Module 11: Creating Solids Using Quilts

Lab Exercises If you are ready to start on the exercises for this module, please click the links below. Exercise 1: Completing the Bottle Design Exercise 2: Completing the Upper Body of the Shaver Exercise 3: Creating the Shaver Head Cover (Challenge) Exercise 4: Completing the Lower Body of the Shaver (Challenge) Introduction Surfaces are used to define the complex shapes that you cannot define using solid modeling tools. You can merge the surfaces to create quilts. You can then create solids using the quilts as references by using editing tools such as Solidify and Thicken. The process of converting the quilts to solids requires you to add material thickness. Adding thickness can lead you to limitations when you try to apply the feature. You may not be able to add thickness beyond a particular dimension, due to the geometry of the surface. You can also use quilts to modify existing solid surfaces or use them to cut solids in design models. Also, in complex situations where standard solid rounds and chamfers do not provide satisfactory results, you can create fillets using surfaces. Objectives After completing this module, you will be able to: Replace a solid surface with a quilt. Patch a solid surface with a quilt. Create cuts using quilts. Create rounds and chamfers as surfaces instead of solids.

Creating Solids Using Quilts Surface geometry can be converted to solid geometry in the following ways: Thickening surfaces Material is added to either or both sides of the surface using the Thicken tool from the Edit menu. Solidify closed quilts If the quilt is closed, with no gaps at the edges, you can add material to the inside of the quilt using the Solidify tool from the Edit menu. Solidify quilts intersecting the model When a quilt intersects with the solid geometry such that there are no gaps or openings, the engulfed volume can be filled with material using the Solidify tool from the Edit menu.

Creating Solid Geometry from Surfaces Thickening surfaces The first set of figures show the open surface being thickened using the Thicken tool. Solidify closed quilts The second set of figures shows the closed quilt being solidified using the Solidify tool. Solidify quilts intersecting the model In the third set of figures, the desired shape has been visualized over built surfaces. These are merged to form the desired quilt. The quilt is then merged with the solid using the Solidify tool.

Replacing Solid Surfaces You can replace an entire solid surface using the Replace option in the Offset tool. Surface replacement differs from protrusions and cuts because it can add material in some places and remove it in others. Surface replacement is a surface deformation feature and creates a separate feature. Guidelines to use the Replace option: If the replacing quilt does not extend beyond the boundaries of the existing solid, the system interpolates the existing surface, sometimes leading to undesirable or unexpected results. If surface replacement adds material in some places and removes it in others, then the replacement quilt must consist of one surface only.

Surface replacement cannot be done in the Assembly mode as an assembly feature. It is not recommended to create two replacement features on top of each other. It is good design practice to delete one replacement quilt before creating a new one. Or, you can redefine the existing tweak/replace feature such that it replaces a different surface or uses a different replacement quilt. A quilt that has replaced a feature's surface cannot, in turn, be replaced by another quilt. The replacement surface must be deleted first. About the figures In the first set of figures, the selected surface of the solid block is replaced with the selected quilt positioned above it, resulting in the figure on the right. In the second set of figures, the Replace tool is used to add and remove material at the same time. The third set of figures shows the replacement, using a quilt that partially covers the solid surface.

Replacing Solid Surfaces (cont.) This slide displays an example of how to use the Replace option in the Offset tool to create a smooth shaped button. You start by creating the approximate shape of the button using a solid feature such as an Extruded protrusion. You also create a quilt using surfacing techniques that will be used to create the final shape of the button. You select the solid surface to be replaced, as shown in the first figure. 4

Next, you use the Replace option and the quilt as a reference to replace the solid surface, as shown in the second figure. The resultant solid will have the smooth shape of the quilt in place of the original solid surface, as shown in the third figure.

Patching Solid Surfaces You can use the Patch option in the Solidify tool to replace a specified portion of a surface or surfaces with a quilt. All the boundaries of the replacement quilt must lie on the surfaces that you are patching. The patch feature can add or remove material using a single surface definition. This feature differs from the replace feature as it can affect more than just one solid surface. You can use it to add or remove material from portions of solid surfaces or the entire solid surface.

Cutting Solids Using Quilts You can use open or closed quilts to cut solids. Using open quilts to cut away a solid You select a quilt as the cutting entity and you remove all material on one side of the quilt. You use the Solidify tool to access this functionality. Using open quilts to create a thin cut Similar to the first method, you select an open quilt as the cutting entity. However, in this case, you make a cut using the Thicken tool. For example, you can remove material a specific distance from either side of the cutting quilt, or symmetrically about the cutting quilt.

Using Surfaces to Create Rounds and Chamfers You can create rounds and chamfers as solid features or surface features. The default is to create them as solid features. During design, it is sometimes convenient to create these features as surface type features instead of solid features. The primary benefit of this technique is to enable you to edit the surface before the creation of the round or chamfer, adding a great amount of flexibility to this type of geometry creation. This is especially useful in situations where a round/chamfer would normally fail. In this case, you can create the round/chamfer as a surface, manipulate the resulting surfaces, and finally, create a solid feature using the surface for a protrusion, cut, replace, or patch.
The figure above is intended for illustration purposes only. In this case, a round will automatically produce the result shown on the right.

Exercise 1: Completing the Bottle Design

Objectives After successfully completing this exercise, you will know how to: Use the Thicken Tool. Create a Full Round. Scenario You are tasked with completing the design of the Bottle part. Task 1. Open the BOTTLE_THICKEN.PRT. 1. In the Folder Browser , right-click the module_11 folder and select Set Working Directory. 2. Open the BOTTLE_THICKEN.PRT. 3. If necessary, click Datum Planes , Datum Axes , Datum Points , and Datum Coordinate Systems from the main toolbar to disable their display.

BOTTLE_THICKEN.PRT

Task 2.

Use the Thicken tool to create a material thickness.

1. Select Quilts as the active selection filter.

o

Select the bottle quilt. If necessary, flip the yellow arrow outward. Edit the thickness value to 2. Click Complete Feature from the dashboard.

2. Click Edit > Thicken from the main toolbar.

o o o

Adding Thickness to the Bottle

Task 3. Create a Full Round at the Bottle opening. 1. Start the Round Tool from the feature toolbar. o Press CTRL, and select the edges shown in the following figure. o Right-click and select Full Round.
o

Click Complete Feature

from the dashboard.

Creating a Full Round

2. Click Save from the main toolbar and click OK. 3. Click File > Erase > Current > Yes. This completes the exercise.

Exercise 2: Completing the Upper Body of the Shaver

Objectives After successfully completing this exercise, you will know how to: Add thickness to a surface. Mirror the completed model. Scenario You are tasked with completing the BODY_UPPER model. Task 1. Open the BODY_UPPER model. , browse to the module_11\shaver folder.

1. In the Folder Browser

2. Right-click and select Set Working Directory. 9

3. Open the SHAVER.ASM.

Shaver Assembly

4. Select the BODY_UPPER.PRT, right-click and select Open.

o

Review the surfaces available in the part. Remember, we copied geometry from the master part and trimmed the surface using the available curves.

BODY_UPPER Part

Task 2.

Add material thickness to the model.

1. Select the quilt, and then click Edit > Thicken.

o o o

Flip the direction downward if necessary. Edit the thickness value to 1.5. Click Complete Feature .

Adding Thickness to BODY_UPPER

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2. Click Window > SHAVER.ASM to return to the assembly.

o

Zoom in and examine the material thickness in the assembly.

Thickened Model in the Assembly

Task 3.

Mirror the BODY_UPPER model.

1. Click Window > BODY_UPPER>PRT to return to the model. 2. Select the BODY_UPPER.PRT node at the top of the model tree.
o o o

Start the Mirror Tool Click Complete Feature

from the feature toolbar. .

Select datum plane FRONT from the model tree.

Mirroring the Model

3. Click Window > SHAVER.ASM to return to the assembly.

o o

Examine the UPPER_BODY model in the assembly. Notice that the material thickness needs to be increased to match the step thickness in the head assembly.

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Thickened Model in the Assembly

Task 4. Increase the thickness of the BODY_UPPER.PRT and compare thickening options. 1. Click Window > BODY_UPPER.PRT to return to the model.

BODY_UPPER Part

2. Select the Mirror 1 feature from the model tree. o Right-click and select Delete, then click OK. 3. Select the Thicken 1 feature from the model tree. o Right-click and select Edit Definition.
o o o

Type 2.0 for the thickness value. Click Preview Feature . Read the dialog box and notice the green highlighted areas.

The thickness value is too large for the sharply curved rib areas.

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Problem Areas in Green

4. Click Yes and then click Resume Feature . o Select the Options tab from the dashboard. o Notice the system has automatically excluded the problematic surfaces from the thicken operation. o Click Preview Feature . o Orient the model as shown.
o

Notice the surfaces of the ribs have been excluded from the thicken operation.

If desired, we could complete the thicken operation, leaving these surfaces excluded. Additional curves and surfaces could then be created manually, merged with the adjacent surfaces, and patched into the model. We will explore other options first.

Excluded Surfaces

6. Right-click and select Exit Verify. 7. Select the Options tab. o Change the Normal to Surface option to Automatic Fit.
o o o

Click Preview Feature . Orient the model as shown. Notice that the ribs were successfully thickened, but an archshaped surface has been created near each rib, along the mirror line of the model.

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Automatic Fit

8. Right-click and select Exit Verify. 9. Select the Options tab. o Change the Automatic Fit option to Controlled Fit.
o o o o o

Clear the Z check box, disabling translation of the model surfaces in that direction. Click Coordinate Systems their display. Click Complete Feature . from the main toolbar to enable

Orient the model as shown. Notice that the ribs were successfully thickened, leaving a smooth surface for the mirror. Click Coordinate Systems their display. from the main toolbar to disable

Controlled Fit (CSYS shown for reference)

10.
o o

Examine the model in more detail. Notice the material thickness was not normal to the surface in all areas due to the shape of the surface. This is not an acceptable solution because the BODY_LOWER will not mate properly.

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Indicating a Problem area

Task 5. Thicken using Normal to Surface and construct curves and surfaces manually. 1. Select the Thicken 1 feature from the model tree. o Right-click and select Edit Definition.
o o

Select the Options tab. Change the Controlled Fit option to Normal to Surface.

2. Click Preview Feature . o Read the dialog box and click Yes.
o o o

Click Resume Feature . Right-click and select Exclude Surfaces. Press CTRL and select the additional rib surfaces shown in the following figure.

Additional Surfaces Selected

3. Click Complete Feature

Surfaces Removed from Thicken

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Task 6.

Merge surfaces.

1. Specify Quilts as the selection filter option. 2. Press CTRL and select the two quilts shown in the following figure.
o o

Start the Merge Tool Click Complete Feature

from the feature toolbar. .

Selecting Quilts

3. Repeat the merge procedure for the remaining three rib surfaces. 4. Specify Smart as the selection filter option when finished. Task 7. Create curves to be used as boundaries in the first direction. 1. Click Datum Curve from the feature toolbar. o Click Thru Points > Done.
o o

Select the eight vertices, as shown in the following figure. (Be sure to select the lowest vertex available for each location.) Click Done.

Selecting Vertices

2. Double-click Attributes. Click Quilt/Surf > Done.

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o o

Select the surface shown in the following figure. Click OK to complete the feature.

Selecting a Surface for Curve to Lie On

3. Start the Sketch Tool from the feature toolbar. o Select datum plane FRONT from the model tree as the sketching plane. o Click Flip to reverse the sketch view direction. o Select datum plane TOP from the model tree as the reference plane. o Select Top as the orientation direction. 4. Click Sketch.
o o o

Click Specify References . Select the two vertices shown in the following figure as references. Click Close.

Selecting References

5. Click Entity from Edge from the Sketcher toolbar. o Select the three edges shown in the following figure.
o

Click Close.

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Selecting Edges

6. Zoom in on the gap on the left. o Click Conic Arc from the Sketcher toolbar. o Sketch and dimension the conic, as shown in the following figure.

Sketching a Conic

7. Sketch three additional conics, one in each of the remaining gaps (the completed sketch is shown in red in the following figure). o Use the same dimensioning scheme as the previous conic. o Click Complete Sketch .

Completed Sketch

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Task 8.

Create curves for you to use as boundaries in the second direction.

1. Select the edge shown in the following figure.

Selecting and Edge

2. Press SHIFT and select the edge again to begin the one-by-one selection.
o

Continue pressing SHIFT and select the adjacent edge, as shown in the following figure.

Selecting One by One Chain

3. Click Copy
o

and then Paste

from the main toolbar. .

Click Complete Feature

4. Repeat the procedure to copy another one-by-one chain on the right side, as shown in the following figure.

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Second Copied Curve

Task 9.

Create a boundary blend surface using the previous curves.

1. De-select all items by selecting the background. 2. Start the Boundary Blend Tool
o

Press CTRL and select the upper and lower curves, as shown in the following figure.

Selecting Curves in the First Direction

3. Right-click and select Second Direction Curves.

o

Press CTRL and select the left and right curves, as shown in the following figure.

Selecting Curves in the Second Direction

4. Right-click the lower boundary handle and select Tangent.

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Changing Lower Boundary to Tangent

5. Click Complete Feature Task 10.

Create a sketch that you will use with a fill feature. from the feature toolbar. from the Sketcher toolbar.

1. Start the Sketch Tool

o o o

Click Use Previous. Click Entity from Edge Select the edges (16) to form the outline of the sketch shown in the following figure (also shown completed). Click Complete Sketch .

Creating and Completed Sketch

2. With the sketch still selected, click Edit > Fill.

Task 11.

Create a series of merge features to form a single quilt.

1. De-select all items by selecting the background. 2. Specify Quilts as the selection filter option.
o

Press CTRL and select the two quilts shown in the following figure. 21

o o

Start the Merge Tool Click Complete Feature

from the feature toolbar. .

Selecting Quilts

3. De-select all items by selecting the background. 4. Press CTRL and select the two quilts shown in the following figure.
o o

Start the Merge Tool Click Complete Feature

from the feature toolbar. .

Selecting Quilts

5. Repeat the previous merge procedure for the remaining three rib quilts, merging them into the main quilt.

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Task 12.

Hide curves and patch the surface quilt into the solid.

1. Select the following four features that come before the boundary blend in the model tree.
o

Right-click and select Hide.

Selecting Features

2. Select the merged quilt.

o o o o

Click Edit > Solidify. Accept the default of Patch Click Complete Feature . . Flip the arrow downward if necessary.

3. View the completed solid.

o

We have accomplished our goals of having a material thickness of 2 and having the desired rib geometry.

Completed Solid

Task 13.

Mirror the model.

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1. Press CTRL + D to orient to the standard orientation. 2. Select the BODY_UPPER.PRT node from the top of the model tree.
o o o

Start the Mirror Tool Click Complete Feature

from the feature toolbar. .

Select datum plane FRONT from the model tree.

3. With the Mirror 1 feature still selected, right-click and select Hide to hide the curves within the mirror. 4. Examine the underside of the model.
o

Notice that the mirrored halves do not blend together smoothly in the area near the ribs.

Mirrored Surfaces not Smooth

5. Select Boundary Blend 1 from the model tree, right-click and select Edit Definition.
o o o o o

Select the Constraints tab. Select Direction 1- First Chain. Enable the Add Side Curve Influence option. Click Complete Feature . Notice that the halves now blend smoothly.

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Side Curve Influence Enabled

The Side Curve Influence and Inner Edge Tangency options can be toggled separately for each boundary curve.

Task 14.

View the completed model in the assembly.

1. Click Window > Close to return to the assembly.

o

Examine the UPPER_BODY model in the assembly.

Completed BODY_UPPER

2. Click Save

from the main toolbar and click OK.

3. Click File > Erase > Current > OK. This completes the exercise.

Exercise 3: Creating the Shaver Head Cover (Challenge)

Objectives After successfully completing this exercise, you will know how to: Modify the shape of a solid by replacing a solid surface with a quilt. Modify the shape of a solid by patching a solid surface with a quilt. Scenario You continue to design the shaver. You are designing the cover for the head of the razor. Using the references, you have developed the base solid and you

25

want to refine the shape by making it aesthetically pleasing. Also, you want to provide an indentation in the cover that can be used to remove the cover easily. Task 1. Retrieve the model and review the available geometry.

1. Ensure that all previous models are erased from the session. 2. In the Folder Browser
o

, select the module_11 folder.

Right-click the module_11 folder and select Set Working Directory.

3. Open the COVER.PRT.

o

Click View > Display Settings > Model Display. Select the Shade tab and clear the Transparency check box.

Transparency Disabled

4. Notice that there are four suppressed features and one suppressed group in the model tree.

Model Tree

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5. Select the THUMB_IMP_PROFILE, press SHIFT, and select Surface Merge 5209.
o o

Right-click and select Resume. Notice that the thumb indentation surface appears on the model.

Surface Resumed

6. Start the View Manager tab.

o o o

from the main toolbar, and select the X-Sec

Double-click the saved section Middle to activate it. Click Display > Visibility. Click Display > Flip if necessary to view the model, as shown in the following figure. Zoom in and notice that the thumb indentation is only surface geometry.

Reviewing the Base Model Geometry

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7. Double-click No Cross Section.

o o o

Right-click Middle and select Visibility to disable it. Click Close from the View Manager dialog box. Press CTRL + D to view the default orientation. Replace the inside surface of the cover.

Task 2.

1. Select the INSIDE_SURF feature from the model tree.

o

Right-click and select Unhide.

Replacement Quilt for the Inside Surface

2. Drag the Insert Indicator THUMB_IMP_PROFILE.

in the model tree just above the

3. Change the selection filter from Smart to Geometry.

o

Right-click to query and select the solid surface, as shown in the following figure.

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Solid Surface Selected

4. Click Edit > Offset.

o o o o

In the dashboard, click Replace Surface Select the overhanging surface quilt. Click Complete Feature .

The model appears, as shown in the following figure.

Solid Surface Replaced

Task 3. Replace the outside surface of the cover. 1. Press CTRL + D to view the default orientation. 2. Edit the selection filter to Smart. 3. Select the OUTSIDE_SURF feature from the model tree. o Right-click and select Unhide. 4. Select the solid surface, as shown in the following figure.

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Solid Surface Selected

5. Click Edit > Offset.

o o o o

Click Replace Surface in the dashboard. Select the overhanging surface quilt. Click Complete Feature . The model appears, as shown in the following figure.

Replacing a Solid Surface

6. Start the View Manager from the main toolbar, and select the X-Sec tab. o Double-click the saved section Middle to activate it. o Click Display > Visibility.
o

Notice the solid geometry is now dome-shaped on the inside and out.

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Reviewing the Base Model Geometry

7. Double-click on No Cross Section. o Right-click Middle and select Visibility to disable it.
o

Click Close from the View Manager dialog box. Add round to the inside and outside top edges. from the feature toolbar.

Task 4.

1. Start the Round Tool

o o o

Select the edge shown in the following figure. Drag the radius handle to 6. Click Complete Feature .

Creating a Round on the Inside Edge

2. Start the Round Tool

o o o

again.

Select the intent chain shown in the following figure. Drag the radius handle to 7.5. Click Complete Feature .

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Creating a Round on the Outside Edge

Task 5. Add a thumb indentation to the cover. 1. Right-click the Insert Indicator from the model tree, and select Cancel. o Click YES from the message window. o Notice that the surface that defines the thumb indentation was modified to match the new shape. 2. Select the thumb indentation quilt, as shown in the following figure.

Selecting the Quilt

3. Click Edit > Solidify. o Notice that the dashboard automatically defaults to the Patch Tool . o If necessary, flip the patch direction, as shown in the following figure. o Click Complete Feature .

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Patching the Thumb Indentation Geometry

Task 6. Review the final geometry using the cross-section. 1. Start the View Manager from the main toolbar, and select the X-Sec tab. o Double-click the saved section Middle to activate it.
o o

Click Display > Visibility. Notice that the patch feature has added material in some places and removed material in other places.

Reviewing the Modified Solid Geometry

2. Double-click No Cross Section. o Right-click Middle and select Visibility to disable it. o Click Close from the View Manager dialog box. 3. Click View > Display Settings > Model Display. o Select the Shade tab and enable Transparency.
o

Click OK.

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The Completed Cover

4. Click Save from the main toolbar and click OK. 5. Click File > Close Window. Task 7. To view the final cover, retrieve the Shaver Head assembly. to view the

1. In the Folder Browser , click Working Directory contents of the folder in the browser. 2. Open the SHAVER_HEAD.ASM.

Cover in Head Assembly

3. Click Save

from the main toolbar and click OK.

4. Click File > Erase > Current > OK. This Completes the exercise.

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Exercise 4: Completing the Lower Body of the Shaver (Challenge)

Objectives After successfully completing this exercise, you will know how to:

Offset individual surface patches of a quilt. Use offset surface to add thickness to a part.

Scenario You continue to create the lower body of the shaver. Unlike the upper body, in this case a series of steps have been performed for you. Geometry has been copied from the BODY_MASTER, and a surface for the switch base has been added. The first step in detailing it is to add thickness to the part. Task 1. Locate and open the lower body part. , click Working Directory .

1. In the Folder Browser

o

Open the BODY_LOWER.PRT.

2. If necessary, click Datum Planes , Datum Axes , Datum Points , and Datum Coordinate Systems from the main toolbar to disable their display.

Lower Body Part

3. Review the surfaces available in the part.

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Task 2.

Add thickness to the part.

1. Select anywhere on the quilt.

o o o

Click Edit > Thicken. Flip the direction downward. Edit the thickness value to 2.

Adding Material Thickness to the Inside of the Part

2. Click Preview Feature

o o o o o o

The feature fails to regenerate. Click Tools > Environment and enable 3D Notes. Click OK from the Environment dialog box. Select the two Note check boxes in the Troubleshooter dialog box. Read the notes on the screen and identify the trouble spot. Click OK from the Troubleshooter.

Troubleshooter Message

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The geometry fails to create due to intersecting surfaces. The offset geometry becomes selfintersecting at the defined offset value. We cannot use the Thicken tool to add thickness to the part. Cancel the Thicken feature creation.

3. Click Resume Feature .

o

Click Cancel Feature

, and click Yes.

Task 3.

We use alternate surfacing techniques to resolve this problem. Offset the body surfaces.

1. Select Quilts as the active selection filter.

o

Select anywhere on the quilt. Flip the direction toward the inside of the model, as shown in the following figure. Edit the offset value to 1.

2. Click Edit > Offset.

o

Offsetting the Inside of the Part

3. Right-click and select Exclude Surface.

o o

Orient the model to view it from the underside. Press CTRL and select the 17 surfaces from the switch base to exclude them from the offset, as shown in the following figure.

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Excluded Switch Base Surfaces

4. Drag the offset handle to 2. 5. Select the Options tab in the dashboard.
o o

Enable Create Side Surface. Click Complete Feature from the dashboard.

Offset Surfaces of Body

Task 4. Offset the switch base surfaces. 1. Orient the model, as shown in the following figure.

Orienting the Model

2. Select the original quilt surface. o Click Edit > Offset. o Flip the direction to add material on the inside of the model.
o

Edit the offset value to 2.

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3. Right-click and select Exclude Surface. o Orient the model as shown.

o

Press CTRL and select the 6 surfaces, as shown (highlighted in red) in the following figure.

Excluded Surfaces

4. Click Complete Feature Task 5.

from the dashboard.

Merge the quilts and convert to solid part.

1. Press CTRL and select the small quilt and then the large quilt, as shown in the following figure.
o o o

Start the Merge Tool Click Complete Feature

from the feature toolbar. from the dashboard.

Flip each arrow once as shown.

Merging Quilts

2. Press CTRL and select the two quilts shown in the following figure.
o o

Start the Merge Tool

from the feature toolbar.

Right-click and select Join.

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Click Complete Feature

from the dashboard.

Merging Quilts

3. Press CTRL and select the two quilts shown in the following figure.
o o o

Start the Merge Tool Click Complete Feature

from the feature toolbar. from the dashboard.

Right-click and select Join.

Merging Quilts

4. Select the quilt, and click Edit > Solidify.

o

Click Complete Feature

from the dashboard.

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Solidified Quilt

5. The model can now be detailed by adding additional solid features, as shown in the following figure.
o

This basic solid modeling task is outside the scope of this course.

Detailed Lower Body Part

6. Click Save

from the main toolbar and click OK.

7. Click File > Erase > Current > Yes. This completes the exercise.

Summary
After successfully completing this module, you should know how to:

Replace a solid surface with a quilt. Patch a solid surface with a quilt. Create cuts using quilts. Create rounds and chamfers as surfaces instead of solids.

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