UNIGRAPHICS

PRACTICAL APPLICATIONS
OF UNIGRAPHICS
WORKBOOK
September 2002
MT10050 - Unigraphics NX

EDS Inc.
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UGR, UG/...R, UG SOLUTIONSR, iMANR are trademarks or registered trademarks of Electronic
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Practical Applications of Unigraphics Workbook Publication History:

Version 15.0 . . . . . . . . . . . . . . . . . . . . . . . February 1999

Version 16.0 . . . . . . . . . . . . . . . . . . . . . . . January 2000
Version 17.0 . . . . . . . . . . . . . . . . . . . . . . . December 2000
Version 18.0 . . . . . . . . . . . . . . . . . . . . . . . September 2001
Unigraphics NX . . . . . . . . . . . . . . . . . . . . . September 2002
 Project Description

Project Description

Toy Radio Controlled Car

The objective of this workbook is to provide you with an an ongoing indication
of your comprehension of the course material. The workbook will lead you
through a modeling project with high level prompts. Detailed steps will not be
present as they are in the student manual. However, feel free to reference the
student manual as needed.

In this project you will model some of the component parts of a toy car and add
them to an assembly. Some of the parts have already been modeled but need to
be added to the assembly in the proper orientation. Other parts will require the
documentation of a drawing.

This project will reinforce your Unigraphics skills of capturing design intent,
modeling, assemblies, and drafting.

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Project Description

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 Rear Differential Modeling

Rear Differential Modeling ÉÉÉ

ÉÉÉ
Section 1
ÉÉÉ
1
ÉÉÉ
The first part to be built for the toy car assembly is the rear differential. This
activity will show how a primitive may be used to start the model, then new
features may be used to add detail to the part.

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 Rear Differential Modeling

ÉÉÉ
ÉÉÉ
ÉÉÉ
1
ÉÉÉ
The design intent of the rear differential is to hold the rear drive
gear and the rear axle. The bosses that protrude from the sides to support the
axle need to be centered on the central square section, and should act as one
feature should the part change. The rear differential also must have the ability
to rotate to a certain degree, allowing the rear wheels to travel over uneven
surfaces. The bosses used to mount the differential therefore are required to be
aligned. The walls of the central square section should be of uniform thickness.
The rear drive gear will protrude from the top of the differential so that it can
mesh with the drive gear from the power source. This means that the bottom of
the central square section must accommodate the rear drive gear passing
through it. The hole that allows the rear axle to pass through the part should be
centered in the bosses that are provided to support it.

Step 1 Open pau_seedpart_mm save it as ***_rear_diff_1 where

*** represent your initials.

Step 2 Start with a primitive as shown below. Be sure to enter the

entire expression as the value in the length fields (i.e.
BLLG=27.50). Locate the block at WCS origin 0,0,0.

The expression names will help in referencing the values later.

Unigraphics builds the block and locates it in the location specified. Note the
orientation of the block with respect to the WCS. Expressions are also stored
for the three equations that were keyed in. These expressions store the
parameters for the block and allow future editing to change the values defining
the block if desired.

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 Rear Differential Modeling

Step 3 Use the Hollow operation to remove material from the

ÉÉÉ
center of the block. Remove the top face and leave the
ÉÉÉ
other faces a thickness of 1.
ÉÉÉ
1
ÉÉÉ

Step 4 On each of the 27.5 x 17.5 faces (front and back) create a
Boss feature 17.5 in diameter by 21 high. When
positioning the first boss use the values BLLG/2 and
BLHT/2 to place the bosses in the center of the face.
BLLG and BLHT are expression names that were created in step 2.
Expressions are case sensitive. Referring to these expression names links the
values to the expressions, so that when the value for the expression changes the
feature location updates accordingly.

When creating the second boss, link its diameter and height to those of the first
boss by using the expression names (p values) that were stored during creation
of the first boss.

Locate the second boss relative to the first boss to assure that they move
together.

Step 5 Create edge blends with a radius of 4 along the bottom

two long inside edges.

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 Rear Differential Modeling

ÉÉÉ Step 6 Create edge blends with a radius of 5 along the bottom
ÉÉÉ two long outside edges.

ÉÉÉ
1
ÉÉÉ

Step 7 Use a Pocket feature to create a Rectangular opening 18

long by 12 wide in the bottom of the part for gear
clearance. A depth of 5 for the pocket should accomplish
what is required. Center the pocket in the part using
previously created expressions.

It is important to think of what is to be accomplished while using the various

tools. A rectangular pocket created from the outside bottom face of the part
will take away material upward as desired to create the clearance opening for
the gear. Note that the pocket takes material from the blended faces and the
bottom. A rectangular pocket created from the inside bottom face would not
remove the material from the inside blended faces. They are above the
placement face.

Step 8 Place the 5.5 diameter axle clearance Hole through the
part. Be sure that the clearance hole is centered in the
boss features.

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 Rear Differential Modeling

Step 9 Create Single Offset Chamfers with a value of 1 on the

ÉÉÉ
outer edges of the hole.
ÉÉÉ
ÉÉÉ
1
ÉÉÉ

Step 10 Create the mounting bosses.

- Create the two 5 diameter by 6.5 high mounting Bosses

centered on the 18 x 17.5 faces. Apply design intent during
creation as was done earlier.

Step 11 Save and close the part.

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 Rear Differential Modeling

ÉÉÉ
ÉÉÉ
ÉÉÉ
1
ÉÉÉ

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 Rear Differential Assembly

Rear Differential Assembly

Section 2

Assemblies

The purpose of this section is to begin the assembly of the toy car. This
assembly will be revisited throughout the course.

ÉÉÉ
ÉÉÉ
2
ÉÉÉ
ÉÉÉ

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 Rear Differential Assembly

Step 1 Open pau_seedpart_mm save it as ***_assembly_1 where

*** represent your initials.

Step 2 Add the pau_chassis_pan_1 to the assembly using the

BODY reference set.

ÉÉÉ
ÉÉÉ
2
ÉÉÉ
ÉÉÉ
Step 3 Add the pau_rear_diff_1 to the assembly using the BODY
reference set.

The pau_rear_diff_1 part is owned by another user and is write protected. It

may not be modified and saved, however the assembly file is owned by you and
may be modified and saved.

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 Rear Differential Assembly

Step 4 Reposition the pau_rear_diff_1 as required to locate the

arc center at the end of front mounting boss with the arc
center at the front of the cradle provided.

Arc Center

ÉÉÉ
ÉÉÉ
2
ÉÉÉ
ÉÉÉ

Arc Center

Step 5 Save and close the part.

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 Rear Differential Assembly

ÉÉÉ
ÉÉÉ
2
ÉÉÉ
ÉÉÉ
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 Rear Differential Drafting

Rear Differential Drafting

Section 3

The next step in the rear differential process is to create a drawing of the rear
differential in the master model assembly.

ÉÉÉ
ÉÉÉ
ÉÉÉ
3
ÉÉÉ

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 Rear Differential Drafting

In this section you will create a discipline specific single part assembly for
drafting purposes.

Because of the associative nature of Unigraphics assemblies, changes to the

solid model will update its depiction in the discipline specific single part
assemblies.

The downstream application that will be used in this example is Drafting. Other
discipline specific assemblies could be created to support analysis,
manufacturing, etc..

Step 1 Open pau_seedpart_mm save it as ***_rear_diff_1_dwg

where *** represent your initials.

Step 2 Add the pau_rear_diff_1 part from the parts directory to

the assembly using the BODY reference set.

ÉÉÉ
ÉÉÉ
ÉÉÉ
3
ÉÉÉ

This will ensure that the solid model and all of its construction tools remain
segregated onto individual layers.

This completes the first step in the creation of a drawing for the rear
differential of the car assembly.

Step 3 Save the part.

Step 4 Enter the Drafting Application and edit the drawing such
that the units are metric, the scale is 2/1, the drawing size
is A3, and the drawing name is DWG1.

The current drawing, created when the drafting application was entered, is
changed as specified to better suit the rear differential part file.

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 Rear Differential Drafting

Step 5 Add the views to the drawing as shown below. Remember

to use Orthographic views once the original view is placed
to assure proper alignment. Add the views with the Create
Centerline option toggled on.

Step 6 Save the part.

ÉÉÉ
The next step is to add annotation to the drawing to define the part's size.
ÉÉÉ
ÉÉÉ
3
ÉÉÉ

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 Rear Differential Drafting

Step 7 Dimension the part as shown below. Remember that this

part is metric. Try using the Inferred dimension type first.
If need be, use the Horizontal, Vertical, Hole, and Radius
NOT to center types of dimensions.

ÉÉÉ
ÉÉÉ
ÉÉÉ
3
ÉÉÉ

If time permits, additional drafting activities may be found in Appendix B.

Step 8 Save and close the part.

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 Rear Axle Modeling, Assembly, and Drafting

Rear Axle Modeling, Assembly, and Drafting

Section 4

The rear axle is meant to be driven by the rear drive gear. It has a flat area on a
cylindrical body. The rear drive gear and the rear axle are made of a material
that allows the drive gear to be pressed onto the axle until its mating flat locks it
into the rear axle. The rear wheels are simply pressed onto the rear axle and
held in place by friction. The rear drive gear should always remain centered
along the length of the axle.

ÉÉÉ
ÉÉÉ
4
ÉÉÉ

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 Rear Axle Modeling, Assembly, and Drafting

The second part to be built for the toy car assembly is the rear axle. This activity
will reinforce the use of reference features.

Step 1 Open pau_seedpart_mm save it as ***_rear_axle_1 where

*** represent your initials.

Step 2 Create a Cylinder along the +XC axis with a diameter of

5 and a length of 30.

The rear axle has a notch centered along its length with the purpose of keeping
ÉÉÉ the rear drive gear from slipping. A rectangular pocket will be used to create
ÉÉÉ
4 this notch, but first reference features must be created to aid in the placement

ÉÉÉ of the pocket.

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 Rear Axle Modeling, Assembly, and Drafting

Step 3 Make layer 61 the Work Layer.

Step 4 Create the first reference feature through the cylindrical

face of the part.

Step 5 Create the second reference feature through the axis of

the cylindrical face and at an angle to the newly created
datum plane of 905.

This reference feature will be used to locate the notch in the axle in the center
of the cylinder width.

ÉÉÉ
ÉÉÉ
4
ÉÉÉ

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 Rear Axle Modeling, Assembly, and Drafting

Step 6 Create the third reference feature parallel to the original

datum plane and tangent to the top of the cylindrical face.

This reference feature will be used as the planar placement face for a
rectangular pocket.

Step 7 Create the final reference feature halfway between the two
planar faces on the ends of the cylinder.

This reference feature will be used to position the pocket in the center of the
part regardless of changes in length.

ÉÉÉ
ÉÉÉ
4
ÉÉÉ

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 Rear Axle Modeling, Assembly, and Drafting

Step 8 On the datum plane that is tangent to the cylindrical face,

create a Rectangular Pocket feature with a value of 10
along the length of the cylinder, a value of 5 across its
width, and a depth of .5. Position it so that the centerlines
of the pocket are collinear with the two centering datum
planes.

Step 9 Add chamfers with an offset of 1 to each end of the

cylinder.

Step 10 Make layer 1 the Work Layer and make layer 61 Invisible.

ÉÉÉ
ÉÉÉ
4
ÉÉÉ

Step 11 Save and Close the part.

Now that some of the component parts have been created for the toy car it is
time to start the assembly.

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 Rear Axle Modeling, Assembly, and Drafting

Step 12 Open ***_assembly_1.

Step 13 Add the ***_rear_axle_1 to the assembly using the BODY

reference set.

Step 14 Reposition the ***_rear_axle_1 so that its notch is

centered in pau_rear_diff_1.

TIP Analysis→Distance may be helpful in determining how to locate the

rear axle.

ÉÉÉ Step 15 Save the part.

ÉÉÉ
4
ÉÉÉ

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 Rear Axle Modeling, Assembly, and Drafting

In the rear differential part the Master Model technique was used to facilitate
concurrent engineering when the designer is not the drafter. Should these tasks
fall to the same individual there may be no advantage to using the Master
Model technique. In this case the drawing may be created in the same file as
the model.

Step 16 Change the displayed part to ***_rear_axle_1.

Step 17 Enter the Drafting application and edit the drawing to

meet the following specifications:

- the drawing units are in System International.

- the drawing size is A4.

- the drawing scale is 2/1.

- the drawing name is DWG1.

ÉÉÉ
ÉÉÉ
4
ÉÉÉ

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 Rear Axle Modeling, Assembly, and Drafting

Step 18 Add the views, utility symbols, and dimensions as shown

below.

Step 19 Save and Close all parts.

ÉÉÉ
ÉÉÉ
4
ÉÉÉ

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 Power Pack Sketching

Power Pack Sketching

Section 5

The power pack is actually the housing for the electronics and radio receiver.
This housing also contains gear sets that would connect the electric motor to
the drive wheels. The power pack should be compact and yet accommodate the
gear sets and rack spur gear.

This section will reinforce your freehand sketching and constraining skills. In
this activity you will create two profiles that represent the shape of the power
pack. ÉÉÉ
ÉÉÉ
5
ÉÉÉ
ÉÉÉ
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 Power Pack Sketching

Step 1 Open pau_seedpart_mm save it as ***_power_pack_1

where *** represent your initials.

Step 2 On layer 21 create a sketch named, s21_top, on the

XCĆYC.

Step 3 Freehand sketch a shape similar to the one shown below.

ÉÉÉ
ÉÉÉ
5
ÉÉÉ
ÉÉÉ
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 Power Pack Sketching

Step 4 On layer 1 extrude the profile up a distance of 60.

Step 5 Move the reference features to layer 61.

Step 6 On layer 22 create a sketch named, s22_front. Define the

attachment face and horizontal reference as shown below.

Select the horizontal

reference here.

Attachment
Face

Step 7 Make layers 1 and 21 invisible.

Step 8 Freehand sketch a shape similar to the one shown below.

ÉÉÉ
ÉÉÉ
5
ÉÉÉ
ÉÉÉ
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 Power Pack Sketching

Step 9 Save the part file.

Step 10 Activate the sketch named S21_TOP and apply the

dimensional and geometric constraints as shown below as
required.

There are 4 horizontal constraints.

There are 2 vertical constraints.

There are 2 pairs of horizontal lines

that have a equal length constraint.

The sketch is located in space by

applying a collinear constraint on a
vertical line and a datum axis and
a horizontal line and a datum axis.

ÉÉÉ
ÉÉÉ
5
ÉÉÉ
ÉÉÉ
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 Power Pack Sketching

Step 11 Activate the sketch named S22_FRONT and apply

collinear constraints to locate the sketch as shown below.

The right side of the sketch is aligned

with the right side of the solid body
and the bottom of the sketch is aligned
with the bottom of the solid body.

ÉÉÉ
ÉÉÉ
5
ÉÉÉ
ÉÉÉ
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 Power Pack Sketching

Step 12 Apply the dimensional and geometric constraints as

shown below as required.

There are 4 horizontal constraints.

There are 4 vertical constraints.

This should be the name

of the expression that
controls the extrusion
(=60). The name of your
expression may be
different.
This should be the name of the expression that
controls the over all length in the S21_TOP
sketch. See the illustration on page 6-4. The
name of your expression may be different.

ÉÉÉ
ÉÉÉ
5
ÉÉÉ
ÉÉÉ
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 Power Pack Sketching

Step 13 Extrude the FRONT sketch across the solid body (+YC).
Apply a parametric value so that if the solid body changes
the extrusion will update with it. Use the intersect
boolean type to get a resultant shape that is the shared
area of the extrusions.

Step 14 Hollow the part to a thickness of 2 removing the 3 faces

shown below.

Remove these faces

with the Hollow
operation

ÉÉÉ
ÉÉÉ
5
ÉÉÉ
ÉÉÉ
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 Power Pack Sketching

Step 15 Create a hole through both side flanges with a diameter of

15 with its center located .06 above the bottom edge and
set back from the front of the part a distance of 20.

Step 16 Create a hole through both side flanges with a diameter of

2.5 with its center located a distance of 17 up from the
bottom edge and set back from the front of the part a
distance of 27.

ÉÉÉ
ÉÉÉ
5
ÉÉÉ
ÉÉÉ
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 Power Pack Sketching

Step 17 Create a hole through both side flanges with a diameter of

2.5 with its center located a distance of 29.5 up from the
bottom edge and set back from the front of the part a
distance of 40.

Step 18 Create a hole through both side flanges with a diameter of

2.5 with its center located a distance of 17 up from the
bottom edge and set back from the front of the part a
distance of 62.5.

ÉÉÉ
ÉÉÉ
5
ÉÉÉ
ÉÉÉ
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 Power Pack Sketching

Step 19 Create a hole through the back side with a diameter of 6

with its center located a distance of 21 up from the
bottom edge and centered in the rear face.

Step 20 Save and close the part file.

ÉÉÉ
ÉÉÉ
5
ÉÉÉ
ÉÉÉ
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 Left Pinion Modeling, Assembly, and Drafting

Left Pinion Modeling, Assembly, and Drafting ÉÉÉ

ÉÉÉ
Section 6
ÉÉÉ
6
ÉÉÉ

The next part to build for the toy car assembly is the left pinion. This activity
will reinforce the use of swept features.

The left pinion is used to mount and steer the left front wheel. The right and
left pinions are attached to the chassis pan by snapping into place.

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 Left Pinion Modeling, Assembly, and Drafting

ÉÉÉ NOTE: Consider the use of reference features to aid in the

ÉÉÉ creation and/or positioning methods.

ÉÉÉ
6
ÉÉÉ

Step 1 Open pau_seedpart_mm save it as ***_left_pinion_1

where *** represent your initials.

Step 2 Create a block 25 long by 10 high by 7.5 deep.

Step 3 Create a center plane to aid in the positioning of objects.

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 Left Pinion Modeling, Assembly, and Drafting

Step 4 Create a Boss on the top face of the block with a diameter
ÉÉÉ
of 7.5 and a height of 5. Position it so that it is centered
ÉÉÉ
along the width of the block and tangent to the end as
shown. ÉÉÉ
6
ÉÉÉ

Step 5 Create another Boss on the top face of the previously

created boss. The boss is to have a diameter of 5 and a
height of 10. Constrain it to be concentric with the last
boss.

This boss will be used to connect the steering rack.

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 Left Pinion Modeling, Assembly, and Drafting

ÉÉÉ Step 6 Create another Boss on the top face of the block 27.5 high
ÉÉÉ by 7.5 in diameter and constrain it so that the axis of the

ÉÉÉ
6
ÉÉÉ
cylinder falls on the right edge of the block and is
centered in the width of the block.

This boss will be used to hold the front spring.

Step 7 Extrude the lower edges of the newly created boss down
12.5 to finish the cylindrical mounting feature. This
boss/extrusion combination is associative in that the
mounting feature is dependant on the boss' diameter for
size purposes.

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 Left Pinion Modeling, Assembly, and Drafting

Step 8 Using the center datum plane create a boss with a

ÉÉÉ
diameter of 5 and a height of 30. Locate the boss a
ÉÉÉ
distance of 5 from the bottom of the block, and so that the
boss stays centered on the axis of the mounting/spring ÉÉÉ
6
ÉÉÉ
feature.

Mounting spring feature

Step 9 Create another boss using the planar face of the last boss
as the placement face. This last boss should be 7.5 in
diameter by 7.5 high. Locate this boss concentric with the
last one.

The front wheel will snap onto this feature.

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 Left Pinion Modeling, Assembly, and Drafting

ÉÉÉ Step 10 Create an edge blend on the placement face edge of the
ÉÉÉ last boss with a radius of 2.

ÉÉÉ
6
ÉÉÉ This blend will allow ease of front wheel operation.

Step 11 Create an edge blend on the other end of the last boss
with a radius of 3.75.

This blend will allow easier front wheel operation and mounting.

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 Left Pinion Modeling, Assembly, and Drafting

Step 12 Move the datum plane to layer 61.

ÉÉÉ
ÉÉÉ
ÉÉÉ
6
ÉÉÉ

Step 13 Save and close the part.

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 Left Pinion Modeling, Assembly, and Drafting

ÉÉÉ Update the assembly to reflect the new parts.

ÉÉÉ
ÉÉÉ
6
ÉÉÉ Step 14 Open ***_assembly_1 where *** represent your initials.

Step 15 Add the pau_left_pinion_1 to the assembly using the

BODY reference set.

Step 16 Add the pau_right_pinion_1 to the assembly using the

BODY reference set.

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 Left Pinion Modeling, Assembly, and Drafting

Step 17 Reposition both pinions as required to locate the arc

ÉÉÉ
center where the bottom of the block intersects with the
ÉÉÉ
extrusion coincident with the respective arc centers in the
opening in the chassis pan. ÉÉÉ
6
ÉÉÉ

Reference
Arc Center

Destination
Arc Center

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 Left Pinion Modeling, Assembly, and Drafting

ÉÉÉ Step 18 Save and close the part.

ÉÉÉ
ÉÉÉ
6
ÉÉÉ Step 19 Create a Master Model assembly called
***_left_pinion_dwg.

Add the ***_left_pinion_1 part to the assembly.

Create a drawing to the following specifications:

Drawing units are System International
Drawing size is A3 size
The scale is 2/1.

Create the utility symbols and dimensions as shown

below.

Step 20 Save and close the part.

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 Rear Drive Gear Modeling

Rear Drive Gear Modeling

Section 7

The rear drive gear takes the power from the power pack and applies it to the
rear axle so that the wheels turn. As mentioned in the rear axle activity, the two
parts have matching flats to keep the gear from spinning on the axle. Each of
the gear teeth should be the same profile, and the spacing between the gear
teeth should be equal.
ÉÉÉ
ÉÉÉ
7
ÉÉÉ
ÉÉÉ

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7-1
 Rear Drive Gear Modeling

The next part to be built for the toy car assembly is the rear drive gear. In this
section you will start the construction of the rear drive gear by creating
reference features, the center hole, and a sketch to define the tooth profile.

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Step 1 Open pau_seedpart_mm save it as ***_rear_drive_gear_1
where *** represent your initials.

Step 2 Create a Cylinder with a diameter of 24 and a height of

10.

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 Rear Drive Gear Modeling

Step 3 On layer 61, create a Datum Plane Through face axis of

the cylindrical face.

This datum plane will be used to locate a central gear tooth.

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Step 4 Create a second Datum Plane Through face axis and at
an Angle to plane of 905.

Step 5 Create a third Datum Plane with an offset of 2 above the

second datum plane.

This plane will be the planar placement face for a rectangular pad that will
form the flat to match the one on the rear axle.

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 Rear Drive Gear Modeling

Step 6 Create a hole through the center of the cylinder with a

diameter of 5.

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ÉÉÉ Step 7 Create a sketch named tooth on layer 21. Define the
attachment face and horizontal reference direction as
shown below.

Horizontal reference

Attachment face

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 Rear Drive Gear Modeling

Step 8 Create the sketch geometry and constraints as shown

below.

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Step 9 Sweep and Subtract the triangular shape from the

cylinder to create a groove.

This groove is the side of two gear teeth.

Step 10 Save and close the part file.

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 Rear Drive Gear Modeling

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 Part and Assembly Editing

Part and Assembly Editing

Section 8

The assembly process quite often will show problems with the design. In this
case the rear axle was found to be too short to serve its purpose. Parametric
modeling allows for parts to be easily modified.

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8-1
 Part and Assembly Editing

Step 1 Open ***_rear_axle_1.

Step 2 Change the length of the cylinder feature from 30 to 195.

Step 3 Save the part.

ÉÉÉ Step 4 Enter the Drafting application and update the views.
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8
ÉÉÉ Step 5 Edit the drawing size from A4 to A3.

Step 6 Move the views as required.

Step 7 Change the origin of the dimensions and notes as

required.

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 Part and Assembly Editing

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Step 8 Save and Close the part.

Since the size of the axle has changed, you will now realign the axle in the
assembly so that it is positioned correctly.

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8-3
 Part and Assembly Editing

Step 9 Open ***_assembly_1.

Step 10 Reposition the ***_rear_axle_1 so that its notch is

centered in pau_rear_diff_1.

TIP Analysis→Distance may be helpful in determining how to locate the

rear axle.

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ÉÉÉ Step 11 Save and close the part.
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 Rear Drive Gear Completion

Rear Drive Gear Completion

Section 9

Use your newly acquired modeling techniques to complete the solid model of
the rear drive gear.

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9-1
 Rear Drive Gear Completion

In this section you will create a pad and apply an instance feature to create the
teeth of the gear.

Step 1 Open the ***_rear_drive_gear_1 where *** represent

your initials.

Step 2 Create a 5 x 10 x 1 rectangular pad on top of the offset

plane and center it in the part to form the flat.

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 Rear Drive Gear Completion

Step 3 On layer 61, create a relative Datum Axis through the

center of the cylinder.

Step 4 Create 24 copies of the extrusion around the Datum Axis

at an angle of 360/24.

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9-3
 Rear Drive Gear Completion

Step 5 Create edge blends at the top and bottom of all of the
teeth with a radius of .25.

Step 6 Save and close the part file.

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 Assembly Completion

Assembly Completion
Section 10

In this section you will complete the assembly of the toy car.

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 Assembly Completion

Step 1 Open ***_assembly_1 where *** represent your initials.

Step 2 Add the pau_rear_drive_gear_1 to the assembly using the

BODY reference set.

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 Assembly Completion

Step 3 Reposition the rear drive gear as required to locate the

arc center of the hole in the gear with the corresponding
arc center at the end of the flat on the rear axle.

Destination
Arc Center

Reference
Arc Center

Step 4 Add the pau_rack_1 to the assembly using original layers.

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 Assembly Completion

Step 5 Reposition the pau_rack_1 as required to locate the arc

center where the hole pierces the bottom of the rack
coincident with the respective arc centers on the pinions.

Reference
Arc Centers

Destination
Arc Centers

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 Assembly Completion

Step 6 Add the pau_power_pack_1 to the assembly using the

BODY reference set.

Step 7 Reposition the power pack as required to locate the

bottom left corner of the power pack with the upper left
corner of the battery enclosure on the chassis pan.

Destination
End Point

Reference
End Point

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10-5
 Assembly Completion

Step 8 Add the pau_rack_spur_gear_1 to the assembly the

BODY reference set.

Step 9 Reposition the rack spur gear as required to locate the

arc center on the end of the rack spur gear shaft with the
arc center of the power pack.

Destination
Arc Center

Reference
Arc Center

Step 10 Use Analysis"Distance to find the distance that the rack

spur gear must move to match with the steering rack and
move it into position.

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 Assembly Completion

Step 11 Add the pau_rear_wheel_1 to the assembly using the

BODY reference set.

Step 12 Reposition the rear wheel as required to locate the arc

center on the inside of the hub coincident with the arc
center at the end of the axle.

Destination
Arc Center

Reference
Arc Center

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10-7
 Assembly Completion

Step 13 Repeat the process to add the second rear wheel to the
other end of the axle.

Step 14 Add the pau_front_spring_1 to the assembly twice using

the BODY reference set. Use the arc centers shown below
as the origin points when placing the parts.

Origin
Arc Centers

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 Assembly Completion

Step 15 Add the pau_front_wheel_1 to the assembly using the

BODY reference set.

Step 16 Reposition the front wheel to the left pinion so that the
arc center at the end of the mounting hole is coincident
with the arc center at the end of the wheel mounting
shaft.

Reference
Arc Center

Destination
Arc Center

Step 17 Repeat the process to add the second front wheel to the
right pinion.

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10-9
 Assembly Completion

Step 18 Add the pau_gear_set_1 to the assembly using the BODY

reference set. Reposition the gear set so that the two arc
centers shown below are coincident.

Destination
Arc Center

Reference
Arc Center

Step 19 Add the pau_gear_set_2 to the assembly using the BODY

reference set. Reposition the gear set so that the two arc
centers shown below are coincident.

Destination
Arc Center

Reference
Arc Center

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 Assembly Completion

Step 20 Add the pau_gear_set_3 to the assembly using the BODY

reference set. Reposition the gear set so that the two arc
centers shown below are coincident.

Destination
Arc Center

Reference
Arc Center

The graphic below shows the car from the rear with the three
gear sets in place.

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 Assembly Completion

Step 21 Add the pau_frt_spoiler_1 to the assembly using the

BODY reference set.

Step 22 Reposition the frt spoiler so that the end points shown
below are coincident.

Destination
End Point

Reference
End Point

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 Assembly Completion

Step 23 Add the pau_body_1 to the assembly using the BODY

reference set.

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 Assembly Completion

Step 24 Reposition the body so that the arc centers shown below
are coincident.

Reference
Arc Center

Destination
Arc Center

Step 25 Save and Close the part.

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 Additional Modeling Projects

Additional Modeling Projects ÉÉÉ

Appendix A
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A
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EDS Practical Applications of A-1

All Rights Reserved Unigraphics Workbook
 Additional Modeling Projects

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A-2 Practical Applications of EDS

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 Additional Modeling Projects

Activity 1 - The Steering Rack ÉÉÉ

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This activity will reinforce the application of a rectangular instance array.
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A
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Step 1 Open pau_seedpart_mm save it as ***_rack_1 where ***

represent your initials.

Step 2 Create a block 100 long by 3.75 high by 10 deep.

EDS Practical Applications of A-3

All Rights Reserved Unigraphics Workbook
 Additional Modeling Projects

ÉÉÉ Step 3 On layer 61, create a Center Datum Plane halfway along
ÉÉÉ the length of the block.

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A
ÉÉÉ This datum plane will be used to locate the central gear tooth.

Step 4 Create rounds with a radius of 5 at the four edges of the

part to completely round off the edge along the edge that
is 10 long.

Step 5 Create holes with a diameter of 5 through the part and

concentric with the rounded ends.

A-4 Practical Applications of EDS

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 Additional Modeling Projects

Step 6 Create a rectangular pad across the 10 width 2.5 high and
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2.5 wide, use a 12 degree taper from the bottom of the
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pad, and center it on the part.
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A
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Step 7 Create 9 instances of the pad along the top face in each
direction (total 17), 4.5 apart.

EDS Practical Applications of A-5

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 Additional Modeling Projects

ÉÉÉ Step 8 Create .75 radius rounds and fillets on the long edges of
ÉÉÉ each copy (all instances) of the pad.

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A
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Step 9 Save and close the part file.

A-6 Practical Applications of EDS

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 Additional Modeling Projects

Activity 2 - The Steering Rack Spur Gear ÉÉÉ

ÉÉÉ
To create this part you will have to apply the following functionality: cylinder,
boss, reference features, pocket, sketching, swept body, and instance array. ÉÉÉ
A
ÉÉÉ

Step 1 Open pau_seedpart_mm save it as ***_rack_spur_gear_1

where *** represent your initials.

Step 2 Create a Cylinder with a diameter of 5 and a height of 75.

EDS Practical Applications of A-7

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 Additional Modeling Projects

ÉÉÉ Step 3 On layer 61, create a Datum Plane Through the face axis
ÉÉÉ of the cylindrical face.

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A
ÉÉÉ This datum plane will be used as the placement face to create the notch on the
end of the shaft.

Step 4 Create a second datum plane through the axis of the

cylinder and at an angle of 905 to the first datum plane.

This plane will be used to center the notch.

Step 5 Create a 5 x 5 x 5 rectangular pocket on the top of the

datum plane to make a 5 unit long notch halfway through
the cylinder.

A-8 Practical Applications of EDS

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 Additional Modeling Projects

Step 6 Create a boss with a diameter of 15 and a height of 10 on

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the opposite end of the cylinder from the notch and make
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it concentric with the cylinder.
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A
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Step 7 Create a sketch named tooth on layer 21. Define the

attachment face and horizontal reference direction as
shown below.

Horizontal reference

Attachment face

EDS Practical Applications of A-9

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 Additional Modeling Projects

ÉÉÉ Step 8 Create the sketch geometry and constraints as shown

ÉÉÉ below.

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A
ÉÉÉ

Step 9 Extrude and Subtract the triangular shape to create a

groove.

This groove is the side of two gear teeth.

A-10 Practical Applications of EDS

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 Additional Modeling Projects

Step 10 Create a relative Datum Axis through the center of the

ÉÉÉ
cylinder.
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A
ÉÉÉ

Step 11 Create 10 copies of the extrusion around the Datum Axis

at an angle of 360/10.

EDS Practical Applications of A-11

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 Additional Modeling Projects

ÉÉÉ Step 12 Create fillets and rounds at the top and bottom of all of
ÉÉÉ the teeth with a radius of .75.

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A
ÉÉÉ

Step 13 Save and close the part file.

A-12 Practical Applications of EDS

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 Additional Modeling Projects

Activity 3 - Rear Wheel ÉÉÉ

ÉÉÉ
This activity will challenge you to select and apply the appropriate functionality
to create a parametric solid body of the rear wheel. ÉÉÉ
A
ÉÉÉ

Step 1 Open pau_seedpart_mm save it as ***_rear_wheel_1

where *** represent your initials.

Step 2 Create a model of the rear wheel based on the drawing

attached.

Step 3 Save and close the part file.

EDS Practical Applications of A-13

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 Additional Modeling Projects

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A
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A-14 Practical Applications of EDS

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 Additional Drafting Projects

Additional Drafting Projects

Appendix B

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B
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EDS Practical Applications of B-1

All Rights Reserved Unigraphics Workbook
 Additional Drafting Projects

Activity 1 - Rear Drive Gear

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B
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B-2 Practical Applications of EDS

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Unigraphics Workbook
 Additional Drafting Projects

Step 1 Create a Master Model assembly called

***_rear_drive_gear_dwg to facilitate drafting of the
pau_rear_drive_gear_1 part as shown below. The drawing
is A3 size, the scale is 4/1.

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Step 2 Save and Close the part file.

EDS Practical Applications of B-3

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 Additional Drafting Projects

Activity 2 - Steering Rack

Create the drawing of the steering rack.

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B
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B-4 Practical Applications of EDS

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 Additional Drafting Projects

Step 1 Create a Master Model assembly called ***_rack_dwg to

facilitate drafting of the pau_rack_1 part as shown below.
The drawing is A3 size, the scale is 2/1.

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Step 2 Save and close the part.

EDS Practical Applications of B-5

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 Additional Drafting Projects

Activity 3 - Spur Gear

Complete the drawing for the rack spur gear.

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B
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B-6 Practical Applications of EDS

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 Additional Drafting Projects

Step 1 Create a Master Model assembly called

***_rack_spur_gear_dwg to facilitate drafting of the
pau_rack_spur_gear_1 part as shown below. The drawing
is A3 size, the scale is 2/1.

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B
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Step 2 Save and close the part.

EDS Practical Applications of B-7

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 Additional Drafting Projects

Activity 4 - The Power Pack

Complete the drawing for the power pack.

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B
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B-8 Practical Applications of EDS

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 Additional Drafting Projects

Step 1 Create a Master Model assembly called

***_power_pack_dwg to facilitate drafting of the
pau_power_pack_1 part as shown below. The drawing is
A3 size, the scale is 1/1.

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B
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Step 2 Save and close the part.

EDS Practical Applications of B-9

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 Additional Drafting Projects

Activity 5 - Rear Wheel

Complete the drawing for the rear wheel.

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B
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B-10 Practical Applications of EDS

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 Additional Drafting Projects

Step 1 Create a Master Model assembly called

***_rear_wheel_1_dwg to facilitate drafting of the
pau_rear_wheel_1 part as shown on the next page. The
drawing is A3 size, the scale is 1/1.

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B
ÉÉÉ

Step 2 Save and close the part.

EDS Practical Applications of B-11

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 Additional Drafting Projects

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B
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B-12 Practical Applications of EDS

All Rights Reserved
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