Lesson 4 Extrusions

Figure 4.1 Clamp

OBJECTIVES
Create a feature using an Extruded protrusion Understand Setup and Environment settings Define and set a Material type Create and use Datum features Sketch protrusion and cut feature geometry using the Sketcher Understand the feature Dashboard Copy a feature Save and Delete Old Versions of an object

Extrusions
The design of a part using Pro/E starts with the creation of base features (normally datum planes), and a solid protrusion. Other protrusions and cuts are then added in sequence as required by the design. You can use various types of Pro/E features as building blocks in the progressive creation of solid parts (Fig. 4.1). Certain features, by necessity, precede other more dependent features in the design process. Those dependent features rely on the previously defined features for dimensional and geometric references. The progressive design of features creates these dependent feature relationships known as parentchild relationships. The actual sequential history of the design is displayed in the Model Tree. The parentchild relationship is one of the most powerful aspects of Pro/E and parametric modeling in general. It is also very important as you modify a part. After a parent feature in a part is modified, all children are automatically modified to reflect the changes in the parent feature. It is therefore essential to reference feature dimensions so that Pro/E can correctly propagate design modifications throughout the model. An extrusion is a part feature that adds or removes material. A protrusion is always the first solid feature created. This is usually the first feature created after a base feature of datum planes. The Extrude Tool is used to create both protrusions and cuts. A toolchest button is available for this command or it can be initiated using Insert > Extrude from the menu bar. Figure 4.2 shows four different types of basic protrusions.
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Extrude

Revolve

Blend

Sweep
Figure 4.2 Basic Protrusions

The Design Process

It is tempting to directly start creating models. Nevertheless, in order to build value into a design, you need to create a product that can keep up with the constant design changes associated with the designthrough-manufacturing process. Flexibility must be integral to the design. Flexibility is the key to a friendly and robust product design while maintaining design intent, and you can accomplish it through planning. To plan a design, you need to understand the overall function, form, and fit of the product. This understanding includes the following points:
Overall size of the part Basic part characteristics The way in which the part can be assembled Approximate number of assembly components The manufacturing processes required to produce the part 150

Lesson 4 STEPS

Figure 4.3 Clamp and Datum Planes

Clamp
The clamp in Figure 4.3 is composed of a protrusion and two cuts. A number of things need to be established before you actually start modeling. These include setting up the environment, selecting the units, and establishing the material for the part. Before you begin any part using Pro/E, you must plan the design. The design intent will depend on a number of things that are out of your control and many that you can establish. Asking yourself a few questions will clear up the design intent you will follow: Is the part a component of an assembly? If so, what surfaces or features are used to connect one part to another? Will geometric tolerancing be used on the part and assembly? What units are being used in the design, SI or decimal inch? What is the parts material? What is the primary part feature? How should I model the part, and what features are best used for the primary protrusion (the first solid mass)? On what datum plane should I sketch to model the first protrusion? These and many other questions will be answered as you follow the systematic lesson part. However, you must answer many of the questions on your own when completing the lesson project, which does not come with systematic instructions. Launch Pro/ENGINEER WILDFIRE 5.0 > File > Set Working Directory > select the working directory > OK > Create a new object > > Name CLAMP > > OK > File > Properties [Fig. 4.4(a)] > Units change (Units Manager dialog box opens) [Fig. 4.4(b)] > millimeter Newton Second (mmNs) > Set > > OK

> Close
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Figure 4.4(a) Model Properties

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Figure 4.4(b) Units Manager

Click: Material change > steel.mtl >

[Fig. 4.4(c)] > double click on

[Fig. 4.4(d)]

Figure 4.4(c) Material File

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Figure 4.4(d) Material Definition, Structural Tab

Click: Thermal tab [Fig. 4.4(e)] > investigate other options and tabs > Ok > OK > Close > [you can end commands by Enter or OK or MMB (middle mouse button)]

> Enter

Figure 4.4(e) Material Definition, Thermal Tab 154

Since was selected, the default datum planes and the default coordinate system are displayed in the graphics window and in the Model Tree. The default datum planes and the default coordinate system will be the first features on all parts and assemblies. The datum planes are used to sketch on and to orient the parts features. Having datum planes as the first features of a part, instead of the first extrusion, gives the designer more flexibility during the design process. Picking on an item in the Model Tree will highlight that item on the model (Fig. 4.5).

Figure 4.5 Default Datum Planes and Default Coordinate System

Select on the FRONT datum plane in the Model Tree >

Sketch Tool from Right Toolchest > Sketch

dialog box opens [Fig. 4.6(a)] > accept the default selections, click:

Figure 4.6(a) Sketch Dialog Box 155

Click: RMB > References [Fig. 4.6(b)] (the RIGHT and TOP datum planes are the positional/dimensional references) > Close > Toggle the grid on (from Top Toolchest) [Fig. 4.6(c)]

Figure 4.6(b) References Dialog Box

Figure 4.6(c) Grid On

The sketch is now displayed and oriented in 2D [Fig. 4.6(c)]. The coordinate system is at the middle of the sketch, where datum RIGHT and datum TOP intersect. The X coordinate arrow points to the right and the Y coordinate arrow points up. The Z arrow is pointing toward you (out from the screen). The square box you see is the limited display of datum FRONT. This is similar to sketching on a piece of graph paper. Pro/E is not coordinate-based software, so you need not enter geometry with X, Y, and Z coordinates. Use Shift+MMB and Ctrl+MMB to reposition and resize the sketch as needed. Since you now have a visible grid, turn on the grid snap to have your sketch picks lock to the grid position. Click: Tools from Top Toolchest > > [Fig. 4.6(d)] > Apply > OK

You can control many aspects of the environment in which Pro/E runs with the Environment dialog box. To open the Environment dialog box, click Tools > Environment on the menu bar or click the appropriate icon in the toolbar. When you make a change in the Environment dialog box, it takes effect for the current Pro/E session only. When you start Pro/E, the environment settings are defined by Pro/E configuration defaults. Config settings can also be set using: Tools > Options.

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Depending on which Pro/E Mode is active (here it is the Part Mode), some or all of the following options may be available in the Environment dialog box: Display:
Dimension Tolerances Display model dimensions with tolerances Datum Planes Display the datum planes and their names Datum Axes Display the datum axes and their names Point Symbols Display the datum points and their names Coordinate Systems Display the coordinate systems and their names Spin Center Display the spin center for the model Reference Designators Display reference designation of Cabling, ECAD, and Piping components Thick Cables Display a cable with 3-D thickness Centerline Cables Display the centerline of a cable with location points Internal Cable Portions Display cable portions that are hidden from view Colors Display colors assigned to model surfaces Textures Display textures on shaded models Levels of Detail Controls levels of detail available in a shaded model during dynamic orientation

Default Actions:
Ring Message Bell Ring bell (beep) after each prompt or system message Save Display Save objects with their most recent screen display Snap to Grid Make points you select on the Sketcher screen snap to a grid Keep Info Datums Control how Pro/E treats datum planes, datum points, datum axes, and coordinate systems created on the fly under the Info functionality Use 2D Sketcher Control the initial model orientation in Sketcher mode Use Fast HLR Make possible the hardware acceleration of dynamic spinning with hidden lines, datums, and axes

Display Style:
Wireframe Model is displayed with no distinction between visible and hidden lines Hidden Line Hidden lines are shown in gray No Hidden Hidden lines are not shown Shading All surfaces and solids are displayed as shaded

Standard Orient:
Isometric Standard isometric orientation Trimetric Standard trimetric orientation User Defined User-defined orientation

Tangent Edges:
Figure 4.6(d) Environment Dialog Box Solid Display tangent edges as solid lines No Display Blank tangent edges Phantom Display tangent edges in phantom font Centerline Display tangent edges in centerline font Dimmed Display tangent edges in the Dimmed Menu system

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Because you checked , you can now sketch by simply picking grid points representing the parts geometry (outline). Because this is a sketch in the true sense of the word, you need only create geometry that approximates the shape of the feature; the sketch does not have to be accurate as far as size or dimensions are concerned. No two sketches will be the same between those using these steps, unless you count each grid space (which is unnecessary). Even with the grid snap off, Pro/E constrains the geometry according to rules, which include but are not limited to the following: RULE: Symmetry DESCRIPTION: Entities sketched symmetrically about a centerline are assigned equal values with respect to the centerline RULE: Horizontal and vertical lines DESCRIPTION: Lines that are approximately horizontal or vertical are considered exactly horizontal or vertical RULE: Parallel and perpendicular lines DESCRIPTION: Lines that are sketched approximately parallel or perpendicular are considered exactly parallel or perpendicular RULE: Tangency DESCRIPTION: Entities sketched approximately tangent to arcs or circles are assumed to be exactly tangent

The outline of the parts primary feature is sketched using a set of connected lines. The parts dimensions and general shape are provided in Figure 4.6(e). The cut on the front and sides will be created with separate sketched features. Sketch only one series of lines (8 lines in this sketch). Do not sketch lines on top of lines. It is important not to create any unintended constraints while sketching. Therefore, remember to exaggerate the sketch geometry and not to align geometric items that have no relationship. Pro/E is very smart: if you draw two lines at the same horizontal level, Pro/E assumes they are horizontally aligned. Two lines the same length will be constrained as so.

Figure 4.6(e) Front View of Drawing Showing Dimensions for the Clamp (commands start on next page)

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With your cursor anywhere in the graphics window, but not on an object, click: RMB [Fig. 4.6(f)] > Centerline > pick two vertical positions on the RIGHT datum plane to create the centerline [Fig. 4.6(g)]

Figure 4.6(f) RMB Options

Figure 4.6(g) Create the Centerline

Click: MMB > LMB > RMB > Line > sketch the eight lines of the closed outline [Fig. 4.6(h)] > MMB to end the line sequence [Fig. 4.6(i)] > MMB to end the current tool > LMB

Figure 4.6(h) Sketching the Outline

Figure 4.6(i) Default Dimensions Display 159

A sketcher constraint symbol appears next to the entity that is controlled by that constraint. Sketcher constraints can be turned on or off (enabled or disabled) while sketching. Simply click your RMB as you sketch- before picking the position- and the constraint that is displaying will have a slash imposed over it. This will disable it for that entity. An H next to a line means horizontal; a T means tangent. Dimensions display, as they are needed according to the references selected and the constraints. Seldom are they the same as the required dimensioning scheme needed to manufacture the part. You can add, delete, and move dimensions as required. The dimensioning scheme is important, not the dimension value, which can be modified now or later. Place and create the dimensions as required. Do not be concerned with the perfect positioning of the dimensions, but in general, follow the spacing and positioning standards found in the ASME Geometric Tolerancing and Dimensioning standards. This saves you time when you create a drawing of the part. Dimensions placed at this stage of the design process are displayed on the drawing document by simply showing all the dimensions. To dimension between two lines, simply pick the lines with the left mouse button (LMB) and place the dimension value with the middle mouse button (MMB). To dimension a single line, pick on the line (LMB), and then place the dimension with MMB. > (it is easier to position the dimensions with Snap to Grid Click: Tools > off) > Apply > OK > RMB > Dimension > add and reposition dimensions

(To move a dimensionclick: the LMB > move it to a new position > release the LMB)

> pick a dimension > hold down

______________________________________________________________________________________________

If any of the dimension values are light gray in color, they are called weak dimensions. If a weak dimension matches your dimensioning scheme, you can make them strongclick: a weak dimension value (will highlight in Red) > RMB > Strong [Fig. 4.6(j)] > pick on

Figure 4.6(j) Strong

Next, control the sketch by adding symmetry constraints, click: > > Symmetric [Fig. 4.6(k)] > pick the centerline and then pick two vertices (endpoints) to be symmetric [Fig. 4.6(l)] > repeat the process and make the sketch symmetrical [Fig. 4.6(m)]

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Pick the centerline first, and then pick the two endpoints of the line

Figure 4.6(k) Constraints Palette

Figure 4.6(l) Adding Symmetry Constraint

Your original sketch values will be different from the example, but the final design values will be the same. DO NOT CHANGE YOUR SKETCH DIMENSION VALUES TO THOSE IN FIGURE 4.6(m).

Figure 4.6(m) Sketch is Symmetrical (your values may be different!)

Do not change your sketch dimension values to these sketch values. Later, you will modify your sketch to the required design dimensional values.

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Click: off > Tools > > > OK > > Window-in the sketch (place the cursor at one corner of the window with the LMB depressed, drag the cursor to the opposite corner of the window and release the LMB) to capture all four dimensions. They will turn red. > RMB > Modify [Fig. 4.6(n)] > > > click twice on length dimension (here it is 660, but your dimension may be different) in the Modify Dimensions dialog box and type the design value at the prompt (123) > Enter [Fig. 4.6(o)] > Regenerate the section and close the dialog [Fig. 4.6(p)] > doubleclick on another dimension on the sketch and modify the value > Enter > continue until all of the values are changed to the design sizes [Fig. 4.6(q)]

Figure 4.6(n) Modify Dimensions

Figure 4.6(o) Modify the 660 Dimension to 123 (your sketch weak dimension may be different)

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Figure 4.6(p) Modify each Dimension Individually

Figure 4.6(q) Modified Sketch showing the Design Values 163

From the Top Toolchest, click: Standard Orientation [Fig. 4.6(r)] > Refit [Fig. 4.6(s)] >

Color the inside of closed chains of sketched entities >

>

Continue with the current section from the Right Toolchest >

> OK (OK or Enter or MMB)

The datum curve (Sketch1) will remain highlighted, active and therefore selected.

Figure 4.6(r) Regenerated Dimensions

Figure 4.6(s) Completed Sketched Curve (Datum Curve) 164

With the sketch still selected, click:

Extrude Tool [Fig. 4.7(a)] > double-click on the depth value on

the model > type 70 [Fig. 4.7(b)] > Enter > place your pointer over the square white drag handle (it will turn black) > RMB > Symmetric [Fig. 4.7(c)] > [Fig. 4.7(d)] > > Enter

Figure 4.7(a) Depth of Extrusion Previewed

Figure 4.7(b) Modify the Depth Value

Figure 4.7(c) Symmetric

Figure 4.7(d) Completed Extrusion (Sketch is hidden in the Model Tree) 165

Click:

Tools

>

>

> >

> Apply > OK [Fig. 4.7(e)] > > Standard Orientation > Ctrl+S > Enter > File > Delete > Old Versions > Enter > LMB to deselect

Storing an object on the disk does not overwrite an existing object file. To preserve earlier versions, Pro/E saves the object to a new file with the same object name but with an updated version number. Every time you store an object using Save, you create a new version of the object in memory, and write the previous version to disk. Pro/E numbers each version of an object storage file consecutively (for example, box.sec.1, box.sec.2, box.sec.3). If you save 25 times, you have 25 versions of the object, all at different stages of completion. You can use File > Delete > Old Versions after the Save command to eliminate previous versions of the object that may have been stored. When opening an existing object file, you can open any version that is saved. Although Pro/E automatically retrieves the latest saved version of an object, you can retrieve any previous version by entering the full file name with extension and version number (for example, partname.prt.5). If you do not know the specific version number, you can enter a number relative to the latest version. For example, to retrieve a part from two versions ago, enter partname.prt.3 (or partname.prt.-2). You use File > Erase to remove the object and its associated objects from memory. If you close a window before erasing it, the object is still in memory. In this case, you use File > Erase > Not Displayed to remove the object and its associated objects from memory. This does not delete the object. It just removes it from active memory. File > Delete > All Versions removes the file from memory and from disk completely. You are prompted with a Delete All Confirm dialog box when choosing this command. Be careful not to delete needed files.

Figure 4.7(e) Isometric Orientation

Next, the cut through the middle of the part will be modeled.

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Click:

Extrude Tool > click on Sketch 1

in the Model Tree [Fig. 4.8(a)] > [Figs. 4.8(d-e)]

from

the dashboard >

[Fig. 4.8(b)] > OK [Fig. 4.8(c)] >

Figure 4.8(a) Click on the Sketch in the Model Tree

Figure 4.8(b) Unlink

Figure 4.8(c) Unlink Dialog Box

Figure 4.8(d) Edit the Internal Sketch

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Figure 4.8(e) Outline of Sketch 1

Click:

Hidden line > double-click on each value and modify to the design size [Fig. 4.8(f)]

Figure 4.8(f) Modify Dimensions Dialog Box

Click:

Shading >

> Standard Orientation

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Click: from the Right Toolchest > RMB > Remove Material > note the yellow direction arrow [Fig. 4.8(g)] > Options from the dashboard > Side 1 > Through All > Side 2 > Through All [Fig. 4.8(h)] > from dashboard > > Enter [Fig. 4.8(i)] > LMB to deselect

Figure 4.8(g) Cut Preview

Figure 4.8(h) Options Depth Side 2 169

Figure 4.8(i) Completed Cut

The next feature will be a 20 X 20 centered cut (Fig. 4.9). Because the cut feature is identical on both sides of the part, you can mirror and copy the cut after it has been created.

Figure 4.9 Top View of Drawing Showing Dimensions for Cut

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Click:

Extrude Tool > RMB > Remove Material >

from the dashboard [Fig. 4.10(a)] >

Sketch dialog box opens > Sketch Plane--- Plane: select TOP datum from the model as the sketch plane [Fig. 4.10(b)] > from the Sketch dialog box [Fig. 4.10(c)]

Figure 4.10(a) Placement

Figure 4.10(b) Top Datum Selected as Sketch Plane

Figure 4.10(c) Sketch Dialog Box

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Click: RMB > References > pick the left edge/surface of the part [Fig. 4.10(d)] to add it to the References dialog box [Fig. 4.10(e)] > Close > check to see if your grid snap is off, click: Tools from Top Toolchest > Environment > > Apply > OK

Figure 4.10(d) Add the left edge/surface of the part

Figure 4.10(e) References Dialog Box

Click: Hidden line > RMB > Centerline [Fig. 4.10(f)] > create a horizontal centerline through the center of the part by picking two positions along the edge of the FRONT datum plane > MMB > LMB

Figure 4.10(f) Horizontal Centerline 172

Click: RMB > Line > place the mouse on the left edge and create an open section with three lines [Fig. 4.10(g)] > MMB to end the line sequence > MMB to end the current tool [Fig. 4.10(h)] > from the

Right Toolchest [Fig. 4.10(i)] > Symmetric > pick the centerline [Fig. 4.10(j)] > pick a vertex (endpoint) [Fig. 4.10(k)] > pick a second vertex [Fig. 4.10(l)] to be symmetric > MMB [Fig. 4.10(m)]

Figure 4.10(g) Three Line Sketch

Figure 4.10(h) Default Dimension

Figure 4.10(i) Constraints

Figure 4.10(j) Pick the Centerline

Figure 4.10(k) Pick First Endpoint

Figure 4.10(l) Pick Second Endpoint

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Modify and reposition the values for the two dimensions (20 X 20) [Fig. 4.10(n)] > Orientation > Change depth direction > Options tab >

>

> Standard

[Fig. 4.10(o)]

Figure 4.10(m) Weak Dimensions

Figure 4.10(n) Modify Values to Design Sizes

Figure 4.10(o) Options Through All 174

Click:

from the dashboard >

>

Shading [Fig. 4.10(p)] >

> OK

Figure 4.10(p) Completed Cut

With the cut still highlighted (the extrude cut must be selected-highlighted for this tool to become active),

from the Right Toolchest, click: the Model Tree (Fig. 4.11) >

> select the RIGHT datum plane from the model or in or MMB > LMB (to deselect) > File > Save > Enter

Figure 4.11 With the Extruded Cut Highlighted (Selected) pick on the RIGHT Datum Plane 175

Rotate the model [Fig. 4.12(a)] >

> Standard Orientation > File > Exit > No

> > File > Save > OK > File > Exit > Yes

> RMB > Unhide [Fig. 4.12(b)]

Figure 4.12(a) Rotated Model

Figure 4.12(b) Unhide the Sketch

A complete set of extra projects are available at www.cad-resources.com > Downloads.

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