TOY TRUCK Prepared by: Harry Hawkins The following project is of a small, wooden toy truck. This exercise will provide you with the procedure for constructing the various parts of the design then assembling them into the final unit. Directions for creating an album of this project are also included. You will use a variety of Pro/D tools such as extrude, revolve and others. The orthographic drawing for this project is shown in figure 1. Figure 1. Orthographic projections of project. Figure 2 shows the dimensions for the Truck Cab and figure 3 shows the dimensions for the dump bed. Figure 4 shows the dimensions for the wheels, axel and undercarriage.
These drawings are also located at the end of this tutorial. You will need to refer to them for accurate numerical information while you construct each part. 0.125 0.0730 0.375 0.1875 Ø0.5210 Headlight Detail 2.750 2.085 72 R0.375 All not marked 2.500 1/2 Button Ø0.521 Ø0.375 4.500 R1.250 1.250 0.125 2.750 0.750 1.500 0.750 0.625 5.000 Truck Cab Figure 2. Truck Cab dimensions. 0.750 5.381 0.500 4.500 4.000 1.500 1.500 0.500 1.986 0.667 R0.125 Typical 0.750 5.631 0.250 Dump Bed 39 5.381 R0.125 0.712 1.064 2.229 141 1.415 1.500 1.165 2.391 1.500 72 0.125 0.500 Ø0.281 0.375 0.500 - Figure 3. Dump bed dimensions. Harry Hawkins 2005 Page 2
Axel (Rear) 4.630 4.500 1.500 Axel (Front) Ø0.250 R0.125 Ø2.000 Ø0.250 0.500 9.000 6.500 1.000 0.500 0.969 1.500 0.969 Wheel (6 Req'd) 0.500 1.000 Ø0.281 1.000 0.500 3.438 Base Center Figure 4. Wheels, Axels and Base Center or Undercarriage dimensions. The procedures for executing the design of each part will be presented separately. Each step is numbered and they should be done in the order presented. After all parts are completed, you will proceed to the assembly. Each section is appropriately named and furnishes appropriate places where breaks may be taken if so desired. The numbers will continue throughout the tutorial rather than be separate for each part. Harry Hawkins 2005 Page 3
AXELS 1. Open a new design and under Tools, select Options and set the Units to inches. Edit the Workplane notation from initial to Front Axel. Your screen should look like figure 5. Figure 5. New design for Front Axel. 2. Draw a 0.25 (1/4 ) diameter circle at the center of the drawing field such as shown in figure 6. This will be the profile that will be extruded. Figure 6. Axel profile. Harry Hawkins 2005 Page 4
3. Rotate the field so that you can see it in 3D such as figure 7. Figure 7. Field rotated for 3D viewing. 4. Select the Extrude Profile button. The extrude profile dialog box will appear. Edit it according to figure 8. You should see a trial version of the extrusion in yellow. Press the OK button to execute the extrusion. Figure 8. Extrude Profile dialog edited for extrusion. 5. Figure 9 is the completed axel. Save this design and name it Front Axel. Figure 9. Completed Front Axel. Harry Hawkins 2005 Page 5
6. Create a new design. Name it Rear Axle. Use the same procedure just completed to create the rear axle. Notice it is slightly longer than the front. This so the dump bed will fit properly on the truck. Figure 10 shows the completed rear axle. Figure 10. Completed rear axle. Harry Hawkins 2005 Page 6
BASE (UNDERCARRIAGE) 7. The base unit or undercarriage contains a main strip that runs from the front to the rear of the vehicle and on which the cab and dump bed are eventually placed. It also contains the structures that will support the axels and wheels. First start by opening a new design and editing the initial workplane to base center. 8. Draw a Profile as shown in figure 11. You will need to use the orthographic drawings to obtain the exact dimensions. Be sure to delete all construction lines so that the profile will fill with color to indicate a valid profile. Figure 11. Base Profile ready for extrusion... 9. Rotate the view so you can see it in 3D then select the extrude profile button. Edit the dialog box according to figure 12. Press the OK button to execute. Figure 12. Extrude Profile dialog box and trial view. Harry Hawkins 2005 Page 7
10. The extrusion should look like figure 13. Figure 13. Extruded Base or Undercarriage Strip. 11. We will now extrude or add parts onto the front to extend the housing for the front wheels. First use the face selection tool to select the top face as shown in figure 14. The face will turn red. Figure 14. Face selected for new sketch. 12. With the face selected, right click and select New Sketch. Name it Right Front Hub. Check create workplane then click the OK button to create the sketch. 13. Click the orthographic view and zoom in on the right front of the object. Construct the new profile for the hub by drawing over the existing center hub. You will be able Harry Hawkins 2005 Page 8
to use the snap points of the center hub to place the lines. Be sure to delete any unwanted lines. The profile should fill and be ready to extrude such as in figure 15. Figure 15. Right front hub ready for extrusion. 14. Rotate the view so it will be in 3D then select the Extrude Profile button. Complete the dialog box to extrude a distance of 0.969. Press the OK button to execute the extrusion. It should look like figure 16. Figure 16. Right front hub extruded. Rotated for clear view. Harry Hawkins 2005 Page 9
15. In a similar fashion we will extrude the left front hub. First rotate the object to see the left face and select it with the select face tool. It will turn red as in figure 17. Figure 17. Left face selected for left front hub sketch. 16. With the face selected, right click and select New Sketch. Name the sketch Left Front Hub. Press the OK button to create the sketch plane. 17. Use the view orthographic button to view the sketch. 18. As you did with the right front hub, construct a profile for the left front hub. It should look like figure 18. Figure 18. Left front hub profile. Harry Hawkins 2005 Page 10
19. Use Extrude Profile to extrude the part a distance of 0.969. After rotating, it should look like figure 19. Save this design as the Base Center. Figure 19. Completed Base Center or Undercarriage. 20. We will now design the wheel. There will be 6 wheels on the finished vehicle, 2 on the front and 4 on the rear (double on each side). The wheel is relatively easy to create and will take little time. Harry Hawkins 2005 Page 11
WHEEL 21. Open a new design and edit the Initial to wheel. 22. Draw a 2.0 diameter circle at the work center and then a 0.25 diameter circle at the center of the 2 circle. This should result in a profile such as shown in figure 20. Figure 20. Wheel profile. 23. Rotate the image so it will be in 3D then select the Extrude Profile button. Configure the dialog box as shown in figure 21. After configuring, press the OK button to extrude the profile. Notice the yellow trial visual of the extrusion. Figure 21. Wheel profile ready to be extruded. Harry Hawkins 2005 Page 12
24. Figure 22 shows the resulting extrusion. This view has been rotated to better visualize the illustration. Figure 22. Profile after extrusion. 25. Use edge selection to select the two outside edges of the wheel. Use the shift key to select more than one edge. The edges will turn red as in figure 23. Figure 23. Edges of wheel selected for rounding. 26. With the edges selected, right click to see the drop down menu. Select Round Edges and another dialog box will appear. Edit it according to figure 24 for rounds of 0.13. Notice that trial rounds will appear in yellow. The wheel is in transparent mode for better visual effect. Press the OK button to have the rounds completed. Harry Hawkins 2005 Page 13
Figure 24. Round Edges dialog box ready for execution. 27. Figure 25 is the wheel after the rounds have been completed. Save this file and name it Wheel. Figure 25. Finished Wheel. Harry Hawkins 2005 Page 14
CAB 28. Open a new design and name it Cab. Edit initial to cab. Construct the profile shown in figure 26. We will add the rounds later. Refer to the Truck Cab dimensions to complete this profile. Figure 26. Cab profile. 29. To construct the wheel well, delete the bottom 5 cab line then draw a.75 line from the right end of the nose to the left. Draw another line 2.75 from the left towards the nose. At the gap between these two lines, construct 3 circles of R1.25. Use the snaps to do this. Figure 27 shows the three circles drawn. The top of the red circle will be the arc. Delete all circle elements except the top arc of the red circle. The profile should fill with color. Figure 27. Constructing the wheel well arc using circles. Harry Hawkins 2005 Page 15
30. Rotate the image to see it in 3D then select the Extrude Profile button. Edit the dialog box as shown in figure 28. You will note a yellow trial extrusion. Figure 28. Cab Extrusion ready to be executed. 31. Press the OK button to execute the extrusion. The result should look like figure 29. The image has been rotated for a better 3D look. Figure 29. Completed Cab Profile Extrusion. 32. Use faces selection to select the front or nose of the cab where the headlights will be placed. The face will turn red. With the face selected, right click to show a drop down menu and select New Sketch. Edit the name to Headlight Harry Hawkins 2005 Page 16
holes and click the OK box to create the sketch. Figure 30 shows the dialog box with the selected face in the background. Figure 30. New Sketch dialog box for the headlight face. 33. Select view orthographic to display the new sketch face. You may need to rotate it for better vision. 34. Use lines to locate and place circles of 0.37 diameter at the locations where the headlights will be located. Figure 31 shows this layout for the left headlight. Be sure to delete any construction lines so you will have a filled profile. Figure 31. Layout for left headlight hole. Harry Hawkins 2005 Page 17
35. Once the profile of both headlight holes are filled, select the Extrude Profile. Edit the dialog box as indicated in figure 32. Notice that you will be removing material below the workplane a distance of 0.13. Notice the trial visual of the extrusion in figure 32. Press the OK button to execute. Figure 32. Headlight holes ready to be extruded. 36. Figure 33 shows the completed headlight holes. Figure 33. Headlight holes completed by removal extrusion. Harry Hawkins 2005 Page 18
37. We will now make the edges of the cab round. All rounds will be 0.38. The bottom edges will be left square. Use edge selection to select the edges at the front of the hood, at the lower end of the windshield and the top front and back of the cab. Hold down the shift key to select more than one edge. With the edges selected, right click to see a drop down menu. Select Round Edges. Figure 34 shows the dialog box and the trial round above it in the background. Click OK to execute the rounds. Figure 34. Using the Round Edges feature. 38. In the same manner, select the edges on the left side of the cab as shown on figure 35. Press OK to execute. Figure 35. Selected left edges for rounding. Harry Hawkins 2005 Page 19
39. In a similar fashion select the edges on the right side of the cab and round them to the same value as previous rounds. The completed cab should look like figure 36. Save it and give it the name Cab if you have not already done so. Figure 36. Completed Cab. Harry Hawkins 2005 Page 20
HEAD LIGHT 40. The headlight is a simple wooden hole plug. The following procedure is used to create it. Open a new design and edit initial to headlight. 41. Draw the profile shown in figure 37. This is a half profile. It may be easier to create the 0.52 circle first then delete line segments to arrive at the arc rather than drawing the arc from point to point. You can draw a straight line then use the Arc or Fillet tool to create the arc. Figure 37. Full profile before deleting line segments. 42. After deleting unwanted lines, the profile will fill with color as in figure 38. Figure 38. Half Profile ready for revolution. Harry Hawkins 2005 Page 21
43. Click on base in the browser window. The three workplanes will show as glass. The one on which the profile is contained, in figure 39, has a red perimeter. The other two will be seen as cross hairs. The one with the red perimeter is selected. This will be the axis about which the profile will revolve. It must be on the same workplane as the profile but in a different sketch. Right click and select New Sketch. Edit the dialog box as in figure 39. Make sure Add to workplane (base) is selected. Press the OK button to proceed. Figure 39. New Sketch added to the base workplane. 44. Draw a line over the bottom horizontal line. This will be the axis. 45. Rotate the profile sketch for 3D viewing then select Revolve Profile. A dialog box will appear. Edit it to the contents of figure 40. Note that Headlight is the profile that should show in the box sketch to use as profile. If it is not, click on the arrow at the right of the box and select Headlight. Notice that you will see a yellow trial view of the revolution. When you have the trial view, click the OK box to finish. Harry Hawkins 2005 Page 22
Figure 40. Revolve Profile dialog box edited for revolving the headlight. 46. Figure 41 is a view of the completed headlight part. Name it Headlight and save it with the other designs in this project. Figure 41. Completed Headlight. Harry Hawkins 2005 Page 23
DUMP BED 47. Start a new design profile. Edit the initial to Dump Bed in the browser. In the drawing field, construct a profile such as in figure 42. This will be the bottom and front of the bed. Make sure the profile is filled with color to indicate that it is valid. Refer to the drawings at the end of the tutorial for accurate dimensions. Figure 42. Profile for Dump bed. 48. Select Extrude Profile to extrude this profile. Edit the dialog box as in figure 43. You will be adding material a distance of 4.5 below the workplane. Notice you will see a yellow trial view. Click the OK button to complete the extrusion. Harry Hawkins 2005 Page 24
Figure 43. Extrude Profile dialog box with trial view in background. 49. Figure 44 shows the completed extrusion, rotated for a better view. Harry Hawkins 2005 Page 25
Figure 44. Extrusion of bed and front of dump bed. 50. We will now extrude the two sides of the dump bed. First use face selection to select the inside face of the bed. It will turn red. Right click and create a New Sketch. Name this sketch Bed Sides. Click OK to create the sketch then use the View Ortho Workpane to view it. Construct two rectangle shapes as shown in figure 45. Figure 45. Two side boards profile outlined for extrusion viewing from above. 51. Rotate the view to see it in 3D then use Extrude Profile to extrude the sides 1.42 above the workplane as shown in figure 46. Click OK to finish. Harry Hawkins 2005 Page 26
Figure 46. Side Boards ready to be extruded. 52. Figure 47 shows the completed bed with side boards. Save the design at this time. Figure 47. Completed bed with side boards. 53. Rotate the bed to show the bottom. We will extrude the rear axel supports so that they are part of the bed. With the bottom showing, use Faces selection to select the bottom face. Right click and select New Sketch. Name the sketch Axel Support. Draw the profiles for the supports according to figure 48. Figure 48 shows dimensional constraints. Refer to the drawings at the end of the tutorial for accuracy. Harry Hawkins 2005 Page 27
Figure 48. Layout for Axel Supports. 54. Use delete line segments to remove all construction lines leaving only the two rectangular profiles of the supports as shown in figure 49. They should fill with color to indicate they are valid. Figure 49. Axel support profile ready for extrusion. 55. Use Extrude Profile to extrude these supports by adding material a distance of 1.5 above the workplane. Figure 50 shows the results. Harry Hawkins 2005 Page 28
Figure 50. Axel supports extruded. 56. Select the face of the top axel support as shown in red in figure 51. After it is red, right click and select New Sketch. Edit the dialog box as in figure 51. Figure 51. Axel hole and taper Sketch on new workplane. 57. View the new sketch in orthographic and construct the triangular and hole profiles as shown in figure 52. Be sure to remove all construction lines so that you have a filled, valid profile. Harry Hawkins 2005 Page 29
Figure 52. Profile for axel support hole and taper. 58. Use Project Profile to see the dialog box. Edit the dialog box according to figure 53. Be careful to Subtract material, Below the workplane and Thru entire part. Press the OK button to execute. Figure 53. Project Profile dialog box set up to remove material from axel supports. 59. Figure 54 shows the result. The material removed has left the supports with a hole for the axel and a taper to the front and rear. Save this design and name it Dump Bed. Figure 54. Completed Dump Bed. 60. Select the rear 4 vertical edges of the side boards and right click. Select Round Edges and use a radius of 0.12. Press OK to execute. Select the front edges of Harry Hawkins 2005 Page 30
the bed and round them to 0.12 also. Figure 55 shows the completed bed with rounds applied. Figure 55. Completed bed with rounds applied. 61. This completes the design of the parts for the toy truck. Be sure to save the final design of the dump bed. Our next step will be to assemble the parts into an assembly that will show all the parts mated together to create the toy truck. Harry Hawkins 2005 Page 31
ASSEMBLY 62. Open a new design. Save it as Truck Assembly. Under the Assembly drop down menu, select Add Component and navigate to select the Base Center design. Click OK to load it. It should appear in 3D on the work surface. Rotate and move it to a position as shown in figure 56. With the part selected, right click and Fix Components. Figure 56. Base Center Component added to Assembly. 63. In a similar fashion, add the component Dump Bed design. The design may be behind the base center. Use select part and then select the bed. When the cursor turns into a move unchanged symbol Figure 57 shows where the dump bed is located after moving it., you can drag the part around. Harry Hawkins 2005 Page 32
Figure 57. Axel located near front axel support. 64. Use edge selection to select the outside circle edge of the axel hole in the support and the outside circle of the axel hole through the base center. Use the shift key to select more than one face. Figure 58 shows these faces selected with arrows pointing to the selected edges. The transparent mode is on for easier viewing and clarity. Figure 58, Selected edges in red. 65. With the two edges selected, right click and select Center Axis. The two parts will center to the selected holes. This is shown in figure 59. Harry Hawkins 2005 Page 33
Figure 59. Axel holes centered in support and base center. 66. Use faces selection to select one face on the rear axel support and one facing face on the base center. Figure 60 shows these faces selected. Move the image around for the best view when selecting faces or edges. Right click and select Mate. The two faces should come together. Figure 60. Axel support and base center faces selected.. 67. At this point you should have the dump bed attached to the center base so that you can move the bed to simulate dumping. Figure 61 shows what the image should look like at this point. Harry Hawkins 2005 Page 34
Figure 61. Dump bed attached correctly to undercarriage. 68. At this point you can orient the image and use parts selection to select the dump bed. When the moving cursor appears, click and drag near the top front of the bed. You will notice that the bed rotates so that it appears to dump. Figure 62 shows the bed in the upright or dump position. Figure 62. Dump bed rotated to show upright or dumping position. 69. Use Add Components to add the Rear Axel (it is slightly longer than the front axel) (it will turn red). Orient it relative to the parts such as in figure 63 Harry Hawkins 2005 Page 35
Figure 63. Rear Axel added. 70. Zoom in on the intersection of the rear axel and its support housing. Use select faces and select the outside surface of the axel and the inside hole surface in the base center or undercarriage (use shift to select more than one item). With both surfaces selected (red), right click and select Center Axis. The axel will now center on the housing hole as shown in figure 64. Move the axel so that an equal amount of axel is protruding on each side of the support. Figure 64. Axel centered in housing hole. 71. Using the same procedure, add the front axel (it is slightly shorter than the rear axel). Be sure to center it as closely as possible. Harry Hawkins 2005 Page 36
72. From the Assembly menu, add the component Wheel. Use faces selection to select the inside surface of the center hole in the wheel and the front axel outside surface. Figure 65 shows the selection. Figure 65. Surfaces selected prior to Centering Axis. 73. While the surfaces are selected, Right click and select Center Axis. The wheel will center on the axel. Use surface selection to select the outside surface of the wheel and the end surface of the axel as in figure 66. Right click and select Align. Figure 66. Surfaces selected prior to aligning. 74. The wheel surface should align with the end of the axel as shown in figure 67. Harry Hawkins 2005 Page 37
Figure 67. Wheel aligned with axel. 75. Using the procedure you have just completed, add another wheel to the other side of the front axel. You should now have a design such as shown in figure 68. The transparency mode is turned off and the assembly is viewed as a solid in this illustration. Figure 68. Front wheels installed. 76. The rear wheels are dual. To make the dual wheel, add components and add two wheels. You may also install these wheels one at a time. To make a dual wheel, select the inside surfaces of the holes through both wheels then right click and select Center Axis. Figure 69 shows the surfaces selected prior to centering the axis. Harry Hawkins 2005 Page 38
Figure 69. Surfaces selected for centering axis. 77. Select the inside wheel surfaces that face each other as in figure 70. Right click and select Mate. The two wheels will come together to form a dual wheel. Figure 70. Wheel surfaces selected prior to mating. 78. Use edge selection to select the hole edge of the outside dual wheel. Hold the shift key down and select the outside circle edge of the rear axel. Right click and select Center Axis. The dual wheel will center on the axel as in figure 71. Harry Hawkins 2005 Page 39
Figure 71. Left rear dual wheel aligned. 79. Use surface selection to select the outside surface of the dual wheel and the outside surface of the end of the axel. Right click and select Align. The dual wheel will align with the end of the axel as shown in figure 72. Figure 72. Left Rear Dual Wheel Installed. 80. Using the same procedure used to create and install the left rear dual wheel, create another dual wheel and attach it to the right end of the rear axel. When completed it should look like figure 73. Harry Hawkins 2005 Page 40
Figure 73. All wheels Installed. 81. Under Assembly, select Add Component and insert the Cab design. Orient the design to show the cab similar to figure 74. Figure 74. Cab before mating to the wheel unit. 82. Use edge selection to select the bottom front edge of the cab and the top front edge of the Base Center. Right click and select Center Axis. 83. Use face selection to select the top face of the Base Center and the bottom face of the cab. Right click and select Mate. The view will need to be moved and rotated Harry Hawkins 2005 Page 41
so that you can see the front view of the cab and base center. Select the cab (it will turn red) and move it until it is in alignment with the outside of the wheels. Figure 75 shows what it should look like. Figure 75. Cab installed on Base Center. 84. Use Add Component to add a headlight. Move the headlight until it is at a position similar to figure 76. Figure 76. Headlight ready to be installed. 85. Use edge selection to select the circular rear edge of the lamp and the front edge of the left headlight hole. Right click and select Center Axis. This selection should look like figure 77. Harry Hawkins 2005 Page 42
Figure 77. Edges selected to Center Axis. 86. Select the circular face of the rear end of the headlight and the rear circular face of the hole into which it will be placed. With both faces selected, right click and select Mate. The headlight should be installed and look like figure 78. Figure 78. Right headlight installed. 87. In the same fashion, add another headlight and install it in the left front hole. The completed unit should look like figure 79. Harry Hawkins 2005 Page 43
Figure 79. Headlights installed. 88. All parts have now been added to the assembly. You can rotate it and turn on the 3D view to see the solid. You can move the dump bed to simulate the dumping position. It should look similar to figure 80 (top view) and figure 81 (bottom view). Save the completed assembly design. Name it assembly if you have not yet done so. Figure 80. Finished truck viewed from the top. Harry Hawkins 2005 Page 44
Figure 81. Finished truck view from the bottom. PHOTO ALBUM Harry Hawkins 2005 Page 45
89. An album is a single illustration of a design that can be saved as a JPEG or other graphic standard file. You can also vary the background and material in the image. 90. To create an album, select Photo Album under the File drop down menu. A new album page will be shown. Under the Image drop down menu, select New Image. A Choose Modeling View dialog box will be shown as in figure 82. This dialog box will list all the design files you have open at the time. If you have no files open, you will need to navigate to the Toy Truck file and load the Assembly drawing. Figure 82. Files that are currently open. 91. Select and load the assembly drawing. It will appear in 3D on the screen. You can use the zoom + and zoom feature as well as normal rotation using the mouse wheel. Orient the image according to figure 83 (or the view you want). Figure 83. Image rotated for desired view. Harry Hawkins 2005 Page 46
92. Notice the stop light or update icon at the top of the screen. Any time you do anything to the image such as changing material, color or move it around, this will light green. This means that you must click on the icon to update the screen. 93. In the browser at the top left, there are a number of selections. Select Material. You will note that there are a number of selections with a + in front of each. If you click the + an additional list of materials will show. Click the Metal category and notice the long list of materials available. Notice the bag at the left of each material. If you click on a bag and drag it the cursor will turn into a spilling paint bottle. When you cursor over an element in the design, the element will highlight. While it is highlighted, release the mouse button to pour the material into the part. Notice that duplicate parts such as wheels need only have material poured into one wheel. All the rest will assume the same material. Figure 84 is an illustration of a cab of Polished Gold, the under carriage is Cast Aluminum, the wheels are Rubber, the axels are Polished Brass and the dump bed is Stainless Steel. Figure 84. Image rendered using different materials. 94. You can also use special materials such as checkerboard or polka dots with foreground and background settings. Also the background can be of different styles. Harry Hawkins 2005 Page 47
To experiment with changing color, simply double click on a part. The dialog box will direct you to color selections. 95. To make changes on foreground and background of special materials such as checkerboard and polka dot patterns, use the Image Properties under the Image drop down menu. You can change the background or foreground as well as the relative size of the pattern. You can change lighting settings as well as other aspects of the image presentation. Figure 85 is a case where a number of materials were used and a JPEG sunset background is shown to demonstrate some of the capabilities for an album. Experiment and enjoy. Figure 85. Rendering using Polka dots, checkerboard patterns and various colors with a sunset background. Harry Hawkins 2005 Page 48
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