Module 4: Project I

Lab Exercises
If you are ready to start on the exercise for this module, please click the link below. Exercise 1: Creating the Inner Door Panel Design Framework

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

Introduction
This module contains a self-paced project. The purpose of this project is to provide you with an opportunity to practice the skills you have learned in the class without relying on step-by-step instructions. In this project, you create the design framework to build the parts for a car door inner panel.

Objectives
After completing this module, you will be able to: Apply the skills you've learned to real-world design projects.

Course Project Designing the Inner Door Panel

Scenario Orion Motors is designing a new car. The digital model of the exterior surfaces is ready. Currently, stiffener body parts and interior trims are being designed. You are part of the design team, which is designing the inner door panel. The digital surface model of the exterior surface is available for reference. You design the inner door panel. The car door assembly is provided for you and you are to create an inner door panel that fits to the assembly. The assembly contains a skeleton model with references required for creating the inner door panel. Throughout the next few days, you design the assembly components using a topdown design approach. Use the supplied models to complete sections of the project laboratories.

Course Project Designing the Inner Door Panel (cont.)

The project laboratories take you through the design of the door inner panel. You model the panel surfaces, the surfaces for the lock detail, the design details for the trim panel to be housed, and add strengthening details to the part.

Project I Creating the Inner Door Panel Design Framework

You start the first project by copying the references from the skeleton part supplied to you. You copy the references required for creating the shut line of the door, the door lock, the window opening, and the door trim panel zone.

Exercise 1: Creating the Inner Door Panel Design Framework

Objectives
After successfully completing this exercise, you will know how to: Copy design references from a skeleton model to a part to be modeled. Create design references in the model.

Scenario
As a member of the design team working on the door inner panel, you begin by copying the references from the skeleton part supplied to you. You copy the references required for creating the levels in the door. Task 1. Open the car door assembly.

1. Set the working directory to: C:\users\student\Surface_WF3\module_04. 2. Open the CAR_DOOR_RIGHT.ASM.

3. If necessary, click Datum Planes , Datum Axes , Datum Points , and Coordinate Systems from the main toolbar to disable their display. 4. Review the structure of the assembly. Notice there is a skeleton and a surface model of the outer door panel.

Car Door Assembly

5. Select the CAR_DOOR_RIGHT_SKEL.PRT from the model tree, right-click and select Open.
o

Click Datum Planes

, Datum Axes

, Datum Points

, and

Coordinate Systems from the main toolbar to enable their display. Expand the model tree and notice the various publish geometry features for the window, door lock, speaker, and door inner panel supplied in the skeleton part.

Skeleton Model

6. Click File > Close Window to return to the assembly. 7. Select the DOOR_OUTER_RIGHT.PRT from the model tree, right-click and select Open. o Examine the model tree and notice that the references for the outer door surface are available as a publish geometry feature.

Car Outer Right Door Part

8. Click File > Close Window to return to the assembly.

Task 2. Create the DOOR_INNER_PANEL_RIGHT.PRT and assemble it.

1. Click Create Component from the feature toolbar. o In the Component Create dialog box, select Part as the type. o Type DOOR_INNER_PANEL_RIGHT.PRT as the name. o Click OK. 2. In the Create Options dialog box, select Copy From Existing for the creation method. o Click Browse to copy from a template model. o Select the START_PART.PRT and click Open in the Choose Template dialog box. o Click OK. o Right-click and select Default Constraint. o Click Complete Component from the dashboard.

Task 3. Copy the required references from the DOOR_OUTER_RIGHT and CAR_DOOR_RIGHT_SKEL models.

1. Select the DOOR_INNER_PANEL_RIGHT.PRT from the model tree, right-click and select Activate. 2. Click Insert > Shared Data > Copy Geometry. o In the model tree, expand DOOR_OUTER_RIGHT and select the DOOR_SURFACE publish geometry feature. o Click Complete Feature from the dashboard.
You can use the Copy Geometry and Publish Geometry data sharing features to transfer a collection of references from one model to another. It is easier to select a publish geometry feature than selecting individual references when transferring references with a copy geometry feature. Also if the source model changes, the copy geometry and publish geometry features update and therefore the geometry referencing them also updates correspondingly.

3. Click Insert > Shared Data > Copy Geometry. o In the model tree, expand CAR_DOOR_RIGHT_SKEL and select the SHUT_LINE_REFERENCE copy geometry feature. o Click Complete Feature from the dashboard. 4. Click Insert > Shared Data > Copy Geometry. o In the model tree select GLASS_REFERENCE. o Click Complete Feature from the dashboard. 5. Click Insert > Shared Data > Copy Geometry. o In the model tree, select LOCK_REFERENCES. o Click Complete Feature from the dashboard. 6. Click Insert > Shared Data > Copy Geometry. o In the model tree, select DOOR_LEVEL_1. o Click Complete Feature from the dashboard. 7. Click Insert > Shared Data > Copy Geometry. o In the model tree, select EMBOSS_REFERENCES. o Click Complete Feature from the dashboard. 8. Click Insert > Shared Data > Copy Geometry. o In the model tree, select WINDOW_PROFILE. o Click Complete Feature from the dashboard.

Task 4. Review the created geometry. 1. Select the DOOR_INNER_PANEL_RIGHT.PRT from the model tree. o Right-click and select Open.
o

Notice that many of the required curves, surfaces, axes, and planes have been easily added to the part as copy geometry features.

Geometry Transferred with Copy Geometry

2. Click File > Close Window to return to the assembly.

Task 5. Continue copying references.

1. Select the DOOR_INNER_PANEL_RIGHT.PRT from the model tree, right-click and select Activate. 2. Click Insert > Shared Data > Copy Geometry. o In the model tree, expand CAR_DOOR_RIGHT_SKEL and select DOOR_LEVEL_2. o Click Complete Feature from the dashboard. 3. Click Insert > Shared Data > Copy Geometry. o In the model tree, select DOOR_LEVEL_3. o Click Complete Feature from the dashboard. 4. Click Insert > Shared Data > Copy Geometry. o In the model tree, select INNER_TRIM_PROFILE. o Click Complete Feature from the dashboard. 5. Select the DOOR_INNER_PANEL_RIGHT.PRT from the model tree. o Right-click and select Open.

Notice that additional curves, surfaces, axes, and planes have been added by using the copy geometry to reference publish geometry features.

Additional References Copied from the Skeleton

Task 6. Rename the copy geometry features for easy reference.

1. In the model tree, select Copy Geometry id 23. o Right-click and select Rename. o Type DOOR_SURFACE as the new name. o Repeat the previous step to rename the remaining copy geometry features, as shown in the following figure.

Renaming Features

Task 7. Define the clearance of the door inner panel from the glass pane. 1. In the model tree, select all the copy geometry features except GLASS, as shown in the following figure.

Selecting Features to Hide

2. Right-click and select Hide.

Displaying the Required Reference Features

3. Select the GLASS feature from the model, and then select it again to select the quilt. o Click Edit > Offset.
o

Type 3 as the offset value in the dashboard.

o o

Flip the direction to offset the surface, as shown in the following figure. Click Complete Feature .

Offset Surface Defining Clearance from Glass

The Offset tool is discussed in detail later in the course.

Task 8. To define the edge surfaces of the door inner panel, offset the outer door surface.

1. In the model tree, select GLASS, right-click and select Hide. 2. Select DOOR_SURFACE, right-click and select Unhide.

Displaying the Required Reference Features

3. Select the DOOR_SURFACE feature from the model tree, and select it from the model to select the quilt. o Click Edit > Offset.
o o o o o

Type 2 as the offset value in the dashboard. Flip the direction to the left, as shown in the following figure. Select the Options tab, and select Controlled Fit from the drop-down list. Clear the Y and Z Allow Translation check boxes. Click Complete Feature .

Offset Door Surface Quilt

Task 9. Project the inner window profile onto the glass.

1. Press CTRL and select Offset 2 and DOOR_SURFACE in the model tree. o Right-click and select Hide. 2. Select WINDOW_PROFILE. o Right-click and select Unhide.

Displaying the Required Reference Features

3. Rotate the model, as shown in the following figure. o With the WINDOW_PROFILE still selected, zoom in and select a segment of the inner curve. o Press SHIFT and select the tangent chain, as shown in the following figure.

Selecting the Tangent Chain

4. Click Edit > Project. o Select the offset window surface (surface closest to selected curve). o Right-click and choose Select Direction Reference. o Select datum plane RIGHT and click Complete Feature .

Projecting a Curve

Task 10.

Project the outer window profile.

1. Press CTRL and select Offset 1 and Project 1 in the model tree. o Right-click and select Hide. 2. Select SHUT_LINE. o Right-click and select Unhide.

Shut Line Visible

3. Select the WINDOW_PROFILE feature, zoom in, and then select a segment of the outer curve. o Press SHIFT and select the tangent chain, as shown in the following figure.

Selecting the Tangent Chain

4. Click Edit > Project. o Right-click to query the entire quilt and select it. o Right-click and choose Select Direction Reference. o Select datum plane RIGHT and click Complete Feature

Projected Curve Created

5. Click View > Visibility > Save Status. 6. Save the model and close the window. This completes the exercise.

Summary
After successfully completing this module, you should know how to: Apply the skills you've learned to real-world design projects.