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Learning Objectives:

Create an extruded surface.

Create a revolved surface.

Create a sweep surface.

Create a blended surface.

Create a swept blend surface.

Create a helical sweep surface.

Create a surface by blending the boundaries.

Create a surface using variable section sweep.

Create surfaces using style environment. Understand surface editing tools.

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Surface Modeling

Surface models are a type of three-dimensional (3D) models with no thickness.

These models are widely used in industries like automobile, aerospace, plastic,

medical, and so on.

In Pro/ENGINEER, the surface modeling techniques and feature creation tools arethe same as those used in solid modeling.

Creating Surfaces in Pro/ENGINEER Wildfire 4.0 In Pro/ENGINEER Wildfire 4.0, a sketch can be toggled between a solid model

and a surface model.

The two buttons that are used to toggle between the solid feature and a

surface feature are available on dashboards.

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Creating an Extruded Surface

To create an extruded surface, choose the Extrude button from the Base Features

toolbar.

The Extrude dashboard will be displayed, as shown in figure below.

TheExtrudedashboard

In this dashboard, the Extrude as solid button will be chosen by default.Choose the Extrude as surface button to extrude the sketch and create a

surface model.

A surface model can be extruded with capped ends or with open ends.

Figure A shows the open end surface model and Figure B shows the

capped end surface model.

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Figure ASurface with open ends Figure BSurface with capped ends

Creating a Revolved Surface

To create a revolved surface, choose theRevolve button fromtheBaseFeaturestoolbar.

TheRevolvedashboard will be displayed, as shown in figure given below.

TheRevolvedashboard

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Choose theRevolve as surfacebutton to create a revolve surface.

You can create a revolved capped end surface or an open end surface.

Figure A shows the open end revolve surface and Figure B shows the

capped end revolve surface.

Figure ARevolved surfacewith open ends

Figure BRevolved surfacewith capped ends

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Creating a Sweep Surface

To create a sweep surface feature, chooseInsert >Sweep >Surfacefrom themenu bar.

TheSWEEP TRAJmenu will be displayed.

Figures A and B show the sweep surfaces with the open and closed ends respectively.

Figure ASweep surface withopen ends created using aclosed sketch

Figure BSweep surface withcapped ends created using aclosed sketch

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Creating a Blended Surface

To create a surface blend, chooseInsert > Blend > Surfacefrom the menu bar.

TheBLEND OPTSmenu will be displayed.

Figure Ashows the blended surface with open ends andFigure Bshows theblended surface with capped ends.

Figure ABlended surface withopen ends

Figure BBlended surfacewith capped ends

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Creating a Swept Blend Surface

To create a swept blend surface, chooseInsert >Swept Blendfrom the menu bar.

TheSwept Blenddashboard will be displayed.

Figure A shows the swept blend with open ends and Figure B shows the sweptblend with capped ends.

Figure ASwept blend surfacewith open ends

Figure BSwept blend surfacewith capped ends

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Creating a Helical Sweep Surface

To create a surface helical sweep, chooseInsert>Helical Sweep>Surfacefromthe menu bar.

Figure Ashows the helical sweep surface with open ends andFigure B shows thehelical sweep surface with capped ends.

Figure AHelical sweep surface withopen ends created using an opensketch

FigureBHelical sweep featurewith capped ends created usingthe closed sketch

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Creating a Surface by Blending the Boundaries

To create a surface by blending the boundaries, datum curves, or points,choose theBoundary Blend button from theBase Featurestoolbar.

TheBoundary Blenddashboard will be displayed, as shown infigure givenbelow.

The use of this dashboard is discussed next.

The Boundary Blend dashboard

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Curves Tab

When you choose theCurvestab, the slide-down panel will be displayed.

Select the curves from the drawing area.

The surface is created as shown in figure given below.

Boundary blend surface

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Creating a Surface Using the Variable Section Sweep

To create a surface by using the variable section sweep, chooseInsert>Variable

Section Sweep from the menu bar.

TheVariable Section Sweepdashboard will be displayed.

The figure shows the section and the trajectories that are used to create the variable

section sweep surface.

Variable section sweep

surface with open ends

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Creating Surfaces Using the Style Environment of

Pro/ENGINEER Wildfire 4.0 Style is an environment available in Pro/ENGINEER that is used to draw free style

curves and create surfaces by joining them.

The surfaces created using the Styleenvironment are called Super features.

To enter the Styleenvironment, choose the Style buttonfrom the Base Features

toolbar or choose Insert> Stylefrom the menu bar.

Figure on the next slide shows the appearance of the Styleenvironment.

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TheStyleenvironment

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Style Tools Toolbar

Figure Ashows theStyle Toolstoolbar in theStyleenvironment.

The tools in this toolbar are discussed next.

Figure ATheStyle Toolstoolbar

Select Button

This button is used to select the surfaces, curves, planes, and so on in theStyleenvironment.

Set Active Plane Button

This button is used to select the datum plane on which the drawing or the editing

operation needs to be performed.

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Internal Plane Button

This button is chosen by selecting the black arrow on the right of theSet

Active Planebutton.

Choose theInternal Planebutton to create an internal datum plane in the

Styleenvironment.

Curves Button

When you choose this button, theCurvedashboard will be displayed asshown infigure given below. The options in this dashboard are listed inthe next slide.

TheCurvedashboard

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Free Radio Button

Planar Radio Button

COS Radio Button

Control Points Check Box

Curves Edit Button

This button is used to edit the curves that are created as style features. When

you choose this button, theCurve Editdashboard will be displayed and youwill be prompted to select a curve.

The options in the Curve Editdashboard are listed in next slide.

The Curve Editdashboard

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Curve collector

Free radio button

Planar radio button

COS radio button

Proportional Update check box

Control Points check box

Shortcut menu options

Surfaces Button

This button is used to create a surface among a closed boundary of curves.

When you choose this button, the Surfacesdashboard will be displayed.

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After selecting the four curves (Figure A), press the middle mouse button.

The surface is created, as shown in Figure B.

Figure A Four curves Figure B The Surface created

usingcurves

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Surfaces Connect Button

This button is used to connect the surfaces.

When you choose this button, theSurfacesConnectdashboard will bedisplayed and you will be prompted to select the two surfaces.

The connections may be of two types: curvature connection representedby a dashed line and the tangent connection represented by an arrow.

TheSurfacesConnectdashboard

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Figure ASurface connected atthe top by curvature connection

Figure BSurface connected atthe top by tangent connection

Surface Trim Button

This button is used to trim a surface.

Figure A shows the style surface when the type connection is a curvature and Figure B

shows the surface when it is connected tangentially.

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Figure Ashows the surface and the curve that are selected for trimming and Figure Bshows the surface after trimming.

Figure ASurface is dividedinto two portions

Figure BSurface after trimming

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Surface Editing Tools The surface editing tools help in decreasing the modeling time.

The surface editing tools that you will be learning in the next section are asfollows:

Mirroring the Surfaces

TheMirrorbuttonis used to mirror the surface about a plane.

When you choose this button, theMirrordashboard will be displayed, as

shown infigure given below.

TheMirrordashboard

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Figure Ashows the mirror plane andFigure Bshows the mirrored feature.

Figure AMirror plane andthe surface to be mirrored

Figure BSurfaces after mirroringand keeping the original surface

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Chapter 15

Merging Surfaces

TheMergedashboard

Figures A, BandCon the next slide shows the Two surfaces to merge, Part of thesurface to be retained, and Merged surface respectively.

TheMerge buttonis used to merge the two surfaces and make them a

single surface.

A surface is also known as a quilt.

When you choose theMerge button, theMergedashboard will bedisplayed, as shown in figure given below.

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Chapter 15

Figure ATwo surfacesto merge

Figure BArrowsshowing the part of the

surface to retain

Figure CMerged surface

Trimming Surfaces

TheTrim buttonis used to trim the selected surfaces using a trimming object.

TheTrimdashboard is shown in figure given on the next slide.

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The Trimdashboard

Figure Ashows the surface selected as the trimming object, the trimming surface,and the yellow arrow.

Figure Bshows the surface obtained after trimming.

Figure ATrimming surfaces Figure BSurface obtained after trimming

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Chapter 15

Creating the Fill Surfaces

When you choose Filloption from theEditmenu in the menu bar, theFill

dashboard will be displayed, as shown below.

TheFill dashboard

Figure Ashows the sketch plane andFigure Bshows the surface that is created

using theFill option.

Figure AThe sketch planefor creating a fill surface

Figure BFill surface

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Chapter 15

Creating the Intersect Curves

TheIntersectoption is used to create a curve at the intersection of two surfaces.

TheIntersectdashboard

Figure Ashows the two selected surfaces , and the intersecting curve created by them.

Figure ASurfaces selected to create the intersecting curve

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Creating the Offset Surfaces

A surface can be copied to an offset distance.

To offset a surface, select the surface to offset and chooseEdit>Offsetfrom themenu bar.

TheOffsetdashboard will be displayed, as shown below.

In Pro/ENGINEER, there are three methods to offset a surface. These methods are

discussed next:

TheOffsetdashboard

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Standard Offset Feature

Using this option, you can offset the surface as a whole.

The figure given below shows the original surface and the offset surface.

Original and the offset surfaces

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Figure ADraft offset surfacewith straight profile

Figure BDraft offset surfacewith tangent profile

With Draft Feature

Using this option, you can sketch the section and then give a draft angle to the side

surfaces.

Figure A and B shows the draft offset surface with the Straight and Tangent radio

button selected from the Optionsslide-down panel.

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Expand Feature

Using this option, you can sketch the section and then choose to offset the inside

or the outside of the sketch.

Figure A shows the offset surface when the inside of the sketch is selected to offset.

Figure B shows the draft offset surface when the outside of the sketch is selected to

offset.

Figure AInside of the sketchselected to offset

Figure BOutside of the sketchselected to offset

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Giving Thickness to a Surface

To add thickness to a quilt or a surface, select the quilt and choose theThicken

option from the Editmenu.

TheThicken dashboard will be displayed, as shown in the figure given below.

TheThicken dashboard

Figures A andBgiven on the next slideshow the surfaces after adding thickness bycontrolling the thickness using theNormal to surfaceoption and theAutomatic fitoption respectively.

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Figure AThickening the surface usingtheNormal to surfaceoption

Figure BThickening the surfaceusing theAutomatic fitoption

Converting a Surface to a Solid

You can convert a closed surface into a solid by choosingEdit>Solidifyfrom themenu bar.

This option is available only when a closed surface with capped ends is selected.

This option fills the hollow surface with material.

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Chapter 15

Creating a Round at the Vertex of a Surface

The vertices of a surface or quilt can be rounded

using theVertex Roundoption.

TheSURFACE TRIM:Vertex Rounddialog box isshown in figure given on right.

Figure AandBshows the vertices to round, and thevertices after creating the round respectively.

TheSURFACE TRIM:

Vertex Rounddialog box

Figure AVertices to round Figure BVertices after creating round

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Chapter 15

In this tutorial, you will create the surface model shown in Figure A. The orthographic

views of the surface model are shown in Figure B. (Expected time: 45 min)

Tutorial 1

Figure AIsometric viewof the surface model

Figure BTop view, front view, and theright-side view of the surface model

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a. Examine the model and determine the number of features in it.

b. Create the base feature, which is a blend surface. Figures C and D shows the

sketches for the blend feature. The trimetric view of the model after creating thebase feature appears as shown in Figure E.

Figure ETrimetric viewof the base feature

Figure CSketch ofthe first arc

Figure DSketch of thesecond arc

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c. Create the second feature, which is a blend feature. To create this feature you

need to cerate a datum plane. The sketch of the two arcs for the blend feature

is shown in Figure F. The model after creating the second feature appears as

shown in Figure G.

Figure FSketch of the secondfeature

Figure GSecond feature

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d. The third feature is a mirror feature that will be created by mirroring the second

feature about a plane passing from the center, refer toFigure H.

Figure HSurface model aftercreating the third feature

e. Create the fourth feature which is also a blend feature, refer to Figures I and J.

Figure ISketch of the fourthblend feature

Figure JModel aftercreating the fourth blend

surface

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f. Next, select the surfaces individually and merge them, refer toFigures KandL.

Figure KSurface model aftermerging the left blend surface

with the middle blend surface

Figure LSurface model aftermerging all the surfaces

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Chapter 15

Figure MSketch for thefill surface

Figure NSurface aftercreating the fill surface

Figure OSurface model aftercreating the fill surfaces

h. Merge the fill Surfaces that you have created with the other surfaces in order to

create a round on their edges.

g. Create the fill features which will be used to create surfaces on the blend features,

refer to Figures M, N and O.

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i. Create rounds on the edges. The surface model, after creating the rounds, is as

shown in Figure P.

Figure PSurface modelafter creating rounds

j. Save the model and close the window.

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Chapter 15

In this tutorial, you will create the surface model shown in Figure A. The front and the

right-side views of the surface model are shown in Figure B.(Expected time: 45 min)

Tutorial 2

Figure AIsometric view ofthe surface model

Figure BFront view and the right-side view ofthe surface model

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a. First, examine the model and determine the number of features in it.

b. Create the base feature, which is an extruded surface with open ends, refer to

Figures CandD.

Figure CSketch ofthe base surface

Figure DBase surface with open ends

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c. Create the second feature, which is a blend feature. The sketch for the blend

feature is shown in Figure E. The model, after creating the blend feature, appears

as shown in Figure F.

Figure ESketch of the blend surface Figure FBlend surface

d. The third feature is a mirror copy of the second feature, refer toFigure G.

Figure GModel after creatingthe mirror copy of the blend

surface

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C apte 5

e. The fourth feature is the cylindrical surface. The sketch for the cylindrical feature

is shown in Figure H. The model, after creating the surface extrusion, is shown in

Figure I.

Figure HSketch of the cylindricalsurface

Figure ICylindrical surface

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p

Figure JSketch of the fill surface Figure KModel after creating the fill surface

g. Mirror the fill surface to cap the other end of the base feature. The model, after

the creating the mirror feature, appears as shown in Figure L.

Figure LModel after creating themirror copy of the fill surface

f. Create the fill Surface to cap the ends of the base feature. The sketch for the fill

surface is shown in the Figure J. The model, after the fill surface is created, is

shown in Figure K.

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p

h. Merge all surfaces by selecting them individually, refer toFigures M, Nand O.

Figure MModel after merging the blendsurface with cylindrical surface

Figure NModel after merging the blendsurface with the base surface

Figure OModel after merging the mirror copyof the blend surface with the base surface

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p

i. Merge the fill Surfaces with the base surface in order to create a single quilt or a

single surface. When the surfaces are merged, you will use the edge formed by

the merge feature to create rounds.

j. Create the round features, refer toFigures P and Q.

Figure PEdges selectedto create rounds

Figure QRound created on the mergededge of the cylindrical slot, edge on the

intersection of blend surfaces and thebase surface, and on the edges forming

the corners of the base surface

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p

k. Creating a full round between the front and the back sides of base feature. The

round is created, as shown in Figure R.

Figure RCompleted surface model

j. Save the model and close the window.

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p

Exercise 1

In this exercise, you will create the surface model shown inFigure A. The orthographic

views of the surface model are shown inFigure B. (Expected time: 40min)

Figure AIsometric view ofthe surface model

Figure BTop, front, right-side, and thedetailed views of the surface model

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p

Exercise 2In this exercise, you will create the surface model shown in Figure A. The orthographic

views and the detailed view of the surface model are shown in Figure B.(Expected time: 1 hr)

Figure ASurface model Figure BTop, front, right-side, and the detailedviews of the surface model