S4S Creo Pro

Creo Elements/Pro
W5-SE-L2-0202-1.0
S4S Creo Elements/Pro
Written by These materials are 2010, Parametric Technology Corporation (PTC) Tim Brotherhood All rights reserved under copyright laws of the United Kingdom, United
States and other countries. PTC, the PTC Logo, Creo Elements/Pro, Pro|ENGINEER, Pro|DESKTOP, Wildfire, Windchill, and all PTC product names and logos are trademarks or registered trademarks of PTC and/or its subsidiaries in the United States and in other countries.
Conditions of use Copying and use of these materials is authorized only in the schools
colleges and universities of teachers who are authorised to teach Creo Elements/Pro in the classroom. All other use is prohibited unless written permission is obtained from the copyright holder.
Acknowledgements Initial idea and ongoing development - Chris Jarman & David Eyre,
Edgecliff High School PTC Mike Brown, Phil Darlington, Andy Deighton, Mark Fischer, Alister Fraser, Tom Malloy Hornby Paul Chandler, Adrian Norman, Darren Rye, Victoria Reed, Tom Malloy. ITEA 2009 - Mark Harmsworth Boxford Howard Barrett, Paul Barraclough, Gary Smith CR Clarke Maurice Clarke Dimension 3D Printing Paul Gateley Staffordshire University - Dave Cheshire Trialing Wolgarston High School, Alleynes High School
Feedback In order to ensure these materials are of the highest quality, users are
asked to report errors to the author. tbrotherhood@ptc.com Suggestions for improvements and other activities would also be very welcome.
Product code W5-SE-L2-0202-2.0
The following organizations share a common goal of promoting STEM subjects and endorse PTCs Education Programme.
Contents
Creo Elements/Pro .............................................................................................................. 1 Contents .............................................................................................................................. 3 Session one Scalextric4Schools challenge....................................................................... 5 Task one Starting Creo Elements/Pro ........................................................................... 8 Task two Exploring Creo Elements/Pro ......................................................................... 9 Task three Prepare for modeling ................................................................................. 10 Task four Body profile ................................................................................................. 11 Task five Side taper..................................................................................................... 19 Task six Rounds .......................................................................................................... 22 Task seven Complete the mold ................................................................................... 23 Task eight Model properties ........................................................................................ 24 Task nine - STL file for machining .................................................................................. 25 Session two Physics of car performance ........................................................................ 26 Task one - Review homework. ....................................................................................... 26 Task two Review design factors .................................................................................. 27 Session three Modify Creo Elements/Pro models........................................................... 27 Task one Hornby the company ................................................................................... 27 Task two Modify an existing part ................................................................................. 27 Task three - Dealing with failed features ........................................................................ 31 Task Four - Reverting to a previous version of a part .................................................... 33 Session four - Own Design ................................................................................................ 42 Session five Machining ................................................................................................... 46 Session six Car assembly ............................................................................................... 46 Session seven Testing, analysis and simulation ............................................................. 46 Task one - Mass/C of G measurement........................................................................... 47 Task two - Frontal area .................................................................................................. 49 Task three - C of G and stability ..................................................................................... 50 Task four - Acceleration ................................................................................................. 51 Session eight - Presentation preparation ........................................................................... 55 Task one - CAD modeling the vacuum formed body ...................................................... 55 Task two Convert mold to body shell........................................................................... 55 Task three - Part properties............................................................................................ 58 Task four Add body shell to the assembly ................................................................... 59 Session nine Visualizing ................................................................................................. 61
Task one Applying textures ......................................................................................... 62 Task two Sponsorship and logos ................................................................................ 63 Task three - Applying a decal ......................................................................................... 64 Task four - Final render .................................................................................................. 70 Session ten Races .......................................................................................................... 73 Session eleven - Presentation ........................................................................................... 75 Appendix Car design template ........................................................................................ 76
Creo Elements/Pro W5.0
Scalextric4Schools
Session one Scalextric4Schools challenge

Scalextric4Schools is an exciting Design Make Race challenge managed by a partnership between PTC and Hornby. In the UK, Boxford and CR Clarke have supported the challenge since its inception. Full information including guides, rules and links to order components and track can be downloaded from www.scalextric4schools.org Introduction By taking part in the PTC Scalextric4Schools challenge you will be taught how to use Creo Elements/Pro3D parametric modeling software to create a 1:32 scale racing car. It should be possible for most schools to manufacture their cars. Where schools do not have certain equipment, a number of centres around the UK have offered to help. Details are on the challenge web site. A combination of track testing and simulation using the advanced mechanism dynamics tools in Creo Elements/Pro will help you to understand the physics of car performance and redesign your car to make it faster. Competitions give your team the opportunity to race your car against those designed by other teams. Prior learning This tutorial assumes you are already familiar with Creo Elements/Pro and comfortable creating parts, assemblies and testing movement using kinematic motion. If you are not confident about these techniques you should complete the Sports Drink Bottle and Cam Toy modules prior to attempting this one. Your teachers have access to PTC University- Precision LMS, a virtual learning environment with over 400 hours of self paced tutorials covering all of the tools and techniques available in Creo Elements/Pro.
The slot car challenge was originally developed by design & technology teachers at Edgecliff High School in Staffordshire, England. The cars you see on the right and below were created at the school. http://www.edgecliff.staffs.sch.uk/
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Scale models Most slot cars are designed to scale of 1:32 which means a model car of one 12 feet long in real life will be 4.5 inches long. Later in this tutorial you will be shown how to transfer your sketches into Creo Elements/Pro and trace around them to create the shape of your very own slot car.
The design challenge Can you design and make a slot car based around a standard chassis? Models should be to a scale of 1:32 and comply with the rules for the challenge. This tutorial and others will prepare you for the challenge.
After designing and making your car you will be able to test it on any analogue Scalextric track. It will even work on old track which many homes have stored away. Online auction sites are another source of second hand or new Scalextric. Schools can buy sets of parts and a special track layout for this challenge at heavily discounted prices. Details on: www.scalextric4schools.us and in the Windchill ProductPoint project Baseline for car performance With the help of your teacher, you will assemble, set-up and test a standard car to establish a benchmark for future design improvement. The Make assemble - setup booklet will help you get the car working smoothly and efficiently. An important part of design development is to establish a benchmark against which you can measure how quick your design is. Use scientific method to carry out fair tests to quantify the performance of the standard car to establish the benchmark. Later you will carry out the same experiments on your design to measure any improvements in performance. Chassis The parts pack supplied by Scalextric includes two gear sets for sidewinder or inline motor positions.
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This inline chassis layout is used for the Creo Elements/Pro tutorial that follows. A number of flat parts are slotted together and screwed and/or glued together. Do not glue the joints until you are sure you wont need to change any components. Body High quality realistic body shapes are made possible using CNC machining to create a mold which is then used to vacuum form a thin shell from thermoplastic sheet.
Outline In the following section you will be taught how to use the 3D solid modeling tools in Creo Elements/Pro to create the body shape for a standard chassis slot car.
The starting point is a Creo Elements/Pro part with half the base modeled and wheel arch cutouts. You will open the part, suppress the wheel arch features then model the shape of a saloon car on the base.
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With symmetrical designs it is good practice to model half of the car body and mirror the shape late in the modeling process. This cuts down the number and complexity of features, preserves symmetry and makes it easier to change the design later.
Any asymmetric details like driver, steering wheel, windshield wipers and exhaust pipes can be modeled after the mirror feature.
Task one Starting Creo Elements/Pro

When modeling using Creo Elements/Proyou will create a great many different files in numerous formats and there will be occasions when Creo Elements/Prowill also create files. It is important all these files can be found so you must know whether you are working in a Windchill ProductPoint project or in a local/network folder. If a local folder is where your work is being saved you should always Set working directory. 1. 2. Start Pro|ENGINEER. If you are working in a local folder, in the Navigator panel on the left of the screen, 3. the Folder tab .
In the Browser window in the centre of the screen, navigate to the folder where your models will be stored.
4.
on the folder with your slot car components and, from the floating menu, Set Working Directory.
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5.
On the left of the Creo Elements/Pro screen in the Navigator panel, Working directory on to
6.
In the Browser panel, double open the part named 2011_euro_car.asm
You will see a completed Scalextric4Schools car on screen.
Task two Exploring Creo Elements/Pro

This section will show or remind you how to manipulate and position the car in the modeling window. You will also hide and unhide components in the assembly. 1. Move the mouse cursor over the model on screen, hold down the mouse. and move
The model will spin allowing you to see it from any direction. 2. Move the mouse cursor over a part of the model and spin mouse wheel. 3. the middle
The model will zoom with the location of the mouse cursor remaining still.
Mouse cursor Dont be concerned if the model seems to disappear from the screen. There are tools to reset the model in the modeling window. 4. Along the main toolbar across top of the screen on the Refit button.
The model will automatically zoom to fit in the viewing window.
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You may also want to return to a view of the car the correct way up. 5. In the top toolbar on to open the on Trimetric.
Named views list and
6.
In the model tree, move the mouse cursor over the entry for Z_body_mold_detailed.prt entry, then, from the list on Hide.
The body will disappear.
7.
In the model tree, move the mouse cursor over the entry for Z_BODY_MOLD.PRT entry, form the list Unhide. then,
You will see the body mold part overlapping the chassis base. This is important as the bottom part of the mold must fit snugly over the chassis base. There are also cut outs for the wheels.
Task three Prepare for modeling

You will be adding features to the mold until it is ready to be machined and then used to vacuum form the body shell. You have already seen the part in the assembly with features defining the overall size and the position of wheel arches. You will open the file and suppress the wheel arch features ready to insert new features creating the shape of the body.
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1.
In the model tree move the mouse cursor over the entry for BODY_MOLD.PRT, list, Open. and, from the
In the Navigator panel on the left of the Creo Elements/Proscreen you will see the model tree showing how this part has been constructed. It will be easier to model the body if we suppress the features that create the wheel arch cut outs. 2. In the model tree, and drag the Insert Here flag up until it is above the entry BASE-CORNERS
The model tree will look like this with the wheel arch cut outs and corner rounds disappearing from the model.
Notice the small black squares next to the features below the red arrow in the model tree? These indicate the features are now suppressed and not being added to the model.
Task four Body profile

Expert/overview The body profile shown below will be extruded from an internal sketch located on the FRONT datum plane. The sketched profile is referenced to the CHASSIS_TOP datum plane and sketched above the datum with additional references for dimensions created at the two ends of the base extrusion.
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Step by step Begin extrusion 1. In the Features toolbar on the right of the screen the Extrude tool. The Extrusion dashboard will appear across the top of the modeling window. 2. 3. In the dashboard on Placement. on
In the modeling window the FRONT datum plane as the location for the sketch and then, in the sketch dialog, .
On the right of the Creo Elements/Prowindow the feature toolbar will be replaced by the sketcher toolbar. Adding references To locate the sketch accurately we must know exactly where the top of the base is. We can do this by adding sketch references. 4. In the top toolbar then on the Sketch pull-down text menu
References.
The sketch references dialog opens on the right of the screen.
5. 6. 7.
Make sure datum planes are being displayed. Zoom in on one end of the base extrusion. on the top surface of the base extrusion.
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A dashed brown line will appear across the top of the base extrusion and a new entry will be added to the Sketch references dialog. 8. In the References dialog Close.
Sketching the body profile 9. In the Sketcher toolbar on the line draw tool.
10. Draw the shape shown here by at each X starting with number one and finishing back at the same point. When drawing the roof line, make sure there is an H visible showing this line will be constrained to be horizontal.
11. When you finish drawing the shape click
twice to cancel the line draw tool.
Your sketch should look like this with dimensional constraints. Dont worry if your dimensions are not exactly the same as these.
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Creo Elements/Prohas added dimensions (colored grey to show they are weak). We want to specify some of the dimensions and change their values. Sketch diagnostics Before we do that we should check the sketch is a valid profile and will extrude successfully. Creo Elements/Prohas tools to help check whether a sketch is a valid profile. 12. In the top toolbar Sketcher diagnostics group of tools, Loops. The sketch will now be shown shaded to show it is a valid profile for extruding later. on , Shade Closed
If your sketch does not shade in you will need to find out why. The most likely reasons are: Cause Open ends Cure Use the Highlight open ends diagnostic tool to find these, the open end will have a red dot clearly visible. The tool will identify gaps with two red dots close together. Zoom in on each pair of red dots to find the gap, delete the line that is too short and redraw it closing the gap. Use the Overlapping geometry tool to find overlapping lines. The double line and line either side will be highlighted in pink. the middle one of the pink
Gaps - Lines that do not meet properly
Coincident lines - Lines drawn on top of each other
diagnostic tool as lines and delete it. Repeat the many times as necessary to find the each duplicate line. If you accidentally delete a line that is not a duplicate, use undo to restore the last line in that location. Extended lines Use the Overlapping geometry tool to find extended lines. Zoom in on each extended line and use , the trim tool to delete the extended part of the line. Stray lines The Overlapping geometry tool
, will help you find

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these. Look around and inside the profile for red dots and delete the stray lines. If these techniques do not work you may have to delete all the lines and sketch the profile again. Revising the dimensioning scheme You will alter some of the existing dimensions and create new ones to take control of the sketch lines and shapes. Note: There are 3 types of sketch dimension; Weak - these are colored gray and created by Creo Elements/Proautomatically. They report sizes in the sketch but allow changes to be made including letting you drag lines and points. Strong these dimension are white in color. Geometry controlled by Strong dimensions can be dragged on screen. Locked these dimensions are orange in color. Geometry controlled by locked dimensions cannot be changed by dragging on screen. Locked dimension can are changed by double clicking and retyping a different value.
Adding a dimension This is straightforward and involves left clicking on the extents of the dimension then middle clicking to locate the dimension text. 13. Zoom in on one end of the car profile. 14. In the sketcher toolbar on the right of the screen, Dimension tool. 15. Move the mouse over the vertical edge of the base extrusion at X1 and select. to the Create Defining
16. Move the mouse cursor over the point where the end of the base line/boot intersect at X2 then to select. 17. Move the mouse cursor to where you want the dimension text to be placed then middle mouse X3. 18. Type in the dimension value of 2mm then press Enter on the keyboard. Notice the dimension is orange in color denoting it is locked. Also notice the weak gray dimension has now disappeared.
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This is a major strength of Pro|ENGINEER; it constantly manages dimensions to fully specify the sketch. Changing a dimension after placing 19. In the sketcher toolbar activate the Select tool to
20. Double on the text for the dimension you wish to change. In this example the value at X1 has been changed to 30mm. 21. After typing in the new value for the dimension press Enter on the keyboard to complete the change. The sketch will change shape to accommodate the new dimension value.
22. Create another 2mm dimension at the opposite end of the sketch.
Adding other dimensions There are two other types of dimension you may want to create; line lengths and angles.
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Line length 23. In the Sketcher tool bar tool. 24. X1. 25. Move the mouse cursor to one side of the line and at X2 to locate the dimension text. 26. With the Select tool active, double on one of the lines in the car profile to activate
the Create Defining Dimension
on the dimension text, change it to the nearest whole number then press Enter on the keyboard. Angle dimension 27. In the Sketcher tool bar the Create Defining Dimension tool. 28. 29. on one of the lines in the car profile X1. on the adjacent line in the car profile X2. of the lines and dimension text. at X3 to locate the active, to activate
30. Move the mouse cursor to one side
31. With the Select tool
double on the dimension text, type in a new value rounded to the nearest 5 degrees then press Enter on the keyboard. Drag to change shape 32. In the Sketcher toolbar, activate 33. the One by One selection tool.
to select one of the nodes between two lines. The node will turn red to show it has been selected.
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34. With the mouse cursor over the top of the selected node, node to reposition it.
and hold to drag the
Except for any dimensions that have been locked, the sketched lines will change shape as you drag. If the sketch suddenly changes shape unexpectedly use the undo button. Fully constrained sketch Product designers are mostly concerned with shape and proportion so dragging the nodes until the shape is how they want would usually be sufficient. Engineers dont like anything left to chance and would add locked dimensions to the sketch until there were no gray, weak dimensions left. The illustration below has been fully constrained in this way with all the dimensions locked (orange).
35. Once you are happy with your sketched shape, check it is still shaded and there is a horizontal constraint H on the roof. 36. On the right of the screen, in the sketcher toolbar sketcher. 37. In the main toolbar on to close
on
to open Trimetric.
the saved views list and
On the right of the Creo Elements/Prowindow the feature sketcher toolbar will be replaced with the feature toolbar and the extrude dashboard will no longer be grayed out. 38. Change the dashboard option to those shown here.
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39. When you select , the Extrude to option in the dashboard, you should the long thin surface of the base extrusion, shown here highlighted in red. 40. In the dashboard on complete the extrusion. to
A new Extrude entry will appear in the model tree and the body will display as shown on the right.
Task five Side taper

In the following instructions the sketcher blue background has been changed to white for clarity. Expert/overview Looking from the front of the car, the side needs to be tapered. This will be done by drawing a diagonal line on the RIGHT datum plane referenced to the roof and the point where the bonnet meets the side of the car. The sketch will be extruded removing material symmetrical about the sketch and Through all in both directions.
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Step by step Start a sketch 1. 2. 3. 4. Make sure datum planes are visible. In the feature creation toolbar, start a New Sketch. In the model tree, Either, dialog. on to
the RIGHT datum plane. to close the sketch
on Sketch or
You will enter sketcher and the model will rotate to view from the front of the model. 5. Turn off the display of datum planes.
Create sketch references 6. In the Main toolbar, down text menu and on the Sketch pullReferences.
The Sketch References dialog opens.
7.
on the top surface of the model at X1 to create a surface reference. Note: only surfaces perpendicular to the sketch plane can be referenced.
An orange dashed line will appear along the top of the model and a new entry will be added to the references dialog.
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8.
Move the mouse cursor down the left side of the model over the intersection with the bonnet at X2. When you see the vertex, shown here pre-highlight in light blue, vertex reference. to create a
A new vertex entry will be added to the references dialog. 9. In the references dialog creating references. Close to finish
10. In the sketcher toolbar, the Line draw tool.
on
to activate
11. Draw the diagonal line shown here making sure the ends snap to the references you have just created. 12. Add an angle dimension of 20 degrees.
13.
on
to finish sketching. on then
14. In the Main toolbar Trimetric view.
15. In the feature toolbar on the right of the screen extrude.
16. In the dashboard change the choices to those shown below.
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17. In the dashboard Options to open the drop-down panel. 18. Change both sides to Through All.
19. Make sure the yellow check mark is pointing away from the body.
20.
on feature.
to complete the Extrude
The side of the car body will now be tapered.
Task six Rounds

Expert/overview Three rounds will be added to the edges arrowed in the order 30mm, 8mm then 5mm.
Step by step 1. In the Feature toolbar on the right of the screen, 2. 3. the Round tool.
to select the edge shown here in red. In the dashboard change the radius to 30 mm, press Enter on the keyboard, and then on round feature. to complete the
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4.
Start a new Round feature. Holding down the Ctrl key on the keyboard, on each of the edges shown here and set the radius to 8 mm. Release the Ctrl key.
5.
In the dashboard, on to complete the round feature.
6.
Add a new Round of 5 mm radius to the edge show here.
Notice how Creo Elements/Projoins up all the edges that are tangential?
Task seven Complete the mold

Expert/overview To complete the mold you will move the Insert here flag down one entry in the model tree then mirror the model about the FRONT datum plane. Step by Step 1. In the model tree LMB drag the Insert Here flag below the entry for BASE_CORNERS. The corners of the base extrusion will be rounded.
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2. Make datum planes visible. 3. In the model tree on the top entry BODY_MOLD.PRT to select it. 4. On the right of the screen, in the Feature toolbar, tool. the Mirror
5. Either in the model tree or in the graphics window the FRONT datum plane as the mirror axis. 6. on feature. to complete the mirror
7. Save the model.
Task eight Model properties

Expert/summary While the shape of the body mould is complete, we still need to specify the material is will be made of together with the names of the part, who modelled it and the project it is part of. Step by step Model properties 1. From the Creo Elements/Promain toolbar open the File pull-down menu and Properties. This will open the Creo Elements/ProModel Properties dialog.
2.
Under the sub heading for Materials next to the Materials entry on change.
Creo Elements/Prowill now display the Material dialog.
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3. 4.
balsa_wood.mat. the Assign button followed by .
Creo Elements/Prowill now apply this material to the body mould. 5. In Menu Manager, Done to finish assigning material properties. Note: this will not alter the external appearance of the part. It has changed the density/mass and physical properties of the model. Model parameters The next step is to assign none geometric parameters to the part.
6.
From the Creo Elements/ProModel Properties dialog, next to the Parameters entry on change.
The Parameters dialog will open. 7. In the Parameter dialog under the Value column, type in the text for DESCRIPTION, MODELLED_BY and PROJECT. 8. 9. to accept your changes to Parameters. Close in the Model Properties dialog.
10. Save your work. The purpose of the part you have created is to generate manufacturing tool paths so the appearance is not important. If you would like to apply a surface texture such as a wood finish, detailed instructions are in the F1 in Schools tutorials.
Task nine - STL file for machining

The most common file format used to transfer 3D shapes to machining software is STL. The companion Make - assemble - setup booklet contains a full description of the STL file format, post processing and CNC machining.
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Expert/summary Here you will be show how to export an STL file of your model configured for a fine mesh surface. 1. 2. 3. 4. 5. 6. Open the File pull-down menu and Save a Copy.
Change the Type option to STL (*.stl). Accept the default filename or type in a new one. on OK to close the dialog. A new Export STL dialog will open. Change the Chord Height value to 0 (zero).
Note: Creo Elements/Prowill enter the smallest practical value for Chord Height. The resulting number is based on the size and complexity of the part. 7. 8. Change the Angle Control value to 1 On OK to close the dialog and the STL file will be created in the working directory
The display will change to show the faceted surface of the STL file although you may not be able to see any difference at first. 9. Zoom in to a curved corner and you will see the triangular surfaces created by the STL conversion. on to repaint the screen and return to the parametric model.
10.
Note: A fuller description of the machining process can be found in the accompanying Make assemble setup document.
Homework one Car performance Read through the section Car performance in the Design guide booklet for this project, this will help you with the next session.
Session two Physics of car performance

Task one - Review homework.
At the start of the session your teacher will help the group collate a list of key physics principles affecting car performance. These will be useful later when re-designing your car.
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Task two Review design factors

In design teams you will summarize your investigations and create a set of bullet points to guide the development of your car design. Competitions You will be entering a competition so you will need to work within the regulations published in your Windchill ProductPoint project or online at www.scalextric4schools.us Next you will be shown how to convert your paper sketches into a 3D CAD model, then how to make changes to existing parts and finally learn about alternative 3D modeling features. Homework two Design sketches Refer to the Design guide for detailed instructions on creating sketches of your own ideas for body shapes. Read through the Hornby the company section of the Design guide for this project.
Homework three Hornby the company
You will be asked questions on this at the start of the next session.
Session three Modify Creo Elements/Pro models

Outline During this session you will learn how to modify existing designs, correct some of the faults that can occur and hear about other 3D modeling tools. But first
Task one Hornby the company

Your teacher will ask the class to show their knowledge of Hornby, one of the foremost companies in the world designing and manufacturing slot cars.
Task two Modify an existing part

A key strength of 3D parametric modeling is the ability to make changes to a model. The model tree provides access to a chronological record of all the features used to create the model including; datum, sketches, features, etc. Edit or Edit Definition? Right clicking on an entry in the model tree opens a floating menu. Among the options will be Edit and Edit Definition. Edit this option gives you immediate access to dimensions within that feature.
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Edit Definition Allows access to all the options used to create the original feature including; geometry dimensions, offsets, etc. Dynamic Edit Provides drag handles on geometry to drag the size location and key dimensions of features in the model. Edit Edit allows the designer to make changes to dimensional constraints very quickly. 1. Open the part named WHEEL_AMR.PRT This is part of the initial accreditation tutorial for Creo Elements/Proand will be used to demonstrate how to make changes to a model.
2.
In the model tree, on the + next to the entry for Pattern 1 of Extrude 6 and the + next to the Extrude 6 [1] to show the internal sketch.
This will reveal the feature and sketch used to create the pattern. 3. Move the mouse cursor over the sketch named S2D0002 in the list and 4. From the floating menu Edit. .
The dimensions used to create the sketch will display on the model in the graphics window. 5. Double on the angle dimension to activate it, change the value to 15mm then press ENTER on the keyboard to confirm the change. In the Main toolbar on Regenerate the model. to
6.
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You will see the effect of the change in the model.
Edit Definition Edit Definition gives the designer access to all the options used to create an entry in the model tree. 7. The modified part named WHEEL_AMR.PRT should still be open on screen
In the model tree, the sketch used to define the shape of the removed material should still be visible. 8. Move the mouse cursor over the sketch named S2D0002 in the list and 9. From the floating menu this time Edit Definition. .
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The sketch will open with the sketch toolbar on the right of the screen. 10. Edit the angle dimension back to 25 degrees. 11. on in the sketcher toolbar to confirm the change and close sketcher.
Note: Because you used Edit Definition the model regenerates as soon as you close sketcher.
You will see the effect of the change immediately in the model. Tip: Because of parent - child relationships editing entries in the model tree can cause later features to fail. Before making major changes to geometry it is useful to suppress the features below. After making the changes, each feature can be resumed individually to isolate and correct any parent/child failures as they occur.
Dynamic Edit Dynamic Edit updates the model as you move geometry drag handles. 12. Rotate the model to this position. 13. In the model tree move the mouse cursor over the entry for Extrude 1 and 14. From the floating menu . on Dynamic Edit.
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Small white square drag handles will appear on the model. 15. Move the mouse cursor over one of these handles, hold down and very slowly drag. You will see the rim of the wheel get wider or narrower. 16. If the model fails top toolbar. on the undo button in the in a blank
17. When finished with dynamic edit, area of the model window.
Parent/child relationships This is nothing to do with who looks after you at home! The model tree in Creo Elements/Prolists all the steps taken in creating a model. Entries in the model tree build up chronologically but are also likely to reference or rely on previous entries. This is called Parent - child relationships. You should expect modeling failures when modifying designs and time practicing how to edit the model tree to correct the faults will pay dividends later.
Task three - Dealing with failed features

This example shows changes to the body mold profile. Read through this so that you will know what is happening when failures occur. In the following example the body profile has been edited changing it from a saloon to a coupe. Before After
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Lower down the model tree a round relies on six edges running across the body. The round is child to the six parent edges. The changes made to the profile sketch have removed one of the parent edges so the round will fail when Creo Elements/Proregenerates the model.
Creo Elements/ProWildfire 5.0 reports modeling failures with a drop-down message like the one below.
Details of the failures are shown in red in the model tree. In this example the first failed feature is the round described above. Edit and Edit Definition tools are used to correct the errors.
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Here Edit Definition is used to interrogate the Round 2 model tree entry. The Sets tab is where edge references and radii are recorded. Scrolling down the references list reveals one failed edge reference ( ) and two ambiguous edge references ( ). All three entries were removed by and choosing Remove. Holding down CTRL on the keyboard allows the missing edges to be selected and the round dashboard can be closed.
In this example, correcting the first failed Round has resulted in the lower failures being resolved automatically.
Creo Elements/Prowas able to regenerate the model successfully.
Note: Making changes to complex models may generate several failed features that should be corrected before continuing to model.
Task Four - Reverting to a previous version of a part

We shouldnt need to mention the importance of saving your work regularly!
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When a part or assembly is created in Creo Elements/Proa number is added after the file extension. Each time you save the part or assembly a new file is created with the number incremented. Here is an example where the base part was saved sixteen times during development. If changes to a model go seriously wrong you can close the part, erase the model from memory and then open a previous version of the part. 1. In the Navigator panel on the Folder Browser tab. In the Folder Browser, Working directory. In the Type list and choose Part (*.prt) Open the Tools list and All Versions then . You will now be able to see all the versions of each file. 5. on one of the earlier versions of Body_mold.prt and open the Preview panel at the bottom of the browser window. The earlier part version of the part will preview. on
2. 3. 4.
6.
Homework three Competition rules Take a copy of the competition rules home with you. They are available in the Windchill ProductPoint project and on www.scalextric4schools.org Read through them carefully. Read through again looking for opportunities to design a car that will be quick around the track. Write down a list of the top five things you think will make a car quick. Bring the list with you to the start of the next session.
You now have some of the knowledge to design your own car.
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Extension one - Alternative modeling strategies If you found the Creo Elements/Promodeling so far easy, you may want to know about a few other 3D features and modeling strategies that could be used to create a car body. Some of these are summarized next. Swept blend The swept blend is sometimes called a Loft. A series of sketches define sections through the shape. In addition to the profile sketches, Creo Elements/Proneeds a line to show the trajectory or direction for the swept blend. Here the trajectory is shown in red with a yellow arrow indicating the starting point and direction for the swept blend.
Here is the end result of a Swept blend solid with rounds added.
The model tree for a swept blend car body is shown here. It is made up of a trajectory sketch and five parallel profile sketches. One of the profile sketches is located on the RIGHT datum plane and the others on the four new datum planes DTM1 DTM4. The trajectory sketch was created on the TOP datum plane. Note: The first and last profile sketches must be positioned at the ends of the trajectory line. With all the geometry needed for the swept blend in place the swept blend feature was created. The swept blend dashboard looks like this.
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Note: Swept blend defaults to creating a surface so the Create Solid button has been selected. The Trajectory is stored in the References pop-up panel.
Although profile sketches can be created after starting the Swept Blend feature, in this example the sketches were created first so under the Sections tab, the Selected Sections option was selected. Sketches were added to the list of sections by clicking each time.
Once all the options have been chosen, the model looks like this. Clicking on in the dashboard completes the feature. Tip: If the green tick/check mark is grayed out, selections in the dashboard are not complete. Look in the message area of the screen for feedback on what Creo Elements/Prois expecting you to do.
PTC University Precision LMS For more examples plus hands-on practice on swept blends look on PTC University in the Online courses >Advanced Modeling section. Note: Teachers and instructors with an account on PTC University can register their students to give them access to the learning materials
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Variable section sweep This very powerful modeling feature uses a cross section sketch that runs along one or more control curves to create a variable cross-section surface or solid. Here there are four control curves; Origin - a straight line under the centre of the car defining the direction Chain 1&3 - two straight lines either side defining the width of the section Chain 2 - a curved spline defining the top
The model tree for a variable section sweep is shown here. It is made up of a trajectory sketch a side profile sketch and a roof profile sketch, The trajectory and side profile sketches are located on the TOP datum plane and the Roof profile sketch is located on the FRONT datum plane. Note: DTM1 and DTM2 are used to locate the ends of the variable section sweep 2mm inside the base. Note: The cross section sketch does not appear in the model tree. It is created within the variable section sweep dashboard. The variable section sweep dashboard looks like this:
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Note: Variable section sweep defaults to creating a surface so the Create Solid button has been selected. The section sketch is defined by clicking on in the dashboard.
When creating the section sketch it is very important to attach the sketch to the ends of the trajectory and profile sketches. Creo Elements/Prohelps by snapping sketch lines to profile sketches. Once all the options had been chosen the model looks like this. Clicking on in the dashboard completes the feature. Tip: If the green tick/check mark is grayed out, selections in the dashboard are not complete. Look in the message area of the screen for feedback on what Creo Elements/Prois expecting you to do.
Tip: Variable section sweep is very powerful but can fail particularly when asked to make very sudden changes in section. PTC Curriculum Another curriculum project that uses the variable section sweep is the RP Car. PTC University Precision LMS For more examples plus hands-on practice on variable section sweeps look on PTC University in the Online courses >Advanced Modeling section. Note: Teachers and instructors with an account on PTC University can register their students to give them access to the learning materials Warp The warp feature is a collection of tools that allow existing shapes to be squashed, bent and twisted in a very organic way. There are no sketches involved; instead, frames surround the affected area while points and edges on a mesh are pushed and pulled to change the model. These two images show the model before and after a warp feature is applied.
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Before
After
The warp feature is a single entry in the model tree but does rely on there being 3D shapes to act on.
The Warp dashboard looks like this.
Initial selections expect you to identify the solid the warp will be acting on, and the direction the warp will be applied. The direction is often a datum plane located perpendicular to the intended direction for the warp. These initial selections are stored in the References pop-up panel.
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The pop-up panel List stores each warp that is applied to the model. In this example two warps are listed.
The first warp modifies the side profile of the block acting on the top surface of the model.
The second warp curves the side of the car body and uses , the symmetric option so that it is applied to both sides of the model.
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Tip: Warp is a very dynamic tool but can disturb previous geometry such as flat surfaces and cylinders. If this happens drag the frame for the warp so that it does not act on the geometry you want to retain In this model the base of the warp frames was dragged above the base shape to ensure it remains a precise fit on the chassis. On the right is the model tree for the warp body and below the finished body shape..
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PTC Curriculum www.ptcacademy.com provides access to many more tutorials written specifically for middle and high schools. Your teacher/instructor can access these and make them available to you. PTC University Precision LMS For more examples plus hands-on practice on warp look on PTC University in the Online courses >Advanced Modeling section. Note: Teachers and instructors with an account on PTC University can register their students to give them access to the learning materials Homework Change request When a commercial product requires modifying the design team agrees a change request. This looks a bit like a product specification and lists the changes needed. Create a change request listing the modifications needed to change the standard car body design to match your revised design. Tip: Use your experience of the model tree to help you order your list of changes. You will need your change request in the next session.
Session four - Own Design

You now have sufficient experience to model your own body. However you may find the following design guidance helpful From previous homework you should have several sketch ideas for car shapes drawn on templates.
You should also have a change request list of modifications to make. Task one - Scanning your drawings 1. 2. 3. Choose one of your design sketches. Add dimensions in the positions shown below to your drawing. Use a scanner to capture your drawings into the computer. Create two tightly cropped images of the areas shown below as dotted red rectangles.
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35mm
10mm
45mm 160mm
28mm
4.
Name the files Sketch-side.jpg and Sketch-front.jpg
Schools Edition Using the Schools Edition of Creo Elements/Pro, you can trace over a scale drawing. The notes that follow are based on work done by Dave Cheshire at Staffordshire University. He produced a datasheet titled Creating a trace sketch without Style explaining how to do this and kindly allowed us to make this available in this Document. Dave Cheshire has created tutorials for many of the features in Creo Elements/Pro and schools can purchase these at: http://www.cdcweb.co.uk/ 5. 6. 7. Make a copy of the part bodymould.prt with a new name. Open the new file. Drag the finish flag up to below the DEFAULT_CSYS
8. 9.
Create a sketch datum plane
on the FRONT
Draw a rectangle and dimension it like this using the values from your sketch. on to
10. In the sketcher toolbar close sketcher.
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11. The sketch you just created should be selected (colored red). 12. Open the Edit pull-down menu and Fill The sketch should now be shaded to show it has been filled shown here in trimetric.
13. In the Main toolbar across the top of the screen, open the Appearance Gallery pull-down menu and Manager Appearances
The Appearances Manager dialog will open.
14.
on at X1 the Create a new appearance button.
15. Type in a name for the new appearance in the field at X2. 16. In the Color Texture options at X3 change Off to Image. 17. on the Map button at X4 and in the Open dialog, navigate to find your Sketch_side.jpg, then on Open the file
18. In the main toolbar on the Appearance Gallery button and the mouse cursor will change to a paint brush. 19. on the filled sketch to apply the texture you created.
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20. Your scanned drawing will be applied to the filled sketch. 21. Save your work.
You may have wondered why we located the centre of the rear wheel over the intersection between the FRONT and RIGHT datum planes. This helps you position the sketch in the correct placement in relation to the rolling chassis.
22. Repeat the process creating a filled sketch on the RIGHT datum plane and pasting your Sketch-front.jpg image on it. Remember the picture is automatically scaled to fit the original rectangle you drew so if the overall size, proportions or position are wrong edit the dimensions of the sketch.
Your instructor/teacher will now help you create a Creo Elements/Promodel of your own design of car. Tracing with Schools Advanced Edition The Schools Advanced Edition of Creo Elements/Proincludes advanced surfacing tools. Two PTC DesignQuest tutorials explain how to do this; Deodorant bottle and Kettle. Both are available on www.ptcacademy.com Homework four CNC machining Research CNC machining and write a description of how: A 3D CAD model is transferred to the computer controlling the machine tool. How the machine tool software creates instructions for the machine. How the machine removes material. Advantages of CNC machining. Disadvantages of CNC machining.
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Session five Machining

The Make-assemble-setup booklet contains a detailed description of taking the Creo Elements/Promodel of the body mold through to the machined vacuum forming mold. Homework five Parts manufacture Would it be cool to spend your working day recreating the latest dream cars as Scalextric models? Interested in how its done? Read the section about Darren in the Design guide document for this project.
Session six Car assembly

The Make-assemble-setup booklet contains a detailed guide on how to assemble the chassis for this project.
Session seven Testing, analysis and simulation

Simulating car performance In the past, designers and engineers would build real prototypes to test their designs. The results of testing were used to improve the design but the cost and time taken to build the designs meant the entire process lasted months or even years. Testing could also be hazardous to the operator. This prototype was the forerunner of the Harrier /AV8B jump jet. The air intake cuffs are evidence of significant changes made as a result of testing and before production started. There is famous footage of a prototype harrier crashing at the Farnborough air show in front of large crowds.
www.wikepedia.org
A major advantage of computer 3D modelling is the ability to test and evaluate virtual designs. This cuts out the time and materials needed to make physical prototypes. Analysis tools in 3D modelling software are developing all the time and the following tests have been developed for your Scalextric car.
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Creo Elements/Prohas extensive measurement and analysis tools and these can be used to evaluate the virtual model to assess how well it might perform before making and testing a physical prototype. There are obvious benefits in doing this including faster development of design variations and reduced cost of materials and manufacture. The analyses covered here include: Static measurements: Mass/position of centre of gravity Frontal area
Dynamic analyses: The effect of centre of gravity on lateral stability Acceleration in a straight line
Creo Elements/Promodels Several simulations have been created based on the standard car model. These should help you learn about the science and maths of movement and help you understand how to design a faster and more efficient car. The Creo Elements/Promodels for these analyses are available in the ProductPoint project or can be downloaded from the challenge web site at: www.scalextric4schools.us
Task one - Mass/C of G measurement

The mass of a design will have a major impact on acceleration. A lighter car will accelerate faster than a heavy car providing the wheels do not spin. Most racing formulae restrict the mass of a car usually with a lower limit. This is usually to make sure designers do not reduce the mass to the point the structure is not strong enough to protect the driver.
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1. Start Creo Elements/Pro 2. Make sure you are connected to the ProductPoint project or, set the working directory to the location for your tutorial models 3. Open the model Analysis_car.ASM 4. In the main toolbar open the Analysis pull-down menu, follow the Model option then on Mass Properties. The mass properties dialog opens. 5. In the dialog analysis. on to compute the
The dialog will now report the mass statistics and coordinates for the C of G position.
While the Mass Properties are displayed in the dialog, the model will display two sets of coordinates. The x,y,z coordinate system at the centre of the rear axle already exists in the model and is used as a reference to report the centre of gravity for the entire model. The dialog lists the x,y and z distance between these two coordinates. 6. Try rotating and zooming the model to examine where the C of G is located. 7. Close all dialogs. You may want to check out some of the following items. Mass Open a part. Check the material e.g. HDPE_vac_form find density. Carry out mass measurement. Change material to polyethylene check density. Carry out another mass measurement. Compare the results and densities between the two models. What would be the effect of using one of the following materials? o acetal, acrylic, nylon, polycarbonate. You may need to look on the web for the densities of some of these materials.
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www.matweb.com Design hint: Reduce the mass of your car by removing material where it is not needed. Move heavy components as low as possible and reduce the overall height of the car as much as possible. Density Find the density of a material by experiment Predict the impact on performance of using the new material. Make the changes to your model then take measurements of mass. Interpret the results in terms of performance. Use your conclusions to prompt further changes to your design.
Task two - Frontal area

This uses the same model as the previous analysis. 1. Open the model 2011_euro_car.ASM 2. In the model tree unhide. over the entry Fill_1 then on
3. In the top toolbar open the Analysis pull-down menu, follow Geometry then The Shadow dialog will open. 4. the filled sketch behind the car. inside the Model field then, in the on SLOT_CAR1.ASM in the Direction field then on the Shadow.
5. In the dialog, model tree 6. In the dialog filled sketch.
7. Reverse the direction for projection by on the yellow arrow in the model window. The model will show the shadow and the dialog will report the area of the shadow and the percentage of the screen in shadow. This analysis shows the size hole the car must make in the air as it travels along. 8. Close all files and Erase memory.
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Task three - C of G and stability

The centre of gravity will determine how well the car will go around corners. Cornering The slot guide steers the front of the car round the corner while friction between the wheels and track stops the car sliding or spinning. Analyses have been provided for you to experiment with. Impact of C of G on cornering Remember the cartoon in this design guide booklet showing a bus being tilted on a platform until it falls over? Here is the real thing. The test for buses was a 28 degree tilt. All four tyres must remain in contact with the platform at this angle. Notice the sloping wall to catch the bus should it begin to tilt!
http://www.20thcenturylondon.org.uk/
An assembly has been created with the standard car hinged to the track by the edge of the tyre. Using the mechanism module in Pro|ENGINEER, gravity is applied and the track gradually tilted. When the force vector (arrow) showing gravity acting at the centre of gravity falls outside the wheelbase the model tips over.
Form this we can suggest a tall car will be more likely to topple over so we will analyse the design by gradually tipping the track until the car falls over. The track angle gives an accurate guide to how stable a car will be. 1. Creo Elements/Proshould be running. 2. The working directory should be set to 04 Scalextric4Schools 3. Open the assembly c_of_g.asm 4. You will be looking at the rear of the car sitting on a section of track.
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5. In the top toolbar open the Applications pull-down menu and Mechanism. on c_of_g 6. In the Mechanism tree on the left of the screen expand the entry ANALYSES, (DYNAMICS) and Run. on
7. Once the analysis has finished, expand the mechanism tree entry for PLAYBACKS, c_of_g entry and Play.
8. Use the playback controls to view the analysis pausing the movement at the instant the car begins to tip. 9. Open the Analysis pull-down menu and choose Measure then Angle. 10. In the model tree ASM_TOP then on the model
the top surface of the track. Both the model and the dialog will display the angle of the track. 11. Close all dialogs and models and Erase from memory.
Task four - Acceleration

1. Creo Elements/Proshould be running. 2. The working directory should be set to your ProductPoint project or the location of the tutorial files 3. Open the assembly Wheelspin.asm 4. Zoom to view the model like this.
5. In the top toolbar open the Applications pull-down menu and
Mechanism. on
6. In the Mechanism tree on the left of the screen, expand the entry ANALYSES, wheelspin (DYNAMICS) and Run.
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7. Once the analysis has finished, expand the mechanism tree entry for PLAYBACKS, on wheelspin entry and Play. 8. Use the playback controls to view the analysis. 9. While the playback is running rotate and zoom the model to inspect the behavior more closely. Coefficient of friction A cam connection links each of the rear wheels of the car and the track surface. These cam connections contain properties for coefficient of restitution and friction. To make the analysis realistic it is important the correct values are used for these so the next step is to find out the coefficient of friction between the tyres and the surface of the track. Coefficient of friction is an empirical value and so can only be found by experiment. The car is pulled along the track using a force meter. The experiment came up with a pulling force of 0.053 Newtons Example Mass of Slot car=0.085 kg Weight = Mass x gravity Weight = 0.085 x 9.81 Weight (FN) = 0.083 Newtons Pulling force (Ff) = 0.053 Newtons Coefficient of Friction () Ff = x FN 0.053 = x 0.083 0.053 = 0.083 0.64 = Design guide: Increase tire friction, reduce bearing friction.
Mass (m)
Pulling force (Ff)
Weight (FN) Your calculations Mass of Slot car= Weight = Weight (FN) = Pulling force (Ff) = Coefficient of Friction () Ff = x FN =x = = kg x 9.81 Newtons Newtons Weight = Mass x gravity
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Changing the analysis 10. The wheelspin.asm model should still be open. 11. Make sure the Mechanism module is activated. 12. In the mechanism tree, expand the entry for CONNECTIONS and CAMS. 13. on Cam Follower 1 (WHEELSPIN) and, from the floating menu, Edit Definition. the Properties
14. In the Cam-Follower dialog tab.
15. Enter the value you have derived for coefficient of friction into the two fields shown here in red.
16.
OK to close the dialog.
17. Rerun the analysis wheelspin (DYNAMICS) and use the playback controls to examine the results of the analysis. Explain any differences in the two analyses. Design hint: Match gearing to each track. For example low gearing for acceleration on tight, twisty circuits or high gearing for high speed circuits. Aim: Maximise revs at fastest part of circuit. Track Note: - This is a summary of an analysis using Creo Elements/ProWildfire 5.0 Objects want to go straight on unless a force makes them change direction. The slot provides a centripetal force on the slot guide making the car turn. Interrogate the slot mechanism connection. Run Andys sim. Car corners OK. Increase power of motor. Re-run sim and see car leave the track.
Design guide: Tyres with sharp edges are less likely to slide but may suddenly dig in making the car roll out of the slot. A crashed car loses lots of time so enthusiasts radius the edges of the rear tyres to stop them digging in allowing the car to slide or drift around corners. Further analyses/simulations Here are other analyses Creo Elements/Prowould allow you to apply to your design. Gearing - Change the gear ratio and re-run the acceleration analysis.
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Cornering static as for C of G stability but with the tyres free to slip on the track surface. Cornering dynamic - Creo Elements/ProWildfire 5.0 allows the slot guide to release and all points contact shows the car tumbling off the track. See video Scalextric4Schools-W5.wmv Hill climb as for acceleration but with the track at increasing angles until the driving wheels spin or the car tips over backwards.
Setting up analyses from scratch is an advanced technique. If you would like to learn these techniques take a look at the Precision LMS courses on mechanism dynamics.
Teachers and instructors using Creo Elements/Procan register to use PTC University Precision LMS, a comprehensive range of online tutorials covering most of the features in this software. Once registered, your instructor can allow students to access the materials. This is an excellent way for you to learn Creo Elements/Profrom the professionals.
Each unit of material is organized into Concept What the unit aims to do including animated images and audio-visual presentation. Application Step-by-step on-screen text tutorial with animated illustrations explaining every action, dialog and menu picks Demonstration A screen video recording with commentary by an expert user of Pro|ENGINEER. This can be paused and replayed as often as you like. Most of the units have Creo Elements/Profiles you can download and work alongside the tutorials.
Homework Have you ever thought about industrial designer as a career and what you would have to study to become one? Read how Victoria became a designer, the subjects she studied at school and the work she did at university to land a job at Hornby designing the Scalextric cars you can buy in toy stores around the world.
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Session eight - Presentation preparation

Outline By the end of this session you will have started creating an electronic presentation showing how your design developed. Make sure you structure your presentation with evidence for all sections in the competition rules. To help you we will show how to convert your body mould into a body shell and add it to an assembly. Rendering the finished car will provide one of the images you will need for your presentation. Starter Your teacher will ask you questions about the career of product designer and the education route to become one.
Task one - CAD modeling the vacuum formed body

Outline Adding features to convert the body mould into a body shell is straightforward and involves re-instating the model tree and making changes to the order of features
Task two Convert mold to body shell

Expert/Overview The following section will teach you how to convert the body mold into a body shell. This involves: Moving the Insert here flag above the mirror. Shell the half mold outside by 0.5mm with the underside and centre face open. Move the Insert here flag to the bottom of the model tree. Drag the Mirror feature to the bottom of the model tree.
The result will be a body shell representing the vacuum formed component needed to complete the assembly.
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Step by Step 1. Start Creo Elements/Pro and check your Scalextric4Schools folder is available. Set the working directory to where your Scalextric4Schools models are stored. Open the body mold you created previously. Open the File pull-down menu and Save a copy In the New Name field type a new name e.g. Z_BODYSHELL.PRT then 6. OK. Close the body mold model and open the new part you just created.
2. 3. 4. 5.
7.
In the model tree on the right of the screen, drag the Insert here flag above the mirror feature.
8.
In the feature toolbar on the right of the screen , the Shell tool.
9.
In the Shell dashboard, change the Thickness to 0.5mm and shell the model externally. on , to
10. Rotate the model and holding down CTRL, the bottom and centre faces of the half mold to remove them from the shell.
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11. In the Shell dashboard, complete the feature.
to
Now you will reinstate the last few features in the model tree. 12. In the model tree, drag the Insert Here flag to the bottom of the model tree. The wheel arches will now be visible in the model but only through the front half of the model.
To correct this we need the mirror feature at the bottom of the model tree. 13. In the model tree drag the Mirror feature down to just above the Insert Here flag. Tip: Do not drag the feature too low in the model tree. If you do you will see a No Entry icon and the feature will not move.
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The model will regenerate, mirroring the extra features and you should now have a symmetrical car body. 14. Save your model.
Task three - Part properties

While the shape of the body is complete, we still need to record other details to form a complete description of the part including a description, the project it forms part of, who created it and the material it is made of. Material properties 1. From the Creo Elements/Promain toolbar, File, and, from the pull-down menu, Properties. This will open the Model Properties dialog.
2.
Next to the Material entry on change.
Creo Elements/Prowill now display the Material dialog.
3.
Navigate through the Plastic and Polyethylene folders then one of the listed HDPE materials.
4.
the Assign button followed by .
Creo Elements/Prowill now apply this material to the body.
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Note: For accurate analysis you should research the properties of actual vacuum forming sheets you will be using, create a new material definition and apply this to your model. Part properties The next step is to assign none geometric parameters to the part. 5. 6. 7. The Model Properties dialog should still be open. Next to the Parameters entry on Change. In the Parameter dialog fill in the values for DESCRIPTION, MODELLED_BY and PROJECT. to accept your Parameters. 9. In the Model Properties dialog, . 10. Save your work. Notice the material parameter has been entered automatically.
8.
You should now be comfortable using Creo Elements/Proto model a body shape ready for when you design your own shape car.
Task four Add body shell to the assembly

1. 2. 3. Open the model 2011_Euro_car.asm Hide any mold or body components that may be visible. In the features toolbar down the right of the screen, part. 4. on to add a new the body shell
In the Open dialog, .
you have just created and then
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The assembly dashboard opens and the part will appear in the model window attached to your mouse cursor. 5. Move the mouse until the body shell is close to where it needs to be placed then LMB to release the mouse cursor.
In the Assembly dashboard, open the Automatic list and The body shell will be fixed in the correct position and turn a mustard color to signify this is the case. 6. In the dashboard on to complete adding the body shell to the assembly. Save the assembly.
7.
Extensions
By creating additional features, you can make your model more realistic.
Project sketches to create cut-outs for windows and grill Project a sketch onto the car surface then variable section sweep a small circle along the projected spline. Used here to create shut lines around doors and headlights.
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Homework six - Industrial designer The job of product designer is well paid and varied. If you would like to know more about becoming a designer you may be interested in the story of Victoria, one of the Scalextric designers. Her story is in the Design guide document for this project.
Session nine Visualizing

Creo Elements/Prohas a wide range of powerful tools for presenting your design. Rendered CAD model Creo Elements/ProSchools Edition is supplied with a set of fully featured rendering tools allowing you to create a photo-realistic image of your design. In this section you will be taught how to apply textures and graphics to parts and present them as finished image.
Key principles The Advanced Rendering Extension (ARX) module in Creo Elements/Prois very powerful with many adjustments possible to the room environment such as materials, lighting, reflections, etc possible. This session will provide a brief overview and hands-on experience of just a few features, enough to produce a final rendered image of your slot car assembly. The sequence you will work through is: Apply a texture to the surface of your car body Apply a logo graphic to surfaces on your car body Open your slot car assembly Define initial render settings Load a scene definition Position the model in the room Change the view of your model Try a draft render Make any adjustments. Perform the final render Save the rendered image
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Task one Applying textures

Applying textures is very straightforward and Creo Elements/Procomes with a comprehensive library of material textures. 1. Your car body should be open in Pro|ENGINEER
2. 3.
In the main toolbar, the Appearance Gallery. menu,
, to open
In the Appearance gallery drop-down on Library and from the list a category of material textures. Here we are choosing a library of spray painted textures X2.
4.
In the library section of the Appearance Manager, painted textures. one of the
The drop down menu will close, the mouse cursor will change to a paintbrush and the Select dialog will open in the top right of the screen. 5. Move the paintbrush mouse cursor over the part name at the top of the model tree and LMB. Either or OK in the Select dialog to finish applying this material texture.
6.
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The model will appear colored with the new texture on all surfaces.
Task two Sponsorship and logos

In motor sport it is common to sell advertising space on cars to sponsors. The cost depends how visible the space is to spectators and TV coverage. Which surfaces of your car do you think will be worth the most? The following organizations already sponsor this challenge with curriculum, branding and resources. The competition rules dictate you must have their logos on your car at the sizes shown. Global sponsors
16mm x 6mm
18mm x 4mm
Regional sponsors - UK
10mm x 10mm
18mm x 5mm
12mm x 8mm
18mm x 8mm
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12mm x 14mm
18mm x 5mm
Are they all the same size? The logos are all different proportions so how would you measure the amount of space each one has. Would you include the white spaces? What mathematical techniques could you use to measure the area of each logo? Sponsors will want proof their logos are the correct size. Creating a decal from a logo Where logos are not rectangular it is important to make the background color transparent. You will need a bit map file of image with an alpha channel layer of the masked area. A guide to doing this with your own image using Paint Shop Pro is available at: http://www.axialis.com/tutorials/tutorial-misc002.html
This example uses a PNG format image of the PTC Logo.
After conversion, the surrounding transparent or masked area is shown as a chequer board.
The chequerboard pattern shows where the transparency will apply around the lettering and blue hoops. The PTC logo above is available for you to practice PTC_logo_no_backgrnd.png
Task three - Applying a decal

Expert/Overview Applying a decal to a model is straightforward.
Scalextric4Schools
A material texture is applied to the model. A copy of the material texture is made and the decal applied to this copy. The new material texture with the decal is applied to selected surfaces on the model. The decal placement is altered to rotate and position the decal.
Step by Step We assume the correct Creo Elements/Pro texture is already applied to the part and you know the name of that texture. 1. Open your car body in Creo Elements/Pro.
2.
In the main toolbar across the top of the Creo Elements/Proscreen Appearance Gallery. on to open the
3.
At the bottom of the Appearance Gallery roll-down menu, X1 to open the Appearance Manager.
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Appearance Manager is where you add, delete and modify material appearances for your model. 4. 5. The material for the model is listed in the model section X2. over the model material X2 and, from the floating menu, My Appearances. 6. Copy to
In the My Appearances section of the dialog, move the mouse over this new material X1, the floating menu, and, from New.
The new material will be listed X1 in My Appearances. 7. Type a new name at X2 for the material. Use a name which identifies the parent texture and the decal used. In the Decal drop down list at X3 Image. on the color swatch X4 and, in the Open dialog, navigate to the logo image, the file and Open.
8. 9.
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You must now save the new list of textures to make sure the texture you created is available next time the model is opened. 10. Open the File drop down and click Save As. 11. In the Save dialog, click to select the Working Directory then click OK to save the list of appearances in the model. Close the Appearance Manager. Apply the new decal texture The duplicate body texture with logo can now be applied wherever the decal is required.
12. In the main toolbar on to open the Appearance Gallery and select the texture with logo you created is selected. The Appearance Gallery will close automatically and the screen cursor changes to a brush. 13. Move the mouse cursor over the surface you want the logo to appear on and surface. 14. OK or model. to select that
to finish applying textures to the
15. Save your model. It is highly unlikely the decal will be scaled or positioned correctly. Creo Elements/Pro provides tools to refine the size and orientation of decals,
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Scale and position the decal 16. on to open the Appearance Gallery. ,
17. At the bottom of the Appearance Gallery Edit Model Appearances. The Model Appearance Editor opens on the left of the screen. 18. Near the top of the dialog at X1, on . This is used to select the decal surface to be edited. 19. Click to select one of the decal surfaces on the model. 20. In the Model Appearance Editor, the Map tab. 21. In the Decal section X3, on Edit Decal Placement dialog. The Edit Decal Placement tab opens. click on X2 to open the
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22. In the Edit Decal placement dialog Copies section, select Single X1. 23. Use the Repeat spin wheels X2 to scale the decal and the Position spin wheels X3 to move and/or rotate the decal. 24. When you are happy with the decal placement close all dialogs. 25. Repeat the scale and position steps on each decal surface.
26. Save the model.
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Task four - Final render

1. The 2011_euro_car.asm model should be open on screen. 2. On the Main toolbar button. on , the Scene
3. In the Scenes Dialog, scroll to find the photoluxstudio-hard scene and double this scene. to activate
4. Tick/check the Save scene with model option X1 A Scene stores information about several aspects of the render including the size and shape of room, textures on room surfaces, lighting and special effects. 5. In the Scenes dialog, select X2 the Room tab.
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6. Next to the Floor spin wheel, click on snap the floor to the model.
at X1 to
If you rotate the model you will see the floor has attached itself to the bottom of the pick-up guide blade.
We want it to be just touching the wheels. 7. Drag the Floor spin wheel X2 to move the floor up. If needed, type in numbers for the final adjustment. 8. on Close to finish with the Scenes dialog.
9. In the main toolbar button.
on
the Render setup
10. In the Render Setup dialog, change the quality option to High. We wont change any of the other Render settings.
11.
on Close to close the dialog.
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12. In the Main toolbar perspective tool. 13.
on
the
and to position the car how you want to see it.
14. You may want to move the Eye Distance slider in the Perspective dialog to change the amount of perspective and make small changes to the position of the model. 15. When you are happy with the look of the car on in the main toolbar.
Why do you think a tea/coffee pot has been used for this tool? Depending on the spec of your PC the render may take a little while.
16. When you are happy with the overall look of your model, open , the Modify render settings dialog, change the quality to maximum , close the dialog and re-render the model. This may take some time but the result should be much more realistic.
You are now free to try out different settings. Here the Scene was changed to Photoluxstudio-hard, the floor was reset to the bottom of the wheels and the quality increased to maximum. If you want to find out more about render settings your teacher has access to a more detailed guide.
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Graphic design Professional racing teams have full-time designers working on car graphics, promotional materials and branding. The base color schemes on full scale cars is spray painted. Company logos, text and images are then applied using vinyl decals/stickers.
Many schools have computer controlled vinyl cutters. This would work fine for go-faster stripes and large text but fine detail is not easy to create and apply using knife cut vinyl. Water -slide transfer material is ideal for putting detail on your car bodies. Simply print your graphics on the sheet, cut round the graphic, soak in warm water, then slide the graphic on to the model. It works best on flat surfaces or ones with a single curvature. Available from Magic Touch http://www.themagictouch.co.uk/transfer/dct.htm
Session ten Races

Track Competition races will be managed by PTC and Hornby using the Scalextric4Schools Sport track layout. The competition track layout is published on the challenge web site at: www.scalextric4schools.org. This layout, complete with controllers and power supply can be purchased online with education discount.
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You can download the track design as a Creo Elements/Pro assembly and in a format suitable for Scalextric Track Designer software. Scalextric Track Designer software can be downloaded free from the Scalextric web site at www.scalextric.com. When testing your cars, make sure you carry out fair tests. Your instructor/teacher will be able to explain this and help you use testing to identify aspects of your design you could modify and improve.
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Session eleven - Presentation

This is an opportunity for your team to present the story of your design, how it developed and how well it performs. Good luck!
D:\Users\tbrotherhood\Documents\00 Curriculum\02 Middle\S4S\F3\S4S_Creo_Pro_Euro.docx
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Appendix Car design template
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Creo Elements/Pro

S4S Creo Elements/Pro

Product code W5-SE-L2-0202-2.0

Creo Elements/Pro W5.0

Session one Scalextric4Schools challenge

Creo Elements/Pro W5.0

Creo Elements/Pro W5.0

Creo Elements/Pro W5.0

Task one Starting Creo Elements/Pro

Creo Elements/Pro W5.0

In the Browser panel, double open the part named 2011_euro_car.asm

You will see a completed Scalextric4Schools car on screen.

Task two Exploring Creo Elements/Pro

The model will automatically zoom to fit in the viewing window.

Creo Elements/Pro W5.0

Named views list and

The body will disappear.

Task three Prepare for modeling

Creo Elements/Pro W5.0

Task four Body profile

Creo Elements/Pro W5.0

The sketch references dialog opens on the right of the screen.

Creo Elements/Pro W5.0

11. When you finish drawing the shape click

twice to cancel the line draw tool.

Creo Elements/Pro W5.0

Gaps - Lines that do not meet properly

Coincident lines - Lines drawn on top of each other

, will help you find

Creo Elements/Pro W5.0

Creo Elements/Pro W5.0

Creo Elements/Pro W5.0

the Create Defining Dimension

30. Move the mouse cursor to one side

31. With the Select tool

Creo Elements/Pro W5.0

and hold to drag the

the saved views list and

Creo Elements/Pro W5.0

Task five Side taper

Creo Elements/Pro W5.0

the RIGHT datum plane. to close the sketch

The Sketch References dialog opens.

Creo Elements/Pro W5.0

10. In the sketcher toolbar, the Line draw tool.

to finish sketching. on then

14. In the Main toolbar Trimetric view.

15. In the feature toolbar on the right of the screen extrude.

16. In the dashboard change the choices to those shown below.

Creo Elements/Pro W5.0

to complete the Extrude

The side of the car body will now be tapered.

Task six Rounds

Creo Elements/Pro W5.0

In the dashboard, on to complete the round feature.

Add a new Round of 5 mm radius to the edge show here.

Task seven Complete the mold

Creo Elements/Pro W5.0

7. Save the model.

Task eight Model properties

Creo Elements/Prowill now display the Material dialog.

Creo Elements/Pro W5.0

balsa_wood.mat. the Assign button followed by .

Task nine - STL file for machining