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 Figure Orthographic projections of project Figure shows the dimensions for the Truck Cab and figure shows the dimensions for the dump bed Figure 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 Ø0.5210 0.0730 Headlight Detail 0.375 0.1875 2.085 4.500 R0.375 All not marked 1/2 Button 2.500 72° Ø0.521 2.750 Ø0.375 1.250 0.125 R1.250 2.750 0.750 0.625 0.750 1.500 5.000 Truck Cab Figure Truck Cab dimensions 0.750 5.381 0.500 1.500 4.500 4.000 1.500 0.500 1.986 R0.125 0.667 0.750 0.250 Typical 5.631 Dump Bed 39° 5.381 R0.125 0.712 141° 1.064 2.229 2.391 1.165 1.415 1.500 1.500 72° 0.500 0.125 0.375 0.500 Ø0.281 Figure Dump bed dimensions © Harry Hawkins 2005 Page Axel (Rear) 4.630 1.500 4.500 Axel (Front) Ø0.250 R0.125 Ø2.000 9.000 6.500 Ø0.250 0.969 1.500 0.969 1.000 0.500 0.500 0.500 Wheel (6 Req'd) 1.000 Ø0.281 1.000 0.500 3.438 Base Center Figure 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 AXELS 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 Figure New design for Front Axel Draw a 0.25” (1/4”) diameter circle at the center of the drawing field such as shown in figure This will be the profile that will be extruded Figure Axel profile © Harry Hawkins 2005 Page Rotate the field so that you can see it in 3D such as figure Figure Field rotated for 3D viewing Select the Extrude Profile button The extrude profile dialog box will appear Edit it according to figure You should see a trial version of the extrusion in yellow Press the OK button to execute the extrusion Figure Extrude Profile dialog edited for extrusion Figure is the completed axel Save this design and name it Front Axel Figure Completed Front Axel © Harry Hawkins 2005 Page 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 BASE (UNDERCARRIAGE) 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 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 Rotate the view so you can see it in 3D then select the extrude profile 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 button 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 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 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 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 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 © Harry Hawkins 2005 Page 49 © Harry Hawkins 2005 Page 50 © Harry Hawkins 2005 Page 51 © Harry Hawkins 2005 Page 52