# Module 1H: Creating an Ellipse-Based Cylindrical Sheet-metal Lateral Piece

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1 Inventor (10) Module 1H: 1H- 1 Module 1H: Creating an Ellipse-Based Cylindrical Sheet-metal Lateral Piece In this Module, we will learn how to create an ellipse-based cylindrical sheetmetal lateral piece with the Contour Flange tool. The Contour Flange tool can create sheet-metal lateral pieces that are developable by the Flat Pattern tool if the Sketch features contain open profile made up of straight line or circular arcs created with the Line or Center Point Circle tools; if the profile is made up of curved line or elliptical arcs created with the Spline or Ellipse tools, the Contour Flange tool can still be used to create the Contour Flange 3D feature, however, the Flat Pattern tool will not be able to generate the Flat Pattern view; instead, if will give the error message shown if Figure 1H-1A. Therefore, a work-around method will be explored to create an ellipse-based cylindrical sheet-metal lateral piece. In traditional geometry construction, a fairly accurate approximation of ellipse can be drawn by combining two sets of circular arcs (we can call this approximation method arcs combination method ), as shown in Figure 1H-1B, since the Contour Flange features are developable by the Flat Pattern tool if the Sketch features contain open profile made up of circular arcs created with the Line or Center Point Circle tools, we will use this work-around method to create an ellipse-based cylindrical sheet-metal lateral piece and its Flat Pattern view. An ellipse can be considered as a circle rotated to a certain angle (Figure 1H-1C); the diameter of the circle that is parallel to the axis of rotation becomes the major axis (also called major axis; in some textbook, half of the major diameter is also called major radius ) of the ellipse; and the foreshortened diameter that is perpendicular to the axis of rotation is the minor diameter (also called minor axis; in some textbook, half of the minor diameter is also called minor radius ).

2 Inventor (10) Module 1H: 1H- 2 Figure 1H-1A: The error message occurring when the Flat Pattern tool tries to develop an elliptical arc-based cylindrical surface. In this Module, we will create cylindrical sheet-metal lateral piece with a 36-inch major diameter (18-in major radius) and 18-inch minor diameter (9-inch minor radius) elliptical base. Figure 1H-1B: The fairly accurate approximation of ellipse drawn by combining two sets of circular arcs (the arcs combination method ).

3 Inventor (10) Module 1H: 1H- 3 Figure 1H-1C: The relationship between a circle and an ellipse. Step 1: Construct the elliptical base profile with the arcs combination method First, we will create a sheet metal file with inch as units. Launch Autodesk Inventor. Create a new sheet metal file (go to the menu File New, or click on the New icon on Standard Tool Bar. The Open window appears. Select the English tab; then select the Sheet Metal (In).ipt template, click OK button (Figure 1H-2A). Figure 1H-2A: Starting a new Sheet Metal (In).ipt file. Figure 1H-2B: Dismissing the default Sketch1 by clicking the Return button.

4 Inventor (10) Module 1H: 1H- 4 Figure 1H-2C: Deleting the default Sketch1. Figure IH-2D: Switching to Isometric View. Figure IH-2E: Turning on the Visibility option.

5 Inventor (10) Module 1H: 1H- 5 Figure IH-2F: Starting a new Sketch. A new sheet metal file opens with two panels docked on the left side of the screen: 2D Sketch (top) and Model (bottom). The Sketch1 opens automatically on the screen; and Sketch1 feature appears on the Model panel. Click the Return key in the Inventor Standard tool bar (Figure 1H-2B) to dismiss the Sketch1 feature. In the Model panel, click the cross on the left of the Origin folder to view the Planes, Axis and Center Point features; click-select the Sketch1 feature and right-click for the shortcut menu and choose the Delete option to delete it (Figure 1H-2C). Next, go to the View Isometric menu to switch to an isometric view (Figure IH-2D). Next, select the XZ Plane, then right-click to open the short cut menu and check the Visibility option (Figure 1H-2E). Next, click-select the XZ Plane and then the Sketch button on the Inventor Standard tool bar to start a new sketch (Figure 1H-2F); Sketch2 feature appears in the Model panel; highlight the Sketch2 name and type Base Profile to rename the feature. Next, click-select the XZ Plane and then the Look At tool button in the Inventor Standard tool bar (Figure IH-2G, left) to switch to an orthographic normal view (Figure 1H-2G, right). Now, we are ready to start the elliptical base profile. Click-select the Project Geometry tool from the 2D Sketch tool panel and then the Center Point from the Model panel to project it onto the Base Profile Sketch; a green dot appears on the center of the Base Profile Sketch; next, select the Line tool from the 2D Sketch tool panel and create two horizontal major radius lines and two vertical minor radius lines, all from the projected Center Point, right-clicking for the shortcut menu and choose the Restart option each time one line is created to create the subsequent line (Figure IH-3A); next, select the General Dimensions tool to apply an 18-inch linear horizontal dimension to both horizontal lines, and a 9-inch linear vertical dimension to the vertical lines (Figure IH-3B); next, select the Center Point Circle tool,

6 Inventor (10) Module 1H: 1H- 6 move the cursor closer to the projected Center Point, click once when the green dot snap indicator appears to establish the center point of the circle, and then move the cursor to the left endpoint of the left horizontal line (point A ), click once when the green dot snap indicator appears to establish the radius of the circle (the large construction circle; see Figure IH-3C). Figure IH-2G: Selecting the XZ Plane and clicking the Look At tool button (left); switching to an orthographic normal view (right). Figure IH-3A: Using the Line tool to draw two vertical lines and two horizontal lines.

7 Inventor (10) Module 1H: 1H- 7 Figure IH-3B: Applying linear dimensions. Next, use the Line tool to create the inclined line segment BC connecting the right endpoint of the right horizontal major radius line and the top endpoint of the top vertical minor radius line (Figure IH-3D); then create the vertical line starting at point B upward beyond the construction circle (the vertical construction line; Figure IH- 3E). Next, use the Trim tool to trim off excessive line segment beyond the construction circle (Figure IH-3F). Next, use the Center Point Circle tool to create the small construction circle (Figure 1H-3G) centered at point B (the top endpoint of the top minor radius line) and with the radius established at point D (the top endpoint of the vertical construction line ); this small construction circle intersect the inclined line BC at point E. Figure IH-3C: Creating the large construction circle with the radius established at point A. Figure IH-3D: Creating the inclined line segment BC.

8 Inventor (10) Module 1H: 1H- 8 Figure IH-3E: Creating the vertical construction line. Figure IH-3F: Trimming off the excessive line segment beyond the construction circle. Figure 1H-3G: Creating the small construction circle. Figure 1H-3H: Trimming off line segment BE.

9 Inventor (10) Module 1H: 1H- 9 Figure 1H-3J: The green dot midpoint snap indicator. Figure 1H-3K: Creating the perpendicular bisector line of the inclined line BC. Next, use the Trim tool to trim off line segment BE as shown in Figure 1H-3H. Next, select the Line tool, move the cursor to the midpoint M and click once at the appearance of the green dot midpoint snap indicator (Figure 1H-3J), move away downward and leftward beyond the bottom vertical minor radius line and click once at the appearance of the perpendicular constraint indicator ( symbol inside the red circle, as shown in Figure 1H-3K); this is the perpendicular bisector line of the inclined line BC. Next, use the Line tool to create the vertical line starting at the bottom endpoint of the bottom minor radius line and intersecting the perpendicular bisector line (the extension line; as shown in Figure 1H-3L). Next, use the trim tool to trim off the excessive line segments beyond the point of intersection (Figure 1H-3M and Figure 1H-3N).

10 Inventor (10) Module 1H: 1H- 10 Figure 1H-3L: Creating the vertical line. Figure 1H-3M: Trimming off the excessive line segment. Next, select the Mirror tool; click the Select button in the tool s dialog window and then click-select the perpendicular bisector line; click the Mirror Line button in the tool s dialog window and then click-select the top minor radius line (Figure 1H- 3P); click the OK button in the tool s dialog window to create the mirrored line (Figure 1H-3Q). Use the Mirror tool again; click the Select button in the tool s dialog window and then click-select the mirrored line and the extension line; click the Mirror Line button in the tool s dialog window and then click-select the left major radius line (Figure 1H-3R); click the OK button in the tool s dialog window to create the mirrored lines (Figure 1H-3S). Next, window-select all of the lines drawn so far and click the Construction tool button in the Inventor Standard tool bar to change the line Style to Construction (Figure 1H-3T).

11 Inventor (10) Module 1H: 1H- 11 Figure 1H-3N: Trimming off the excessive line segment. Figure 1H-3P: The Mirror tool s dialog window. Figure 1H-3Q: Creating the mirrored line of the perpendicular bisector line on the left side of the top minor radius line. Figure 1H-3R: Selecting the lines to be mirrored and the Mirror line.

12 Inventor (10) Module 1H: 1H- 12 Figure 1H-3S: Creating the mirrored lines. Figure 1H-3T: Changing the line Style to Construction. Next, select the Trim tool to trim off excessive line segments (Figure 1H-3U to Figure 1H-3W) and to leave a clean set of construction lines (Figure 1H-3X).

13 Inventor (10) Module 1H: 1H- 13 Figure 1H-3U: Trimming off excessive line segments. Figure 1H-3V: Trimming off excessive line segments. Figure 1H-3W: Trimming off excessive line segments. Figure 1H-3W: Leaving a clean set of construction lines.

14 Inventor (10) Module 1H: 1H- 14 Figure 1H-4A: The large circles. Figure 1H-4B: The small circles. Next, select the Center Point Circle tool to create a circle centered at the point F and with the radius established at the point G, and another circle centered at the point H and with the radius established at the point I (the large circles; as shown in Figure 1H- 4A). Next, use the Center Point Circle tool again to create two circles centered at the points J and K (the small circles; as shown in Figure 1H-4B). Next, select the Tangent tool, click-select one of the large circles and then one of the small circles to enlarge the size of the small circle so that it becomes tangent to both large circles (Figure 1H-4C); repeat the some process for another small circle (Figure 1H-4D).

15 Inventor (10) Module 1H: 1H- 15 Figure 1H-4C: Enlarging the small circle to tangency with the two large circles. Figure 1H-4D: Enlarging the other small circle to tangency with the two large circles. Next, select the Trim tool to trim off the excessive arc segments of large circles and small circles (Figure 1H-4E through Figure 1H-4G), so as to leave the approximate elliptical profile, and use the Zoom Window tool to zoom in the red circled area, as shown in Figure 1H-4H. Next, create a tiny gap in the closed approximate elliptical profile so that the Flat pattern tool can generate the Flat Pattern view after the Contour Flange lateral piece is created; use the Center Point Circle tool to create a small circle centered at the left endpoint of the left major radius line, and use the General Geometry tool to apply an diameter dimension of inch (Figure 1H-4J); use the Zoom Window tool to zoom in several times if needed.

16 Inventor (10) Module 1H: 1H- 16 Figure 1H-4E: Trimming off the excessive arc segments of large circles. Figure 1H-4F: Trimming off the excessive arc segments of large circles. Figure 1H-4G: The excessive arc segments of the small circles to be trimmed off. Figure 1H-4H: The approximate elliptical profile.

17 Inventor (10) Module 1H: 1H- 17 Next, select the Trim tool to trim off the tiny segment of arc as shown in Figure 1H-4K; right-click for the shortcut menu and choose the Done option to exit the Trim tool (Figure 1H-4L)ext, click-select the tiny construction circle and press the Delete key on the keyboard to delete it (Figure 1H-4M). Next, click the Return button on the Inventor Standard tool bar; go to the View Isometric menu to switch to an isometric view (Figure 1H-4N). In the Model panel, select the Sketch1 feature, highlight the name and retype Base Profile to rename it. Now, start saving the file. Press Ctrl and s keys simultaneously to save the file as Tut-Elliptical Cylinder.ipt with Part File (*ipt) for Save As Type field, in a convenient directory location, in a new folder to be created and named Tut-Eliptical Cylinder in the Save As window in a convenient directory location (Figure 1H-4P). Save often, at least at the end of each step. Figure 1H-4J: Creating the tiny construction circle for the gap. Figure 1H-4K: Trimming a small gap.

18 Inventor (10) Module 1H: 1H- 18 Figure 1H-4L: Exiting the Trim tool. Figure 1H-4M: Deleting the tiny construction circle. Figure 1H-4N: Switching to an isometric view.

19 Inventor (10) Module 1H: 1H- 19 Figure 1H-4P: Saving the file. Step 2: Create the elliptical-based cylinder with the Contour Flange tool Next, switch to the Sheet Metal Features tool bar and select the Contour Flange tool; click the Profile button in the Contour Flange tool s dialog window and clickselect the elliptical profile from the screen; type 24 in in the Distance text field (Figure 1H-5A); the green outlines of the Contour Flange feature appears on the screen; use the Zoom Window tool to zoom in the leftmost area and click the Offset button in the Contour Flange tool s dialog window until the green outline of the Contour Flange feature indicates that it is projected inwardly (Figure 1H-5B); click the OK button to create the Contour Flange feature and rename it Elliptical Cylinder in the Model panel.

20 Inventor (10) Module 1H: 1H- 20 Figure 1H-5A: Selecting the elliptical profile and typing the Distance value.

21 Inventor (10) Module 1H: 1H- 21 Figure 1H-5B: Zooming in the leftmost area and clicking the Offset button in the Contour Flange tool s dialog window until the green outline of the Contour Flange feature indicates that it is projected inwardly. Step 3: Truncate the elliptical cylinder Next, select the XY Plane feature from the Model panel (Figure 1H-5C) and click the Sketch button from the Inventor Standard tool bar to start a new Sketch feature; rename the Sketch feature as Truncation Profile in the Model panel; click the Look At button in the Inventor Standard tool bar and then the to switch the Truncation Profile to an orthographic normal view. Next, select the Project Geometry button and click the top horizontal edge of the cylindrical piece (Figure 1H-5D); select the projected line and click the Construction tool and change its line Style. Next, select the Center Point Circle tool to create a circle centered at the midpoint of the projected top horizontal edge line; and use the General Dimension tool to apply a 18-inch diameter dimension to the circle. Click the Return button to finish the sketch.

22 Inventor (10) Module 1H: 1H- 22 Figure 1H-5C: Select the XY Plane feature from the Model panel to start a new Sketch. Figure 1H-5D: Switching to an orthographic normal view with the Look At tool and projecting the top horizontal edge with Project Geometry tool. Figure 1H-5E: Changing the line Style to Construction. Figure 1H-5F: Starting to create a circle with the help of the midpoint snap indicator. Next, switch to the Part Features tool panel by clicking the downward-pointing triangle to open up a pull-down list and to select the option (Figure 1H-5H); select the Extrude tool, in the tool s dialog window, select the Cut option for Type and Midplane

23 Inventor (10) Module 1H: 1H- 23 option for Direction (red circled); click the Profile button and click-select the circular profile; select the All option from the Extents pull-down menu; click the OK button to create the Extrude feature (Figure 1H-5J) and rename it as Truncation in the Model panel. Figure 1H-5G: Creating and dimensioning the circle. Figure 1H-5H: Switch to the Part Features tool panel. Figure 1H-5J: Creating the Extrude Cut feature. Next, switch to the Sheet Metal Features (Figure 1H-5K); click-select the frontal outer surface of the lateral piece (Figure 1H-5L) and click the Flat Pattern tool button to create the Flat Pattern view (Figure 1H-6A). If desirable, apple a colorful material

24 Inventor (10) Module 1H: 1H- 24 rendering by selecting a material type from the pull-down menu on the Inventor Standard tool bar (Figure 1H-6B); the Flat Pattern view automatically updates (Figure 1H-6C). Figure 1H-5K: Switching to the Sheet Metal Features. Figure 1H-5L: Selecting the frontal outer surface of the truncated elliptical cylinder for Flat Pattern view generation. Figure 1H-6A: The Flat Pattern view. Figure 1H-6B: Applying an Aluminum (Polished) material rendering.

25 Inventor (10) Module 1H: 1H- 25 Figure 1H-6C (left): The Flat Pattern view automatically updating to the assigned material rendering. Figure 1H-6D (right): The Model panel feature list. Congratulations! In this Module, you have learned how to create a truncated elliptical cylinder sheet-metal part and its Flat Pattern view.

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