computer is slowing down due to the amount of detail in the bearingBs #ou can delete the components that wonBt be seen. I ha(e remo(ed the balls, both cages the bac dust shield and circlip from the front (iew and all but the 60@!+ace from the side (iew. The section (iew needs all the components. 7e now need to set the material to gi(e a line drawing effect. )elect the race of the side (iew and in the %aterial panel of the %aterial buttons, change &ol to white (click on the grey s+uare next to it and choose white from the colour picker) &lic )hadeles so the colour isn't affected b# an# lamps in the scene. In the 9in and %aterial panel of the Edit buttons select 6- %at -6 to choose the second material and press 3elete to delete it. In the 9in s and *ipelines panel clic on the small &ar button to auto name the colour. In the %irror Trans tab ma e sure +a# %irror is not selected. In the Te$ture tab clic &lear to remo(e the te$ture. &hange the )iFe8: and )iFe/: to those detailed on the page template, (text outside the &age ,order). )et the output to *'1 and select +1BA. The +1BA button will sa(e the render with a transparent bac ground allowing us to o(erla# the lined drawing o(er the standard render.
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In the +ender 9a#er tab of the +ender Buttons clic 9a#er - which will restrict the render to the objects on this la#er.
4n the 4utput tab clic Edge and then Edge )ettings. In the Edge )ettings pop up window change Eint: to -. This will set the line intensit# so it predominantl# highlights the main edges. &lic on the &amera and in the Edit buttons &amera panel clic on 4rthographic to use the orthographic camera mode. )et the scale to -.>.< as detailed on the page template. 7ith the mouse o(er the ;3 (iew press + to open the Transform *roperties window and set the camera (iew parallel to the *age Template. +ot8:>0, /:0, E:0. Align the &amera with the page boundar#.
In the 7orld panel of the %aterial buttons set the bac ground colour to white. The "ront and side (iew's are now set!up to gi(e us a line render but before we do this we need to section and scale the *art )ection (iew.
3e select ll then in wire (iew Bo$ select the components of the bearing we are going to use for a section (iew. 1o into local (iew +um,ad =. Then (hift%R'B the outer race and join all the components *trl%?. Its easier to cut through the bearing as a single mesh than to ha(e to repeat the cuts for each component.
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In top (iew +um,ad - 3e select ll the (ertices then Bo$ select all the (ertices to the front of the bearing centre (not the vertices on the centre line). 3elete . these (ertices.
Eoom in (W on the centre of the bearing and delete an# remaining (ertices that were missed b# the Bo$ select.
In front (iew +um,ad 9 repeat the process of selecting and deleting (ertices. This time though remo(e the lower Huadrant of the bearing 'ot all the edges finish on the horiFontal centre line. As onl# the inside diameter of the bearing will be seen at this location, ma e sure e(er# (erte$ below the centre line is remo(ed.
In top (iew Bo$ select the single row of (ertices on the bearing centre line. &op# these (ertices (hift%D and mo(e them on the 4 a$is forward of the bearing. )eparate them from the bearing ,. 7e will use this slice through the bearing to add the hatch pattern to the section (iew.
1ab into 4bject %ode and go into 1lobal (iew +um,ad =. select the slice through the bearing we ha(e just created and go bac into 9ocal (iew +um,ad = for this object. 1ab into Edit %ode. 9in select 8 each closed area of the slice and fill the area (hift%0 with faces. Beautif# the fill lt%0 to gi(e a cleaner mesh.
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*ress to de!select the (ertices then repeat the process on the ne$t closed area. &ontinue until all the faces of the section are filled. 3e!select ll (ertices.
8in select the two areas that represent the bearing race and in top (iew +um,ad - mo(e them < forward of the other areas of the bearing, on the 4 a$is. +epeat this for the other areas of the section ma ing sure no two components touch each other on the same plane. This is necessar# so the Edge +ender filter can detect the edge of each component.
8in select the inner and outer race sections. 7e are now going to add a hatch pattern to this area.
In the 9in and %aterials panel of the Editing buttons press 6'ew6 to add a new material. *ress Assign to assign this material inde$ to the selected (ertices.
In the Te$ture Buttons Te$ture tab clic the number ne$t to the TE:Te$ bo$ and accept single user. Add 'ew to add a new te$ture. In the Te$ture T#pe button clic 'one and then select Image from the pop up menu.
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/ou will need to either create #our own or download the hatch patterns from www.rab;d.com in *art!?? of the 60@ bearing tutorial, download R'B &lic on the hatch patterns and 6)a(e Target As...6 to sa(e the images.
In the Image panel load 69ineAngle?.png6. To ma e the hatch render smaller, repeat the te$ture on the section b# changing 8repeat: and /repeat: to - in the %ap Image panel.
If #ou render the image at this stage a hatch pattern will be created on the bearing race. To add further hatch patterns 8in select the area to hatch (for this example both halves of the bearing cage). In the 9in s and %aterials panel of the Edit Buttons &lic 6'ew6 then 6Assign6. %aterial ; has been created and assigned to the selected (ertices. In the Te$ture panel set the te$ture to single user. In the Image panel of the Te$ture Buttons change the te$ture to 69ineAngle-.png6
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+epeat this process until all the section faces are filled with a hatch pattern. &hange 8repeat and / repeat to resiFe the te$tures.
7e are now read# to render the line drawing. In the +ender Buttons, +ender panel , press 6+ender6. 4r use the e#board shortcut 09;. 7hen complete close the +ender window and sa(e the image 03 as 60@! 9ine.png. )a(e #ou wor *trl%W "or the rest of the la#out we won't need to use the edge rendering setup, so on the +ender buttons 4utput tab de!select edge. In the +ender 9a#ers tab select la#er ? To add dimensions to the la#out we will use the Blender &aliper script. The script doesn't come alread# loaded with blender but can be downloaded from alienhelpdes .com "ollow the instructions on their site to load the script. And read the user documentation. In blender split the (iew and open a script window as detailed for the Be(el script in part <. But this time load the 6Blender &aliper6 script from the 67iFards6 section of the scripts pop up list. It ma# also be necessar# to first clic 62pdate %enus6 from the same pop up list to register the script in Blender. Before we can dimension the bearing we need to add some points to dimension. In Edit %ode select (hift%R'B the two (ertices at the widest point of the bearing on the same edge loop. &op# these (hift%D in the 2 a$is below the bearing.
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E$trude these (ertices in the E a$is to the point where #ou want the dimension to be. Then e$trude them again so the dimension lines will pass the dimension arrow. (hift%R'B select the 6 (ertices of the dimension line and separate , them from the 60@!race mesh. 1ab into 4bject %ode and select the 3imension 9ines. 1ab bac into Edit %ode for this object. In the Edit Buttons 9in and %aterials panel change the objects name to 3im. )elect the two middle (ertices of the dimension lines and with Blender &aliper set as indicated abo(e press 6%easure6. A dimension and arrowed line will be created. +epeat this process for the other dimensions, then 1ab into 4bject %ode and select all the dimension lines and Toin them *trl%? to the 3im object.
1ab into Edit %ode for the 3im object and select all the (ertices on the left hand dimension lines. To thic en these lines for rendering e$trude them !0.-mm on the 8 a$is. +epeat this on the right hand lines e$truding them 0.-mm on the $ a$is.
8in select one of the dimension lines and cop# it (hift%D. %o(e it o(er the bearing and re shape it to form the section mar ers. In the %aterial buttons 9in s and *ipeline panel change the material to Blac . In 4bject %ode cop# one of the dimensions te$t objects and 1ab into Edit %ode. &hange the te$t to E, 1ab bac into 4bject %ode. %o(e E to the section mar er. &op# this and mo(e it to the other mar er.
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)elect one of the dimension te$t objects and cop# it to below the section (iew. &hange the te$t as indicated and scale the te$t to a suitable siFe.
To finish editing te$t, fill in the fields in the Title Bo$.
The final part to the la#out is to add the ;3 image of the bearing created in *art >, along with the e$ploded (iew. to do this add a *lane and %o(e it < to the top right corner of the la#out. )cale the plane (hift%( to fit in the area ne$t to the line drawing. In the %aterial buttons 9in s and *ipeline panel add a new material. In the %aterial panel set the material to )hadeless. In the Te$ture buttons Te$ture panel add a new te$ture. set the te$ture t#pe to Image and in the Image panel load the rendered ;3 (iew created in *art >. The image won't be (isible on the plane until it is rendered.
To ensure the *lain is set at the correct aspect ratio for the image, in 4bject %ode select the *lane and press Alt!5. The planes shape will change to suit the loaded image. +eposition the plane if necessar#. Add another *lane in the lower right area of the la#out and repeat the abo(e process but this time load the E$ploded 5iew.png from *art > If #ou render the 9a#out now "?- #ou will get an image with all the 9a#out elements e$cept the line drawings.
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In the "ormat panel of the +ender Buttons lea(e the output as *'1 but change the image format to +1B. 7e don't need an alpha channel on this image. *ress 09; to render the image. &lose the render window, press 03 and sa(e the image as 60@! 9a#out.png The final stage is to combine the 60@!9ine.png created abo(e with the 60@!9a#out.png. This can be carried out either using the 'ode Editor within Blender or b# using an e$ternal image editing program such as gimp. The 'ode Editor is to comple$ to co(er in this part of the tutorial so, In the image editor of #our choice open both 60@!9a#out.png and 60@!9ine.png. &op# 60@!9ine.png to the clipboard and paste it into 60@! 9a#out.png as a new la#er. The line drawing will sit o(er the la#out drawings without obscuring them because it was sa(es with a transparent bac ground. "inall# in the Image Editing program resiFe the image to ;00 dpi. The final result gi(es a good la#out drawing, easil# capable of communicating the essential elements of a product design. 7ith sufficient planning and forethought an# component could be created, rendered and dimensioned in Blender.
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1uide +oller *art!? %odelling the '5' +oller
,art 9 <uide Roller Design *oncept 8inear <uides

%an# engineering situations reHuire the mo(ement of machine parts along set a$es. 4n traditional machine tools this was historicall# achie(ed b# using accuratel# machined and hand scraped guides that run on planed or ground slides. This method of construction when done correctl# offers a great deal of rigidit# between the components but still allowing mo(ement in one a$is. The drawbac of this t#pe of slide is the initial high load reHuired to o(ercome the starting friction. 4n a traditional machine tool this simpl# meant the operator would ha(e to e$ert a little more force on the hand wheel to start the slide mo(ing. 4n Industrial &'& machines o(ercoming friction to allow increased speed and or smaller dri(e units has brought about the de(elopment of linear bearings. These usuall# contain re!circulating balls or rollers that run along hardened and ground guides. Alternati(el# larger dri(e units are fitted to traditional slide wa#s. In both situations o(ercoming friction can be a costl# process. +e!circulating Ball 1uide
Traditional 3o(etail )lide
As an alternati(e to recirculating ball races, some industrial processes use a U5B roller guide running on a pre formed trac . Though not offering the same rigidit# or accurac# of the recirculating ball races the# are perfectl# adeHuate for a light dut# machine. 5!+oller 1uide As a hobb# engineer the use of e$pensi(e 4E% components such as linear bearings is not affordable, therefore an alternati(e must be used. The original router used N4ilite BushesO running on ?@mm Bright drawn steel shafts. The shafts pro(ed ampl# strong enough for the job. The problem was the inabilit# of the stepper motors to o(ercome the starting friction, especiall# when the shafts became slightl# contaminated with dust from the machining process. Though Industrial '5' rollers are still Huite e$pensi(e it is a simple process to machine an alternati(e that will run on the e$isting ?@mm B3%) slides. The following tutorial shows how the 60@ bearing model was used as a base to construct the U5B roller and a$le.
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If #ou are currentl# using Blender sa(e #our wor *trl%W and start a new project *trl%.. 3elete the default cube .. This section assumes #ou ha(e completed and understood the 60@!Bearing tutorial. As the components will be built from the 60@ Bearing geometr# the first step is to append the low (ertices 60@ bearing into the scene. *ress (hift%09 and na(igate to the folder containing the 60@!Bearing)mall.blend made in the Bearing tutorial. &lic on 4bject and select the 4B:60@!Bearing)mall model, *ress 9oad 9ibrar# and the Bearing will be loaded into the scene. (- more detailed description of appending is given in ./(%&art (.) )plit the ;3 (iew and open an 4utliner window. (If you cant remember how this is done it is described in ./(%&art ".) )ome of the design constraints I ha(e are based on the material a(ailable to me. I currentl# ha(e slides at ?@mm diameter so I will reuse these. The U5B +oller will be made the same width as the slide to maintain as small a footprint as possible. I ha(e some <=mm diameter B3%) that I will use for the rollers, so I need to ma e sure the outside diameter is less than this.
In side (iew +um,ad 3 &op# the Bearing (hift%D and mo(e it in the 4!a$is 99mm. This will set the bearings with an e$ternal width of ?@mm.
'e$t we need to add a c#linder to represent the ?@mm diameter slide, centrall# to the bearings. (hift%R'B select both Bearings and snap the cursor to the middle of them (hift%( &ursorM)election. Add a &#linder press (pace Bar to open the Toolbo$ then select Add M %esh M &#linder. "rom the popup menu change radius to > and length to -0, press Enter to accept. Tab bac into 4bject %ode and with the c#linder still selected, mo(e it below the bearings < Cmo(eD 2 to constrain it to the E!a$is and drag it to a position below the bearings.
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7e will now use the outer profile of the bearings to form the bore of the 5!roller. (hift%R'B select both bearings and cop# them (hift%D then press )sc to lea(e the cop# o(er the top of the original bearings. 7ith the two new bearings still selected join them into one object *trl%?. In the 9in and materials panel rename the object 4B:5! +oller. *ress +um,ad = to go into local (iew for the 5! +oller and 1ab into Edit %ode. 'ow is also a good time to sa(e #our wor . *res *trl%W and sa(e the file as 5!+oller.blend (hift% lt%R'B )elect the second outer loops of (ertices from the bearing outside diameter and the loops indicated between the bearings. If #ou added chamfers to the bearing choose loop A otherwise choose loop B. In total < loops should be selected.
3elete these < loops . 0ertices. This will isolate the outer section, from the inner part of the bearing.
R'B select a (erte$ on the far left side of the bearing and snap the cursor to it (hift%( &ursorM)election.
&hange the *i(ot point to ;3 &ursor.
lt%R'B select the loop of (ertices on the outside diameter of the bearing. (cale these along the 4%a$is to the 6 cursor position.
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+epeat this on the +ight hand side of the other bearing. *ress to deselect all (ertices then with the cursor o(er the inner portion of a bearing press 8 to select all lin ed (ertices.
3elete the selected 5ertices .. +epeat this on the other Bearing. /ou are now left with two bores where the bearings sit inside the 5!+oller. These now need to be joined together.
(hift% lt%R'B select the inner loop of both bearings.
*ress 0 to open the %a e "aces menu. A new option is a(ailable ) in "acesIEdge!9oops.
*ressing the ) in option will automaticall# build faces between the two (erte$ loops. It wor s the same as the 9oft function in man# ;3 &A3 pac ages.
The bore of the 5!+oller could be called finished at this stage, but its not reall# good engineering practice to ha(e the inner fillet radius of a bore the same siFe as the object that is going to fit into it.
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To facilitate a better fit for the bearing it is better to ha(e a bore fillet with a smaller radius than that of the bearings outer edge. To achie(e this we need to delete the loops ma ing up the fillet and re model them. (hift% lt%RB )elect the inner loops of the two fillets and delete them .#
R'B select the inner loop of the left hand bearing location and mo(e the loop < on the 4%a$is 6#3mm. This will allow us to reconstruct the fillet with a radius of 0.;mm, half the siFe of the outer fillet on the bearing.
)elect the inner loop of the right hand bearing location and mo(e this !0.; on the /!a$is.
In front (iew +um,ad 9 press 2 for wire frame (iew then B%B to open the paint select tool, select the top (ertices. 0ide all the other (ertices (hift%H.
1o into side (iew 'um*ad ; and +%B select the first (erte$ that will be used to spin the new fillet radius CAD and E$trude it on the E a$is !0.;mm. This gi(es us the centre point for the fillet.
)nap the cursor to the e$truded (erte$ )hift!) &ursorM)election.
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+eselect (erte$ A (the vertex we are going to spin to make the new radius) and in the %esh Tools panel set 3egr:>0 and )teps:=, *ress 6)pin6 to form the new radius. )elect the (erte$ on the fillet centre and delete it ..
elect the two (ertices shown opposite and add an edge between them 0. +epeat this for the +ight hand side, selecting (erte$ B, but in the %esh Tools panel deselect 6&loc wise6 so the fillet is spun in the opposite direction. (hift%R'B select both sets of fillet (ertices including those that join to the e$isting 5!+oller bore. 1o into front (iew +um,ad 9 and 1ab into 4bject %ode.
)nap the cursor to the 4bject &entre (hift%( &ursorM)election then 1ab bac into Edit %ode. In the %esh Tools panel set 3egr:;60 and )teps:;-, press spin to generate the new fillet. )elect ll and +emo(e 3oubles W.
The bore fillet will now be at the smaller siFe.
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1o bac into 1lobal 5iew +um,ad = and #ou will see the bearings sitting in the newl# created bore. At this stage we don't need the Bearings in the (iew. In the 4utliner clic on the e#e icon for the bearings which will close, and remo(e them from (iew.
In side (iew 'um*ad ; select one (erte$ that is sitting on the 5!+ollers horiFontal centreline. E$trude this (erte$ in the E! a$is !--mm, snap the cursor to this (erte$. This will be used as a reference to set the outside diameter.
)elect the two bottom (ertices on the outer edges of the 5! +oller. 7e will build the cross section of the 5!+oller from these.
)$trude the two bottom (ertices in the 2%a$is with a length similar to the reference (erte$.
To position them at the same E!a$is location as the reference (erte$ (cale them constrained to 2 and to a scale location of 6. 3elete . the reference (erte$.
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Add an edge between the two new (ertices.
)ubdi(ide %ulti W the bottom edge with - di(isions. This will split the bottom edge into three eHual di(isions of 6mm each.
In order to cut the angles on the roller we first need to cut a central groo(e. 4n m# lathe I will do this with a ;mm parting tool. To add the groo(e select the two central (ertices. &hange the *i(ot to 6%edian point6 and scale them b# a factor of 0.=
To gi(e a small flat at the edge of the 5!+oller )$trude the bottom left corner (erte$ in the !2 direction then )$trude this (erte$ in the 4!a$is 9mm, then )$trude this (erticall# crossing the bottom edge. This will be used to cut a new (erte$ ?mm from the corner of the bottom edge. )elect All the press > for the Lnife tool, select Lnife CE$actD from the sub menu and holding down *trl snap the cut line to the reference edge crossing the bottom edge. A new (erte$ will be created. 3elete . the reference (ertices. +epeat this to cut a (erte$ from the right hand corner.
)elect the two centre (ertices and mo(e them < in the 2% a$is 7#5mm. This will create the 5 profile with an angle of <= degrees.
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To complete the groo(e )$trude 64nl# Edges6 the central edge in the 2!a$is ;mm, then delete the lower central edge . 6Edges6.
The roller profile is now read# to spin around the central a$is. )elect all the (ertices of the profile, including those attached to the bore.
1o into front (iew +um,ad 9 and 1ab into 4bject %ode. )nap the cursor to the object centre (hift%( &ursorM)election, then 1ab bac into Edit %ode. In the %esh Tools panel set 3egr:;60 and )teps:;-, then press )pin.
The profile will be created around the bore. )elect +emo(e 3oubles W and )et )mooth W.
ll,
In the %odifiers Tab ass an Edge )plit modifier and eep the default settings. (- more detailed description of adding the )dge 1plit modifier is contained in ./(%&art ") The 5!+oller is now complete. In the 4utliner open the e#e icon for the two bearings to bring them into the (iew. )a(e #our wor *trl%W This has been a fairl# long!winded wa# to construct the roller, howe(er I ha(e chosen to do it this wa# to introduce the ) in "aceIEdge loops tool and methods to accuratel# modif# a ;3 mesh. In practice it would be much Vuic er to simpl# construct a complete cross section and spin it around the centre a$is. In the ne$t section we will construct the a$le.
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1uide +oller *art!- The 1uide +oller A$le 7e ha(e now got the 5!+oller with two bearings inside it, so the ne$t thing is to design the a$le. I intend to ma e aluminium castings to hold four rollers and the lead screw nut and at this stage a casting thic ness of ?0mm seems appropriate. 4ne end of the a$le needs to fit into the casting the other end needs to hold the bearings. These are the go(erning factors for the length and profile of the a$le. If it is not still open from part one, open 5! +oller.blend. In the 4utliner ma e sure the e#e icon is open for the two bearings and closed for the 5!+oller and &#linder.
7e onl# need the bearings in (iew to position the 4bject &entre for the a$le and the section of the a$le profile that the bearings sit on.
R'B )elect the right hand bearing and 1ab into Edit %ode. lt% R'B select a loop of (ertices on the outer right hand edge of the bearing and snap the cursor to the centre of this loop of (ertices (hift%( &ursorM)election. 1ab bac into 4bject %ode. 1o into side (iew +um,ad 3.
*ress the (pace Bar and from the Toolbo$ menu select AddM%eshM*lane. In the 9in and %aterials panel change the name to 4B:5!+ollerA$le.
(hift%R'B the top right hand (erte$ to deselect it, then press . to delete the remaining three (ertices. R'B the remaining (erte$ to select it, then 1ab into 4bject %ode. (2he vertex will be easier to locate when we 2ab back into )dit *ode for the 0%3oller-xle).
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)elect the right hand bearing and 1ab into Edit %ode for this object. )elect the top right hand (erte$ of the bearing bore (the vertex on the bearing bore not one of the fillet vertices, check you have the correct vertex in front view NumPad 1), snap the cursor to this (erte$ (hift%( &ursorM)election. 1ab bac into 4bject %ode.
In the 4utliner select 5!+ollerA$le and 1ab into Edit %ode. The single (erte$ is selected so snap it to the cursor (hift%( )electionM&ursor. 1ab bac into 4bject %ode.
)elect the +ight 0and Bearing and 1ab into Edit %ode. )elect an# (erte$ on the outer right hand edge and snap the cursor to it. 1ab bac into 4bject %ode. In the 4utliner select 5!+ollerA$le and 1ab into Edit %ode.
%a e sure the pi(ot point is set to ;3 cursor. 7ith the single (erte$ still selected (cale the (erte$ along the 4!a$is to the cursor position 6.
The (erte$ is now positioned aligned to the bearing bore and right hand edge. In side (iew +um,ad 3 E$trude the (erte$ along the 4 a$is %9-#5mm. R'B select the right hand (erte$ and )$trude it along the 2! a$is ;mm. In the 4utliner close the e#e icon for the two bearings to remo(e them from (iew.
/ou are left with two edges that when spun around the 4bject &entre will form the bearing location area of the a$le.
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"rom the two edges that were positioned on the bearing bore e$trude the following profile constraining the e$trusions to the / or E!a$is and dimensions indicated. The end chamfers are created b# e$truding 0.6mm in the /!a$is then grabbing and mo(ing the (erte$ !0.6mm in the E!a$is. 7hen complete this will form the basic profile of the a$le. A little more refinement is reHuired before we spin the a$le around the 4bject &entre. "illet radius and chamfers need to be added. "irst we will add a fillet radius of 0.;mm to the inside angle of the central up!stand.
)elect the inner corner (erte$ indicated and )$trude this in the 2!a$is 6#3mm to point A (vertex to spin), then e$trude this (erte$ to point B (fillet centre). )nap the cursor to the (erte$ on the centre point.
In the %esh Tools panel set 3egr:>0 and )teps:=, then press )pin. The corner fillet will be formed.
)elect the corner (erte$ and the fillet centre (erte$ CBD and delete them. Before connecting the fillet to the rest of the a$le we can add a chamfer to the top edge.
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)elect the (erte$ on the top edge abo(e the fillet and mo(e it < along the 4!a$is 6#;mm. 'ow )$trude this (erte$ 4 %6#;, then <rab this and mo(e it 2 %6#; A <=! degree chamfer has been added to the edge.
+econnect the other end of the fillet to the end of the bearing location. Add a similar fillet and chamfer to the other side of the central up! stand. 1ab into 4bject %ode and snap the cursor to the 4bject &entre. 1ab bac into Edit mode. 1o into front (iew +um,ad 9 and select All (ertices. In the %esh Tools panel set 3egr:;60 and )teps:;-, then press )pin. The a$le will be formed. 7hen fitting the a$le into the casting we need to be able to stop it rotating whilst tightening the retaining nut. The ne$t step will be to add some spanner flats to the central flange. 1ab into 4bject %ode and add a *lane. )elect the two right hand (ertices and mo(e them < on the .!a$is 3#:mm. )elect the two left hand (ertices and mo(e these !;.>mm on the 8!a$is. This will create a guide to cut flats >.@mm apart for a ?0mm spanner. )elect ll and (cale the *lane on the 2!a$is till it is larger than the flange.
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1ab bac into 4bject %ode and with the *lane still selected (hift%R'B select the a$le. &ombine the two 4bjects into one *trl ?. 1ab bac into Edit %ode and cut new (ertices to form the two spanner flats >nife CE$actD snapping the cut to the (ertices of the plane *trl%8'B.
3e!select ll, then Bo$ select the (ertices that are outside the spanner flats. 3elete . these (ertices.
(hift% lt%R'B select the loop of (ertices around the opening of the spanner flat.
Add faces to the opening (hift%0, then beautif# the fill lt%0 and then con(ert the created triangles to Huads lt%?. +epeat this on the other spanner flat. To complete the a$le select ll (ertices, +emo(e doubles W and )et )mooth W. /ou ma# also need to recalculate the normals to the outside *trl%+. To create a smooth surface with sharp edges, add an Edge )plit modifier with the default settings. *ress *trl%W and sa(e #our wor . At this stage I ha(e deliberatel# left the a$le with plane ends rather than generating a threaded profile. In large assemblies the a$le will use substantiall# less computer o(erheads than one with a detailed thread profile. In part ;, I will detail how to set up and use the screw function to create a detailed thread suitable for producing a realistic render.
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&ontinuing with the 5!+oller assembl#, in the 4utliner open the e#e icon for the two bearings and 5!+oller. The assembl# is starting to ta e shape but still missing a retaining nut and washer. The nut should also impart a small amount of pre!load onto the bearing to remo(e an# side pia#. In true s ateboard fashion I am going to use a 6mm n#loc! loc ing nut and washer. To locate the washer and nut we onl# need the bearings in (iew, so in the 4utliner close the e#e icon for the 5!+oller and 5!+ollerA$le to remo(e them from (iew.
)elect the left hand bearing and 1ab into Edit %ode. lt%R'B select a ring of (ertices on the far left side of the bearing and snap the cursor to the centre of them. Tab bac into 4bject %ode.
*ress the (pacebar to open the Toolbo$ and select AddM%eshM&ircle. "rom the pop!up menu lea(e (ertices at ;-, but change +adius to ;.- then press 4L to accept. This will form the 6.<mm inside diameter of the washer. )$trude (Only )dges) this (erte$ ring then press )sc to lea(e it in place. 7e will scale the e$truded (ertices to form the outside diameter.
The 4utside diameter of the washer is ?-.=mm so to find the reHuired scale factor: ?-.= I 6.< J ?.>=;? 7ith the e$truded (ertices still selected (cale 9#:539 to form the outside diameter. The thic ness of the washer is ?.6mm so select )$trude (3egion) 4 %9#7 ll and
The basic profile of the washer is formed, we now just need to add a chamfer on the corners.
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1o into edge select mode and (hift% lt%R'B select the two outer and two inner edges.
2sing the Be(el &entre script and following the details gi(en in 60@ *art!< add a 0.?mm chamfer. Bac in (erte$ select mode select ll and )et )mooth W, in the %odifiers tab add an Edge )plit modifier with the default settings. If Blac areas are present on the surface of the washer press *trl%+ to recalculate the normals to the outside.
The washer is complete but before going into 4bject %ode we need to set the cursor read# to add the final component. lt%R'B select one loop of (ertices on the left hand side of the washer and snap the cursor to the centre of these. (hift%( &ursorM)election. 1ab into 4bject %ode and in the 9in and %aterials panel rename the washer 4B:6mm7asher. The ne$t thing needed is to model the %6 nut. )ome consideration should be gi(en to how man# (ertices to use for the nut, as the e$ternal he$agonal section will onl# reHuire 6 (ertices and internal circle will reHuire more. )ome e$tra detail on the e$ternal profile will be reHuired to form the cur(es on the top edge of the nut so it would simplif# the modelling to eep the same number of (ertices on the outer and inner diameter. )i$ (ertices should be enough to form the cur(ed detail on the top of the nut so with si$ sides this eHuates to an inner circle of ;6 (ertices. In front (iew +um,ad 9 press the (pacebar to open the Toolbo$ and add a &ircle with ;6 (ertices and a radius of ; AddM%eshM&ircle. 'ow add a circle with 6 (ertices and a radius of =...;= This will form a he$agon with ?0mm across the flats. 7ith the 6 outer (ertices still selected, subdi(ide each edge of the he$agon with = (ertices, 7 )ubdi(ide %ulti. &hange the number in the popup menu to = and press 4L to accept.
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)elect
ll and fill the space between both loops of (ertices with faces (hift%0.
To impro(e the fill pattern and remo(e the long thin triangles press lt%0 CBeautif# "illD. +epeat the beautif# fill command se(eral times until the internal edges no longer change. To con(ert the triangular faces into Huads press lt%?. Blenders beautif# fill attempts to produce triangles with the shortest possible sides and has o(ercompensated on the corners of the nut. If left li e this the mesh would produce ugl# edges when be(elled. It's worth manuall# rearranging these corners to form Huads. In edge select mode (hift%R'B select the two edges indicated and delete them . ()dges).
In (erte$ select mode select < (ertices CA, B, &, W 3D and insert a face 0, select the ne$t four (ertices C&, 3, E W "D and add the ne$t face. The corner will now ha(e a much better face pattern. +epeat this until all 6 corners are done.
To ma e modelling easier we need to rotate the nut so two flats are parallel to an a$is. )elect ll and Rotate %95 degrees.
To ma e the side faces of the nut )hift!+%B select the se(en (ertices of the top edge and E$trude them / !<.
To form the radius on the top of the side face we need to spin a (erte$ from the faces bottom centre (erte$. )elect the (erte$ indicated and snap the cursor to it. To determine the angle of the spin, with the centre (erte$ still selected (hift%R'B select the two (ertices on the corner of the opposite edge and temporaril# form a triangular face. 7ith the face selected clic on the Edge Angle button of the %esh Tools ? panel. The corner angles of the triangle will be displa#ed in the (iew. The spin angle is .?.6;= degrees. *ress *trl%2 to remo(e (undo) the triangle
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In top (iew 'um*ad . select the bottom right hand (erte$ indicated and in the %esh Tools panel set 3egr: .?.6;= and )teps:6.
*ress )pin and the ar at the top edge of the face will be formed.
(hift%R'B select two corresponding (ertices and merge them together lt%' at the (erte$ point on the ar . The selection order will determine whether #ou choose 6at first6 or 6at last6 from the pop!up menu.
%erge the rest of the (ertices on the top edge of the nut face to the ar using this method.
)hift!+%B select all the (ertices on the side face of the nut, then Tab into 4bject %ode. )nap the cursor to the object centre )hift!) &ursorM)election. Tab bac into Edit %ode.
In the %esh Tools panel set 3egr:;60 and )teps:6, press )pin 3up and the other sides of the nut will be generated. )elect ll and +emo(e 3oubles W.
lt%R'B select the inside diameter of the nut and )$trude it on the 4!a$is %5mm, then e$trude it on the /!a$is a further ?mm. )nap the cursor to the centre of the last loop of (ertices. The e$tra loop of (ertices will allow us to set a different material for the n#lon insert of the nut.
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)elect the centre (erte$ of the ar on the top face of the nut and e$trude it on the /! a$is. &hec the *i(ot *oint is still set to ;3 &ursor and (cale the (erte$ on the 4!a$is to the cursor position 6. The abo(e scale has set the (erte$ le(el to the top edge of the nut, but this edge needs a 0.=mm fillet radius. <rab the (erte$ and mo(e it 4 6#5, then e$trude it on the E!a$is !0.= to set the centre of the fillet. )nap the cursor to this (erte$, then select the pre(ious (erte$. In the %esh Tools panel set 3egr:>0 and )teps:= and )pin the fillet radius. To form the profile of the n#lon insert we need to mo(e the inside diameter bac slightl#. lt%R'B select the inside diameters top loop of (ertices and mo(e it < on the 4!a$is 6#5mm. To complete the top profile of the nut e$trude the top (erte$ of the inside diameter to the dimensions shown, constraining to the reHuired a$is and dimensional input. "orm the chamfer b# )$truding the (erte$ 4 %6#;5 then <rabbing this (erte$ and mo(ing it 2 6#;5 (hift%R'B select the end of the fillet radius and join it to the chamfer with an edge 0. (hift%R'B select the ?? (ertices of the top profile. 1o into front (iew +um,ad 9.
In the %esh Tools panel set 3egr:;60 and )teps:;6 and )pin the top profile.
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7e are now left with a series of brea s in the mesh between the top profile and nut sides. To eep the mesh organised its best to manuall# fill these areas.
)elect < (ertices (4 on the corners of the openings) corresponding to where a face should be and press 0 to insert a face. &ontinue around the perimeter of the nut until all faces are filled.
In Edge )elect mode lt%R'B select the bottom edge of the nut, then (hift%R'B select the 6 corner edges. 7e will add a 0.?mm chamfer to these using the Be(el &entre script described in 60@ *art!<.
To finish add an Edge )plit modifier, but because the edge angles are ;0 degrees the same as the default settings for the modifier, ugl# shading patterns will be created on the corners of the nut. &hange the angle setting to -> degrees to o(ercome this problem. In the 9in and %aterials panel change the name to %6'#loc'ut Tab into object mode and in the 4utliner bring the other objects into (iew. )a(e #our wor *trl%W. I hope #ou ha(e found this a worthwhile e$ercise. The intention was to demonstrate how components can be modelled together in assemblies using one component to help set the location and surface geometr# of the ne$t, using Blenders )nap tools to accuratel# locate the new 4bject. *art ; will detail how to use Blenders )crew tool to generate a thread profile
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1uide +oller *art!; 3etailed Thread *rofile Before we can model the thread we need to understand the thread form. I)4 %etric threads come with a )tandard profile and as the 5!+oller a$le will use an %6 thread, I will describe the set!up of this siFe.
8ayout of a 'etric 1hread
Le#: 3 * 0 %ajor 3iameter *itch Thread 0eight
The I)4 %etric thread profile is a fairl# simple shape to construct in Blender and with the screw tool onl# one instance of the thread profile is reHuired. As a model engineer I am not going to discuss thread tolerances or fits in an# detail. /ou should howe(er be aware that the finished male thread profile CboltD should be ept below the bold blue line of the diagram abo(e and the finished female thread profile should be ept abo(e the bold blue line, otherwise the two won't fit together. If #ou need them tolerance classes are defined in I)4 >6=!?. "or this e$ercise we will ma e the thread to the nominal profile abo(e. To construct the thread onl# two pieces of information are reHuired the %ajor 3iameter and the *itch. A few of the more common siFes are detailed in the table below. %ajor 3iameter *itch ; 0.= < 0.. = 0.@ 6 ? @ ?.-= ?0 ?.= ??..= ?6 -
7e will build the thread around the 5!+oller a$le. 4pen a new Blender project and go into front (iew +um,ad 9. Append the 5!+ollerA$le into the scene (hift%09 na(igate to 5!+oller.blend and select 4bjectM5!+ollerA$le. The a$le will appear facing #ou in the front (iew.
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The screw tool spins a profile around the E!a$is so the profile needs to be created and the screw operation performed in front (iew. The A$le needs to be rotated so it is (ertical in the front (iew. Rotate . %:6. 1ab into edit mode and (hift%R'B select the . (ertices ma ing up the left!hand profile of the threaded section.
&op# these (ertices (hift%D then )sc to lea(e them in place. )eparate the copied (ertices from the 4bject ,. Its easier to wor on the separated profile rather than the complete a$le.
1ab into 4bject %ode and select the profile. 1ab bac into Edit %ode. 7e now need to wor out the Thread height. It could be done with trigonometr# gi(en that the pitch is ?mm and the thread angle is 60 degrees. But I find it easier to do in Blender. 3e!select ll (ertices then to the left of the a$le *trl%8'B clic to add a new (erte$. )$trude this (erte$ on the .!a$is 9mm. The thread form is an eHuilateral triangle so the sides of the thread triangle will be the same length as the pitch. 8in select both (ertices of the edge and cop# them (hift%D on the 2!a$is 9mm Cthe thread pitchD. )elect the top left (erte$ of the two edges and snap the cursor to it (hift%s &ursorMselection. Then select the (erte$ on the other end of the edge and with the *i(ot set to ;3 &ursor Rotate it 36 degrees. )nap the cursor to the bottom left (erte$ and +otate this !;0 degrees. )elect ll and remo(e doubles W.
)elect the centre (erte$ and )$trude it on the .!a$is then scale it to the cursor (cale . 6.
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In the %esh Tools ? panel press Edge 9ength and select the centre edge. The Edge 9ength shown is the Thread 0eight.
3elete . the (erte$ on the left!hand side of the central edge. )elect the three (ertices of the thread profile and mo(e < them towards the undercut at the bottom of the thread.
If #ou ha(en't alread# got one open split the ;3 (iew and open the 4utliner. &lic the e#e icon for the a$le to remo(e it from (iew. )elect the (erte$ on the major diameter of the thread and )$trude it on the .!a$is %6#96@mm C?I@ 0D 7e can now use the snap tool to position the thread 5 profile. &lic on the magnet Icon on the (iew header. )elect the ; (ertices of the 5 and mo(e them <, whilst mo(ing hold down *trl and mo(e the cursor towards the end (erte$. The 5 will snap into position. 7e now need to add reference geometr# to allow us to cut new (ertices on the major and minor diameters. )$trude (erte$ A on the .!a$is )$trude (erte$ B on the 2!a$is as detailed, then )$trude this .
%6#;97mm C?I< 0D then )$trude again on the %2!a$is ensuring the edge crosses the 5.
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To finish the reference edges, e$trude a (erte$ from the major diameter across the (.
)elect the three (ertices of the 5 and cut >nife CE$actD, snapping the cut *trl%8'B to the (ertices of the major diameter.
+epeat the cut snapping the nife to the (ertices of the minor diameter.
3elete the reference (ertices, but ensure the top chamfered edge of the thread is not deleted, as this will be used to locate the cursor when we spin the thread.
Add Edges 0 to the (ertices of the major and minor diameter. Threads usuall# ha(e a radius at the root of the thread so we will add a fillet. )elect the (erte$ at the bottom of the minor diameter and snap the cursor to it (hift%( &ursorM)election.
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(hift%R'B )elect both (ertices of the minor diameter and cop# them (hift%D, then )sc to lea(e them in place. 7ith the *i(ot in ;3 &ursor Rotate the edge %36 degrees.
)elect the (erte$ at the top of the minor diameter and snap the cursor to it (hift%( &ursorM)election. Again (hift%R'B )elect both (ertices of the minor diameter and cop# them (hift%D, then )sc to lea(e them in place. This time Rotate the edge 36 degrees.
7here the two edges cross is the centre point for the bottom fillet. &ut a (erte$ on the intersect >nife CE$actD and using *trl% 8'B to snap the cut to the rotated edge.
)nap the cursor to the intersect and 3elete the reference (ertices.
)elect the (erte$ at the top of the major diameter and in the %esh Tools panel set 3egr:?-0 and )teps:< *ress )pin and the profile for one pitch of the thread will be created. )elect ll and +emo(e 3oubles W. )elect the (erte$ on the thread centreline Cright hand (erte$ on the top chamfer profileD and snap the cursor to it.
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ll (ertices, then 8in select the thread profile.
7e need the thread to continue past the chamfer so we can later combine the chamfer detail to the thread. &ounting the grid sHuares we will need ?0 turns.
In the %esh Tools panel set 3egr: ;60 )teps:;- and Turns:?0 %a e )ure &loc wise is not selected. *ress )crew and the thread will be formed.
1o into top (iew +um,ad -. 3e!select ll then 8in select the centre and chamfer (ertices. 3elete these .. )elect ll and +emo(e 3oubles W.
1ab into 4bject %ode and in the 4utliner open the e#e icon for the a$le, bringing it bac into (iew. If necessar# mo(e the thread in the E!a$is to align with the a$le. &lose the e#e for the thread.
7e now need to prepare the a$le to accept the thread. 1o bac into front (iew and select the a$le. 1ab into Edit %ode and select the top right (erte$ of the chamfer and cop# it (hift%D mo(ing it to the right of the a$le on the .!a$is. )$trude this (erte$ on the .!a$is to the left of the a$le. +epeat this on the bottom (erte$ loop of the thread section.
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1o into edge select mode and paint a selection B B across the straight section of the thread.
3elete these . (edges). 1o bac into (erte$ select mode.
1ab into 4bject %ode and in the 4utliner bring the thread bac into (iew. R'B select the thread then (hift% R'B select the a$le. *ress *trl%? to join them into one mesh. 1ab into Edit %ode and 3e!select ll then 8in select the thread. 7ith the Lnife tool, cut two rows of (ertices across the thread, >nife CE$actD and snapped *trl%8'B to the reference edges. 3e!select ll then Bo$ select the (ertices below the bottom reference edge. Eoom in 'W to ma e sure all the (ertices below the edge are selected (not the vertices on the edge) 3elete these (ertices ..
Bo$ select the (ertices abo(e the top reference edge and delete these. )elect the two reference edges and delete them. The thread is now the correct length for the a$le but there is still more to do. 7e must join the base of the thread to the under!cut and the top of the thread to the chamfer.
If #ou Foom in on the base of the thread #ou will see the flange that was originall# on the a$le stic ing out past the edge of the thread Chighlighted in greenD.
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To correct this we need to manuall# merge the (ertices of the original a$le flange onto the corresponding (erte$ of the thread. +%B )elect a (erte$ on the flange then )hift!+%B select the corresponding (erte$ on the thread. *ress Alt!% to merge the (ertices and choose 6At 9ast6 from the pop!up menu. +epeat this around the circumference of the a$le. The intersect between the top chamfer and the thread is a much more complicated detail. Because the intersect doesn't occur on a set plane there are no (ertices on the line of intersection. Therefore we cannot simpl# merge (ertices to obtain the correct profile. The first part of combining the thread and chamfer will be to create a line of (ertices on the intersect between the two sets of faces. 1o into face select mode and bo$ select the top section of thread and chamfer. *ress (hift%H to hide all the other (ertices. 7e can now use another of the p#thon scripts to cut the (ertices on the intersect of the faces. )plit the ;3 (iew and open a )cript 7indow Cdetailed description in 60@!<D. 7ith all the faces still selected, in the )cript window clic on )criptsM%eshM1eom Tool and from the popup menu clic on 6intersect: faceCsD CcutD6. A new loop of (ertices will be created on the intersect between the faces. 1o bac into (erte$ select mode, select ll and +emo(e 3oubles W. The 1eom Tool script isn't bundled with Blender but can be downloaded from the Blender 7ebsite. http9##*i8i:blender:org#index:php#Script%#-atalog A description for loading the script is also a(ailable from this page.
7ith the new edge created on the intersect its now simpl# a matter of deleting the (ertices, edges or faces that are not reHuired. It sounds simple but this will test #our patience and call on man# of the editing techniHues #ou ha(e learned.
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4nl# delete . a few (ertices at a time, if necessar# *trl% 2 will undo the change. In places #ou ma# need to merge (ertices lt%' and other places #ou will need to add new faces 0. Its also worth noting on one side of the a$le the thread intersects the chamfer in two places. As a new user this ma# ta e a fair amount of time, but as #our e$perience grows this will onl# ta e a few minutes and the end result is well worth the effort. 4nce complete press lt%H to bring bac all the hidden (ertices. )elect ll, +emo(e 3oubles W and )et )mooth W.
That completes the top thread. +ather than repeating all that wor on the bottom thread we can simpl# cop# the top one and reposition the cop# to complete the a$le.
In front (iew Bo$ select the thread (ertices, then loop select (hift% lt%R'B the inner loop of (ertices on the undercut ne$t to the main bod# of the a$le. &op# these )hift!3 and mo(e them to the side.
In front (iew Rotate the copied (ertices 9@6 degrees. )eparate the copied thread from the a$le ,. 1ab into 4bject %ode, )elect the copied thread and then 1ab bac into Edit %ode. )elect the top row of (ertices and snap the cursor to them (hift%( &ursorM)election.
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1ab into 4bject mode and in the %esh panel clic the &entre &ursor button. This will mo(e the object centre to the centre of the top row of (ertices.
)elect the a$le and delete the (ertices of the bottom thread. lt%R'B select the inner loop of (ertices where the under cut was.
)nap the cursor to the centre of these (ertices. 1ab bac into 4bject %ode and select the thread.
)nap the thread to the cursor (hift%( )electionM &ursor.
7ith the thread still selected (hift%R'B select the a$le and joine the two objects into one *trl%?. 1ab bac into Edit %ode, select ll and +emo(e 3oubles W. to complete the a$le. This a$le will ha(e .-.< (ertices, compared to ?<?@ (ertices of the a$le without the detailed thread. /ou ma# also want to set up a camera and lights and render an image of the shaft as detailed in 60@!>. 1ab into 4bject %ode and sa(e #our wor . In the ne$t section we will do a dimensioned drawing of the 5!+oller components.
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1uide +oller *art!< 9a#ing out The &omponent 3rawing %ost of the techniHues necessar# to la#out an orthographic drawing were co(ered in *art ?? of the 60@ Bearing Tutorial so rather than just repeating what's in that section this will be just a brief description of the la#out process. Initiall# though I thought it would be good to mention the two standard methods of la#ing out a drawing. ?st Angle *rojection and ;rd Angle *rojection. To see how the (iews are represented on paper it's easier to fold the paper into a cube around the component and project the (iew onto the cube. 7hen the cube is unfolded it gi(es the correct la#out. 9st ngle ,ro&ection
In "irst Angle projection the (iew is projected through the component, so the front (iew is projected onto the bac wall and the top (iew is projected onto the base.
7hen the ?st Angle (iew is folded out the front (iew is at the bac of the top (iew and the side (iew is on the opposite side of the front (iew. This t#pe of la#out often causes confusion with people who aren't completel# familiar with orthographic la#outs.
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3rd ngle ,ro&ection
In ;rd Angle projection the side facing the cube is projected onto the cube, so the top (iew is on the top of the bo$ and the front (iew is on the front of the bo$.
In ;rd angle projection the (iews are positioned on the same side of the (iew ne$t to them, so the top (iew is on top of the front (iew and the side (iew is on the side of the front (iew that it represents. This is a much easier la#out to understand and m# preferred choice.
0opefull# that,s enough for #ou to appreciate the formal aspects of orthographic la#outs, Its a subject where #ou can go into e(er increasing detail and this is just a brief primer to get #ou started. If #ou want to learn more about la#outs there is a lot of detail on www.technolog#student.com, it's worth a (isit as it contains a lot of in depth ad(ice. I thin that's enough on la#outs so let's get bac to Blender. In part ?0 we created a page 9a#out for an A< *ortrait *age. 7e can start b# importing this and then rotating the border to form an A< 9andscape la#out. )tart a new Blender project. If #ou alread# ha(e Blender open sa(e #our wor *trl%W then press *trl%. to open a new file. 3elete the &ube 4bject that opens with each new project ., as we don't need it.
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Append all the A<p objects from the *ageTemplate.blend file created in the 60@!Bearing tutorial. (hift%09 to open the "ile Browser window in Append mode and from the 6*ageTemplate.blend6 file 8'B clic 4bject then R'B select all the A<p objects. &lic on 9oad 9ibrar# to bring them into the new file. The# will be placed on 9a#er one, as this was the la#er the# were created on. 1o into front (iew to see the la#out +um,ad 9. In the outliner select the A<pBorder object then in the 9in and %aterials panel change its name from A<p CportraitD to A<9 C9andscapeD. +epeat this for all the other A<p 4bjects. It's now time to rotate the border. The onl# problem is that the Title bo$ is part of the Border mesh so we first need to separate the Title Bo$ from the Border. Either in the 4utliner or ;3 (iew select the A<9Border 4bject and 1ab into Edit %ode. )elect ll (ertices, it's easier to deselect the (ertices of the title bo$ than select the (ertices of the Border. To de!select the (ertices of the title bo$ press B for bo$ select, but this time drag a selection bo$ o(er the (ertices #ou need to de!select using the R'B. The (ertices will no longer be selected. 4n the ;3 5iew 0eader press selectMMIn(erse, this will in(ert the selection so the title bo$ is now selected and the Border isn't. (5ou could have 6ust de%selected all then box selected the 2itle ,ox, but I wanted to show the ,ox 7eselect feature8) 7ith the Title Bo$ (ertices selected press , CpartD to separate them from the current mesh and choose 6)election6 from the pop!up menu. 1ab bac into 4bject %ode and select A<9Boundar#, 1ab bac into Edit %ode and select R'B the bottom +ight 0and (erte$ snap the &ursor onto this (hift%( &ursorM)election. 1ab into 4bject %ode and R'B select the A<9Border 4bject and )hift!+%B select the A<9Boundar# 4bject. In the ;3 5iew 0eader set the *i(ot point to ;3 &ursor, then Rotate the Border and Boundar# :6 degrees. The Border is now disjointed from the Title Bo$ so <rab the Border and mo(e it on the .!a$is until the bottom +ight 0and corner sits around the Title Bo$. The final thing to do is amend the &amera and output "ormat settings detailed in A<9Te$t.00. so )iFe 8 becomes ;;00 and )iFe / becomes -<00. /ou now ha(e an A< 9andscape page template that can be appended bac into the *ageTemplate.blend file.
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Append the 5!+oller 4bject from 5!+oller.blend onto the scene and position it within the Border. (If it doesn't appear on the view after appending check the )ye icon in the Outliner is open or it's layer is active) &op# this (hift%D and mo(e it on the .!a$is to the right of the original. Rotate the copied 5!+oller on the 2!a$is :6 degrees. &op# the rotated 5!+oller and position this to the right of the original. 7e will use the second cop# to form a sectioned (iew. Append the 5!+ollerA$le from the same file and position this within the border. &op# this on the E!a$is and position it abo(e the original. (4rd -ngle pro6ection 2op view sits above 9ront 0iew) )a(e the file as 5!+oller9a#out.blend 7e now need to change the material for all the components. )elect the ?st 5!+oller and In the 9in s and *ipeline tab of the %aterial Buttons press the 8 to remo(e its material, then clic Add 'ew to add a new material. In the %aterials tab set the colour to white and clic )hadeless so it renders as a pure white colour.
In the 7orld )ettings change the Bac ground to white.
7ith the material set on the first 5!+oller (hift%R'B select all the other components, then (hift%R'B select the ?st 5!+oller to ma e it the acti(e object. *ress *trl%8 C%a e 9in sD and select %aterials from the popup menu. This will cop# the material from the acti(e object onto all the other selected objects. In the 4utput tab of the )cene Buttons clic Edge to allow the Edge filter to draw an outline around the components and then clic on Edge )ettings and set Eint CEdge Intensit#D to ? to gi(e lines onl# on the most prominent edges. In the "ormat tab change siFe 8 to ;;00 and )i$e / to -<00. )elect the camera, go into camera (iew +um,ad 6 and align the camera with the Boundar# 4bject. )et the &amera to 4rthographic in the scene buttons &amera tab
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Because we are wor ing with such a large output siFe #ou can select areas of the camera (iew to do a test render. In the camera (iew press (hift% B and drag a selection bo$ o(er the area #ou would li e to test. The render will then be confined to the area of the selection. To come out of Border render de!select Border in the +ender tab. In side (iew +um,ad 3 cut the right hand 5!+oller in half b# deleting all the (ertices forward of the centreline. This is easier carried out in local (iew 'um*ad =. lt%(hift%R'B select the (ertices on the two open ends and cop# (hift%D them forward of the ?I- 5!+oller on the 4!a$is. (hift%0 fill these faces, beautif# the fill lt%0 and con(ert to Vuads lt%?. The faces ha(e been separated from the 5! +oller to allow the edge filter to detect the edges cleanl#. 7ith the (ertices of the disconnected faces still selected we need to add an image te$ture with a hatch pattern. If #ou ha(en't alread# got one a(ailable use one of the te$tures from the 60@!Bearing tutorial *art ??.
In the 9in and %aterials tab of the Editing Buttons clic 'ew to add a second material to the mesh and then press Assign to assign the second material to the selected (ertices. In the )hading Buttons, Te$ture sub conte$t add a new image te$ture and load #our hatch pattern. If #ou need more detail of how to do this go bac to the 60@!Bearing tutorial, *art ?? describes the process in detail.
Because Image te$tures are stretched to fit the object's bounding bo$ siFe the hatch will ha(e been s ewed (erticall# so increase / repeat to - or ; in the %ap Image tab of the te$ture buttons. This will repeat the te$ture - or ; times in the /!a$is. If #ou do a test render #ou should end up with something li e the image opposite.
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Radial Dimensions To construct a diameter dimension select a (erte$ either side of the horiFontal centreline and add an edge 0. &lic on Edge 9ength in the %esh Tools ? tab of the Editing &onte$t buttons. 7e can use this figure for the dimension te$t. )eparate this edge from the 5!+oller ,A choose 6)elected6 from the pop!up menu. 1ab into 4bject %ode and select the new edge, which will be used to form the dimension line. 1o into 9ocal (iew +um,ad = for dimension line, then 1ab into Edit %ode (:ote I have removed the material to make the images clearer for this tutorial). )elect both (ertices and )$trude them 2 6#9. )elect the bottom two (ertices and )$trude these 2 %6#9 This adds thic ness to the dimension line. )elect ll and cut > through the horiFontal edges choosing Lnife C%ulticutD from the pop!up menu and accepting the default - cut's. )elect the si$ new (ertices that ha(e been cut and (cale them along the horiFontal edges . until the# are around <mm from the ends of the dimension line. )elect the two (ertices A W B and E$trude them in the E a$is ?mm +epeat this on the other three edges. /ou should end up with a dimension line that has a bo$ on either end. )elect the fi(e left hand (ertices and with the *i(ot *oint set to %edian *oint (cale the (ertices to 6 then +emo(e 3oubles W. /ou will end up with an arrow shaped end. +epeat this on the other end of the dimension line. The ne$t reHuirement is to add a leader line for the dimension te$t. )elect the three (ertices in the #ellow bo$ opposite. Toggle bac into 1lobal 5iew +um,ad = and e$trude these (ertices on the .!a$is out past the edge of the component. Add the Blac shadeless material from the border to the dimension line. 1ab into 4bject %ode and in side (iew +um,ad 3 mo(e the dimension line in front of the 5!+oller. 7ith the dimension line selected snap the cursor (hift%( to its object centre &ursorM)election.
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Insert a Te$t object and in the Editing buttons "ont tab, increase its siFe to suit the page scale C< on m# la#outD Bac"space through 6Te$t6 to remo(e it, then add the dimension siFe using the number e#s on the main e#board (not the :um&ad keys) 1ab into 4bject %ode and mo(e < the te$t o(er the leader line. "inall# add the Blac material to the te$t object. 7ith the cursor snapped to the 4bject centre cop# the the dimension line and te$t, then rotate the cop# from the horiFontal. The original dimension line can now be modified b# mo(ing the arrows on the 8!a$is to a new diameter. This techniHue can also be used for radius dimensions b# cutting the dimension line on the centre!point and deleting all the (ertices to one side of the cut. If #ou ha(en't been doing so it's worth freHuentl# sa(ing #our wor . *ress *trl%W and sa(e the file.
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8inear dimensions 9inear dimensions using the Blender &aliper script were co(ered in detail in the 60@!Bearing tutorial *art ?? along with scaled (iews. If #ou can't remember how to add the dimensions please re(isit *art ??. As a Huic refresher, in Edit %ode select the two (ertices where #ou want the dimension measurement to be ta en from. &op# the (ertices and mo(e them awa# from the model (constrained to an axis). This gi(es a brea between the e$tension line and the model. E$trude these (ertices to the point where #ou want the dimension line, then e$trude again past this point. To thic en each edge so it will show on the render, select the three (ertices of one edge and e$trude it awa# from the other edge 0.-mm. 3o the same with the other edge.
To add the dimension select the two (ertices on the inner edge of the e$tension lines. 4pen Blender &aliper, adjust the measurement settings for the dimension line and press measure. C/ou ma# need to pla# with the settings to get a suitable font siFe and dimension line scaleD.
)elect the (ertices of the e$tension lines and separate them from the models mesh ,. 1o into 4bject %ode and join the e$tension lines to the dimension line created b# Blender &aliper b# selecting both objects and pressing *trl%?#
As #ou progress through #our la#out join all the dimension and e$tension lines into one object. It helps to change the colour of the dimensions to help differentiate them from the model.
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The models are going to be rendered using the edge settings so need to be rendered separatel# to the drawing border and dimensions. )elect all the models and mo(e them onto la#er - 'o(e then clic the second la#er bo$ in the pop! up. In the +ender 9a#er tab of the scene buttons select la#er - to limit the render to this la#er. In the 4utput tab ma e sure Edge is still selected. In the "ormat tab select *'1 as the file format and chec the +1BA button. +ender the line drawings of the components. 7hen #ou sa(e the render it will sa(e the component la#out onto a transparent bac ground. )a(e 03 the drawing as 5!+oller9a#out?.png
To combine this drawing with the border and dimensions, we can use the 'ode Editor. The 'ode editor is a comple$ image editor and needs a boo of its own to describe its full capabilities. I will just touch on what's needed to combine the two la#ers. In the render 9a#ers tab select la#er ?. In the 4utput tab deselect Edge to turn off the edge filter. +ender the la#er and close the render window.
In the ;3 5iew clic the window t#pe button and choose 'ode Editor. 4n the 'ode Editor 0eader clic on the face icon to select composite nodes, then clic 2se 'odes. A +ender 9a#er 'ode and &omposite node will appear in the (iew joined with a cur(ed line. The nodes will ha(e a thumbnail (iew of the Border and 3imensions. 7e now need to add an input node so we can load the image with the line drawings.
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*ress the (paceBar to open the node menu choose AddMInputMImage, a new node will appear in the 5iew. /ou can mo(e the nodes around b# 8'B dragging the 0eader at the top of the node. *osition the Input 'ode below the +ender 9a#er 'ode.
*ress 9oad 'ew and load the drawing 5! +oller9a#out?.png. The thumbnail of the image will appear in the node. 'odes are arranged with inputs on the left!hand side and outputs on the right!hand side.
7e now need to add a node that can combine both the +ender 9a#er and Image nodes together. To do this press the (paceBar and choose AddM&olorMAlpha4(er. The Alpha4(er node will be placed in the (iew. 7e need to re!wire the nodes to gi(e us the correct output. 8'B clic and drag the cursor across the lin between the +ender 9a#er 'ode and the &omposite 'ode. This will cut the connection. 8'B clic and hold on the #ellow output soc et on the +ender 9a#er node and drag the mouse to the bottom #ellow input soc et on the Alpha 4(er node. A new connection will be made. In the same wa# connect the output of the image node to the top input of the Alpha 4(er node. Then connect the 4utput soc et of the Alpha 4(er node to theinput soc et of the &omposite node. The connections are now complete.
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Before rendering the la#out #ou must tell Blender to use the composite output. In the )cene buttons Anim tab clic 3o &omposite, then render the la#out. If all has gone well #ou will get a composite la#out with a dimensioned line drawing of the components. In the )cene buttons "ormat tab &lic +1B as we no longer need alpha in the image and )a(e the 9a#out drawing 03. )a(e #our file *trl%W. The final thing necessar# to print the drawing to scale, is to adjust the pi$els per inch to ;00 in an image!editing program such as 1imp or *hoto)hop.
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! ?-> !
3esigning a &asting *art!? *ositioning the &omponents B# now #ou should be fairl# familiar with Blenders modelling capabilities. The 60@ Bearing and 5!roller tutorials ha(e co(ered most of the commonl# used tools and techniHues, so this wonBt be so much of a tutorial as a discussion on the steps needed to use Blender as a tool to help #ou design a casting. As the ne$t stage of m# &'& router upgrade is to redesign the 8!a$is slides I will use this as the moti(e for designing the casting. 7e will again reuse the bearing and 5!roller as the building bloc s for the casting la#out. There are man# casting techniHues that could be used for this component such as sand casting, die!casting and centrifugal casting, but because of m# limited wor shop facilities and the a(ailabilit# of a potter# iln, I ha(e chosen to use the in(estment casting techniHue. This is where a wa$ model of the part is fabricated then dipped into a refractor# slurr# which is dried, the wa$ is melted out lea(ing the refractor# casing which when fired becomes the mould for the molten aluminium. The mould is then bro en awa# from the aluminium when it has cooled. The benefit of this method is #ou can produce an accurate wa$ model without worr#ing too much about withdrawal tapers or undercuts, If #ou can ma e the component in wa$ #ou should be able to produce an in(estment mould from it. I will go into a little more detail about the mould ma ing and casting process in the foundr# section. 0ere I will concentrate on using Blenders modelling capabilities to design the casting. If #ou ha(enBt alread# got blender running this is the time to start it upG 3elete the default cube . and then append into the scene (hift 09 the 5!+oller, bearings, shaft, nut and washer assembl# created in the 5!+oller tutorial. The# will be placed into the scene rotated so the roller will run along the 8!a$is. 1o into side (iew +um,ad 3 as we need to add a shaft for the 5!+oller to run along. To ma e sure the shaft is centred to the 5!+oller, select the 5!roller and in the Edit Buttons clic N&entre 'ewO this will ensure the object centre is on the centre of the 5!+oller. 7e can now snap the cursor to the 5!+ollers object centre (hift%( &ursorM)election. Add a c#linder to represent the shaft (paceBar AddM%eshMc#linder and in the pop!up menu set 5ertices: ;-, +adius: >, 3epth: ?00. In its current position the shaft penetrates through the 5!+oller so we need to mo(e it down so that the shaft sits below the U5B.
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! ?;0 !
1ab into 4bject %ode then <rab the shaft and mo(e it on the 2!a$is until it sits just below the 5!+oller. Eoom in full# and repeat this if necessar# to get the closest possible alignment. /ou can also Foom into a selection bo$ b# pressing (hift%B and dragging a selection bo$ o(er the Foom area #ou reHuire. In front (iew +um,ad 9, 1ab into Edit mode and Bo$ select the right!hand (ertices. %o(e these (ertices < along the .!a$is 366mm. This will ma e the shaft <00mm long. 1ab bac into 4bject %ode. It's possible to ha(e the 5!+oller rigidl# aligned to the 8!a$is using just ; rollers, as I am going to reuse this set!up on other areas of the machine I am going to use < rollers. In front (iew +um,ad 9, Bo$ select the 5!+oller assembl# and cop# it (hift D. %o(e it along the .!a$is 956mm. 'ow Bo$ select both 5!+oller assemblies and cop# them (hift%D, mo(ing the copies on the 2!a$is until the U5B is below the shaft. In side (iew +um,ad 3 Eoom in close to position them as accuratel# as possible Its not feasible in a home wor shop to ma e components to micron accurac# so some form of adjustment will be necessar# to position the 5!+ollers tight to the shaft. I am going to fi$ the top two rollers into the main casting, but allow the bottom rollers to be adjusted on the E!a$is. "or this I will use a simple rebated bloc with elongated bolt holes. This can simpl# be located within a rebate in the main casting.
1he d&uster Bloc"

To ma e the adjustable bloc , +%B select the bottom right hand 5!+oller a$le and go into 9ocal 5iew +um,ad =. )elect (hift% lt%R'B the loop of (ertices at the bac of the fillet and snap the cursor to the centre of them, (hift%( &ursorM)election. This gi(es us the location point for the adjuster. 1o into 4bject %ode and in front (iew Insert a mesh circle, (paceBar AddM%eshM&ircle, in the pop!up menu set 5ertices: ;-. and +adius: ;.
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! ?;? !
7hilst still in Edit %ode add a *lane and (cale it b# a factor of ;; to gi(e a <<mm sHuare. 3elete the face from the plane . N4nl# "acesO then subdi(ide the edges . times. W N)ubdi(ide %ultiO and set - in the popup menu. This will gi(e our outer sHuare the same number of (ertices as the inner circle. Add faces between the inner circle and outer sHuare b# pressing 0 and selecting 6) in "acesIEdge 9oops6. )elect all and )$trude 6+egion6 along the 4!a$is 96mm, to add thic ness to the component. In order for the adjuster bloc to be able to be positioned in the casting it needs some side flanges that will also incorporate the elongated bolt holes. In side (iew +um,ad 3 cut a loop of (ertices > 6%idpoint6. <rab the new loop of (ertices and mo(e them on the 4!a$is %;mm, this will gi(e us a ;mm face to form the flange from. )elect the flange face's, one side at a time and e$trude them ?0mm. The top and bottom flange will shield the components of the slide from dust produced b# the router. 3elete the two corner faces indicated, . 6"aces6 on each of the corners. %a e sure the edge between the two faces is also deleted. )elect the (erte$ indicated and snap the cursor to it. (hift%( &ursorM)election. Then select the four (ertices from one of the deleted faces. In front (iew spin a corner radius with fi(e (ertices.
7hen all the four corners ha(e been spun )elect and remo(e doubles W.
ll
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! ?;- !
7e now need the centre line of the flange to position the elongated bolt holes. It can't be loop cut because the corner faces are triangles. 2se the Lnife tool C%idpointsD and cut the loop indicated.
To add a chamfer to the edge of the adjuster loop cut *trl%R the outer loop of faces. 7ith the Edge 9ength button acti(ated, slide these to 0.=mm from the edge. 3o this on the front and bac of the flange. 'ow select the front outer edge loop and mo(e it 0.=mm on the /!a$is. 3o the same on the bac outer edge but mo(e this !0.=mm.
)nap the cursor to the middle of the two (ertices shown.
In front (iew add a circle, 5ertices: ?6, +adius: -.- Cclearance for a <mm boltD.
&op# the (ertices from the circles centreline and abo(e and mo(e the cop# <mm on the E!a$is. Then cop# the (ertices of the circle from the centreline and below mo(ing them !<mm on the E! a$is. 3elete the original circle and the flange (ertices closest to it. This lea(es #ou with the outline of the slot positioned centrall# on the flange.
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! ?;; !
lt%R'B select the (ertices of the elongated hole, then (hift% lt%R'B select the (ertices of the flange that surround it. (hift%0 to fill the area with faces. lt%0 to beautif# the fill and lt%? to con(ert to Huads. &op# the new faces and mo(e them ;mm on the /!a$is. (hift% lt%R'B select the two elongated slots and loft faces between them 0 6) in "aceIEdge 9oops6. )elect all and remo(e doubles.
)elect the (ertices central to where the other three slots are reHuired and delete them. &op# the slot faces and surrounding faces. and use Blenders snap tools to snap the cop# to the other locations.
"irst +otating the two left!hand copies ?@0 degrees.
"inall# select all and remo(e doubles to complete the adjuster.
4nce the flange is complete go bac into 1lobal (iew +um,ad = and cop# the adjuster to the other 5!+oller (hift%D . %956
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! ?;< !
1he 8ead (crew B Roller%nut 7E ha(e now got the locations for the fi$ed rollers and the adjuster bloc s. A few other components are needed on the casting because it will also hold the lead screw roller!nut. I am using an %?6 threaded rod as the lead screw and ha(e designed a simple roller!nut based on the 5!+oller and a$le. ItBs simpl# a series of slots at -mm pitch to marr# in to the %?6 thread. To stop the lead screw from fle$ing awa# from the nut a couple of bearings will be located abo(e the lead screw and offset slightl# to either side of the centreline. These bearings will use a shortened (ersion of the 5!+oller a$le.
The roller!nut and bearings will also need to be adjustable, so the brac ets that hold them bac to the main casting will also need to allow some mo(ement in the E!a$is. %# &'& machine is configured with two 8!a$is slides, one either side of the table. The /!a$is runs between them forming a bridge t#pe la#out. The 8!a$is therefore also has to locate the mounting points for the /!a$is. If #ou ha(e a loo at the photos of m# old machine on the &'& page at www.rab;d.com this will ma e more sense. At this stage of the design, things are (er# fle$ible, none of the component positions are fi$ed and it's eas# to mo(e things around to optimise their location. 7e ha(e now accounted for all the parts of the 8!a$is, so in part!-, I will start constructing the main casting around them.
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! ?;= !
3esigning a &asting *art!- The Initial 9a#out 7e now ha(e all the components needed for the 8!a$is roughl# positioned. )o it's time to put a little thought into what shape the casting needs to be to accommodate the components. In front (iew the components are fairl# spread out and could possibl# be mo(ed closer to the centre to reduce the footprint of the 8!a$is.
In side (iew its clear that some of the components will penetrate the front mounting face of the casting. It will be necessar# to pro(ide a recess behind the roller nut and top right hand bearing. The siFe and location of the recesses will determine how close the other components can be to the centre of the casting.
The first part of the casting to model is the recess behind the +oller!nut. To ma e modelling easier #ou can hide the slide shaft and lead screw b# clic ing the e#e icon in the 4utliner. )elect an adjuster bloc and in Edit mode snap the cursor to the front face of one of the adjuster bloc s. Tab into 4bject mode and in front (iew add a plane. In object mode mo(e the plane central to the +oller nut and resiFe it so it is larger than the nut. 4ne side should be aligned with the bac of the a$le flange. 3elete 8 4nl# "aces to remo(e the face from the plane )$trude the four edges 4 @mm. This will add depth to the recess. In side (iew <rab the top bac (ertices and mo(e them, 2 %@ mm to gi(e a <= degree angle. %o(e the bottom (ertices up @mm.
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! ?;6 !
In top (iew mo(e the bac side (ertices in ?mm to add a withdrawal taper. "inall# add a face to form the bac wall.
I ha(e repeated the process for the top +ight!hand bearing. This time ma ing a little e$tra room for the a$le and nut which also penetrate the front plane of the casting.
7ith the two recesses modelled it's eas# to see where the rest of the components can be repositioned to ma e the casting more compact.
Theirs plent# of room to allow me to mo(e the 5!roller centres from ?=0mm to ??0mm. It's also apparent the Adjuster bloc s are larger than the# need to be so I will reduce their siFe.
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! ?;. !
)elect one of the adjuster bloc s and 1ab into edit mode. It's not possible to just scale e(er#thing to a smaller siFe because this will also resiFe the centre hole, slots and flange widths. )o I need to resiFe it in stages. The sHuare centre hub is <<mm and I am going to reduce it to ;6m. Bo$ select the centre hub and flange (ertices directl# abo(e and below it. (cale this on the .!a$is b# 9#;;;; C<< I ;6D. 'ow bo$ select the (ertices of the right hand flange and mo(e < these on the .!a$is %3mm C?I- the @mm differenceD. +epeat this with the left!hand flange. %o(ing it <mm on the 8!a$is. Bo$ select the (ertices of the centre boss and the flange (ertices directl# to the left and right of it and again scale this ?.---- but on the E!a$is. Then grab and mo(e the top and bottom flanges <mm. /ou should now ha(e a sHuare adjuster bloc . In scaling the adjuster on the E!a$is we ha(e also just scaled the slotted bolt holes. These need to be returned to their original siFe. 7e can do this b# scaling the (ertices of the slots b# the in(erse of the original scale C? I ?.---- J 0.@?@?@D. )elect the (ertices of the first slot and (cale it 2 6#@9@9@ +epeat this on the other three slots.
"inall# scale the centre hole on the 8 and E!a$is b# the same amount to return the hole to the correct diameter. C(cale (hift%4 6#@9@9@D 7ith the adjuster bloc s reduced in siFe I ha(e been able to further reduce the 5!roller centres, which are now ?00mm apart. I ha(e also mo(ed the bottom 5!rollers in 6mm so the edge of the adjuster bloc s are le(el with the outside of the top 5!roller's.
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! ?;@ !
To form the poc ets in the casting where the adjuster bloc s sit we can cop# both adjuster bloc s (hift%D then press )scape to lea(e them in position. 7e can then cut and adapt the copied adjuster bloc s mesh to form the adjuster locations in the casting. 7ith the copied bloc s still selected go into local (iew +um,ad =. In side (iew select the front face of the adjusters. )nap the cursor to the selection so it's on the same plane as the front face, then delete the (ertices. Because of the chamfer the front loop of (ertices is no longer aligned on to the front face of the casting. 9oop select the front edge and in cursor select mode (cale the (ertices on the 4 a$is to 6. This will bring the edge bac into alignment.
)elect and delete the (ertices of the central hole, to lea(e us with a recess the same shape as the adjuster. If it were left li e this there wouldn't be an# room for the adjuster to slide on the E!a$is. )o we need to mo(er the top and bottom flange to allow the adjuster to mo(e.
)elect the (ertices of the top flange and <rab them mo(ing them on the 2!a$is 3#5mm. %o(e the bottom flange !<.=mm. This will gi(e us the room for the adjuster bloc to mo(e up and down.
The adjusters will be secured with a <mm bolt, so the casting needs a <mm!tapped hole centrall# to the slot. It's not practical to model the thread so it will simpl# be represented b# a hole at the tapping drill siFe, which is ;.;mm. )elect the four (ertices from the straight edges of the slot and snap the cursor to their centre. Add a circle with ?6 (ertices and a radius of ?.6=mm.
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! ?;> !
3elete the (ertices of the slot then rebuild the faces around the hole.
2sing Blenders snap tools, cop# and paste the hole and surrounding faces to the other locations. At this stage it will also be good to delete unnecessar# (ertices and rebuild the faces as larger Huads. Blenders s in "aceIEdge 9oop feature will be useful for this.
4nce one adjuster recess is complete, cop# it and mo(e it @@mm on the 8!a$is so it sits behind the other adjuster.
To position the fi$ed a$le holes, R'B select a fi$ed a$le and go into 9ocal 5iew +um,ad =. )elect (hift% lt%R'B the loop of (ertices at the bac of the fillet and snap the cursor to the centre of them, (hift%( &ursorM)election. This gi(es us the location point for the adjuster. 1o into 4bject %ode and in front (iew Insert a mesh circle, (paceBar AddM%eshM&ircle, in the pop!up menu set 5ertices: ;- and +adius: ;. +epeat this for the other a$le.
www.rab;d.com
! ?<0 !
)elect the a$le location circles, the poc ets behind the roller!nut and bearing and the adjuster recesses and combine them into one mesh, *trl%?. These are the first features of the casting.
In order to locate the roller!nut and bearings, three adjuster brac ets are reHuired. I will construct these in *art! ;. This will then allow me to add their mounting locations to the casting.
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! ?<? !
3esigning a &asting *art!; The +oller!'ut %ounting Brac ets
To finish off all the mounting locations on the casting, we need three more components, the mounting brac ets for the +oller!nut and support bearings. Because the design of the brac ets relies on the position of the casting face from the a$le centres and also an# poc ets in the casting, it has not been possible to design the brac ets until now. 0ide all the components other than the +oller!nut assembl#, casting and lead screw. It will be easier to see the a(ailable space for the brac et without the other components. Tab into Edit %ode for the casting and snap the cursor to the front face. I ha(e selected the two (ertices of the recess, so the cursor is on the edge of the recess and aligned with the mounting face of the a$le. Bac in 4bject %ode, add a *lane. )cale the left!hand side (ertices to the cursor, its height to ;0mm and width to <mm. E$trude the right hand (ertices on the 8!a$is 6mm then again on the 8!a$is ?0mm, the 6mm section will be used to form a locating e#, the ?0mm section will become the bolt flange. E$trude the three faces to gi(e a thic ness of ;mm.
Tab into Edit %ode for the a$le and snap the cursor to the (ertices on the flange fillet as detailed in *art ?. Tab bac into the adjuster Brac et. In side (iew add a circle with ;- (ertices and a ;mm radius. )$trude these (ertices then press )scape to lea(e them in position. cale the e$truded (ertices b# a factor of < to gi(e a -<mm flange. 3elete some of the (ertices from the outer circle and add edges bac to the mounting flange. 7ith careful choice #ou can get a tangential alignment. %idpoint cut a row of (ertices on the mounting flange and delete the (erte$ that would become inside the brac et. This will remo(e four faces from the mounting. +ebuild new faces around the hole.
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! ?<- !
)elect the (ertices indicated and E$trude them on the 8! a$is <mm then again 6mm. In wire (iew delete the (erte$ that has been created internal to the brac et. )elect all and remo(e doubles. /ou will also need to rebuild the faces of the original face, as these will be remo(ed b# the e$trusion process.
As detailed in *art!? for the 5!roller adjuster brac ets add two elongated holes to the flange and also a fillet to the outer corners. "inall# the brac et needs to be constrained to a mo(ement perpendicular to the lead screw.
To achie(e this I ha(e purposefull# created (ertices that will allow the incorporation of a e#, which will be located in a slot machined into the face of the casting. )elect the two faces indicated and e$trude them -mm.
The support bearing adjusters are modelled in a similar wa# to the +oller!nut adjuster brac et. I ha(e slimmed down the brac et to 6mm and mo(ed the mounting flange abo(e the bearing. The right hand adjuster will be set bac into the poc et pro(ided in the casting.
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! ?<; !
The (iew from the bac shows the 6mm e#, which penetrates the face of the casting. )ome wor will be reHuired to pro(ide the mating slot in the casting and the bolt holes.
The left!hand adjuster stands out further from the casting to allow support forward of the lead screw centreline.
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! ?<< !
1ransferring <eometry to the *asting )elect an adjuster and 1ab into Edit %ode. In top (iew +um,ad - select the (ertices on the bac face of the adjuster.
&op# the (ertices (hift%D then )scape to lea(e the cop# in place. )eparate the cop# from the adjuster mesh ,. 1ab into 4bject %ode and select the copied adjuster face, then (hift%R'B select the casting. Toin the copied face to the casting *trl%?. +epeat this for all three adjuster brac ets. )ome wor is now needed to modif# the copied geometr# to suit the casting. As with the 5!roller adjuster, the lead screw adjusters will be secured with <mm bolts, so the casting needs <mm!tapped holes centrall# to the slot. Again these will be represented b# a hole at the tapping drill siFe, which is ;.;mm. Alt!+%B )elect the (ertices from the slot and snap the cursor to their centre. Add a circle with ?6 (ertices and a radius of ?.6=mm. +epeat this for all slots. 3elete the unnecessar# (ertices, lea(ing the e# wa# slot and tapped hole circles.
In order for the adjuster to mo(e in the slot the slot length needs to be increased b# at least the amount of mo(ement a(ailable on the elongated bolt holes. 1rab the top (ertices of the slot and mo(e them on the E!a$is =mm.
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! ?<= !
I ha(e also cut the slot lengthwa#s with a mid point cut. This has enabled me to spin a radius at the top of the slot, which on the casting will be cut using a 6mm slot drill, gi(ing the radius on the ends. A mid point cut has also been made horiFontall# across the recess to align (ertices with the centre (ertices of the e# slot.
The slot on the top right adjuster poses a different problem, as it has to penetrate the face of the bearing recess. To add (ertices and edges for this penetration use the 1eom tool. )elect the intersecting faces and in a script window choose )criptsM%eshM1eom Tool )elect Intersect: "aceCsD C&utD
The 1eom Tool will cut a new series of edges around the intersection. It will also triangulate all the selected faces. 3elete all the unnecessar# faces and con(ert the remainder to Huads, lt%?.
E$tend the top of the slot =mm to allow the adjuster brac et room to slide. &ut a (ertical row of (ertices down the slot and bearing recess, using the nife with a mid point cut. )pin the top radius.
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! ?<6 !
The left!hand adjuster slot just needs to be e$tended =mm top and bottom. A (ertical mid point cut will allow the ends to ha(e a radius spun to match the slot width.
All the mating geometr# needed to complete the casting has been accuratel# e$tracted from the component assembl#.
In the ne$t part I will complete the casting b# building faces between all the e$tracted geometr# elements.
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! ?<. !
3esigning a &asting *art!< &ompleting the &asting 7ith the location of the bolt holes, Le# wa# slots, adjuster housings and recesses now positioned all that remains is to build the face of the casting between the edges alread# modelled.
0owe(er, to eep an organised mesh, it is necessar# to build up a framewor of edges, before auto filling indi(idual areas.
%ost of the parts we ha(e created for the casting are not in horiFontal alignment so a little bit of wor is needed to pro(ide (ertices in the best location for the auto fill.
)ection off areas of the casting b# e$truding edges horiFontall# or (erticall#. )nap the cursor to e$isting (ertices and in cursor select, )cale the other reHuired (ertices along their a$is to 0 to align them.
2se Auto "ill (hift%0 in aligned regions. Beautif# the fill lt%0 and con(ert trie's to Huads lt%?.
B# constraining regions (erticall# and horiFontall# #ou can construct an organised mesh. The ad(antage of doing this are that if alterations are reHuired to the model selection of aligned rectangles will be much easier than selecting areas of a mesh made up of disorganised triangles.
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! ?<@ !
Before completing the face of the casting there is one other element that needs to be fi$ed to the 8!a$is slide. That is the support for the /!a$is.
As I ha(e alread# roughed out m# design I now the locating area for this needs to be ;@mm wide. The top section of the 8!a$is needs an area that the /!a$is can be bolted on to. To sa(e ha(ing a left and right!hand 8! a$is casting I will incorporate the mounting on both sides of the casting.
As part of the casting's inner face I ha(e incorporated a loop of faces around the outer edge, these will become a flange to help stiffen the casting and also gi(e the mounting location for the /!a$is support brac et.
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! ?<> !
E$trude the holes and the outer edge bac to gi(e the casting thic ness. 4nce all the elements of the bac face are on the correct alignment build faces between them in a similar manner to the front face.
Because I ha(en't done an# in(estment casting before I am not sure how thin the mould can be before it won't fill properl#. Because of this I ha(e increased the thic ness behind the poc ets to <mm.
)elect the loop of faces from around the outer edge of the inner face. These will be e$truded to pro(ide a mounting point for the /!a$is and also offer some protection to the components of the 8! a$is. E$trude the fa$es ;0mm to clear the 5!rollers then cut clearance holes for the lead screw and guide shaft.
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! ?=0 !
This completes the casting for the 8!a$is of m# &'& router. All that remains is for me to ma e a wa$ pattern, which will be fabricated, from templates printed at a scale of ? to ? from the Blender model. This model is constructed at finished siFe. E$tra metal will be reHuired on the areas that are to be machined. I will detail the progress of the casting in the Engineering section of m# web site.
This is the final part of the Engineers 1uide to Blender. 0opefull# #ou ha(e been able to understand the processes introduced in the 1uide and will be able to build on #our e$perience b# producing designs of #our own. If #ou were new to Blender when #ou started the guide and ha(e wor ed through to this final page, #ou should now be comfortable with Blenders wa# of modelling. Theirs still a lot to learn and man# more tools and techniHues a(ailable to impro(e #our modelling s ill. 0ow #ou progress from here is up to #ou, but the Internet communit# offers numerous tutorials and guidance, so #ou ha(e no e$cuses for not progressing and becoming a Blender pro.
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! ?=? !

Precision Modelling 006

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The )mall *rint

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%odelling a 60@ Bearing *art!- Inner and 4uter +ace

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Blender ! *recision %odelling 1uide B#: +obert Bur e

Blender ! *recision %odelling 1uide B#: +obert Bur e

Blender ! *recision %odelling 1uide B#: +obert Bur e

Blender ! *recision %odelling 1uide B#: +obert Bur e

1ab bac into Edit %ode and press all (ertices.

Blender ! *recision %odelling 1uide B#: +obert Bur e

Blender ! *recision %odelling 1uide B#: +obert Bur e

3elete plane and re name the object 60@!+ace

Blender ! *recision %odelling 1uide B#: +obert Bur e

60@ Bearing *art!; Adding the Ball Bearings

Blender ! *recision %odelling 1uide B#: +obert Bur e

Blender ! *recision %odelling 1uide B#: +obert Bur e

Blender ! *recision %odelling 1uide B#: +obert Bur e

Blender ! *recision %odelling 1uide B#: +obert Bur e

60@ Bearing *art!< %odelling the Bearing &age

Blender ! *recision %odelling 1uide B#: +obert Bur e

Blender ! *recision %odelling 1uide B#: +obert Bur e

&lic bac into (erte$ select mode.

Blender ! *recision %odelling 1uide B#: +obert Bur e

8'B clic and a new ;3 (iew will be created.

Blender ! *recision %odelling 1uide B#: +obert Bur e

Blender ! *recision %odelling 1uide B#: +obert Bur e

Blender ! *recision %odelling 1uide B#: +obert Bur e

Blender ! *recision %odelling 1uide B#: +obert Bur e

60@ Bearing *art!= 3etailing the &age )ecuring &lasp

)elect all and remo(e doubles.

Blender ! *recision %odelling 1uide B#: +obert Bur e

Blender ! *recision %odelling 1uide B#: +obert Bur e

Blender ! *recision %odelling 1uide B#: +obert Bur e

Blender ! *recision %odelling 1uide B#: +obert Bur e

Blender ! *recision %odelling 1uide B#: +obert Bur e

)in ?I-A J +adiusI 0#potenuse 0#potenuse J +adiusI C)in CA I-DD

Blender ! *recision %odelling 1uide B#: +obert Bur e

3elete the reference (ertices.

+e ma e the edges between the fillet and surrounding (ertices.

Blender ! *recision %odelling 1uide B#: +obert Bur e

+epeat this procedure to produce the bottom fillet.

Blender ! *recision %odelling 1uide B#: +obert Bur e

Blender ! *recision %odelling 1uide B#: +obert Bur e

Blender ! *recision %odelling 1uide B#: +obert Bur e

Blender ! *recision %odelling 1uide B#: +obert Bur e

Blender ! *recision %odelling 1uide B#: +obert Bur e