LESSON 4

MODELLING A CASTING OR
FORGING
UPON SUCCESSFUL COMPLETION OF THIS LESSON,
YOU WILL BE ABLE TO:

• Use the view display and modification commands.

• Copy and paste features.
• Edit the definition and parameters of a feature and
regenerate the model.
• Use Up To Next and Mid Plane end conditions to capture
design intent.
• Use symmetry in the sketch.
CASE STUDY: RATCHET

• The Ratchet contains many of

the features and procedures
that you will use frequently. It
contains bosses, cuts, sketch
geometry, fillets and draft.
STAGES IN THE PROCESS
SOME KEY STAGES IN THE MODELING PROCESS OF THIS PART ARE SHOWN
IN THE FOLLOWING LIST. EACH OF THESE TOPICS COMPRISES A SECTION IN
THE LESSON.

• Design intent • Up To Next end condition

• The overall design intent for the part is • The second portion of the model is the
discussed. Transition. It uses the Up To Next end
condition to connect to the Handle’s faces.
• Boss feature with draft
• The first portion of the model to be created • Sketching inside the part
is the Handle. The Handle uses sketched • The third boss created is the Head. It is
lines and is extruded in two directions with sketched within the solid created by the
draft forming a solid. It is the initial feature Transition.
of the part and demonstrates the use of
mirroring in the sketch.
STAGES IN THE PROCESS
SOME KEY STAGES IN THE MODELING PROCESS OF THIS PART ARE SHOWN
IN THE FOLLOWING LIST. EACH OF THESE TOPICS COMPRISES A SECTION IN
THE LESSON.

• Cut using existing edges • Cut using copy and paste

• The Recess is the first cut type feature • The Wheel Hole feature will be copied and
created. It uses an offset from the existing pasted.
edges of the model to create the sketch. It • Filleting
is extruded as an offset cut to a specific • Fillets and rounds are added to the solid
depth. using several different techniques.
• Cut with trimmed sketch geometry • Editing a feature’s definition
• The Pocket is another cut feature, this time • Features that already exist can be changed
using circles that are trimmed to the proper using Edit Feature. Fillets will be edited in
shape. this way.
DESIGN INTENT
DESIGN INTENT THE GENERAL DESIGN INTENT OF THE RATCHET IS SUMMARIZED IN THE
ILLUSTRATION AND LIST BELOW.

Centering: The Head, Handle and

Transition features are centered
along an axis.

Symmetry: The part is symmetrical,

both with respect to a longitudinal
centerline and with respect to the
parting plane.
BOSS FEATURE WITH DRAFT

• The first part of the Ratchet we

will model is the Handle. The first
feature in any model is
sometimes referred to as the
base feature. All other features
are built onto the first feature.
BOSS FEATURE WITH DRAFT

• The first part of the Ratchet we

will model is the Handle. The first
feature in any model is
sometimes referred to as the
base feature. All other features
are built onto the first feature.
BUILDING THE HANDLE

• The Handle has a rectangular cross section. It is extruded with

draft an equal distance in opposite directions from the sketch
plane.
DESIGN INTENT OF THE HANDLE
• The Handle is a sketched feature that uses lines and
mirroring to form the basic outline or profile, a
rectangular cross section.
• Draft: The draft angle is equal on both sides of the parting
plane.
• Symmetry: Feature is symmetrical with respect to parting
plane and the centerline axis of the Handle.

• A centerline, a piece of reference geometry, will be

used to position and sketch the Handle sketch.
• The centerline represents distance from the end of the
handle to the center of the furthest hole and is also used
in mirroring sketch geometry.
PROCEDURES
STEP 1: NEW PART

• Open a new part using the Part_MM template on the Training

Templates tab. Save the part and name it Ratchet.
STEP 2: SKETCH PLANE

• Select the plane Top as the sketch plane.

INTRODUCING: INSERT CENTERLINE
• Insert Centerline Insert Centerline is used to create a reference line in a sketch.
The centerline can be vertical, horizontal, or an arbitrary angle
depending on how the inferences are used. Because the
centerline is considered reference geometry, it does not have
to be fully defined in the sketch.
• Where to Find? Click Tools, Sketch Entity, Centerline.
• Note Any piece of sketch geometry can be converted into
construction geometry or vice-versa. Select the geometry and
click the Construction Geometry tool on the Sketch toolbar. The
Property Manager can also be used to change sketch
geometry into construction geometry. Select |the geometry and
click For construction.
STEP 3: SKETCH A CENTERLINE

• Sketch a centerline running vertically from the

origin. The length is not important.
STEP 4: DISPLAY OFF

• Toggle the display of relations off using View, Sketch Relations.

SYMMETRY IN THE SKETCH

• Symmetrical geometry in a sketch can be created easily using the Mirror

option. You can mirror as you sketch — real time mirroring. Or, you can
select already sketched geometry and mirror it — after the fact
mirroring. Also, Symmetric relations can be added to geometry after
sketching.
• In any case, mirroring creates copies that are related to the originals by
the Symmetric relation. In the case of lines, the symmetric relation is
applied to the endpoints of the lines. In the case of arcs and circles, the
symmetric relation is applied to the entity itself.
INTRODUCING: DYNAMIC MIRROR

• Mirroring requires a line, linear edge or centerline. The line is activatedbefore

sketching the geometry to be mirrored.

Where to find it?

• From the Tools menu choose: Sketch Tools, Dynamic Mirror.
• Or, on the Sketch toolbar, click Dynamic Mirror.
STEP 5: DYNAMIC MIRROR

• Select the centerline and click the Dynamic

Mirror tool. The Dynamic Mirror symbol
appears at both ends of the centerline.
STEP 6: SKETCH A LINE

• Sketch a line from the upper end of the

centerline moving to the right. A mirror
image of the line is created on the
opposite side of the centerline.
STEP 7: COMPLETE THE SKETCH

• Add a line in the vertical direction and then

horizontal, stopping at the centerline. Turn off the
mirror tool.
• Note: Do not cross the centerline while sketching in
the Dynamic Mirror mode. If you do, duplicate
geometry can be created. Stopping at the centerline
caused the symmetrical lines to be merged into a
single line.
STEP 8: DIMENSION

• Fully dimension the sketch.

STEP 9: BASE/BOSS EXTRUSION

• Click the Extruded Boss/Base tool on the Features toolbar or click

Boss/Base Extrude from the Insert menu.
STEP 10: EXTRUSION

• Choose the Mid Plane option from

the list and enter a depth of 15mm.
• Click Draft and set the angle to 8°.
The Draft outward check box should
be cleared.
• Click OK to create the feature.
STEP 11: COMPLETE FEATURE

• The completed feature is shown at the

right. Name the feature Handle.
SKETCHING INSIDE THE MODEL
• The second feature in the part is the Transition, another boss that will connect to
the Handle feature. The sketch for this feature is created on a standard plane.
DESIGN INTENT OF THE TRANSITION

• The Transition feature is a simple circular

profile that is extruded up to the existing
Handle feature.
• Centering: The circular profile is centered on
the Handle feature.
• Length: The length of the section is
determined using existing locations.
STEP 12: SHOWING THE FRONT PLANE

• Switch to an Isometric view and select the

Front plane from the Feature Manager
design tree. It will be highlighted on the
screen.
• To make sure the plane stays visible, right-
click the Front plane in the
FeatureManager design tree, and select
Show. The plane will appear shaded and
transparent.
STEP 13: OPEN A NEW SKETCH

• With the Front plane still selected, click the

Sketch tool.
STEP 14: ADD A CIRCLE AND DIMENSION IT

• Using the Circle tool, add the circle

at Front Plane the origin.
• Add the diameter dimension to
fully define the sketch. Set the
value to be12mm. The sketch is
fully defined.
STEP 15: CHANGE TO ISOMETRIC VIEW

• Unlike when you created the

first feature, the system will not
switch view orientations
automatically for any other
bosses or cuts. Change to an
Isometric view.
STEP 16: UP TO NEXT EXTRUSION

• Click Insert, Boss/Base, Extrude...

and watch the preview display.
Change the direction so that the
preview shows the extrusion running
towards the Handle.
• Change the end condition to Up To
Next.
• Click OK.
STEP 17: HIDE PLANE

• Right-click the Front plane and

click Hide.
UP TO NEXT VS. UP TO SURFACE
• The end conditions Up To Next and Up To Surface generate different results in
many cases. The image on the left is for Up To Surface when the angled (red)
face is selected. The extrusion is shaped by the selected surface. Only one surface
selection is allowed. The image on the right is for Up To Next. All faces in the path
of the extrusion are used to shape the extrusion.
STEP 18: CENTERLINE

• Select the plane Top as the sketch plane.

Orient the view to the same direction. Start
off the sketch with a centerline as shown.
STEP 19: LINES AND ARCS

• Create a line and transition

directly into a tangent arc
using Auto-transitioning.
STEP 20: RETURN TO A LINE

• After the are is complete, the

line tool again becomes active.
Sketch a line using the tangent
inference line. End the line at
the end of the first line.
STEP 21: TANGENT ARC

• Use auto-transitioning again to close

the profile starting with a tangent arc
from the last endpoint.
STEP 22: ADD RELATIONS

• Add relations to attach the arc

centerpoints to the ends of the
centerline as shown.
STEP 23: ADD DIMENSIONS

• Add dimensions as shown to

fully define the sketch.
STEP 24: EXTRUSION

• Change to an Isometric view and

click Insert, Boss/Base, Extrude...from
the menu. Set the type to MidPlane,
depth to 20mm and draft to 8°.
Rename the latest feature to Head.
• The three main features that make
up the overall shape of the part are
now complete.
DISPLAY OPTIONS
• The following illustrations of the Ratchet illustrate the different types of display options.
MODIFY VIEW
OPTIONS

• The modify options are

listed in the right next to
their corresponding tools.
MIDDLE MOUSE
BUTTON FUNCTIONS

• The middle or wheel mouse

button on a three button
mouse can be used to
dynamically manipulate the
display. Using the middle or
wheel mouse button you can:
MIDDLE MOUSE
BUTTON FUNCTIONS

• The middle or wheel mouse

button on a three button
mouse can be used to
dynamically manipulate the
display. Using the middle or
wheel mouse button you can:
REFERENCE TRIAD FUNCTIONS
• In a drawing, only the Zoom and Pan functions can be used.
• The Reference Triad can be used orientation. Selecting an axis, with or
without additional keys, can be used to control rotations.
 KEYBOARD SHORTCUTS

• Listed in the right are the

predefined keyboard shortcuts
for view options:
SKETCHING AN OFFSET
• Offsets in a sketch rely on existing model edges or sketch entities in another
sketch. The edges are projected onto the plane of the sketch, regardless
whether they lie on that plane or not.

• Offset Entities Offset Entities is used to create copies of model edges in

a sketch. These copies are offset from the original by
some specified amount.
• Where to Find? From the Tools menu, select Sketch Tools, Offset Entities
STEP 25: OFFSET THE FACE BOUNDARIES

• Select the top face and click the

Sketch tool. With the face still
selected click the Offset tool on the
toolbar. Set the distance value to
2mm and Reverse the direction if
necessary, moving the offset to the
inside and click OK.
STEP 26: RESULTING OFFSET.

• The offset creates two lines and two arcs.

This geometry is dependent on the solid
face it came from and will change with
the solid. The sketch is automatically fully
defined and ready to extrude as a cut.
STEP 27: SETTINGS FOR THE CUT.

• Choose a Blind cut with 2mm for the

depth value and click OK.
STEP 28: RENAME THE FEATURE

• Change the name of the feature to

Recess.
STEP 29: SKETCH CIRCLES.

• Select the top, inner face created by the last

feature as the sketch plane. Using the Circle
tool, create a circle using the existing
centerpoint location as the circle’s origin.
Snapping to this location will relate the circle to
it automatically. Create a second circle off to
the side of the model.
STEP 30: RELATE THE CENTERS.

• Click Add Relation to open the Add

Relations PropertyManager. Select the
second circle and the edge of the cut.
• Choose the Concentric option and click OK.
Concentric forces the two arcs the circle and
the circular edge to share a common center.
This will pull the circle into position.
TRIM AND EXTEND

• Trim can be used to shorten sketch geometry.

• Extend can be used to lengthen sketch geometry.
STEP 31: TRIM THE CIRCLES.

• Click on the Trim Entities tool and select the

Power trim option.
• Drag across the portions of the sketch entities
that you want to remove.
• The system will find the intersections between
the circles and remove the excess.
STEP 32: ADD DIMENSIONS.

• Add dimensions to the arcs. This will

fully define the sketch.
INTRODUCING OFFSET FROM SURFACE

• The Offset From Surface end condition is

used to locate the end of an extrusion as a
measurement from a plane, face or surface
rather than the sketch plane of the feature.
• In this example the end of the extrusion is
measured from the bottom face of the part.
STEP 33: OFFSET FROM SURFACE

• Click the Extruded Cut icon and

choose the Offset From Surface end
condition. Set the Offset Distance to
5mm.
STEP 34: OPEN A SKETCH

• Click on the inner bottom “figure eight”

face and open a new sketch.
STEP 35: CREATE A CIRCULAR HOLE.

• Sketch a circle concentric to the upper

circular edge as shown. Add a
dimension, set the diameter to 9mm
and create a Through All cut.
• Name the feature Wheel Hole.
STEP 36: ADD ANOTHER CIRCLE

• The circle and the diameter dimension are in the

sketch. No other relations or dimensions exist to locate
the circle. Delete the dimension.
• Click Add Relation. Select the edge of the circle and
the edge of the solid and use Concentric. Or, use
Coincident to align the origin and circle centerpoint.
• Add a concentric circle dimension by dimensioning the
circle and edge. The sketch is now fully defined.
STEP 37: EXTRUDE CUT

• Extrude cut the circle using through

all condition
STEP 38: ADD FILLETS

• Add fillets on edges and faces

as shown:
STEP 39: SELECT AND EDIT THE FILLET.

• Right-click the feature H End

Fillets, and select Edit Feature.
Select the additional edges
around the upper and lower
edges of the Head. The selection
list should now indicate a total of
6 edges selected.
STEP 40: FINISHING TOUCH

• Save and close the part.

END OF LESSON 4

THANK YOU FOR

LISTENING!
LABORATORY EXERCISE 1: TOOL
HOLDER
• Note: All fillets and rounds are R2mm unless
otherwise specified.