Project 5: Modeling a Rocker Device (Using Sketch Curves)

In this project you will model a rocker device or "bell crank" which has two arms connected to the cylindrical pivot. You will want to design this part so that it can satisfy various requirements (such as a different angle between he arms, different size holes, and so on).

Prerequisites
To model this part you must be able to:

Create sketches

Create and constrain sketch curves

Create cylinders

Create holes

Create edge blends

Create datum planes

Create datum axes

Create extrusions

Create and edit instances

Create conditional expressions

The Dimensions of the Part

The Design Intent

When you have finished, you will want to be able to vary these dimensions: ? The length of the arms. ? The size of the hole in the arms. ? The size of the central hole. You also want to be able to define two different versions of this part: ? If the length of the arms is 100 mm or less, you want the angle between the arms to be 102 degrees. ? If the length of the arms is greater than 100 mm, you want the angle between the arms to be 90 degrees.

The Methods Used in This Project to Model the Part

In this project you will: Begin with a cylinder.

Sketch the profile of one arm and associate it with the circumference of the cylinder.

Extrude the sketch to form one arm.

Add the small hole at the end of the arm.

Use an array to create the second arm (including its hole) at a specific angle to the first.

Creat a large hole through the cylinder.

Finish by basing the angle of the arms on the length of the

arms.

Task 1. Begin With a Standard Metric Part File

Open the standard metric part file, standard_mm, from the project sub-directory. If you want, you can save this part file in your own directory using a name such as bell_crank_1. The standard part file uses the following layer standards: Solid geometry on layers 1 through 20. Sketch geometry on layers 21 to 40 Curve geometry on layers 41 to 60 Reference geometry on layers 61 to 80 Sheet bodies on layers 81 to 100 Drafting objects on layers 101 to 120 Start the Modeling application. Leave the WCS in its default location and orientation. If you need to, replace the current view with a TFR-TRI view.

Task 2. Create the Central Portion of the Part

Since the central portion of this part is cylindrical, you decide to begin with a cylinder feature. Create a cylinder feature at this location.

Choose the Cylinder icon from the toolbar or choose InsertForm FeatureCylinder. Use the Diameter, Height method. On the Vector Constructor dialog, use the ZC Axis icon to align the axis of the cylinder along the +ZC axis of the WCS. ? OK the Vector Constructor dialog. ? On the Cylinder dialog, key in the diameter and height values. ? Use the Point Constructor dialog to place the origin of the cylinder at the 0,0,0 location of the WCS. Fit the view.

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Task 3. Planning the Next Task

You know that at this point you could create the hole in this cylinder. But you feel that this would best be done last because the next operations might fill material in there. You just don't know for sure at this point. So the next task will be to create an arm. If you had to make the arms different lengths, you could use two sketches. For this part, however, both arms will always be of equal length. So you will only need to sketch the profile of one arm.

You would prefer to create the sketch on the same plane as the bottom cylinder (the current XY plane of the WCS) so that you can extrude it upward and unite it with the solid. Although you could create the sketch on the bottom face of the cylinder, you would end up looking "upward" at the sketch as you created it (since the direction arrow of the sketch would point away from the solid. You would rather that you be able to look downward on the sketch (from above the cylinder) as you create sketch curves.

You know that creating a sketch on a datum plane will allow you to control the direction of the sketch placement arrow.

Task 4. Create the Reference Geometry That You Will Need For the Sketch
On a simple part like this, the placement of objects on separate layers is not critical. For this project, however, you can follow the layer standards mentioned earlier.

Change the work layer to layer 61. Optional: Change the display of the part to Gray Thin Hidden Edges. Create a datum plane on the bottom face of the cylinder. - It's OK if the datum plane vector points downward. ? ? ? ? ? Choose the Datum Plane icon from the toolbar or choose InsertForm FeatureDatum Plane. Select the bottom face of the cylinder. Be sure the constraint is "Offset To Plane" Be sure that the offset value is zero. Apply these constraints.

Task 5. Create a Second Datum Plane

Looking ahead, you know that you will need to define a horizontal or vertical direction for the sketch. One way to do this is to use a datum plane that passes through the axis of the cylinder. Change the work layer to layer 62. Create a datum plane through the axis of the cylinder.

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Be sure the Datum Planes dialog is still up. Select the cylindrical face of the cylinder. Be sure the constraint is "Through Face Axis";. Apply the dialog.

Task 6. Create a Third Datum Plane

You plan to use one of these datum planes through the axis of the part to define the horizontal direction on the sketch. Create another datum plane through the axis of the cylinder, but perpendicular to the first one.

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Select the cylindrical face again. Select the datum plane you just created. For the axis vector, select the dashed arrow along the axis of the cylinder. Be sure the constraints will be "Through Face Axis" and "Angle To Plane" Be sure the angle value is 90 degrees. OK the dialog.

Task 7. Create Reference Geometry for the Circular Array

Looking even further ahead, your plan is to use a circular array to create the second arm after you create the first arm. Because you want the array to be associative, you want to use a datum axis as the axis of revolution. (If you used the point and direction method for the circular array, it would not be associative.) You would like to have the datum axis on its own layer. Change the work layer to layer 63. Create a datum axis through the center of the cylinder solid.

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Choose the Datum Axis icon from the toolbar or choose InsertForm FeatureDatum Axis. Use all the default options on the Datum Axis dialog. Select the cylindrical face. Be sure the constraint is "Through axis of face", then OK the dialog.

Task 8. Prepare to Create a Sketch

You plan is to sketch the shape for one arm of this part, extrude it, then make an instance of it to create the second arm.

For this project, you will want to create the sketch on a layer reserved for sketches. (However, if you did create it on the same layer as the solid, you could move it later.) Make layer 21 the work layer. Be sure the datum geometry remains selectable.

Task 9. Create a Sketch

Create the sketch on the datum plane associated with the bottom face of the cylinder. - Be sure the sketch will be displayed as if you were looking down onto the part. - You want the horizontal reference direction of the sketch to be parallel with the datum plane along the XC axis.

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Choose the Sketch icon or choose InsertSketch. On the Sketch Tools dialog, turn the Change View Orientation option on. Choose the Create option. On the Create Sketch dialog, be sure the Sketch Plane option is set to Face/Plane. If you want, you can set the Filter option to Datum Plane. Use the default sketch name, SKETCH_000. Select the datum plane associated with the bottom face of the solid. Be sure the direction arrow points from the datum plane into the solid (by using the Reverse Direction option if you need to). Select the Reference Direction Selection Step icon. Be sure the reference direction will be Horizontal. Select the datum plane that is parallel with the XC axis of the WCS. Verify that the horizontal direction arrow points in the positive XC direction. OK the dialog.

Task 10. Create the Sketch Curves of the Perimeter of the Arm
Since you know that you are going to constrain this sketch, you can create it away from the solid.

Create the sketch curves that will define the profile of the arm. - Watch the length value in the dialog bar to try to make them as close to their final sizes as possible. - Use Shift+MB3 to shift from lines to arcs and back. - Avoid sketching the lines within the snap angle.

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Choose the Basic Curves icon on the Sketch Tools dialog. Be sure the Line icon is highlighted. Use the Infer method. Be sure the String Mode option is on. Draw an angled line about 97 mm long. Use Shift+MB3 to choose the Arc creation option, then draw an arc. Shift back to Line and draw another straight line. Finally, draw a second arc that connects with the end of the first line, and break the string (with MB2).

Task 11. Prepare to Create a Reference Curve in the Sketch

In order to control the length of the arm, you will need a reference line that is associated with the arcs at each end of the arm. Draw a line from one arc center to the other.

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Display the Basic Curves dialog. Be sure the Line icon is highlighted. Move the cursor over an arc to display its control points, then select its arc center symbol. Use the same method to select the centerpoint of the other arc.

Task 12. Use a Reference Curve to Control the Length of the Arm
You can convert this line into a sketch reference line before you continue on to the next task. Cancel the Basic Curves dialog.

Convert the "arc centers" line into a reference line.

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Choose the Convert To/From Reference icon on the Sketch Tools dialog. Be sure the Reference option is on. Select the straight line between the arc centers. OK the Convert To/From Reference dialog.

Task 13. Prepare to Track Constraints on the Sketch Curves

Right now you would expect only two types of constraints to be on these curves (depending on how you created them): possibly a horizontal constraint on the reference line. possibly some tangencies between some of the arcs and lines. Check the geometric constraints that have been added by the system. If you need to, remove any wrong constraints.

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Choose the Show/Remove Constraints icon on the Sketch Tools dialog. Run the graphics window cursor over the sketch curves to reveal the geometric constraint symbols. If necessary, select the sketch curves you need to remove a geometric constraint from. Choose the Remove Highlighted Constraint option.

Task 14. Check the Reference Curve for the Correct Geometric Constraint
You will want the reference line of this sketch to be horizontal (parallel with the XC axis). If you need to, add a horizontal geometric constraint to the reference line.

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Choose the Constraints icon on the Sketch Tools dialog. Choose the Geometric icon on the Constraints dialog. Select the reference line. Choose Horizontal from the list of possible constraints, then Apply it.

Task 15. Constrain Arcs and Lines to Be Tangent

Add tangent constraints between the arcs and lines.

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Be sure the Geometric icon on the Constraints dialog is active. Select an arc then a line near their meeting point (and avoid control points). Choose Tangent from the dialog, then Apply it (with MB2). Continue on around the sketch curves adding a tangent geometric constraint wherever needed.

Task 16. Constrain the Reference Curve

You want to be able to define the exact length between the two arc centers of the sketch in order to control the length of the arm. Constrain the length of the reference line with a dimensional constraint (and note the expression number for this constraint). - Be sure you don't constrain it to always be horizontal.

Choose the Dimensional icon on the Constraints dialog.

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Choose the Parallel icon, then select the reference line. Indicate a location for the origin of the dimensional constraint. In the Current Expression field, key in the length value you need.

Task 17. Constrain the Radius of the End of the Arm

You also need to control the radius of the end of the arm. One way to do this is to use a dimensional constraint. Add a dimensional constraint to the small arc.

Task 18. Constrain the Large Arc of the Sketch

You want the radius of the large arc at the left end of the sketch to be constrained to the cylinder in case the diameter of the cylinder is changed. Place a concentric geometric constraint and equal radius geometric constraint on the large arc and the cylinder. ? Choose the Constraints icon on the Sketch Tools dialog. ? Choose the Geometric icon on the Constraints dialog. ? Select the large arc and the cylinder. ? Use the Control key to choose the Concentric and Equal Radius geometric constraints. ? Apply them.

Task 19. Deactivate the Sketch

The sketch should now be fully constrained.

Cancel the Constraints dialog. Deactivate the sketch.

Task 20. Create One Arm

You are ready to extrude this sketch to create the solid arm on one side of the part.

Optional: Return the work layer to layer 1. Extrude the sketch upward. - Unite it with the cylinder.

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Choose the Extrude icon from the toolbar or choose InsertForm FeatureExtrude. For the section string, select the sketch curves. OK the dialog. Use the Direction, Distance method. If you need to, reverse the direction of the arrow or just choose the Accept Default Direction option. Key in the end distance value. Be sure all the other values are set to zero. Unite the two solids.

Task 21. Add a Small Hole at the End of the Arm

In a moment you will instance the arm to create the second arm. However, you would like to instance both the solid and the hole that is in the small end of the arm at the same time. (This is not absolutely necessary. It is just one way to do it.) Make layers 21, 61, and 62 invisible. - Be sure the layer the datum arrow is on (layer 63) remains selectable.

Create a hole in the small end of the arm that completely penetrates the solid.

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Choose the Hole icon. Be sure the Simple icon is active. For the placement face, select the top face of the arm. For the thru face, select the bottom face. Key in the diameter of the hole.

Task 22. Position the Small Hole

Position the hole at the center of the arc at the end of this arm.

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Choose the Point Onto Point icon on the Positioning dialog. Select the arc at the end of the arm. On the Set Arc Position dialog, choose the Arc Center option.

Task 23. Create the Second Arm

This rocker device has two arms. You deliberately included the hole in the first arm so that it would be included in an array.

Be sure the vertical datum axis is selectable. Create an instance of the arm including the hole.

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Choose the Instance icon from the toolbar or choose InsertFeature OperationInstance. On the Instance dialog, choose the Circular Array option. On the Feature Selection dialog, choose the Extruded feature and the Simple Hole feature (use Drag-Select). OK the dialog. On the Instance dialog, use the General method. Be sure the total number of instances will be 2. Key in the angle between the two arms. OK the dialog. For the rotation axis, use the Datum Axis method. Select the datum axis at the center of the cylinder. OK the dialog. If the tool looks correct, choose Yes on the Create Instances dialog.

Task 24. Round an Edge

You need a blend at the join between the two arms.

Make layer 63 invisible. Add a blend at the join between the two arms.

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Choose the Edge Blend icon from the toolbar or choose InsertFeature OperationEdge Blend. On the Edge Blend dialog, be sure the blend type is Edge. Key in the default radius of the blend. Select the vertical edge between the two arms. OK the dialog.

Task 25. Add a Pivot Hole to the Part

Your last construction task is to add the central hole that the part will pivot on.

Add a hole in the center of the cylinder that penetrates the solid.

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Choose the Hole icon. Be sure the Simple icon is active. For the planar placement face, select the top face of the cylinder. For the thru face, select the bottom face of the part. On the Simple Hole dialog, key in the diameter of the hole.

Task 26. Position the Hole

Position the hole in the center of the cylinder. ? Choose the Point Onto Point icon on the Positioning Method dialog.

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Select the edge of the cylinder. Use the arc center method.

Task 27. Creating New Expressions to Control the Arms

You'll remember that the design intent requires two different conditions for this part: If the length of the arms is 100 mm or less, the angle between the arms must be 102 degrees. If the length of the arms is greater than 100 mm, the angle between the arms must be 90 degrees. This means you will first need to create an expression for arm length that you can change. Create a new expression: arm_length=100 ? Choose ToolsExpression. ? In the edit field, key in arm_length=100, then press Enter/Return.

Be sure the new expression appears in the list box. You also need an expression for the arm angle that you can change. Create another new expression: arm_angle=102 ? In the edit field, key in arm_angle=102 then press Enter/Return.

OK the dialog.

Task 28. Edit the Appropriate Sketch Dimension

Next you want to replace the value of the sketch dimension that controls the length of the arm with the "arm length" expression you can vary.

Edit the sketch dimension that controls the length of the arms to be equal to the arm_length expression.

- Hint: Start with the Edit Parameters dialog. ? ? ? ? ? ? Choose the Edit Feature Parameters icon or choose EditFeatureParameters. For the feature to edit, select one of the arms on the graphics screen. OK the Edit Parameters dialog. On the Edit Parameters dialog, choose Edit Sketch Dimension. Select the dimension that controls the length of the arm. (The value will be 100 mm). In the value field, replace the current value with the expression name, arm_length.

Task 29. Edit the Appropriate Instance Array Value

You also need to replace the angle value of the instance array with an expression that you can vary. Edit the instance array angle to be equal to the arm_angle expression. - Hint: Start with the Edit Parameters dialog. ? Choose the Edit Feature Parameters icon or choose EditFeatureParameters. ? Select one of the arms in the graphics screen. ? OK the Edit Parameters dialog. ? On the new Edit Parameters dialog, choose Instance Array Dialog. ? In the Angle field, replace the current value with the expression name, arm_angle.

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OK the dialogs until the part updates. Optional: List all of the expressions to be sure that the arm length expression has been changed.

Task 30. Make an Expression Conditional

Finally, you need to change the expression, arm_angle, so that it will allow the angle between the arms to change based on the length of the arms: If the arm length is made less than or equal to 100 mm, the arm angle must be 102 degrees. But if the arm length is more than 100 mm, the arm angle must be 90 degrees.

To do this, you must use a conditional expression. Change the expression, arm_angle so that it will allow the angle to change based on the arm length. ? ? ? ? Choose ToolsExpression. Select the arm_angle expression. Delete the current value (use the Backspace key). For the right hand side of the expression, key in (with no spaces): if(arm_length<=100)(102)else(90)

? Apply the Edit Expressions dialog. Task 31. Test the Model For An Arm Length of 120 It's time to test your work. Change to a TOP view. Be sure the Expressions dialog is up. If the arm length is greater than 100, the angle between them must be 90 degrees. Change the arm_length expression to 120 (and press Enter/Return). Apply the dialog.

Are the arms now at an angle of 90 degrees?

Task 32. Test the Model For An Arm Length of 75 If the arm length is less than 100 mm, the angle between them must be 102 degrees. Change the arm_length expression to 75 (and press Enter/Return).

Apply the dialog. Are the arms now at an angle of 102 degrees?

This completes the project.