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Module 2: Understanding the Surface Modeling Workflow

Lab Exercises
If you are ready to start on the exercise for this module, please click the link below. Exercise 1: Planning the Design of a Shaver

Lecture Review
If you would like to review a text-based version of the materials presented in this lecture, please click here.

In surface modeling projects, the modeling tools and methods often remain similar for a specific type of product. Once you have established this workflow, you may use it to build similar models. Understanding a typical surface modeling workflow helps you to establish the workflow that you will use in your projects. To achieve intended results quickly, you need to plan the surface modeling projects carefully. Careful planning is even more critical when you are working in a team and other team members develop part of the model.

After completing this module, you will be able to: Describe the surface modeling workflow. Describe the use of a master model in surface modeling projects. Select appropriate surface modeling tools and methods. Create the assembly structure used in a surface modeling project.

Understanding the Surface Modeling Workflow

The figures in the slides illustrate the Shaver model. You will be designing this model using the surface modeling workflow. You start the design of a surface model by creating the preliminary product or assembly structure. Next, you define the design framework (skeleton) using datum planes, points, and curves. Next, you select the suitable design techniques and tools to create the surface features in the surface models. A body envelope, sometimes referred to as a master model, refers to the overall surface model of a body, shell, or enclosure that defines the shape of the product. It includes basic details that are necessary to define the shape but may not include intricate details (ex: louvers), since they are designed at the part detailing level. Using the body envelope, you design the body components such as the top and bottom halves (or the left and right halves) as well as other components. The figures on the next few slides display the body envelope of the Shaver model. You can copy surface references from the body parts within the assembly structure to capture design intent. Using the copied references and design framework, you finish developing the body parts and the design of the surface model.

Creating the Product Structure

The figures in the slide illustrate the skeleton part and the assembly of the internal parts. The first figure of the model tree displays the main assembly that contains the skeleton part and the internal parts. The other figure displays the assembly structure after creating and assembling the body envelope part and the split body components. In surface modeling projects, you design body envelopes by using references of the internal components. You may also refer to components to which the body envelope touches or to which it is tangent. Also, you may work with other designers who are creating components that are not part of the body, such as internal components. You may use the assembly structure and skeleton parts that your team has created or create a new skeleton part depending upon the needs of the project. Most body shells or enclosures are modeled as an overall body envelope (body shell without the splits). The envelope is used as a reference to develop the body parts. You can apply the Master Model technique to the surface modeling projects by: o Creating the empty part of the body envelope by using references from the assembly or the skeleton part. o Creating empty parts of the body components by using references from the assembly. o Splitting (trimming) the body envelope surface into body part surfaces.
o o

Copying the respective trimmed surfaces into empty body parts. Using the copied surfaces to develop solid parts.

Preparing For Geometry Creation

These figures illustrate the framework and the copied references used to develop the Shaver body envelope. It uses the surface of the head and the power plug as a reference. The Shaver body matches with the head surface in shape and is tangential to it. The surfaces are copied in the master body part using the Copy Geometry tool. Capturing Design Intent Before you start to create the surface model of the body envelope, you need to plan how you will build the model. Consider the following attributes: As body design projects often require modifications late in the design cycle (maybe after a market survey, in the case of a consumer product), you need to build a robust model to accommodate the possible changes. In case of symmetrical geometry, you need to determine and create the plane about which the surface model will be mirrored. Also, you need to determine whether you want to depend on copied reference features. o In the case of conceptual models, you may need to refer to some parts, but you may not want any associativity with the part. Creating the Framework A robust framework of datum planes, points, curves, and axes enables greater flexibility to change the surfaces. You may also create surface features for reference and to build further geometry based on them. Using References In case your envelope refers to the internal geometry or aligns with a developed part, you need to copy the references (such as curves and surfaces) into the part in which you develop the envelope.

Selecting Surface Modeling Tools

Design Intent and Surface modeling paradigm If you are working with constrained or defined geometry (for example, using drawing with views and sections) to create a surface model, then you use parametric surfacing tools. If you are developing a conceptual design, you use freeform surfacing tools. Often, a combination of the two techniques is required. Remember that Pro/ENGINEER Wildfire enables you to work with both of the paradigms in a single model. Design Input You build surface models with simple shapes using sweeps and blends if design inputs are sections and trajectories. In case of complex shapes, you may select Variable Section Sweeps or Swept Blend tools. You build models with Boundary Blend tools if the available data consists of sections and boundaries. You build models with freeform tools if inputs are either sketches or mockups (actual samples). General Guidelines Begin creating the models with simpler tools. You may use a different tool if the resulting surface does not match with the design intent.

Selecting Surface Modeling Approaches

The figures in the slide illustrate the Using Boundaries and Overbuild approaches in different model building stages. The following are commonly used approaches: Using Boundaries You build models by defining the boundaries and then filling them up with surfaces. You may create curve networks of boundaries and sections. Overbuilding You build intersecting surfaces and then merge or trim to achieve the final shape.

Combining the two approaches

You can combine both approaches while defining the surface models. You can use overbuilt surfaces to initialize the model, and then add a curved network to finish the surface models.

Creating the Body Envelope

The figures in the slide display the development of the Shaver body envelope. Notice the base (parting) surface that defines the parting line. Curves are helpful when designing robust surfaces and enable you to better control the shapes. You create cross-sections, trajectories, and a network of boundaries using curves. In surface models, drafts are not direct features like in solid models. You need to build the drafts in the envelope model while developing it. In case of a non-planar split of the two halves, it is a good practice to use a parting surface to build the model.

Creating the Body Envelope (cont.)

The figures in the slide illustrate the different stages of envelope development: Evaluation of the surface quality. Development of the body envelope with details. Splitting of the body components. Final body envelope. While developing surface models, it is essential that you continuously check and improve the surface quality and the shape. Also, you need to evaluate the surface model for the intended draft angle and modify the model if necessary. Once the body envelope is created, you add the features that define the overall shape of the body. After completing the body envelope, you plan the body components that are going to be split. Although you can create another part and develop the trimmed components in it, it helps to visualize the product and make modifications if you split the essential components within the body envelope part.

Developing Body Components

These figures display copying of the top body cover surface from the master part to the empty part in order to develop them into solids and for further detailing. It also shows all the components of the shaver model that use the envelope as reference. Once you have completed the body envelope with trimmed quilts that define the body components, you can copy the quilts in empty part files for further component design and development.

Exercise 1: Planning the Design of a Shaver

After successfully completing this exercise, you will know how to: Create empty part files using assembly references. Create an empty part file to develop the body envelope. Create empty part files of the body components. Create an assembly of the body envelope part file and the body components part files.

Smoothcut Inc. designs and manufactures electric shavers. They currently manufacture a range of cordless, battery-powered shavers. Due to the increasing demand for rechargeable shavers, they are designing a new model to cater to the changing market scenario.

The brief given to the design team specifies that they should reuse the existing rotary head with three cutters, since it is a reliable and successful design. Also, they are asked to design an ergonomic shape with contemporary looks. Management has finalized the new design based on the concept sketches prepared by the Industrial Design department. They have given their approval to the design team to create the digital models. The mockup is based on the digital model. When it is ready, the Marketing department will conduct consumer surveys to validate the design. Designers are planning to create a robust and flexible digital model to accommodate possible post-consumer survey changes. The Design Manager has prepared the main assembly structure using parts of the developed head and the internal parts. He has asked you to detail the assembly structure by including the parts in which you will develop the body envelope and the body components. During the design process, you may want to make changes in the packaging layout and the size of the PCB (Printed Circuit Board). However, as per the design brief, the Motor and Head cannot be altered, but can only be repositioned. Task 1. Review the shaver assembly structure. 1. Start Pro/ENGINEER Wildfire if necessary.

2. In the Folder Browser , browse to the following folder: C:\users\student\Surface_WF3\module_02. 3. Click the module_02 folder to view the contents of the folder in the browser. 4. Right-click on the module_02 folder, and select Set Working Directory. 5. Select the SHAVER.ASM from the browser to preview the model, and then click Open in Pro/E . 6. If necessary, click Datum Planes , Datum Axes , Datum Points , and Coordinate Systems from the main toolbar to disable their display.

Shaver Assembly

7. Review the components in the model tree.

Shaver Assembly Model Tree (Features not shown for clarity)

8. Notice that your team has already created the SHAVER_SKELETON.PRT to control the basic dimensions. Task 2. Review the SHAVER_SKELETON.PRT.

1. Select SHAVER_SKELETON.PRT from the model tree, right-click and select Open. 2. Click Datum Planes enable their display.
and Datum Axes from the main toolbar to

Skeleton Part

3. Click Tools > Parameters to review the parameters that control the shape and ergonomics. Notice that there are parameters for: o Head angle. o Overall length - distance between the Head from the Power Plug. o Distance of the Head from the PCB plane.


Parameters Dialog Box

4. Click OK from the Parameters dialog box. 5. Click File > Close Window to return to the SHAVER.ASM.
Task 3. Create the BODY_MASTER part in which you will develop the body envelope.

1. Click Create Component from the feature toolbar. o Ensure that the Type is set to Part and the Sub-type is Solid. o Type BODY_MASTER as the name, and click OK. 2. Click Copy From Existing from the Creations Options dialog box. o Click Browse, select Start_Part, and click Open. Click OK. 3. Right-click and select Default Constraint. o Click Complete Component from the dashboard.

Component Created

Each time you create a new model in this course, the system is configured to use 'start parts' stored in the class files Templates folder as model templates. These templates were configured especially for this training course, and do not necessarily reflect the default Pro/ENGINEER templates, or the customized templates your company may use as defaults.


Task 4. Create additional parts for the other body components.

1. Click Create Component from the feature toolbar. o Type BODY_UPPER as the name, and click OK. o Click OK from the Creations Options dialog box. 3. Right-click and select Default Constraint. o Click Complete Component from the dashboard. 4. Repeat the previous three steps to create the following part models: o BODY_LOWER.PRT. o TRIMMER.PRT. o RIGHT_TRIM.PRT. o POWER_SWITCH.PRT.

Components Created

Task 5. Create the LEFT_TRIM part as a mirror of the RIGHT_TRIM part.

1. Click Create Component from the feature toolbar. o Select Mirror as the Sub-type. o Type LEFT_TRIM as the Name, and click OK. o Select RIGHT_TRIM.PRT from the model tree as the part reference. o Expand RIGHT_TRIM.PRT in the model tree and select datum plane FRONT as the planar reference. o Click OK from the Mirror Part dialog box. 2. Select the LEFT_TRIM part in the model tree and drag to reorder it directly after the RIGHT_TRIM.PRT.


Model Tree

3. Click Save from the main toolbar and click OK. 4. Click File > Close Window. 5. Click File > Erase > Not Displayed> OK. This completes the exercise.

After successfully completing this module, you should know how to: Describe the surface modeling workflow. Describe the use of a master model in surface modeling projects. Select appropriate surface modeling tools and methods. Create the assembly structure used in a surface modeling project.