EXERCISE 1.

2 – MODELING A BELT W HEEL

Figure 1: A belt wheel modeled in this exercise.

Kon-41.3006 Computer Aided Design Basic Course Kaur Jaakma
Exercise 1.2 2012

Learning Targets
In this exercise you will learn:

 Using symmetry when sketching

 Using pattern to copy features
 Using RMB when selecting items
 Changing dimension schema in a sketch
 Changing existing features
 Renaming parts

In this exercise it is assumed that Exercises 1.0 and 1.1 are done.

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Starting a new Model

Create a new model (from Quick Access bar, pressing CTRL + N or from File  New) using Part as Type
and Solid as Sub-type and name it as belt_roller (Figure 2). Notice that part’s (and other objects’)
name can’t contain an empty space, that’s why _-char is used.

Figure 2: New window choices and given name.

Creating Basic Geometry

We need to design a roller for a belt. Select Revolve tool ( ) from Shapes group. Hold RMB on
graphical area and select Define Internal Sketch. The Sketch window opens. Select RIGHT plane as
Sketch Plane, TOP as Reference (if not already selected) and Top as Orientation. Click Sketch.

Creating a sketch

Create Centerline ( ) from Datum group to be an Axis of Revolution for our profile. Select two points
from horizontal reference line to attach centerline to it; MMB to close the tool. The geometry for a
belt roller is symmetric, so we can use it when sketching. First, select a (symmetric) centerline ( ) from
Sketching group. Select two points from vertical reference line to attach centerline to it; MMB to close
the tool. Then sketch an open loop containing seven lines using Line ( from Sketching group) as

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shown in Figure 3. Avoid equal line snapping (shows letter L in green) when sketching. Close the loop
with MMB and the tool with MMB again. We don’t care about the dimension values in this state.

Figure 3: Sketching lines, a moment before MMB.

Several weak dimensions are automatically created. Next we use geometric constrains to clean up the
sketch. Select Equal ( ) from Constrain group and select two lines (4 to 3 and 5 to 6) and click MMB.
Then click MMB again to close the tool. Hide the planes ( from Graphics Toolbar) to make
sketching more clear. Then select all sketched lines by selecting one point outside the lines (a) and
hold LMB until all sketch lines are within created box (Figure 4). Then select Mirror tool ( ) from
Editing group and select vertical center line as a mirror line. The sketch is mirrored. Notice, that
topmost and bottommost lines are longer than before.

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Figure 4: Selecting all sketched lines.

Now our sketch’s lines are ready. Next we define dimensions we want to use. In last exercise, we
learned how to use Normal tool for basic dimensioning; now we learn how to use it to make a
diameter dimension. Select the Normal tool ( ) from Dimension group. Select the topmost
horizontal line (1), select the centerline (2), the topmost line again (3) and then click MMB to make a
dimension (Figure 5). Using this method and method learned in previous exercise, finish the
dimensioning as shown in Figure 6. To make things easier, start dimensioning from the smallest
dimension.

Figure 5: Making a diameter dimension (line (1), centerline (2) and line (3) again).

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Figure 6: Ready to accept sketch.

When ready, accept the sketch ( or hold RMB and select OK). Now we are back in the part mode.

Finalizing the revolve

Everything should be fine, accept the feature ( or MMB). Rename the feature as BASE (RMB over
the feature, select Rename from the menu or select the feature and press F2). Save the model!

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Making a Slot for a Belt

Next we need some slot for a belt, the smooth surface is not ideal for holding a belt. This slot can be
modeled into a previous feature, but to make the model easy to read and change, a separate feature
is a must. In general, one function per feature is a good guideline. This allows us to create a fully
different kind of a slot to hold a belt in the future; we don’t need to go to BASE feature and redefine
it. It can be also viewed from manufacturing point of view: The BASE feature is made e.g. with casting
and then the slot for the belt is made with a lathe (by removing material, of course).

Select the Revolve tool ( ), hold RMB on graphics area and select Define Internal Sketch from the
menu. Sketch window opens, select Use Previous. Now we are in the sketching mode, using the same
sketching and reference plane as in a previous revolve feature. Open References by holding RMB and
selecting References from the menu. Remove RIGHT from references (we need another reference).
Select the topmost edge and both sides from the previous feature as references (Figure 7). Close the
References window.

Figure 7: References for sketch (in turquoise).

Next we sketch lines for our slot. Use Line tool and create a open loop with three lines as shown in
Figure 8. End the loop with MMB and close the tool by pressing MMB again. We don’t care about the
dimensions at this point. Use the Equal constraint ( ) and select lines from 1 to 2 and from 3 to 4.
Close the tool when ready (MMB).

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Figure 8: The open profile for the sketch. A moment before pressing MMB.

We need that this sketch is symmetric to FRONT plane. This can be done with two ways: using
midpoint (creating a point in the middle of horizontal line and making it consistent to FRONT) or with
symmetry (making a centerline to FRONT plane and using symmetry constraint by selecting that
centerline along with points 1 and 4). Let’s do it with a middle point. Select a Point tool ( ) from
Sketching group. Hover mouse over horizontal line until it offers a midpoint constraint (letter M,
Figure 9) and select that point. Now we have a point that is always in the middle of the line.

Figure 9: Snapping to midpoint constraint (M).

Next we say to the program that we want that this previously created point is always attached to a
FRONT plane. Select Coincident ( ) from Constrain group. Select that previously created point and
then the vertical reference line that goes through FRONT plane. Close the tool. Now we have only
three dimensions. Finish the dimensioning as shown in Figure 10.

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Figure 10: Ready sketch.

Accept the sketch ( ). We need to define an axis of revolution to our feature, because we didn’t
create one when sketching. Put Axis Display ( ) on, select the axis that is in the center of the
previous feature (there should be only one axis). Notice, that Remove Material is automatically
selected and thus in preview material is also removed (Figure 11). This is because program notices
that it doesn’t make any sense to add material inside existing material, so it offers an option to
remove material. Rename the feature to BELT_SLOT (Properties tab). When ready, accept the feature

( or MMB). Remember to save the model!

Figure 11: Ready to accept the revolve feature.

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Redefining Existing Features

Now we have a dimensional problem: the diameter of the belt contact circle doesn’t exist, we only
have the whole wheel diameter and the depth of the belt slot. The belt contact diameter is something
that we need in our model because it is needed to e.g. calculating the gear ratio; to calculate the gear
ratio we don’t care about the thickness of the belt. So, let’s change our feature in that way that we
have the belt contact diameter in the sketch.

Click the symbol on the left of the BASE_SLOT feature, select its internal sketch (Section 1) and click
RMB (Figure 12). There are two options to edit the selected feature: Edit, which allows changing the
existing dimensions and Edit Definition, which allows changing the sketch (or feature) definition e.g.
sketching new lines, making new dimensions or changing references. Select Edit Definition.

Figure 12: RMB menu for internal sketch of BELT_SLOT feature.

We are back in the sketching mode. Hold RMB and select References. Notice, that there are only two
references (the upper surface of the first revolve feature and the FRONT plane) although as seen in
Figure 7 there were four references. This is because the program removes unused references when
our feature (BELT_SLOT) is ready. This keeps the sketches clean and interdependence with other
features minimal. Select the axis of the previous feature as a reference (Figure 13). To select the axis
be sure that your Axis Display in Graphical Toolbar is set on.

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Figure 13: New reference (axis) for the sketch.

Next create a (symmetry) Centerline ( , from Sketching group) to be on top of the previously defined
reference line (axis A_1). Then select the Normal tool ( ) from Dimension group, select the
horizontal line, select the centerline, select the line again and press MMB to create a diameter
dimension where your mouse is at that time. (If you select horizontal line only one time, it creates a
radius dimension.) The Resolve Sketch window opens (Figure 14). This happens because our sketch is
over-constrained; all the demands can’t be true at the same time, the sketch has only one degree of
freedom in vertical (i.e. only one dimension is needed to define the height of our sketch). The
program has listed all constrains that are overlapping each other. Select the 10 mm dimension from
the list and select Delete. This removes that dimension and now the height of the sketch is defined by
the belt contact diameter. Select MMB to close the Normal tool. Notice that the newly created
dimension is colored blue. This means that the dimension is created by the user (strong dimension),

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but it is not locked. Select the horizontal line, hold LMB and drag the line; you can see that the
geometry moves and also the dimension value updates. To prevent this to happen, double-click the
diameter dimension and give it a value of 380. Notice that the dimension is now green. When you
modify a strong or weak dimension by giving it a new value, program automatically locks that
dimension. (This can be done also by selecting the dimension, holding RMB and selecting Lock from
the menu.)

Figure 14: Resolve Sketch window.

When ready, accept the sketch ( or hold RMB and select OK). We are now back in part mode.
Notice that we didn’t need to accept the revolve feature. This was because we edited the internal
sketch directly. We can also change the internal sketch by selecting Edit Definition for the base
feature (BELT_SLOT), selecting Placement tab and then select Edit (or hold RMB in graphical area and
select Edit Internal Sketch). When the sketch is closed, the dashboard of the base feature stays active
and we can change values there.

Making Cuts
Our wheel is too heavy; we need to make it lighter.

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Select the Extrude tool ( ) from Shapes group. Hold RMB on graphics area, select Define Internal
Sketch, select FRONT as a sketching plane, TOP as a reference plane and Orientation to be Top. Click
Sketch.

Sketching

Using Arc tool with Center and Ends ( ) from Sketching group, sketch two arcs (from 1 to 2 and from
4 to 3) and then using Line tool ( ) connect those arcs (Figure 15). Avoid any snapping (i.e. automatic
constraint adding). At this moment, we don’t care about the dimensions and their values!

Figure 15: Sketched geometry.

Next we use constraints to redefine the geometry. Select Perpendicular ( ) from Constraint tab,
select the bottommost arc (4 to 3) and select the line (1 to 4); now the arc and the line are
perpendicular. Use the same method with the other straight line (2 to 3). Next, select Horizontal ( )
from Constraint tab, select point 4, point 3 and close the tool with MMB; this makes those points to
be at the same horizontal line and thus makes the sketch symmetric to the vertical reference line.

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Figure 16: Two Perpendicular and one Horizontal constraints.

We need that our cut follows the size of the wheel (i.e. BASE feature). For this reason, select
References (from ribbon or from RMB menu) and add two surfaces from BASE feature as shown in
Figure 17.

Figure 17: Added reference surfaces.

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Now it is time for dimensions. Select Normal tool (from ribbon or hold RMB and select Dimension).
Select the upper arc, then the upper reference circle and press MMB between those two; this creates
a distance dimension between those arcs. Give a value of 10. Use the same method for the lower arc
and the reference circle, give also a value of 10. The Normal tool is still active. Select the one straight
line, then the other one and MMB between those two; this creates an angular dimension. Give a
value of 60. Close the tool with MMB. Your sketch should look like in Figure 18. The sketch is ready,
accept it (you should already know how to do it).

Figure 18: Ready to accept sketch.

Making Extrusion to both sides

We are back in the part mode. Notice that the sketch is made in the middle plane of our part and
program offers extrusion with value # to a direction of the positive plane side (blue side is positive,
red is negative) with Remove Material option on (Figure 19).

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Figure 19: Default definition options for Extrude.

Default definition for Extrude is not acceptable. First, we don’t need any dimensions. We want that
this shape is cut through the existing material. Secondly, we want that this cut cuts material to both
sides (positive and negative). Select Options tab from Extrude dashboard. Here you can define
extrusion types for both sides (Side 1 and Side 2). Select Through All for both sides. Now we are
cutting through the material for both directions from the sketching plane (FRONT). If your model
looks like in Figure 20, accept the feature. Rename the feature as CUT.

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Figure 20: Ready to accept Extrude. Notice sketch outline in green.

Our cut’s edges are very sharp; let’s put some rounds. Select the Round tool ( ) from Engineering
group. First we create rounds for four edges of the CUT feature. Hoover the mouse over one edge as
shown in Figure 21. Then right-click until all four edges of CUT feature are highlighted (Figure 22) and
then select them with LMB. In general, clicking the right mouse button selects objects (edges,
surfaces, planes etc.) in the area of the mouse pointer. Give a value of 10 to be as rounding
dimension. Then choose Sets tab and select New set. Using right click(s) choose all edges as shown in
Figure 23. Give a value of 3.

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Figure 21: Hovering the mouse over one edge of CUT feature.

Figure 22: All edges of the feature CUT highlighted using right-clicks, a moment before selecting them.

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Figure 23: Selecting edges for second Set, a moment before selecting.

Now we have two different kinds of rounds within one Round feature. Sets can be used to clean up
the model tree and thus making removing the rounds from model easier (e.g. exporting geometry to
other programs). Remember to save your model.

Some notes about Intersect

When we were selecting edges for rounding, we said to program to select all edges of that feature.
This selection method is called intersecting. In Exercise 1.1, we selected certain edges, but if we
change the geometry enough, the edges may change and thus our rounds will fail. With intersecting
we are safer, because we are not referring to certain edge, but to all edges. For example, in Figure 24
the cut geometry is changed, but the Round feature and its sets are untouched. Do not change your
model!

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Figure 24: CUT feature dramatically changed, but Round feature untouched.

Multiplying Features
To get our wheel balanced, we need more of those cuts. A very bad way to add those is to change the
existing sketch and add them there (program understands multiple closed loops). Also a bad way is to
make entirely new cuts with the same values. The best way is to use a tool that is designed for

multiple features. This tool is called Pattern ( , in Editing group). There is one limitation with
pattern; it can only multiple one feature, but we want pattern both CUT and Round features. We can
do two separate patterns, but a better way is to group two features as one feature and then pattern
them.

Making groups

Select the CUT feature from the model tree, hold CTRL and select the Round feature. Now you have
both features selected, click RMB and select Group. Groups can be also used to clean up the model
tree by grouping features of s same kind (e.g. all rounds and chamfers as one group).

Making patterns

Select the newly created group and select the Pattern ( from Editing group or RMB and select
Pattern); the Pattern dashboard opens. Next we need to define the patterning method. By default

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Dimension is selected, click on that text on the left in the Pattern dashboard and select Axis from a
drop-down menu. Then select the only existing axis in the model (be sure that Axis Display is set on).
The program creates a rotational pattern with four instances (copied features, our group is the first
instance) using 90 as increment. We want five instances that are divided equal to one rotation
(360). To divide instances equal, select from the dashboard; the 90 value grays out and 360
lightens. Next change the amount of instances to five (5). Notice that the amount of preview circles
(location estimations for created instances) changes. Notice the vectors with numbers 1 and 2; those
are patterning directions (1 director along the angle, 2 radial distance from axis). If the preview looks
like in Figure 25, accept the feature (in a usual way). Rename the pattern as CUTS.

Figure 25: Ready to accept pattern.

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Using Edit
The spokes look too thin and therefore we need to do something. One option is to redefine pattern
and say that we only want four cuts, but then the spokes are too thick. Other option is to change the
dimension of the cut (the angular one).

Select previously made pattern (CUTS), RMB, select Edit and notice that you can only change pattern’s
dimension(s). Therefore, select the arrow symbol left to the pattern’s name to see what belongs to
pattern feature. You see that there are five groups under the feature. Select first group, RMB, select
Edit and notice that you can change all dimensions of that group (the dimensions of the cut and the
dimensions of the round). Select the arrow symbol left to the first group to see what is there, select
CUT feature, RMB, select Edit and notice that you can only change dimensions that this feature has
and the dimensions of the pattern where this feature belongs. Change the angular dimension from
60 to 50 by double-clicking it, giving a new value and hitting ENTER to update the geometry (Figure
26). Notice that all other patterned cuts are also updated. Move the mouse, click LMB, move it again,
click LMB to get out of Edit mode. Remember to save your model.

Figure 26: Changed CUT feature. Changed dimension highlighted in bright green.

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Adding Other Features

Create a Round feature with one set (remember to hold CTRL when selecting multiple edges) and a
radius of 4 as shown in Figure 27. Create also a Chamfer of 4 (45 x D) to eight edges shown in Figure
28. Now our part doesn’t have any sharp edges.

Figure 27: Four edges rounded, notice that the geometry is symmetric.

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Figure 28: Eight edges chamfered, notice that the geometry is symmetric.

Changing Part’s Name

We have created a belt wheel, but it is named as belt roller; we need to change our part’s name to be
more corresponding with its function. A bad way to change part’s name is through the operating
system (Windows), because then all the older versions need to be changed also (and in assemblies
you have big problems). Therefore, change the part’s name only through Creo. Select File, Manage
File and select Rename. Rename part as belt_wheel. Notice that all older versions of that file are also
renamed.

Save the model. This ends this exercise; your model should look like in Figure 1.

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