Pro/ENGINEER Tutorial

Lesson #6: Sweeps and Blends

Overview of this Lesson
This lesson will introduce you to the last part design features covered in this series. These are:
Sweeps
a feature that sweeps an open or closed sketch along a specified trajectory
Blends
a feature that allows smooth transitions between specified cross sections
These are very advanced modelling features with many options. In this lesson, we will only look
at the simplest versions. We will create several different parts that are totally independent of each
other, so you can jump ahead to any one of these:
1. Sweeps
o

Sweeping a Closed Section - An S-Bracket

Sweeping an Open Section - A Lawn Sprinkler

2. Blends
o

Straight Blends

Smooth Blends

Sweeps
There are a number of different sweep geometries available in Pro/E. We will look at just two of
them: sweeping a closed section along an open trajectory, and sweeping an open section along a
closed trajectory. A sweep can be used to create a protrusion, slot, or cut. In the following, we
will just create protrusions.
Closed Section, Open Trajectory - The S-Bracket
The part we are going to create is shown in the figure below.

The part consists of two features: the solid protrusion block at the left, and the s-shaped sweep
coming off to the right. The cross section of the sweep is like an I-beam.
Start a new part called s_brack and create the default datum planes. First create the block as a
solid protrusion, one-sided, with a blind depth of 60 using DTM2 as the sketching plane
and DTM1 as the Right reference. The right edge of the sketch aligns with DTM1. The sketch of
the base is shown in Figure 7.

Figure 7
Now we will create the sweep. This is done in two steps: creating the sweep trajectory, then
creating the cross section. To start, select

Create > Solid > Protrusion > Sweep | Solid | Done

In the SWEEP TRAJ menu select
Sketch Traj
and use DTM3 for the sketching plane, and DTM2 as the Top reference plane. Sketch the Sshaped line shown in the following figure:

Figure 8
Don't forget to align the left end of the trajectory with the base block (top and side). Notice the
arrow starting at the left end of the trajectory. This shows the starting point and direction of the
sweep. When the trajectory regenerates successfully, select Done.
The next menu has to do with the end conditions of the sweep. Select
Free Ends | Done
Now you will move on to the second step - creating the cross section. The screen should show
you a light blue cross hair. This is centered on the start point of the trajectory. You might like to
rotate the view a bit to see the orientation of the sketch that is determined automatically by
Pro/E. Use the Sketcher tools to create the following cross section (don't forget alignment):

Figure 9
When this successfully regenerates, you can select Done from the Sketcher menu, and
then Preview the sweep. If everything is satisfactory, select OK. The part should now look like
this:

Figure 10
Use the Modify command to experiment with changes you make make to the sweep.
Before we leave this sweep, you should note that it is not strictly necessary for the cross section
to lie exactly on the trajectory. If the section is offset, then the sweep will be offset. You have to
be careful that during the sweep, the cross section doesn't pass through itself - this occurs when
the radius of a trajectory corner is very small, and the section is on the inside of the curve. Also,
note that you can also sweep a closed section around a closed trajectory. For advanced users, the
trajectory can be formed as a three-dimensional spline.
Open Section, Closed Trajectory - The Lawn Sprinkler

This version of the sweep command will be used to create the part shown below:

Figure 11
This part has only three features: the sweep used to create the base with two arms, a revolved
protrusion to create the hub, and a revolved cut to create the bore. A detailed view of the arm
cross section is shown below. The part is shown on p.272 of Fundamentals of Graphics
Communications (Irwin Graphics Series).

Figure 12
Start a new part called sprinkler and create the default datums as usual. The first feature we will
create is the base, with two extending arms. As before, we do this in two steps: first the sweep
trajectory, then the cross section. We only need to create an open section showing the edge detail.
We will use a special command to fill in the surfaces between the swept edge.
Create > Solid > Protrusion > Sweep | Solid | Done > Sketch Traj

Using DTM2 as the sketching plane, and DTM1 as the Right reference plane, sketch the
trajectory shown below. This trajectory is for the outer edge on the bottom surface of the part.
The swept section will be inside and above this trajectory. Unless you are very good with
Sketcher, don't try to sketch this all at once. Sketcher allows you to cycle through the draw dimension - regenerate - modify - draw sequence as often as you wish. Creating the sketch all at
once will probably lead you to regeneration errors. Doing it in small steps will make it easier to
correct. For example, you can sketch half the trajectory and then use the mirror command, and
you can use the fillet command. Notice how few dimensions are actually required to define the
sketch:

Figu
re 13
After the final successful regeneration, select Done. Since we are only going to sketch the edge
detail, we will want Pro/E to completely fill in the top and bottom inner surfaces of the part from
the free ends of the cross section sketch. Therefore, select
Add Inn Fcs | Done
Again, you are presented with an edge view of the trajectory, with the light blue cross hairs to
show where you will create the swept section. You might have to rotate the view a little to get a
better idea about the orientation of the part. Sketch (including alignment and dimensioning) the
open line shown in Figure 14.

Figure 14
The purpose of the cross hair is to show you the relative position of your sketch and the
trajectory. As stated above, the cross section does not necessarily have to touch the trajectory.
The free ends of the cross section will be closed in by the inner faces of the sweep. When you get
a successfull regeneration, select Done. You can ignore the WARNING about the open ends.
Finally, you can Preview the feature. Select OK if it is satisfactory. The part should look like
Figure 15.

Figure 15
Add the hub as a revolved protrusion using the sketch below for dimensioning details:

Figure 16
Finally, create a hole for the central shaft. This time, instead of a straight hole, we will specify a
cross sectional shape for the hole, including the counterbore.
Create > Hole > Sketch | Done > Linear | Done
The only difference between this and a straight hole is that we have to provide the cross sectional
shape of the hole using Sketcher. Pro/E will automatically revolve the section shape through 360
degrees prior to adding it to the model. In the small window that opens up, create the following
sketch (don't forget the centerline):

Figure 17
The placement plane is the top surface of the hub, and the dimensioning references
are DTM1 and DTM3. Pro/E will take the top edge of the sketched hole and align it
automatically with the placement plane, with the axis of the hole at the placement point.

So, that's the end of sweeps! As you can see, these are quite complicated features, packing a lot
of geometric information into a single feature. You might like to go back and modify any of the
dimensions of the sweeps to see what happens. You can modify either the trajectory, or the
section, or both! Be aware that arbitrary modifications might make the sweep illegal, so save
your part before you try anything drastic.
Blends
A blend is like a sweep with a changing cross section. A blend can be used to create a protrusion,
cut, or slot. Some restrictions apply:

At least two sections are required.

The sections must either be parallel to each other (a parallel blend), or they must all have
a common axis (a rotational blend)

Each section must be created separately and constrained to either the existing geometry,
or a previous blend section.

Each section must have the same number of line (or arc) segments, and the same number
of vertices

Each section has a starting point - these must be placed properly on all the sections or
else the resulting geometry will be twisted.

For a rotational blend, the sections can be no more than 120 degrees apart.

The sections of the blend can be connected either with straight (ie. ruled) surfaces, or with
smooth surfaces.
In the following, we will create two parts that illustrate the basic features of blends.
Straight, Parallel Blend
This is the simplest form of a blend. We will create the part shown below.

Figure 18
This blend has three sections: a square, a rounded rectangle, and a final thin rectangle. These are
shown best in the wire frame view of the part.

Figure 19
Start up a new part called blend1 and create the default datum planes. To create the blend:
Create > Solid > Protrusion > Blend | Solid | Done
Parallel | Regular Sec | Sketch Sec | Done
Straight | Done
Select DTM3 as the sketching plane, and DTM1 as the Right reference plane.

Each section will be sketched separately. This includes dimensioning, aligning, regenerating, and
so on. When each section is completed, we will move on to the next section. The previous
section will remain displayed on the screen in gray. The new sections can use the old ones for
constraint references, or they can be defined with respect to other part features.
The first section is a 10 X 10 square centered on the datum planes, as shown below.

Figure 20
Note the round dot and arrow on the upper left corner. This is called the start point and shows the
direction that vertices will be traversed in the section. Since the square has four vertices, each
section we produce must also have four, and their start points must correspond to each other. If
your sketch's start pointis not in the position shown, select:
Sec Tools > Start Point
and click on the desired vertex.
When you have a successful regeneration, select
Sec Tools > Toggle
This will take us to the next section. The previous one is grayed out, and Sketcher is now used to
create the second section. When that one is regenerated successfully, toggle to the third section.
The dimensions and placement of all the sections is shown in the figure below. Make sure all
your start points at located correctly.

Figure 21
When the third section is complete, select Done. Now you will be asked for the distance between
each planar section. The distance from the first section (the square) to the middle section is 15.
The distance to the next section is 20. This should complete the specification of the
blend. Preview the part, and select OK when you are satisfied with the part.
Shade the image. You might like to try to Modify the dimensions of the cross sections. When
you select the feature, you will see all the section shapes with their dimensions displayed on the
original sketching plane.
Smooth, Rotational Blend
A rotational blend is set up by specifying the cross sectional shape on a number of sketching
planes that have been rotated around a common axis. The usual restrictions apply as to the
number of segments and vertices in each section and the start point. The sections can be no more
than 120 degrees apart.
We are going to make the part shown in the two figures below.

Figure 22 Front isometric

Figure

23

Rear

isometric
Note that the surfaces on the blend are smooth. If we select straight surfaces, we will get the
shape shown here:

Figure 24
Start a new part called blend2 and create the default datum planes. Also, create a default datum
coordinate system (see Lesson #1). Then start the blend creation:
Create > Solid > Protrusion > Blend | Solid | Done
Rotational | Regular Sec | Sketch Sec | Done
The attributes window will open. Click on the Attributes line and the Define button, and select
Smooth | Open | Done
Now select DTM3 as the sketching plane (the view direction is okay), and DTM1 as
the Right reference plane. We are going to create four cross sections, with a separation of 30
degrees. Therefore, the total angle of rotation of the blend will be 90 degrees. Each section must
include a coordinate system in the sketch (discussed below). The rotation will occur around the
y-axis of this system.
The first section will be sketched directly on DTM3. The dimensions of the section, and its
position on the blend, are shown in the figure below.

Figure 25 First Section

Draw and dimension the sketch. When you regenerate, you will get a message about a missing
coordinate system. Select:
Sketch > Adv Geom > Coord Sys
and pick approximately at the origin of the default datum planes. Align this new coordinate
system with the default coordinate system created earlier. Now a regeneration should be
successful. Take note of the start point. When you select Done, you will be asked for the angle to
the next section. Enter 30.
A new sketcher window opens up. In this window, you need to sketch the second section and
supply a coordinate system to allow alignment with the first section. Dimension the sketch to the
coordinate system and make sure the start point is on the correct vertex. The second section has
the following dimensions:

Figure 26 Second Section

When you select Done, proceed on to the next section. The separation angle is again 30 degrees.
The third section has these dimensions:

Figure 27 Third Section

Finally, the last section has these dimensions:

Figure 28 Fourth Section

When the fourth section is complete and you are asked to continue to the next section, type in n.
The message window should indicate that all elements are complete, and you can Preview the
part. Select OK when you are satisfied.
That completes our limited presentation of blends. As you can see, blends contain a lot of
geometric information and are therefore a bit more difficult to set up. However, they offer
considerable flexibility and can create very complex shapes not attainable with the simpler
features.