Module 12: Project III

Lab Exercises
If you are ready to start on the exercises for this module, please click the links below. Exercise 1: Adding Surfaces to the Inner Door Panel Exercise 2: Completing the Inner Door Panel

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 course without relying on step-by-step instructions. In this project, you complete the design of the car door inner panel components.

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

Project III Completing the Inner Door Panel

You complete the design of the car inner door panel. In this project, you create additional surfaces using the Variable Section Sweep and Offset tools. You trim and merge the surfaces and complete detailing the inner door panel by adding rounds.

Exercise 1: Adding Surfaces to the Inner Door Panel

Objectives
After successfully completing this exercise, you will know how to: Use the Variable Section Sweep tool to define surfaces. Trim surfaces. Merge surfaces to a quilt.

Scenario
You are continuing the task of designing the door inner panel. You have built the base surfaces for the part. You now merge the surfaces into a quilt for further detailing. Task 1. Trim the surfaces created for the three levels in the door panel.

1. In the Folder Browser , browse to the module_12 folder. o Right-click on the module_12 folder and select Set Working Directory. 2. Open the DOOR_INNER_PANEL_RIGHT.PRT. o Turn off the display of datum features if necessary.

Door Inner Panel Model

3. In the model tree, right-click SHUT_LINE and select Unhide. 4. Select the SHUT_LINE quilt. o Click Edit > Trim and select the Project 3 curve from the model, as shown in the following figure. o Flip the arrow direction, as shown in the following figure. o Click Complete Feature .

Trimming the SHUT_LINE Surface

5. In the model tree, right-click SHUT_LINE and select Hide. o In the model tree, right-click Extrude 2 and select Unhide. 6. Select the Extrude 2 surface. o Click Edit > Trim and select the Project 5 curve from the model, as shown in the following figure. o Flip the arrow direction, as shown in the following figure. o Click Complete Feature .

Trimming the Extrude 2 Surface

7. In the model tree, right-click Extrude 1 and select Unhide. 8. Select the Extrude 1 surface.
o o o o

Click Trim

from the feature toolbar.

Select the Project 4 curve from the model, as shown in the following figure. Flip the arrow direction, as shown in the following figure. Click Complete Feature .

Trimming the Extrude 1 Surface

Task 2. Create the surfaces in the lock region.

1. In the model tree, right-click LOCK and select Unhide. 2. Turn on the display of datum planes.

References for the Lock

3. Start the Sketch Tool from the feature toolbar. o Select the datum plane LOCK_PLANE_VER as the sketching plane. o Select the LOCK_PLANE_HOR as the reference plane and select Top for orientation. o Click Flip to flip the viewing direction so it points into the screen. 4. Click Sketch. o Select datum plane LOCK_SIDE_PLANE as a sketch reference. o Click Close. o Turn off the display of datum planes. 5. Zoom in to the intersection of the sketch references.
o o o

Click Centerline and sketch horizontal centerlines above and below the horizontal reference. Click Point and place Sketcher points at the intersection of the centerlines and the vertical reference, as shown in the following figure. Ignore the dimension values for now.

Sketching Centerlines and Points

6. Click Line

and sketch four lines, as shown in the following figure.

Sketching the four lines

7. Click Circular Fillet and create two fillets on the right side of the sketch, as shown in the following figure. o Constrain the fillets to have equal radii.

Sketching Lines and Fillets

8. Create and edit dimensions, as shown in the following figure. o Click Complete Sketch .

Completing the Sketch (Shown rotated slightly in 3-D for clarity)

9. With the sketch still selected, click Edit > Fill. o With the Fill surface still highlighted, select an edge of the surface. o Press and hold SHIFT and select another edge to select the tangent chain, as shown in the following figure.

Selecting the Tangent Chain

10. With the tangent chain still selected, start the Variable Section Sweep Tool . o Click the References tab. o Set the Section Plane Control to Normal to Trajectory. o Set the Horizontal/Vertical Control to Normal to Surface.
o

Click Create Section

11.

Sketch an angled line, as shown in the following figure.

Sketch for Variable Section Sweep

12. Click Complete Sketch . o Click Complete Feature

Resulting Side Surfaces of Lock

Task 3. Merge the surfaces created for the three levels and the lock mounting in the door panel. 1. In the model tree, press CTRL and select Extrude 1 and Var Sect Sweep 2.
o o

Start the Merge Tool Click Complete Feature

from the edit toolbar. .

You may wish to toggle the model display to No Hidden for better clarity while merging surfaces.

Merging Quilts of Level 1 (Shading and No Hidden Shown)

2. In the model tree, right-click Project 4 and select Hide. 3. Start the Round Tool from the feature toolbar. o Select the edge, as shown in following figure. o Type a radius of 8. o Click Complete Feature .

Rounding the Merged Edge Chain

4. In the model tree, press CTRL and select Fill 1 and Var Sect Sweep 4.
o o

Start the Merge Tool Click Complete Feature

from the edit toolbar. .

Merging Lock Surfaces

5. In the model tree, press CTRL and select Extrude 2 and Var Sect Sweep 3.
o o

Start the Merge Tool Click Complete Feature

from the edit toolbar. .

Merging Quilts of Level 2 (Shading and No Hidden shown)

6. In the model tree, right-click Project 5 and select Hide. 7. Start the Round Tool
from the feature toolbar.

o o o

Select the edge, as shown in following figure. Type a radius of 12. Click Complete Feature .

Rounding the Merged Edge Chain

8. In the model tree, right-click SHUT_LINE and select Unhide. 9. In the model tree, press CTRL and select SHUT_LINE and Boundary Blend 1.
o o o

Start the Merge Tool

from the edit toolbar. to flip the direction, as shown in the

Click Change First Quilt Side following figure. Click Complete Feature .

Merging Quilts of Level Three

10.
o

In the model tree, press CTRL and select Project 2 and Project 3. Right-click and select Hide.

11. Click View > Visibility > Save Status. 12. Click View > Color and Appearance. o Select All Surfaces from the Assignment drop-down list. o Click Clear. o Click Close.

Color Appearance Cleared

13. Click Save from the main toolbar. Click OK. This completes the exercise.

Exercise 2: Completing the Inner Door Panel

Objectives
After successfully completing this exercise, you will know how to: Use Surface tools to create blending shapes. Use the Offset tool for adding design details.

Scenario
You are completing the task of designing the door inner panel. You add further details to the part and create a blending surface in the corner of the window. Task 1. Round the sharp edges around the window. 1. If necessary, open DOOR_INNER_PANEL_RIGHT.PRT.

2. Start the Round Tool from the feature toolbar. o Select the edge shown in following figure (Do NOT select another edge of the tangent chain). o Type a radius of 10. o Click Complete Feature .

Selecting the Merged Edge Chain

3. Notice the uneven transition at the left corner of the car door window, as shown in the following figure. o You will refine the round to smoothen the transition in the next step.

Undesirable Transition of Round at the Corner

Task 2. Refine the round surface transition at the corner of the window. 1. Select the previous round feature if necessary. o Right-click and select Edit Definition.
o o o

Right-click the radius handle and select Add Radius. Type 0 as the first radius location and 10 as the first radius value. Type 1 as the second radius location and 10 as the second radius value, as shown in the following figure.

Adding Radius Locations

2. Repeat the previous step to add three additional radii on the curve, as shown in the following table and figure. o Click Complete Feature when all five radii are configured.
Table 1: Variable Radius Definitions

Radius Location (Ratio) 0.70 0.50 0.30

Radius Value 20.00 32.00 20.00

Additional Radii Locations

Task 3. Merge the outer surfaces near level one of the door inner panel.

1. In the model tree, right-click DOOR_SURFACE and select Unhide.

Outer Surface of the Door Inner Panel

2. In the model tree, press CTRL and select DOOR_SURFACE and Merge 1.
o o o

Start the Merge Tool

from the edit toolbar.

Click on the yellow arrows to flip them, if necessary, to ensure they point in the correct direction, as shown in the following figure. Click Complete Feature .

Merging the Outer Surface

Task 4. Create an offset region for the trim panel. 1. In the model tree, right-click INNER_TRIM_PROFILE and select Unhide. 2. Select the surface shown in the following figure. o Click Edit > Offset.

Selecting the SHUT_LINE Surface

3. Click With Draft from the dashboard. o Select the References tab and click Define. o Select datum plane RIGHT as the sketching plane. o Select datum plane TOP as the reference plane, and select Top for orientation. o Click Flip. 4. Click Sketch. o Click Entity Offset from Edge . o Select Chain. o Select the two edges shown in the following figure.

Selecting Two Edges for Chain

5. Click Next and then Accept once all the edges are highlighted, as shown in the following figure.

Selecting Curve Chain

6. Near the outside of the chain, type 1.5 as the value, as shown in the following figure. o Click Complete Sketch .

Offset Curve Chain

7. Type 20 as the depth of the offset in the dashboard. o Type 3 as the draft angle. 8. Select the Options tab. o Select Surface for the Side Surface Normal to option. o Select and Tangent for the Side Surface Profile option. o Click Complete Feature . 10. In the model tree, right-click INNER_TRIM_PROFILE and select Hide.

Niche for Trim Panel

Notice that the Tangent option has eliminated the need to create additional rounds.

Task 5. Add strengthening details along the edges of the door panel.

1. In the model tree, right-click EMBOSS and select Unhide. o Select the surface quilt, as shown in the following figure.

Level One Surfaces of Door Inner Panel

2. Click Edit > Offset.

o o o o o

Click With Draft Click Use Previous.

from the dashboard.

Select the References tab and click Define. Click Entity from Edge . Click Loop.

Zoom in and select all four curve loops, as shown in the following figure.

Sketch for the Strengthening Detail

3. Click Complete Sketch . o Type 3 as the depth of the offset. o Type 3 as the draft angle. 4. Select the Options tab. o Select Surface for the Side Surface Normal to option. o Select Tangent for the Side Surface Profile option. o Click Complete Feature . 5. In the model tree, right-click EMBOSS and select Hide. o Select the Offset 4 feature that you just created to highlight it on the screen. o Zoom in and investigate the feature.

Strengthening Details Along the Door Inner Panel

Task 6. Complete the area around the lock.

1. Start the Round Tool from the feature toolbar. o Select the edge, as shown in following figure. o Type a radius of 8. o Click Complete Feature .

Creating a Round

2. In the model tree, right-click LOCK and select Unhide. o Display datum planes. 3. Start Datum Axis Tool from the feature toolbar. o Press CTRL and select datum planes LOCK_LOCATION_PLANE and LOCK_PLANE_VER. o Click OK.

Creating the Datum Axis

4. With the axis still selected, start the Datum Plane Tool from the feature toolbar. o Press CTRL and select datum plane LOCK_LOCATION_PLANE. o Type an angle of 135. o Click OK.

Plane

5. In the model tree, right-click datum axis A_2 and select Rename. o Type LOCK_ OFFSET _AXIS as the new name. 6. In the model tree, right-click datum plane DTM3 and select Rename. o Type LOCK_AXIS_PLANE as the new name. 7. Turn off display of datum planes 8. Select the surface quilt as shown in the following figure. o Click Edit > Offset.

Selecting the Surface

9. Click With Draft from the dashboard. o Select the References tab and click Define. o Select datum plane LOCK_AXIS_PLANE as the sketching plane. o Select datum plane TOP as the reference plane, and select Top for orientation. o Click Flip. 10. Click Sketch.
o o o

Click Specify References

Select datum plane LOCK_PLANE_HOR and datum axis LOCK_OFFSET_AXIS as references from the model tree. Click Close.

11. Click Sketch > Data from File > File System. o Select LOCK_OFFSET.SEC and click Open. o Place the section on the screen. o Right-click and drag to relocate the handle intersection of the centerlines in the sketch. o Drag the section and snap it to the intersection of the Sketcher references. o Type 1 for the scale and click Accept Changes . 12. Create and edit dimensions as necessary. Refer to the following figure.

Importing the Lock Offset Section

13. Click Complete Sketch . o Type 3 as the depth of the offset. o Type 5 as the draft angle. 14. Select the Options tab. o Select Surface for the Side Surface Normal to option. o Select Tangent for the Side Surface Profile option. o Click on the yellow arrow to flip the depth direction inward. o Click Complete Feature .

Completing the Offset

Task 7. Merge the remaining surfaces and create rounds to smooth them.

1. Change the selection filter to Quilts. 2. Press CTRL and select the two surface quilts, as shown in the following figure.
o o

Start the Merge Tool

. .

Click Complete Feature

Merging Surfaces

3. Press CTRL and select the two surface quilts, as shown in the following figure.

Selecting Surfaces

4. Start the Merge Tool . o Flip the arrows if necessary, as shown in the following figure. o Click Complete Feature .

Merging Surfaces

5. Press CTRL and select the two surface quilts, as shown in the following figure.

Selecting Surfaces

6. Start the Merge Tool

o o

Flip the arrows if necessary, as shown in the following figure. Click Complete Feature .

Merging Surfaces

7. Press CTRL and select the surface quilts, as shown in the following figure.

Selecting Surfaces

8. Start the Merge Tool from the Edit toolbar. o Flip the arrows if necessary, as shown in the following figure. o Click Complete Feature .

Merging Surfaces

9. Change selection filter from Quilts to Smart. 10. Start the Round Tool . o Select the Intent edge, as shown in following figure. o Type a radius of 8. o Click Complete Feature .

Creating a Round

11. Start the Round Tool . o Select the edge, as shown in following figure. o Type a radius of 5. o Click Complete Feature .

Creating a Round

12. Start the Round Tool . o Select the edge, as shown in following figure. o Type a radius of 5. o Click Complete Feature .

Creating a Round

Task 8. Trim the window surface.

1. Select Smart as the selection filter. o Select the chain of edges shown in the following figure.

Selecting Tangent Chain

2. Click Copy and Paste from the main toolbar. o Click Complete Feature . 3. Change selection filter from Smart to Quilts. o Select the quilt, as shown in the following figure.

Selecting the Quilt

4. Click Edit > Trim. o Select the curve you copied previously. o Flip the arrow if necessary, as shown in the following figure. o Click Complete Feature .

Trimming the Window Surface

5. In the model tree, right-click Copy 1 and select Hide. 6. Rotate the model and review the completed inner door panel.

Completed Inner Door Panel

7. Click Save from the main toolbar. o Click OK. 8. Open the CAR_DOOR_RIGHT.ASM. o In the model tree, right-click CAR_DOOR_RIGHT_SKEL.PRT and select Hide. 9. Click View > Color and Appearance. o Apply colors of your choice to the door panels.

Completed Assembly

10. Click Save from the main toolbar. Click OK. 11. Close all windows and click File > Erase > Not Displayed. 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.