NX 10 For Engineering Design (1-3)
NX 10 For Engineering Design (1-3)
By
Ming C. Leu
Amir Ghazanfari
Krishna Kolan
CHAPTER 1 – INTRODUCTION.........................................................................2
3.1 Overview.............................................................................................................................33
3.2 Sketching Environment.......................................................................................................34
3.3 Sketch Curve Toolbar.........................................................................................................35
3.4 Constraints Toolbar.............................................................................................................37
3.5 Examples.............................................................................................................................40
3.5.1 Arbor Press Base.........................................................................................................40
3.5.2 Impeller Lower Casing................................................................................................44
3.5.3 Impeller.......................................................................................................................48
CHAPTER 5 – DRAFTING.................................................................................99
5.1 Overview.............................................................................................................................99
5.2 Creating a Drafting............................................................................................................100
5.3 Dimensioning....................................................................................................................105
5.4 Sectional View..................................................................................................................108
5.5 Product and Manufacturing Information...........................................................................109
5.6 Example............................................................................................................................112
5.7 Exercise.............................................................................................................................116
6.1 Terminology......................................................................................................................117
6.2 Assembling Approaches...................................................................................................118
6.2.1 Top-Down Approach................................................................................................118
6.2.2 Bottom-Up Approach................................................................................................118
6.2.3 Mixing and Matching................................................................................................119
6.3 Assembly Navigator..........................................................................................................119
6.4 Mating Constraints............................................................................................................120
6.5 Example............................................................................................................................120
6.5.1 Starting an Assembly................................................................................................121
6.5.2 Adding Components and Constraints........................................................................124
6.5.3 Exploded View..........................................................................................................132
6.6 Exercise.............................................................................................................................135
CHAPTER 7 – FREEFORMING......................................................................137
7.1 Overview...........................................................................................................................137
7.1.1 Creating Freeform Features from Points...................................................................138
7.1.2 Creating Freeform Features from Section Strings....................................................138
7.1.3 Creating Freeform Features from Faces....................................................................139
7.2 FreeForm Feature Modeling.............................................................................................139
7.2.1 Modeling with Points................................................................................................140
7.2.2 Modeling with a Point Cloud....................................................................................141
7.2.3 Modeling with Curves...............................................................................................143
7.2.4 Modeling with Curves and Faces..............................................................................144
7.3 Exercise.............................................................................................................................146
CHAPTER 9 – MANUFACTURING................................................................165
NX is one of the world’s most advanced and tightly integrated CAD/CAM/CAE product
development solution. Spanning the entire range of product development, NX delivers immense
value to enterprises of all sizes. It simplifies complex product designs, thus speeding up the
process of introducing products to the market.
This self-guiding tutorial provides a step-by-step approach for users to learn NX 10. It is
intended for those with no previous experience with NX. However, users of previous versions of
NX may also find this tutorial useful for them to learn the new user interfaces and functions. The
user will be guided from starting an NX 10 session to creating models and designs that have
various applications. Each chapter has components explained with the help of various dialog
boxes and screen images. These components are later used in the assembly modeling, machining
and finite element analysis. The files of components are also available online to download and
use. We first released the tutorial for Unigraphics 18 and later updated for NX 2 followed by the
updates for NX 3, NX 5, NX 7 and NX 9. This write-up further updates to NX 10.
Our previous efforts to prepare the NX self-guiding tutorial were funded by the National Science
Foundation’s Advanced Technological Education Program and by the Partners of the
Advancement of Collaborative Engineering Education (PACE) program.
If you have any questions or comments about this tutorial, please email Ming C. Leu at
[email protected] or Amir Ghazanfari at [email protected]. The models and all the versions of the
tutorial are available at http://web.mst.edu/~mleu.
The product realization process can be roughly divided into two phases; design and
manufacturing. The design process starts with identification of new customer needs and design
variables to be improved, which are identified by the marketing personnel after getting feedback
from the customers. Once the relevant design information is gathered, design specifications are
formulated. A feasibility study is conducted with relevant design information and detailed design
and analyses are performed. The detailed design includes design conceptualization, prospective
product drawings, sketches and geometric modeling. Analysis includes stress analysis,
interference checking, kinematics analysis, mass property calculations and tolerance analysis,
and design optimization. The quality of the results obtained from these activities is directly
related to the quality of the analysis and the tools used for conducting the analysis.
The manufacturing process starts with the shop-floor activities beginning from production
planning, which uses the design process drawings and ends with the actual product. Process
planning includes activities like production planning, material procurement, and machine
selection. There are varied tasks like procurement of new tools, NC programming and quality
checks at various stages during the production process. Process planning includes planning for
all
the processes used in manufacturing of the product. Parts that pass the quality control inspections
are assembled functionally tested, packaged, labeled, and shipped to customers.
A diagram representing the Product Realization Process (Mastering CAD/CAM, by Ibrahim Zeid,
McGraw Hill, 2005) is shown below.
The roots of current CAD/CAM technologies go back to the beginning of civilization when
engineers in ancient Egypt recognized graphics communication. Orthographic projection
practiced today was invented around the 1800s. The real development of CAD/CAM systems
started in the 1950s. CAD/CAM went through four major phases of development in the last
century. The 1950s was known as the era of interactive computer graphics. MIT’s Servo
Mechanisms Laboratory demonstrated the concept of numerical control (NC) on a three-axis
milling machine. Development in this era was slowed down by the shortcomings of computers at
the time. During the late 1950s
the development of Automatically Programmed Tools (APT) began and General Motors
explored the potential of interactive graphics.
The 1960s was the most critical research period for interactive computer graphics. Ivan
Sutherland developed a sketchpad system, which demonstrated the possibility of creating
drawings and altercations of objects interactively on a cathode ray tube (CRT). The term CAD
started to appear with the word ‘design’ extending beyond basic drafting concepts. General
Motors announced their DAC-1 system and Bell Technologies introduced the GRAPHIC 1
remote display system.
During the 1970s, the research efforts of the previous decade in computer graphics had begun to
be fruitful, and potential of interactive computer graphics in improving productivity was realized
by industry, government and academia. The 1970s is characterized as the golden era for
computer drafting and the beginning of ad hoc instrumental design applications. National
Computer Graphics Association (NCGA) was formed and Initial Graphics Exchange
Specification (IGES) was initiated.
In the 1980s, new theories and algorithms evolved and integration of various elements of design
and manufacturing was developed. The major research and development focus was to expand
CAD/CAM systems beyond three-dimensional geometric designs and provide more engineering
applications.
The present day CAD/CAM development focuses on efficient and fast integration and
automation of various elements of design and manufacturing along with the development of new
algorithms. There are many commercial CAD/CAM packages available for direct usages that are
user-friendly and very proficient.
Solid Edge, AutoCAD and Mechanical Desktop are some low-end CAD software
systems, which are mainly used for 2D modeling and drawing.
NX, Pro-E, CATIA and I-DEAS are high-end modeling and designing software systems
that are costlier but more powerful. These software systems also have computer aided
manufacturing and engineering analysis capabilities.
ANSYS, ABAQUS, NASTRAN, and COMSOL are packages mainly used for analysis of
structures and fluids. Different software are used for different proposes.
Geomagic and CollabCAD are some of the systems that focus on collaborative design,
enabling multiple users of the software to collaborate on computer-aided design over the
Internet.
Following are the definitions of some of the terms used in this tutorial.
The most basic role of CAD is to define the geometry of design – a mechanical part, a product
assembly, an architectural structure, an electronic circuit, a building layout, etc. The greatest
benefits of CAD systems are that they can save considerable time and reduce errors caused by
otherwise having to redefine the geometry of the design from scratch every time it is needed.
One of the most important areas of CAM is numerical control (NC). This is the technique of
using programmed instructions to control a machine tool, which cuts, mills, grinds, punches or
turns raw stock into a finished part. Another significant CAM function is in the programming of
robots. Process planning is also a target of computer automation.
CAE tools are available for a number of different types of analyses. For example, kinematic
analysis programs can be used to determine motion paths and linkage velocities in mechanisms.
Dynamic analysis programs can be used to determine loads and displacements in complex
assemblies such as automobiles. One of the most popular methods of analyses is using a Finite
Element Method (FEM). This approach can be used to determine stress, deformation, heat
transfer, magnetic field distribution, fluid flow, and other continuous field problems that are
often too tough to solve with any other approach.
This tutorial is written for students and engineers who are interested in learning how to use NX
10 for designing mechanical components and assemblies. Learning to use this software will also
be valuable for learning how to use other CAD systems such as PRO-E and CATIA.
Chapter 2 includes the NX 10 essentials from starting a session to getting familiar with the NX
10 layout by practicing basic functions such as Print, Save, and Exit. It also gives a brief
description of the Coordinate System, Layers, various toolboxes and other important commands,
which will be used in later chapters.
Chapter 3 presents the concept of sketching. It describes how to create sketches and to give
geometric and dimensional constraints. This chapter is very important since present-day
components are very complex in geometry and difficult to model with only basic features.
The actual designing and modeling of parts begins with chapter 4. It describes different features
such as reference features, swept features and primitive features and how these features are used
to create designs. Various kinds of feature operations are performed on features.
You will learn how to create a drawing from a part model in chapter 5. In this chapter, we
demonstrate how to create a drawing by adding views, dimensioning the part drawings, and
modifying various attributes in the drawing such as text size, arrow size and tolerance.
Chapter 6 teaches the concepts of Assembly Modeling and its terminologies. It describes Top-
Down modeling and Bottom-Up modeling. We will use Bottom-Up modeling to assemble
components into a product.
Chapter 7 introduces free-form modeling. The method of modeling curves and smooth surfaces
will be demonstrated.
Chapter 8 is capsulated into a brief introduction to Design Simulations available in NX 10 for
the Finite Element Analysis.
The examples and exercise problems used in each chapter are so designed that they will be
finally assembled in the chapter. Due to this distinctive feature, you should save all the models
that you have generated in each chapter.
CHAPTER 2 – GETTING STARTED
We begin with starting of an NX 10 session. This chapter will provide the basics required to use
any CAD/CAM package. You will learn the preliminary steps to start, to understand and to use
the NX 10 package for modeling, drafting, etc. It contains five sub-sections a) Opening an NX 10
session, b) Printing, saving, and closing part files, c) getting acquainted with the NX 10 user
interface d) Using layers and e) Understanding important commands and dialogs.
OR
Go through the File drop-down menu at the top-left of the screen and click New
OR
Press <Ctrl> + N
This will open a new session, asking for the type, name and location of the new file to be created.
There are numerous types of files in NX 10 to select from the Templates dialogue box located at
the center of the window. The properties of the selected file are displayed below the Preview on
the right side. Since we want to work in the modeling environment and create new parts, only
specify the units (inches or millimeters) of the working environment and the name and location
of the file. The default unit is millimeters.
Enter an appropriate name and location for the file and click OK
2.1.3 Open a Part File
There are several ways to open an existing file.
Click on the Open or Open a Recent Part button on top of the screen
OR
Go through the File drop-down menu at the top-left of the screen and click Open
OR
Press <Ctrl> + O
The Open Part File dialog will appear. You can see the preview of the files on the right side of
the window. You can disable the Preview by un-clicking the box in front of the Preview button.
Save Work Part Only: This option will only save the
active part on the screen.
Save As: This option allows you to save the part on screen using a different name and/or type.
The default type is .prt. However, you can save your file as IGES (.igs), STEP 203 (.stp), STEP
214 (.step), AutoCAD DXF (.dxf), AutoCAD DWG (.dwg), CATIA Model (.model) and CATIA
V5 (.catpart).
Save All: This option will save all the opened part files with their existing names.
Save Bookmark: This option will save a screenshot and context of the present model on the
screen as a .JPEG file and bookmarks.
If you have files open and have made changes to them without saving, the message will ask you
if you really want to exit.
2.3 NX 10 INTERFACE
The user interface of NX 10 is made very simple through the use of different icons. Most of the
commands can be executed by navigating the mouse around the screen and clicking on the icons.
The keyboard entries are mostly limited to entering values and naming files.
If it is a scroll button, the object can be zoomed in and out by scrolling. Clicking the MB2 will
also execute the OK command if any pop-up window or dialog box is open.
Press and hold both MB1 and MB2 simultaneously and drag
OR
Press and hold <Ctrl> button on the keyboard and then press and drag the MB2
OR
Pan:
Press and hold both the MB2 and MB3 simultaneously and drag
OR
Press and hold <Shift> button on the keyboard and press and drag the MB2
Shortcut to menus:
Press and hold <Ctrl> + <Shift> and MB1, MB2 and MB3 to see shortcuts to Feature,
Direct Sketch, and Synchronous Modeling groups, respectively
2.3.2 NX 10 Gateway
The following figure shows the typical layout of the NX 10 window when a file is opened. This
is the Gateway of NX 10 from where you can select any module to work on such as modeling,
manufacturing, etc. It has to be noted that these toolbars may not be exactly on the same position
of the screen as shown below. The toolbars can be placed at any location or position on the
screen. Look out for the same set of icons.
Ribbon Bar
Top-border
Groups
Tabs Command Finder
Resource Bar
Graphic Window
Cue Line
NX will show you the path to the command: Menu →Insert →Sweep →Styled Sweep
OR
Type sweep in the Command Finder
2.3.2.4 Top-border
The most important button in the top-border is the menu button. Most of the features and
functions of the software are available in the menu. The Selection Bar displays the selection
options. These options include the Filters, Components/Assembly, and Snap Points for selecting
features. Most common buttons in the View tab are also displayed in the Top-border.
Part Navigator
History
Click on the History icon, the seventh from the top on the Resource bar
The History Palette provides fast access to recently opened files or other palette entries. It can be
used to reload parts that have been recently worked on or to repeatedly add a small set of palette
items to a model.
The History Palette remembers the last palette options that were used and the state of the session
when it was closed. NX stores the palettes that were loaded into a session and restores them in
the next session. The system does not clean up the History Palette when parts are moved.
To re-use a part, drag and drop it from the History
Palette to the Graphics Window. To reload a part,
click on a saved session bookmark.
The Layout tab allows you to select the User Interface Environment
The Options tab allows you, among others, to set the precision level (in the Information
Window)
The Journal tab in the Tools allows you to use several programming languages
The Macro tab in the Tools allows you to set the pause while displaying animation
2.3.4.2 Visualization
Choose Preferences →Visualization to find the
options in the dialog box
2.3.5 Applications
Applications can be opened using the File option
located at the top left corner of the main window OR
the Applications tab above the Ribbon bar. You can
select the type of application you want to run. For
example, you can select Modeling, Drafting,
Assembly, and so on as shown in the figure. The default Application that starts when you open a
file or start a new file is Modeling. We will introduce some of these Application in the next
chapters.
2.4 LAYERS
Layers are used to store objects in a file, and work like containers to collect the objects in a
structured and consistent manner. Unlike simple visual tools like Show and Hide, Layers provide
a permanent way to organize and manage the visibility and selectability of objects in your file.
Work
Selectable
Visible Only
Invisible
The Work Layer is the layer that objects are created ON and is
always visible and selectable while it remains the Work Layer.
Layer 1 is the default Work Layer when starting a new part file.
When the Work Layer is changed to another type of layer, the
previous Work Layer automatically becomes Selectable and can
then be assigned a status of Visible Only or Invisible.
Click OK
Move the cursor on to the Cone and click on it so that it becomes highlighted
Click OK
In the Destination Layer or Category space at the top of the window, type 25 and Click
OK
The Cone has now gone to the 25th layer. It can no longer be
seen in Layer 1.
You can see that Layer 25 has the object whereas the
default Work Layer 1 has no objects.
The Cone will again be seen on the screen. Save the file as we
will be using it later in the tutorial.
2.5 COORDINATE SYSTEMS
There are different coordinate systems in NX. A three-axis symbol is used to identify the
coordinate system.
The View Triad on the bottom-left of the Graphics window is ONLY a visual
indicator that represents the ORIENTATION of the Absolute Coordinate
System of the model.
You can save the current location and orientation of the WCS to
use as a permanent coordinate system.
2.6 TOOLBARS
Normally, the default setting should be sufficient for most operations but during certain
operations, you might need additional toolbars. If you want to add buttons pertaining to the
commands and toolbars,
Click on the pull-down arrow on any of the Toolbars and choose Customize.
This will pop up a Customize dialog window with all the Toolbars and commands pertaining to
each Toolbar under Commands tab. To add a command,
Choose a category and drag the command from the Commands list to the desired location.
You can customize the settings of your NX 10 interface
by clicking on the Roles tab on the Resource Bar.
In this chapter, you will learn how to create and edit sketches in NX 10. You can directly create a
sketch on a Plane in Modeling application. In most cases, Modeling starts from a 2D sketch and
then Extrude, Revolve or Sweep the sketch to create solids. Many complex shapes that are
otherwise very difficult to model can easily be drawn by sketching. In this chapter, we will see
some concepts of sketching and then proceed to sketch and model some parts.
3.1 OVERVIEW
An NX 10 sketch is a named set of curves joined in a string that when swept, form a solid. The
sketch represents the outer boundary of that part. The curves are created on a plane in the
sketcher. In the beginning, these curves are drawn without any exact dimensions. Then,
Dimensional Constraints as well as Geometric Constraints are applied to fully constrain the
sketch. These will be discussed in detail later in this chapter.
After sketching is completed, there are different ways to use them to generate 3D parts:
The curves used to create the profile outline are very flexible and can be used to model
unusual shapes.
The curves are parametric, hence associative and they can easily be changed or removed.
If the plane in which the sketch is drawn is changed, the sketch will be changed
accordingly.
Sketches are useful when you want to control an outline of a feature, especially if it may
need to be changed in the future. Sketches can be edited very quickly and easily.
The sketch plane will appear and the X-Y directions will be marked.
The main screen will change to the Sketching Environment. The XY plane is highlighted as the
default plane for sketching. This is the basic sketch window. There is also a special Sketch Task
Environment in NX 10 which displays all sketch tools in the main window. For accessing the
Sketch Task Environment,
Click the More option in the direct sketch tool bar area
There are three useful options next to the Finish Flag. You can
change the name of the sketch in the box. The next one is Orient to
Sketch which orients the view to the plane of the sketch. If the model
file is rotated during the process of sketching, click on this icon to
view the
sketch on a plane parallel to the screen Reattach attaches the sketch to a different planar face,
datum plane, or path, or changes the sketch orientation. It allows you to reattach the sketch to the
desired plane without recreating all the curves, dimensions, and constraints.
This option creates both straight lines as well as arcs depending on the icon you select in the pop-
up toolbar. You can pick the points by using the coordinate system or by entering the length and
angle of the line as shown in the following figures.
Line
Arc
This option creates arcs by either of two methods. The first option creates arc with three
sequential points as shown below.
The second option creates the arc with a center point, radius and sweep angle or by center point
with a start point and end point. The illustration is shown below.
Circle
This trims the extending curves from the points of intersection of the curves. This option reads
every entity by splitting them if they are intersected by another entity and erases the portion
selected.
Studio Spline
You can create basic spline curves (B-spline and Bezier) with poles or through points with the
desired degree of the curve. The spline will be discussed in detail in the seventh chapter
(Freeform Features).
All the curves are created by picking points. For example, a straight line is created with two
points. In a 2D environment, any point has two degrees of freedom, one along X and another
along Y axis. The number of points depends on the type of curve being created. Therefore, a
curve entity has twice the number of degrees of freedom than the number of points it comprises.
These degrees of freedom can be removed by creating a constraint with a fixed entity. In fact, it
is recommended that you remove all these degrees of freedom (making the sketch Fully
Constrained) by relating the entities directly or indirectly to the fixed entities. It can be done by
giving dimensional or geometric properties like Parallelity, Perpendicularity, etc.
In NX 10 smart constraints are applied automatically, i.e. automatic dimensions or geometrical
constraints are interpreted by NX 10. You can turn this option off by clicking on Continuous
Auto Dimensioning as shown below. The following paragraphs show how to manually apply
constraints.
Dimensional Constraints
The degrees of freedom can be eliminated by giving dimensions with fixed entities like axes,
planes, the coordinate system or any existing solid geometries created in the model. These
dimensions can be linear, radial, angular etc. You can edit the dimensional values at any time
during sketching by double-clicking on the dimension.
Geometric Constraints
Besides the dimensional constraints, some geometric constraints can be given to eliminate the
degrees of freedom. They include parallel, perpendicular, collinear, concentric, horizontal,
vertical, equal length, etc. The software has the capability to find the set of possible constraints
for the selected entities. As an example, a constraint is applied on the line in the below picture to
be parallel to the left side of the rectangle (the line was originally at an angle with the rectangle).
Clicking this icon will show all the options pertaining to the entities in that particular sketch in
white.
Show/Remove Constraints
This window lists all the constraints and types of constraints pertaining to any entity selected.
You can delete any of the listed constraints or change the sequence of the constraints.
The number of degrees of freedom that are not constrained are displayed in the Status Line. All
these should be removed by applying the constraints to follow a disciplined modeling.
3.5 EXAMPLES
Now we start by constraining between an entity in the sketch and a datum or a fixed reference.
First, place the center of the arc at the origin. This creates a reference for the entire figure. We
can use the two default X and Y axes as a datum reference.
Repeat the same procedure to place the center of the arc on the X-axis
Do not worry in case the figure gets crooked. The figure will come back to proper shape once all
the constraints are applied. However, it is better to take into consideration the final shape of the
object when you initially draw the unconstrained figure.
Select the two slanted lines and make them Equal Length
Similarly select the two long vertical lines and make them Equal Length
Select the bottom two horizontal lines and make them Collinear and then click on the
same lines and make them Equal Length
If you DO NOT find the two Blue circles (Tangent Constraints) near
the semicircle as shown in the figure, follow the below steps.
Otherwise, you can ignore this.
Select the circular arc and one of the two vertical lines connected to its endpoints
If the arc and line is already tangent to each other, the icon will be grayed out. If that is the case
Click on Edit →Selection →Deselect All. Repeat the same procedure for the arc and the
other vertical line.
Select the two vertical lines and make them Equal
Similarly select the two small horizontal lines at the top of the profile and make them
Collinear and Equal
Similarly select the two vertical lines and make them Equal
So far, we have created all the Geometric constraints. Now we have to create the Dimensional
constraints. If there is any conflict between the Dimensional and Geometric constraints, those
entities will be highlighted in yellow.
Add on all the dimensions as shown in the following figure without specifying the values
For example, to create a dimension for the top two corners,
Click somewhere near the top of the two diagonal lines to select them
While dimensioning, if you find the dimensions illegible, but do not worry about editing the
dimensions now.
Now we edit all the dimension values one by one. It is highly recommended to start editing from
the biggest dimension first and move to the smaller dimensions. Once enough number of
dimensions are provided, sketch color changes indicating it is fully defined.
Edit the values as shown in the figure below. Double click on each dimension to change
the values to the values as shown in figure below
Click on the Finish Flag on the top left corner or bottom right of the screen when
you are finished
Click on the sketch and select Extrude (this Feature is explained in details in the next
sections)
Extrude this sketch in the Z-direction by 60 mm
Make sure the Profile window is showing and draw the following curve
Line 2
Curve 1
Line 1
Curve 2
Create a point at the origin (0, 0, 0) by clicking the plus sign in the Direct Sketch
Click OK
Choose Edit →Move Object or choose Move Curve from the ribbon bar
Select the outer curve. Be sure to select all the four parts of the curve
Move the lower curve in the Y-direction by -1.5 inches. This is the same as translating it
in the negative YC-direction by 1.5 inches
Now we will create the curve required for outside of the casing on the smaller side which will
form the flange portion.
Move the lower curve in the XC-direction by -0.5 inches. This is the same as translating
it in the negative XC-direction by 0.5 inches
Using straight lines join the two lines as shown in the figure on right side
We will use this sketching in the next chapter to model the Impeller Lower
Casing.
3.5.3 Impeller
Create a new file in inches and save it as Impeller_impeller.prt
Click on Sketch
Click on the Arc icon on the side toolbar and click on the Arc by Center and Endpoints
Click on the point at the origin and create an arc with a radius of 1.5 similar to the one
shown in the figure below
Select the top endpoints of the two arcs you just created
and click somewhere in between to create another arc that connects them. Do the same for
the bottom endpoints
Click on the Constraints icon in the side toolbar
and make sure that all the arcs are Tangent to one
another at their endpoints
Give the Radius dimensions for each arc. Edit dimensions so that the two arcs on the
end are 1.5 and 0.5 inches and the two middle arcs are 18 and 15 inches as shown in
the figure below