Toy Car

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PowerSHAPE Toy Car Bumper Design
To perform this demo PowerSHAPE version 5011 or later is required as well as the following parts and filesToyCarStart.psmodel FixingLoopLibrary.psmodel BumperDrawing.bmp CarBody.igs SideSplash.dmt Delcam.dmt SetUp.mac Import the FixingLoopLibrary.psmodel and ToyCarStart.psmodel.
Start
Start PowerShape and run the SetUp.mac macro file. This will set the required default parameters and open the ToyCarStart.psmodel file. Activate the CarBits grouped level and show all of the car components stored in the part. These were created by the car designer and imported into PowerSHAPE previously.
file://E:\Jph\webdemo\datafiles\new\ToyCar\ToyCar\Documentation\BumperDesign....
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Data Fixing
Import the CarBody.igs file into PowerShape and shade the surfaces.
Hit the Tools Find Duplicates button which scans the surfaces and wireframe geometry and leaves selected any duplicates. Delete these surfaces as they are not required.
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Zoom into the bonnet and door areas and activate Inspection Mode from the surface edits toolbar. Use this function to check the wall thickness of the part.
View the part with the Undercut shading and look at the surfaces at the back of the car.
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There is an undercut area on the back region that needs to be fixed. Create a workplane at the location shown below.
Select the outer surface at the back of the car and create a draft surface down to Z 0 with a draft angle of 1 degree.
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The original back surface is trimmed to meet the draft surface thus creating a gap with the edge of the split surface. Select the new draft surface and the split surface in that area and draw them alone.
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Select the split surface and convert it from a nurb into a PowerSurface.
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Select the outside edge of the split surface and perform a surface stich operation to match it to the draft surface. Turn off the Match across seam option.
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All of the car body surfaces are on one level so the inner and the outer surface need to be divided between levels. Select all of the car body surfaces and choose the Tools Core/Cavity Separation Hidden Surfaces tool. This will analyse the surfaces and leave selected all of the surfaces that can not be seen when the part is viewed along the Z axis. Place these surfaces onto level 1.
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Show the surfaces on level 1 and 2.
Switch off level 1 to leave drawn only the outer surfaces.
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Shade the outer surfaces and show that there is a hole in the data. This is a 5 sided hole and quite a difficult area to surface. Create a composite curve around the edge of the hole.
Create a fill-in surface using the default single patch option.
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Delete the composite curve and make a mirrored copy of the fill-in surface about the ZX plane.
Ensure the 2 fill-in surfaces are on level 2 then switch level 2 off. Turn level 1 on to view the surfaces from the inside of the car. Zoom into the area shown below and highlight the untrimmed fillets.
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Select the 3 untrimmed fillet surfaces and choose the Edit Fillet Corner menu. Select the N-Sided option and create the fillet corner.
Perform the same operation on the opposite side to clean up the inside of the car.
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Select both fillet corners and ensure they are on level 1. The designer has decided to alter the shape of the front of the car. The current car front is curved but the designer wants to alter the shape to be more curved. The required change affects many of the surfaces at the front of the car and it would take lots of time to remodel the front with the surface creation tools. It is a very fast modification if done with morphing. Activate levels 1 and 2 and view the inner and outer surfaces from Z.
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Group select the surfaces for the inner and outer car body as shown below.
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Activate level 16 to draw the morphing curves but ensure that only the surfaces are still selected.
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Hold the mouse over the selected surfaces, hold down the right mouse button. And select the Morph control button.
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The Reference Selection curve is the original shape of the car and the Control Selection is the required shape of the car. Hit the Accept button and modify the whole car front.
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To perform the morph operation PowerSHAPE converts the morphed surfaces into a special Morph surface that cant be edited like normal a normal Power Surface. To convert these to Power Surfaces the morph form need to be used again. Deactivate level 1 to leave only the outer surfaces drawn. Group select the surfaces just morphed and hold down the right mouse button to access the Morph Control form.
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Hit the Capture button to convert the surfaces back to Power Surfaces.
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Bumper Design
The customer has provided an engineering drawing of the bumper. This can be viewed in a normal windows explorer window or in the PowerShape browser window using the following commandsBROWSER SHOW BROWSER GO E:\toycar\demodata\bumper.htm"
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Turn off level 1 to leave only the outer body surfaces visible.
Create a composite curve along the front edge of the car. Make sure that the composite curve does not touch the small radii on both corners of the car body, as highlighted below.
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Select the composite curve and create a surface extension accepting all of the default values.
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Select the bottom edge of the extension surface and use the Stitch surface tool to match it to the wireframe shown below.
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Select the bottom edge of the surface and change the tangency across to be +Z.
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Using the Edit Point Limit tool grab the bottom edge of the surface and extend it by a small amount.
Create a workplane on the bumper surface.
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Double click on the workplane to open the workplane edit menu. Lock the X and Y axis and click on the location shown below to obtain the Z value for the workplane.
Select the bottom edge of the bumper surface and project it onto Z 0.
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Insert a new longitudinal into the surface at 10 mm above the bottom longitudinal.
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Select the bottom longitudinal and offset it inwards by 5mm.
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Again, select the bottom longitudinal and free the tangency across the surface curve.
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Change the construction plane to X and create the following box.
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Create a full radius as each end of the box.
Turn the wireframe into a composite curve then create a surface extrusion with a length of 20mm and a draft angle of 10 degrees.
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Check the orientation of the bumper surface and the extrusion and create a 3mm fillet surface between the 2.
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Select one of the 2 arcs read in from the iges file and turn it into a surface extrusion with a 1mm length up the Z axis.
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Select the small extrusion surface and create a blend surface from the top edge of the extrusion onto the 10 degree draft extrusion.
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Repeat the blend surface creation operation to create the blend surface from the bottom of the small extrusion.
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The bumper is symmetrical so select the small extrusion and the 2 blend surfaces and create a mirrored copy about the ZX axis.
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The surface touched by all 4 blend surfaces needs to be trimmed to the 4 blends.
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Ensure that the construction plane is still set to X and create a surface plane at position 20 0 20.
Stretch the plane so that it passes the edge of the main bumper surface.
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Check the surface normals and create 0.5mm radius surface fillets between the plane the bumper as shown below.
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View the car from the side, change the construction plane to Y and lock it.
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Sketch a Fitted Arc with a radius of 40mm onto the wheel arch as shown below.
Sketch a line tangent to the 40mm arc at an angle of 170 degrees.
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Sketch 2 further lines onto the surface data as shown below.
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Undraw the surfaces to leave only the wireframe geometry visible. Create 2 fillet arcs with a radius of 2mm each as shown below.
Delete the 2 construction lines and turn the remaining wireframe into a composite curve.
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Turn the compostite curve into a surface extrusion with a length of 200mm. Modify the position of the extruded surface so it is in the centre of the car.
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Change the construction plane to Z and unlock it. Using the Edit Point Limit tool extend both ends of the main bumper surface.
Choose the Edit Limit Selection option and trim the extrusion to the main bumper surface.
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Delete the trimmed extrusion surface as it is no longer required.
Select all of the surfaces that make up the bumper and convert them into a solid.
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The bumper is to have a 2mm wall thickness. Use the Solid Thicken operation to create the inside wall of the bumper.
View the bumper from the X axis and create a composite curve in the area shown below.
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Select the composite curve and offset it by 0.5mm inwards. Delete the original as it is no longer required.
Select the offset wireframe curve and create a Solid Bulge feature with an angle of 30 degrees.
Select the solid bulge feature in the Solid History Tree and symmetries is about the ZX axis.
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Draw the surfaces on level 1 (Inner body of car body). Select the surfaces at the bottom of the bosses as shown below. Hold down the right mouse button, activate the Morph Control form and hit the Capture button to convert these surfaces to Power Surfaces.
Enter the drafting module. Hit the Create Symbol button and select the Fixing Loop Library.
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Select Fixing Loop symbol from the library and zoom into the bosses shown below. Choose the cross at the bottom of the boss and create 2 fixing loops.
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Use the solid Boolean addition feature to join the fixing loops to the main bumper solid.
Create a solid fillet at the base of each fixing loop with a radius of 1mm.
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The final edit to the bumper solid is to modify a face on the front. Place the cursor over the face of the solid shown below.
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The surface editing tools are now available to the user to modify the face of the solid. The shape of this face will be altered. First, add 2 extra surface curves to the face as shown below.
Hit the Select Pattern of Points button and select points 3 to 9 on the 3rd curve in the face.
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Offset these points inwards by 1mm.
Hit the Accept button to apply the modification to the solid.
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The bumper design is now finished but the car body is to have some fine detail added to it. Draw the outer car surfaces only and select the door surfaces shown below.
View the car from the side in shaded mode and open the label wrap form.
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Hit the New button 2 times and load in the SideSplash.dmt triangle file.
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Hit the Accept button which will draw a 2d representation of the triangle file onto the selected surfaces and open the image edit form.
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Alter the size, aspect, position and angle of the triangle file so it have a good orientation over the door area.
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Hit the Emboss button to raise the embossing form. Turm off the trimming option for the sake of speed and hit the emboss button again.
Accept the Emboss form and the Label Editor form and hit Remove on the Label Selector form to remove the 2D image from the door surfaces. Select the wrapped triangles and change their colour.
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Perform the same operation to wrap the Delcam.dmt triangle file onto the back of the car.
Turn on all of the other levels and shade the complete car.
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Page 1 of 63

PowerSHAPE Toy Car Bumper Design

Show the surfaces on level 1 and 2.

Switch off level 1 to leave drawn only the outer surfaces.

Create a fill-in surface using the default single patch option.

Create a workplane on the bumper surface.

Select the bottom longitudinal and offset it inwards by 5mm.

Change the construction plane to X and create the following box.

Create a full radius as each end of the box.

Sketch a line tangent to the 40mm arc at an angle of 170 degrees.

Sketch 2 further lines onto the surface data as shown below.

Delete the trimmed extrusion surface as it is no longer required.

Offset these points inwards by 1mm.

Hit the Accept button to apply the modification to the solid.

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