Project 18: Modeling a Blower

In this project you will create the impeller (blower) for a positive displacement pump (a supercharger for an
engine). This will be a "serpentine" type of blower.
Prerequisites

To model this part you must be able to:

Create basic curves.

Create sketches.

Create sketch curves.

Constrain sketch curves.

Modify expressions
 Create extruded swept features.

The Methods Used in This Project to Model the Part

In this project you will:

Create curves that will define specific sections of a profile of the blower.

Bring these curves into a sketch.

Constrain the sketch curves geometrically and dimensionally.

Create a helix near the sketch that will be used to guide the extrusion of the sketch curves.
 Sweep the sketch curves to form the blower.

Add a circle to the sketch, then extrude it to create a shaft through the blower.

Task 1. Open a Standard Metric Part File

Open the standard metric part file, standard_mm, from the project sub-directory.

If you want, you can save this part file in your own directory using a name such as blower.

The standard part file uses the following layer standards:

? Solid geometry on layers 1 through 20.

? Sketch geometry on layers 21 to 40
? Curve geometry on layers 41 to 60
? Reference geometry on layers 61 to 80
? Sheet bodies on layers 81 to 100
? Drafting objects on layers 101 to 120

Start the Modeling application.

Task 2. Planning the Development of the Profile of the Blower

You could create the curves you need as sketch curves. But you would like to have the system create a 3
curve fillet using two circles and a line connecting their arc centers.

So you decide to begin by creating regular curves. Then, when you are ready to begin constraining them,
you will bring them into a sketch

Task 3. Create the First Circle

You can begin by creating circles that will eventually define the three lobes of the profile of the blower.

Replace the view with a TOP view.

You would like to have these curves on a layer reserved for curves.

Make layer 41 the work layer.

Create a circle on the XC-YC plane.

- Place it a little above the WCS.

? Choose the Curves icon from the Curve toolbar or

? choose InsertCurvesBasic Curves.
? Choose the Circle icon on the Basic Curves dialog.
? Use the Infer point method.
? Indicate a point a little above the WCS.
? Watch the diameter field as you indicate a location that will
? define the circumference of the circle.

Task 4. Create Two More Circles

Create two more circles with the same diameter as the first.
- Place them at locations that define the apexes of a rough equilateral triangle.
On the Basic Curves dialog, turn the Multiple Positions option on.

Indicate two locations that will create a triangular arrangement

Task 5. Create Lines Between the Centers of the Circles

In order to define the distance between the arc centers of these three circles in the sketch, you can add
straight lines between them.

Create three lines between the arc centers of the circles.

? Choose the Line icon on the Basic Curves dialog.

? You can use the string mode.
? Change the point method to Arc/Ellipse/Sphere Center.
? Select each circle in turn, then break the string.
Task 6. Create a 3 Curve Fillet

Your next step is to define the shape of the blower profile between the lobes.

For this part you can use an arc that is tangent to two circles and the straight line between their arc centers.

When you construct this curve, however, you don't want the system to trim any of the curves you select.
(You'll trim them later yourself.)

Create a 3 curve fillet between these objects.

- Be sure that no curves will be trimmed by this procedure.
- Be sure the fillet you are creating will be tangent to the outside of the two circles.
- HINT: Work in a counterclockwise direction.

? Choose the Fillet icon on the Basic Curves dialog.

? Choose 3 Curve Filet icon on the Curve Fillet dialog.
? Turn the three trim options off.
? For the first object, select the lower left hand circle.
? Choose Tangent Outside on the dialog.
? For the second object, select the straight line between the two
? circles.
? For the third object, select the top circle.
? Choose Tangent Outside on the dialog.
? For the approximate fillet center, indicate to the left of the line
? between the two circles.

Task 7. Create Two More 3 Curve Fillets

Use the same method to create the same type of fillet between the other circles.
Task 8. Trim the Curves

To complete the profile of the blower, you need to change the circles
into arcs.

Trim the top circle.

- You won't want to reuse bounding objects.

Choose Back on the Curve Fillet dialog.

Choose the Trim icon on the Basic Curves dialog.
Be sure the selection step is set to First Bounding Object.
Turn off Reuse Bounding Objects.

? For the first trim boundary, select the left fillet.

? Be sure the selection step has changed to Second Bounding
? Object.
? For the second trim boundary, select the right fillet.
? Be sure the selection step has changed to String to Trim.
? Select the part of the circle you want to throw away.

Task 9. Trim the Other Circles

Use the same method to trim the other circles.

Task 10. Create a Sketch

You have created enough curves for your sketch.

You would like to have the sketch on a layer reserved for sketches.

Make layer 21 the work layer.

Create a sketch on the XC-YC plane.

- You can use the default sketch name.

? Choose the Sketch icon from the Curve toolbar or choose

? InsertSketch.
? Choose the Create icon on the Create Sketch dialog.
? Be sure the Sketch Plane is set to XC-YC.
? Use the system supplied sketch name.
? OK the Create Sketch dialog.

Task 11. Add All the Curve to the Sketch

You are ready to convert all the curves you have created into sketch curves.

You'll remember that when they are converted, they will be removed from layer 41 and placed onto layer
21.
 Add all the curves to the sketch.

? Choose the Add Objects to Sketch icon on the Sketch

? Tools dialog.
? Choose Select All on the Add Curves dialog.
? OK the dialog.
? Be sure all the curves are now displayed in cyan (light blue).

Task 12. Move the Datum Geometry

You won't need the datum geometry for awhile, so you can move it to a layer reserved for reference
geometry.

Move the datum plane and the two datum axes to layer 61.

? Choose the Move To Layer icon or choose

? FormatMove To Layer
? On the Class Selection dialog, choose Type.
? On the Select By Type dialog, choose Datums.
? OK the dialog.
? On the Class Selection dialog, choose Select All.
? OK the dialog.
? In the Destination field, key in 61.
? OK the dialog.

Task 13. Constrain the Three Arcs That Define the Lobes

You want to constrain these curves until the profile is symmetrical.

You can begin with the outer arcs (the outside lobes of the impeller).

Constrain the three outer (smaller) arcs to be the same size.

? Choose the Constraints icon on the Sketch Tools dialog.
? Choose the Geometric icon on the Constraints dialog.
? Select the three outer arcs.
? Choose the Equal Radius constraint.
? Apply this constraint.

Task 14. Constrain the Three Arcs Between the Lobes

Constrain the three inner (larger) arcs to be the same size.

Task 15. Constrain the Arcs to be Tangent

Before you add dimensional constraints, you want to be sure that the meetings between the ends of all the
arcs will remain tangent.

Constrain each pair of arcs that are connected to be tangent.

- You'll need to apply six constrains.
- The sketch curves won't change much because of the way you created them in the first place.

? Select an arc.
? Select the arc that it is connected to.
? Choose the Tangent constraint.
? Apply this constraint.
Task 16. Add a Curve Within the Triangle

There is a curve you can add at this time that will help you control the position and orientation of these
curves after you convert them all into sketch curves.

Create a line from the arc center of the top arc to the midpoint of the horizontal line.
- Be sure you select the midpoint of the horizontal line (not the arc).
- The line will probably only be near the vertical.

? Choose the Basic Curves icon on the Sketch Tools

? dialog.
? Be sure the Line icon is active on the Basic Curves dialog.
? Use the Infer point method.
? Optional: Turn off the String Mode.
? Select the arc center of the top arc.
? Select the midpoint of the horizontal line.
? If you need to, break the string.

Task 17. Constrain the Horizontal Line

Constrain the straight line between the two lower arcs to be horizontal.

? Choose the Constraints icon on the Sketch Tools dialog.

? Choose the Geometric icon on the Constraints dialog.
? Select the horizontal line.
? Choose the Horizontal constraint.
? Apply this constraint.

Task 18. Constrain the Vertical Line

Constrain the straight line between the top arc and midpoint of the horizontal line be vertical.

? Select the vertical line.

? Choose the Vertical constraint.
? Apply this constraint.

Task 19. Constrain the End of the Vertical Line

Constrain the lower end of the vertical line to remain attached to the midpoint of the lower horizontal line
and to always remain on the lower line.

? Select the lower endpoint of the vertical line.

? Select the lower horizontal line.
? Choose the Point On Curve and Midpoint constraints (use
? Shift+Select).

? Apply this constraint.

Task 20. Constrain the Three Straight Lines

When you apply a dimensional constraint to one of the lines between the arc centers, you will want the
similar lines to have the same value.

Constrain the three straight lines to have equal length.

? Select each straight line.

? Choose the Equal Length constraint.
? Apply this constraint.

Task 21. Constrain the Location of the Sketch Curves on the Datum Plane

To fully constrain the sketch, you will need to add some dimensional constraints. Before that, however, you
can constraint these curves to a specific position on the datum plane.

You will need to be able to select the datum axes.

Make the datum geometry on layer 61 selectable.

Constrain the horizontal line to be colinear with the horizontal datum axis.
- Then constrain the vertical line to be colinear with the vertical datum axis.
? Select the horizontal datum axis.
? Select the horizontal line.
? Choose Colinear.
? Apply this constraint.

Task 22. Constrain the Distance Between the Arc Centers of the Lobes

The geometric constraints you have added have made the profile of the blower symmetrical.

So you are ready to being applying specific values to the profile.

You can begin with the distance between the arc centers of the lobes.

Constrain the lower horizontal line to the required value.

? Choose the Dimensional icon.

? Use the Infer method.
? Select the lower horizontal line.
? Key in the required dimension value.

Task 23. Constrain the Size of the Arcs That Define a Lobes
You can constrain the radius of the lobes.

Constrain the radius one of the "lobe" arcs.

? Select an outer arc.

? Key in the required dimension value.

Task 24. Constrain the Size of the Inner Arcs

Finally, you can constrain the radius of the inner curve between the lobes.

Constrain the radius one of the "inner" arcs.

? Choose the Dimensional icon.

? Select an outer arc.
? Key in the required dimension value.

Task 25. Create Another Reference Curve

With this last dimensional constraint, the sketch should now be fully constrained (no more DOFs
displayed).
Later, when you create the helix, you will need to be able to find the exact center of this profile.

One way to do this is to add one more line across the vertical line (then you can use the intersection of
these two lines to define the center of the profile).

Create a line between the arc center of the right arc and the midpoint of the left angled line.

? Choose the Basic Curves icon on the Sketch Tools

? dialog.
? Be sure the Line icon is active on the Basic Curves dialog.
? Use the Infer point method.
? Optional: Turn off the String Mode.
? Select the arc center of the right arc.
? Select the midpoint of the angled straight line on the left side of
? the sketch.
? If you need to, break the string.

Task 26. Change Various Curves into Reference Curves

When you sweep the sketch curves to create the blower solid, you'll want only the profile curves to be
included.

Convert all straight geometry into reference curves.

? Choose the Convert To/From Reference icon on the
? Sketch Tools dialog.
? Select all of the straight lines.
? OK the Convert To/From Reference dialog.

Task 27. Prepare to Create a Helix

Your next task will be to create the helix curves that you will use when you sweep the sketch curves.

You know that you can use the WCS do define the placement and direction of the helix, so you will want it
to be in the center of the blower profile.

Deactivate the sketch.

Replace the view with a trimetric view.

Change the display to Invisible Hidden Edges.

Reorient the WCS to the center of the profile (where the two reference curves cross each other).

? Choose the WCS Origin icon from the WCS toolbar or

? choose WCSOrigin.
? Choose the Intersection Point icon on the Point
? Constructor dialog.
? Select the vertical line and the line that crosses it.
? OK the dialog.
Task 28. Create a Helix

You are ready to create the two helixes that you will need to correctly guide the sketch curves as you create
the serpentine blower solid.

For this part, you will want the helix to turn once in 600 mm (which is the "pitch" value, the length between
turns). But this part only requires you to sweep a half turn.

If you use the default, the system will project the direction of the sweep along the positive ZC.

It will also use 0,0,0 as the center of the radius value and start the bottom of the helix along the XC axis.

Create the helix.

- Sweep just one half turn.
- Sweep one turn per 600 mm.
- Use the Radius method for placing the origin of the helix.
- Place the origin of the helix 100 mm away from the 0,0,0 of the WCS.
- You will want the helix to twist upward in a right hand direction.

? Choose the Helix icon on the Curve toolbar or choose

? InsertCurveHelix.
? In the Number of Turns field on the Helix dialog, key in 0.5.
? In the Pitch field, key in 600.
? Be sure the Radius method is set to Enter Radius.
? In the Radius field, key in 100.
? OK the dialog.

Task 29. Rename the Expressions that Control the Helix

Since you expect to change the values that control the size and shape of the helix (in order to change the
shape of the blower solid), you can set up some names for the helix expressions now.

The first three expressions are the dimensional constraints on the sketch curves.

The next three are the expressions that control the shape of the helix.

Remember:

The value for the number of turns is 0.5.

The value for the pitch is 600 mm.
The value for the radius is 100 mm.

Change the name of the number of turns expression, the pitch expression, and the radius expression.
- For the first expression you change, use the string num_of_turns (no spaces).

? Choose InsertExpression.
? Choose the expression for the number of turns for the second
? helix (probably p3).
? Choose the Rename icon.
? In the Rename dialog, replace the current name with
? num_of_turns (no spaces!).
? Change the name the expression that controls the pitch (probably
? p4) to pitch.
? Change the name the expression that controls the radius
? (probably p5) to radius.

Task 30. Prepare to Create a Second Helix That Matches the First

You need a second helix that matches this first helix so that you will have more control for the swept
surface.

One way to do this is to reorient the WCS, then use exactly the same values on the Helix dialog you used
before.

Rotate the WCS 180 degrees around its ZC axis.

? Choose the Rotate WCS icon from the WCS toolbar or
? choose WCSRotate.
? Be sure the positive ZC option is on.
? In the Angle field, key in 180.
? OK the dialog.

Task 31. Create a Second Helix

You want this helix to exactly match the first (like two guide rails for the system to follow as it creates the
swept feature).

Create the second helix using exactly the same values as you did for the first helix.
- Number of Turns is 0.5.
- Pitch is 600 mm.
- Radius is 100 mm.

Task 32. Associate the Second Helix to the First

When you adjust the parameter values of the first helix (the one you changed the names on), you want the
second helix to exactly match your changes.

This means you must associate the second helix with the first.

A good way to do this is to make the expression values that define the second helix equal to the expression
names for the first helix.

Remember:
? The value for the number of turns is 0.5.
? The value for the pitch is 600 mm.
? The value for the radius is 100 mm.

Use the Edit Expressions dialog to associate the appropriate expression of the second helix with those of
the first helix.

? Choose InsertExpression.
? Choose the expression for the number of turns for the second
? helix (probably p6).
? Backspace out the value.
? Select the expression called num_of_turns.
? Be sure the cursor is at the right end of the letters, then press Enter.
? Do the same thing for the pitch expression and the radius expression.

Task 33. Sweep the Sketch Curves

You are ready to sweep the sketch curves upward with the two helixes guiding their orientation.

You'll need to use a procedure that will allow you to select two guidelines, in other words, a free form
feature.

You will want the solid to be on a layer reserved for solids.

Change the work layer to layer 1.

Sweep the sketch curves using the two helixes to guide the direction and turning of the sweep.
- Use the alignment parameter method.
- Use the default tolerance.
- Scale the swept feature latterly.
- You won't need to define a spine.

? Choose the Swept icon from the Free Form Feature

? toolbar or choose InsertFree Form Feature Swept.
? For the first guide string, select the right helix (select it at its
? bottom).
? OK the dialog.
? For the second guide string, select the second helix (again, near
? its bottom).
? OK the dialog.
? Since you don't need to define a third guide string, just OK the
? dialog.
? For the section string, select any sketch curve.
? OK the dialog two times.
? On the Swept dialog, be sure you will use the Parameter
? alignment method.
? OK the dialog.
? Choose the default, Scale Laterally.
? You don't need to define a spine string, so just OK the dialog.
? Change the display to Shaded.

Task 34. Clean Up the Display

Make layers 21 (the sketch curves and helixes) and 61 (the datum geometry) invisible.

Change the display to Shaded.

Task 35. Prepare to Add a Circle to the Sketch

You need to add a shaft to the top and bottom of the blower.
One way to do this is to extrude a cylindrical solid through the part.

If you extrude a sketch curve, you will be able to define the diameter of the shaft whenever you change the
shape of the blower profile.

You would like to look straight down onto the sketch when you activate it. Also, you don't want to see the
solid while you work on the sketch.

Change the display to Invisible Hidden Edges.

Activate the sketch.

? Choose the Sketch icon.

? On the Sketch Tools dialog, turn the Change View Orientation
? option on.
? Double-click on SKETCH-000.

Task 36. Add a Circle to the Sketch

Create a circle within the boarders of the profile.

- Place its arc center near the center of the profile.

? Choose the Basic Curves icon on the Sketch Tools

? dialog.
? Choose the Circle icon.
? Set the point method to Intersection.
? Select the two straight lines that intersect the center of the profile.
? Use the Diameter field to define the diameter of the circle.
? Cancel the Basic Curves dialog.

Task 37. Constrain the Circle to the Center of the Profile

 Constrain the arc center of the circle first to always remain on the angled reference curve that passes
through it. (HINT: Get in close!)
- Then constrain the arc center to always remain on the vertical
reference curve.

1. Choose the Constraints icon on the Sketch Tools dialog.

2. Choose the Geometric icon on the Constraints dialog.
3. Select the arc centerpoint of the circle.
4. Select the angled reference curve.
5. Choose the Point on Curve constraint.
6. Apply the constraint.
7. Select the arc centerpoint of the circle again.
8. Select the vertical reference curve.
9. Choose the Point on Curve constraint.
10. Apply the constraint.

Task 38. Constrain the Diameter of the Circle

Constrain the size of the circle.

- Deactivate the sketch when you are through.

? Choose the Dimensional icon on the Constraints dialog.

? Select the circle.
? Indicate a good location for the constraint.
? Key in the required value for this constraint.
? Deactivate the sketch.

Task 39. Extrude the Circle to Create the Shaft

Now that you have the shape you need, you can extrude the sketch circle to create the shaft.

Extrude the sketch circle.

- Be sure to select only the circle!

? Choose the Extruded Body icon or choose

? InsertForm FeatureExtrude.
? On the Extruded Body dialog, choose Curve.
? Select just the sketch circle.
? OK the dialog two times.
? Use the Direction_Distance extrusion method.
? If the direction arrow points upward, OK the Vector Dialog.
? Use a start distance of -40 mm.
? Use an end distance of 340 mm.

This completes the lesson