Example use of Pro/Engineer Wildfire 2.

Intent

The intent of this exercise is to show the use of computer-based design tools. In
engineering design the final design is usually the result of extensive design studies and
design modifications. Design tools are needed that enable changing designs easily and
that provide analysis capabilties used in the design process.

A set of step-by-step instructions is provided to create a solid model of a model-size shelf

using Pro/ENGINEER. These instructions provide a very brief introduction to creating
solid models. It is expected that the reader can use these instructions as a starting point
for an individual effort to build up expertise in using this capability of Pro/ENGINEER
and similar design systems. The intent is not to show all widely useful capabilities of the
program or a recommended, or in any sense "best" use of Pro/ENGINEER.

Tasks

The task in this exercise is:

- create a solid model of a model-size shelf that will be used in the Injection Molding
Simulation and Injection Molding Part Production labs,
- the solid model should be such that the number of ribs, the thickness of the ribs, the
existence of the corner holes and the diameter of the corner holes can be easily varied,
i.e., without redrawing the part.

The Example Part

The shelf that will be produced in the Injection Molding lab is shown in the partially-
dimensioned sketch below. A solid model of it is available in the Part Files section of the
course web page.
A set of starting dimensions is provided that are relevant for the shelf to be produced. The
dimensions and other part characteristics need to be modified for other lab exercises (this
is analogous to modifying characteristics in the design process) and so a program is
created to allow such design studies.

General Procedure

Again, only some of the capabilities of design software will be used. The solid model of
the shelf will be created by

• sketching one-quarter of the frame part of the shelf

• using a mirroring facility about two axes to produce a cross-section of the full
frame
• extruding the frame section to produce a 3-d frame structure
• adding the top shelf surface to the frame
• adding the ribs by constructing one rib and patterning it to add additional ribs
• creating the corner holes
• editing the system supplied part description file to enable programming so that the
final result is a useful tool for shelf design

While a program will eventually be created to enable changing dimensions and features,
it may be useful to contruct the initial model using the model part dimensions shown as
this will produce a model that is easy-to-see in terms of its features and accuracy of part
representation.
Step-by-Step Instructions

Much of the following discussion is very specific and the results listed were obtained
when this tutorial was prepared. While not expected, there may be differences when the
program is run at different times.

Start Pro/ENGINEER

log on
create or choose the directory to work in
start Pro/Engineer

Pro/Engineer opens with lauching a browser and an information widow. The small
arrows on the right edge of the browser window can be used to resize and close the
window.

Pro/ENGINEER has an Intent Manager which helps by providing suggested steps in the
design process and the facilities for doing them. In essense, typical construction steps are
assumed and facilities are provided for them automatically. This is why the following
construction is so short - solid model creation by extrusion is a typical procedure and the
program (Intent Manager) is initially set for this procedure . Complete control of the solid
model design process is also available with the Intent Manager switched Off, but this is
not done in the following. (To switch Intent Manager Off, at the point in the procedure
when sketching is to be started in the main menu bar Sketch -> Intent Manager, toggle it
Off.)

Choose File on the main menu bar then Set Working Directory...
create or move to the directory to work in and
OK in Select Working Directory dialog box

Choose File ->New...

Choose (preselected) Part in New and
(preselected) Solid in Sub-type
input a name for the part, e.g., shelf_1 and
Deselect, toggle off, the Use default template checkbox
OK in New dialog box

Select mms_part_solid for system of units and type of part in New File Options dialog
box
Comments can be added in the dialog box
OK in New File Options dialog box

Default coordinate system and datum planes are displayed.

Tools for controlling the display are across the Menu Bar at the top of the display
window, e.g., a button to toggle a grid on and off and View -> Display Settings ->
System Colors...or View -> Color and Appearances
Often-used tools are in the Toolbar or Toolchest along the right edge of the display
window.
Letting the cursor hover over a tool button will bring up the name/description of the tool.

NOTE: There is an Undo facility under Edit in the Menu Bar and this may be useful
throughout the following.

Create the Outside Frame of the Shelf

in the menu bar Insert -> Extrude...

some tools useful for extrusion become available at teh lower left of the display area - the
Dashboard

Select the "Sketch Tool" at the top of the Toolbar - the vertical tool bar at the right edge
of the display

The x-y plane will be used for sketching the part cross-section and the section will be
extruded along the z-direction.

select/pick/click on the x-y FRONT plane

FRONT datum plane is highlighted and listed in References dialog box and viewing
direction shown.
This plane and direction will be used so -

Sketch in the Sketch dialog box

The top view of the sketching plane is displayed. Toggling a grid on may be useful.

References are needed for dimensioning.

In the following procedure in which the shelf outside frame will be constructed first, the
coordinate system will be located at the centrer of the shelf, and since the sketching plane
is for the frame the coordinate system will be at the top plane of the frame, i.e., at the
bottom of the top plate of the shelf that will be added in a subsequent construction step.

Default references are listed in the References dialog box - the edges of the RIGHT and
TOP datum planes.
These will be used and are Fully Placed so-
Close the References dialog box

Sketch the one-quarter shelf frame section shown

Note that end lines are not included and the shelf will be centered on the origin of the
coordinate system.
The x-y plane will be at the frame-top surface common height.

Commonly used sketching tools become available in a vertical Tool Bar along the right
edge of the display - the Toolchest. Letting the cursor hover over the button will cause
the name/function of the tool to be shown. Sketching tools are also available on the main
menu bar under Sketch.

To sketch an arc
select the "Create an arc by 3 points or tangent to an entity at its endpoints" tool in the
Toolchest and click in the display on the endpoints of the arc and then set the center of
the arc by clicking and then click the middle mouse button to end drawing the arc -
double click the middle mouse button to deselect this drawing tool.

To sketch straight lines

select the "Create 2 point lines" tool at the top of the Toolbar/Toolchest
click at the location of one endpoint, then at the other end, then click the middle mouse
button to end this section of sketching - double click middle mouse button to close the
sketching tool

The line, a line label/name and default dimensions are displayed.

To specify a dimension double click on the default dimension value provided, input the
desired value and enter/return

To create center lines about which mirroring will be done

in the menu bar Sketch -> Line -> Centerline
create centerlines along the edges of the TOP and RIGHT datum planes by,
Depending the system, installation, etc., it may be better to create a centerline and do the
mirroring one step at a time, rather than creating two centerlines and then moving on to
two morroring operations.

clicking at the ends of the lines and double click the middle mouse button to exit this
sketching tool

Centerlines and markers are displayed.

To create the entire frame section

select all lines of the sketch by holding down the Control key and clicking on the lines
click the "Mirror selected entities" tool in the Toolchest, and
select the centerline to use for mirroring

A mirrored section is created.

Use the same procedure to mirror the half-section, i.e., select all lines, the mirror tool and
then the other center line

End the sketching process by clicking on the Checkmark near the bottom of the Toolchest

The section is displayed.

With the end of the sketching process the sketching management program is ended and a
new part of the procedure has to be started.

Click the Resume button - the blue arrow button at the lower right corner of the display
A menu becomes available at the lower left corner of the display - the Dashboard
The useful tools for extrusion are avaiable on the Dashboard
Use the "Extrude from sketch plane by a specified depth value" tool, which is probably
pre-selected.

Note that the height of the base part/frame of the shelf (9.4 mm) is the extrusion depth
and it is the height of the frame - doesn't include the top plate thickness.

Input the extrusion depth - the frame thickness or height - and enter/return

The frame of the shelf is finished and displayed.

Hold down the center mouse button and drag to rotate the display.

click the green Checkmark button or enter/return to accept the model and end this part of
the process.

Create the Top Plate of the Shelf

The top plate of the shelf can be created by extruding the frame periphery section.
in the menu bar Insert -> Extrude...
select/click the "Sketch Tool" at the top of the vertical toolbar at the right edge of the
display
select/pick the FRONT, x-y, plane to specify it as the sketching plane if this plane was
used to sketch the shelf frame

This is the original sketching plane with viewing direction used for constructing the
frame part of the shelf. Note that the top of the shelf will have to be extruded in the
opposite direction from the extrusion direction that was used for frame section extrusion.
The program is "smart" enough to do this automatically, but extrusion direction should be
checked in all cases.
The FRONT plane should be listed as the sketch plane in the Sketch dialog box.

Sketch in Sketch dialog box

References should be fully placed and listed as such in the References dialog box.
Close the References dialog box

To sketch/define the perimeter of the top plate of the shelf

select/click the "Create an entity from an edge" tool button in the Toolchest
select Loop in the Type dialog box
pick/click the outer edge of the shelf frame

With selection of an edge loop profile the Menu Manager appears and provides for
accepting the loop, or clicking Next to display and perhaps accept a different loop.
Clicking Next sequentially until the correct loop is selected is an easy way to get to the
desired loop

Note: this is a touchy part of the process. If the wrong edge is picked a way to reset the
process is to click either Single or Chain in the Type dialog box and then select Loop
again.

when the correct loop is identified, Accept in Menu Manage - SEL CHAIN
Close the Type dialog box

click Checkmark in Toolchest to end sketching

Resume by clicking the blue arrow button to start the extrusion phase of model creation

on Dashboard use the (preselected) "Extrude from sketch plane to a specified depth" tool
Input depth/plate thickness - 4.1 mm - and enter/return

the frame-top surface model is displayed

click the green Checkmark or enter/return to accept model

Create a Rib as a Template for Patterning

The ribs will be constructed by creating one rib and then Patterning this feature to
produce a second rib. This procedure allows for a program that will include the capability
of easily modifying the shelf design by changing the number of ribs.

The first rib can be created by specifying the plan view of the rib on the bottom surface of
the top plate of the shelf and then extruding the cross-section normal to the plate surface.

When this tutorial was written the default dimension defining rib location was the
distance from the longitudinal centerline of the shelf. This can be used but results in a
slightly more complicated procedure for specifying the patterning of the ribs. Or the rib
location can be specified as a different dimension by creating another dimension, e.g., the
distance from the edge of the shelf is useful as then the patterning can be across the entire
width of the shelf - rather than having to specify paterning in two direstions around the
shelf longitudinal centerline.

The suggestion is to position the first rib by dimensioning it with reference to the inside
surface of the frame side - the 19.4 mm dimension on the part drawing.

Note that there is also a "Rib Tool" available in the Toolchest. This is not used here since
it adds little to the exposition.

To show a different path through the process, rather than selecting the "Sketch Tool" in
the toolbar -

on the main menu bar Insert -> Extrude then

Insert -> Model Datum -> Sketch...

use the bottom face of the top plate to which ribs will be attached as the sketching plane

pick/click the sketching plane - the bottom surface of the top plate of the shelf
Sketch in the Sketch dialog box

references should be fully placed and indicated so in the References dialog box

Close the References dialog box

Sketch one rib by

select the "Rectangel Tool" in the Toolchest
move cursor to one corner of the rectangle and click, then the diagonally opposite corner
and click and then click the center mouse botton to end rectangle sketching - double click
center mouse button to deselect the sketching tool.
Dimension the rib

Specify a dimension by double clicking on it on the display, input desired value,

enter/return.
Note the dimension specifying rib location since this will be the basis for patterning.
When this was written the default dimension specified the rib location from the
longitudinal centerline of the shelf. As explained above defining a dimension from the
inside edge of the shelf side may be useful.

click Checkmark in the Toolchest to end sketching

click blue arrow Resume button to move on to extruding the section to form a rib

on the Dashboard use the (preselected) "Extrude from sketch plane by a specified depth
value" tool
input the extrusion depth/rib height

model is displayed

green Checkmark or enter/return to accept the model

Create Ribs by Patterning

In the patterning procedure the feature to be patterned/repeated has to be specified along

with a dimension/spacing to specify the location of the repeated feature and the direction
of the patterning.

The rib is shown or if the procedure was stopped and is being resumed - select the rib that
was created

menu bar Edit -> Pattern...

edit options become available on the Dashboard

The general procedure that is given in more detail below is -

on the Dashboard are tools for use in patterning.
dimension and other quantities that can be accessed by pulling down/up menus.
The rib spacing can be changed by re-selecting Dimension in the Dimension pull down
list, clicking on the dimension in the sketch and changing the value. Specifically -

Dimension input box probably shows "Dimension"

and number of features for patterning is preselected to 2

pull down/up the Dimension list and choose Dimension which is then shown blue in the
window
double click on the dimension in the model that defines the rib location
the dimension is shown in an input box
set the value to the desired rib spacing and enter/return
black dots show the current rib location and the location of the rib to be added
Only two ribs are needed since the capability of adding additional ribs will be
programmed Rib spacing will not be programmed in this introductory, limited tutorial..

center mouse button click will regenerate model with the additional/patterned rib

Add the Corner Holes

The corner holes will be created by removing a volume defined by a circular cross-
section on the top of the shelf that extends through the entire shelf thickness. This will be
done by creating one circle, mirroring twice to get the hole layout and the removing the
material in a capabilty similar to extrusion.

menu bar Insert -> Extrude

"Sketch Tool" at top of Toolchest or in menu bar Insert -> Model Datum -> Sketch
select/pick the top plane of the shelf to specify it as the sketching plane

the "extrusion" direction is shown

Sketch in the Sketch dialog box

if the references status is Fully Placed,
Close the References dialog box

Draw a circle concentric to the shelf corner radius by

main menu bar Sketch -> Circle -> Concentric
click on the outside arc of one of the corners of the shelf
create the circle by clicking at the location of the hole edge
dimension the circle

The other circle can be created by mirroring.

in menu bar Sketch -> Line -> Centerline

then for each line click at end of line and double click center mouse button
pick/click the existing circle
select the "Mirror selected entities" tool in the Toolchest
click on one of the centerlines
create the other two circles by Control/clicking on both circles, mirror tool, click
centerline
Checkmark in Toolchest to end sketching process

click blue arrow Resume button to continue process by extruding the circles to form holes

select/toggle on the "Remove material" tool on the Dashboard

the removal direction is shown by the arrow near the center of the model
make certain the material removal direction is correct, it can be changes with the "Change
direction of extude to other side of sketch" tool on the Dashboard
on the Dashboard -> Options
Side 1 -> Through All
Side 2 -> Through All

enter/return and the shelf model is displayed

green Checkmark to end the model creation procedure

Create Program by Modifying the Program File

A part with default dimensions is now available. The following procedure will result in a
program for varying the number of ribs, thickness of the ribs, diameter of the corner holes
and the existance of the corner holes. This is done by modifying a program supplied by
the design system. The first task is to obtain the names the system has attached to the
dimensions.

Default dimension names start with the letter d, e.g., d29. Patterns are denoted by the
letter p, e.g., p36.

There are several methods to display model dimensions, if they are not displayed. Both
will be used below and details are provided. The general procedure is outlined here.
One way is to
- double clicking on the feature in the model,
- click on the desired dimension, and it is hightlighted,
- then Edit -> Properties...
- under the Dimension Text tab the dimension name is listed
- obtain the names of the rib thickness, hole diameter and rib spacing (this is a patterning-
related name and is explained in detail below,
- since the model creation process is not fixed as to sequence of features created the
default names may not be the same as when this tutorial was written and resulted in rib
thickness being called d29 and hole diameter named d39,
Patterning and pattern names are described in more detail below.

Or, another method of obtaining dimensions is to replay the model creation process using
the Model Player> This is often simpler since clicking to select features on complex
models is sometime a frustration process.

To obtain the hole diameter and feature number, e.g.,

Tools -> Model Player...
step througn the features created until the feature of interest is shown
Show Dims in the Model Player dialog box
either dimension names or numerical values are shown
to switch to the other form of dimensions
in the Menu Bar, Info -> Switch Dimensions
note the dimension name of interest for use in programming
also, the feature number will be useful

Ribs are characterized by dimensions and spacing and one way to obtain the relevant
information is
double click on the feature, e.g., the first rib
click on the dimension of interest, e.g., rib width
in the menu bar Edit -> Properties
the Dimension Properties dialog box becomes available
under the Dimension Text tab
dimension name is listed
OK in Dimension Properties dialog box

the second rib is used in patterning

double click on the second rib
the spacing is shown as a dimension - p2 EXTRUDES when this was written
click on this dimension
Edit -> Properties
Dimension Properties dialog box appears
Dimension Text tab in Dimension Properties dialog box
the @D EXTRUDES name is listed, p38 when this was written
for programming purposes change the pnumber/name, p36 here, to RIBS
OK in Dimension Properties dialog box
OK in Dimension Properties dialog box

Now,
Modify the program file to as shown below
menu bar Tools -> Program
Edit Design in PROGRAM menu

the text program is shown in a vi editor window

the file name is partname.pls, i.e., yourfilename.pls
edit this file as shown below using vi OR
use another editor, such as emacs, and to do this in emacs
- leave the vi editor open since Pro/E generates the save command when vi is closed
- open an editor in a terminal/shell/window, e.g., emacs filename.pls
- edit the file as shown below
- save the file in the editor being used, e.g. Save in emacs
- exit the editor being used, e.g., Exit Emacs
- close the vi editor window

There is no reason to believe the actual dimension names will be the same as when this
tutorial was written, but to make some of the following statements more specific - when
this was written the corner hole diameter name was d41, the rib height was d30, the rib
thickness was d31 the rib length was d32, the rib spacing was d33.
N.B. In the following code the rib spacing has to be specified. The code line d33=38.1/
(RIBS-1) is provided only as an example. That is, the example shows that if d33 is the rib
spacing and 38.1 mm is the distance across the shelf in which ribs will be added, and if
the pattern is to consist of the number RIBS of ribs, the rib spacing is 38.1/(RIBS-1). This
code line has to be written to describe the particular situtation/model that is being
described.

INPUT
HOLES YES_NO
"Include holes in model? (YES/NO)"
DIAMETER NUMBER
"If holes included, specify diameter < 20 mm"
RIBS NUMBER
"Enter number of ribs > 1"
THICKNESS NUMBER
"Enter thickness of ribs > 0"
END INPUT

RELATIONS
d31=THICKNESS
d41=DIAMETER
d33=38.1/(RIBS-1)
END RELATIONS

The ability to include corner holes or not can be included by inserting a choice in the part file at the point
when the holes are added to the model
Locate the hole feature in the part file,
e.g., when this was written the hole was FEAT#18 and this was added at the very end of modeling and was
located at the very end of the .pls file.

before the ADD FEATURE line in the file add the line
IF HOLES==YES
and after the END ADD line in the file add the line
END IF
Yes in response to the "Do you want to incorporate changes ..." prompt

With the "yes" response,the PROGRAM menu should become available

The only problem encountered when writing this tutorial was at this point - the
PROGRAM - GET INPUT menu that follows sometimes did not become available. If
this happens open and close the vi editor again, i.e., Tools -> Program -> Edit Design ->
close vi.

If there are errors in the .pls file the Menu Manager provides the PROG ERROR menu
choose Edit in PROG ERROR
the vi editor opens
edit the .pls file to remove errors

Once a successful program is written it can be edited to change program capabilities, part
characteristic, etc.s
Tools -> Program in main menu bar
Edit Design in PROGRAM menu

in the PROGRAM menu

Enter in GET INPUT
in INPUT SELECT toggle on the variables that will be used
Done Sel in INPUT SELECT

To create the model

- enter values in response to prompts

the new model is displayed

Edit and Use Program

e.g., to change dimensions of number of ribs

in Menu Bar
Edit -> Regenerate

Enter in GET INPUT

select variable(s) to be changed in INPUT SEL
Done Sel in INPUT SEL
enter value(s) in response to prompt(s)

Save Part File in Graphical Information Exchange Format

To save a model in a useful form for geometry information transfer to other applications,
e.g., finite element stress analysis or mold filling simulations

in the menu bar

File -> Save a Copy...
in Save a Copy dialog box
pull down Type and choose IGES
type a new export file name or use the default and enter
OK in Save a Copy
check (preselected) Surfaces in Export IGES dialog box
OK in Export IGES

An IGES file with an .igs extension is created in the working directory.

File then Exit to leave Pro/E

This is an expanded version of a tutorial conceived and written by Samuel Kidane.