This document describes a solid modeling assignment for a cell phone completed in Pro Engineer. It includes 13 parts modeled individually then assembled into a full cell phone model. Techniques learned and practiced included sweeps, blends, warps, patterns, revolves, extrusions, cuts, shells and datum planes. The most challenging aspects were the back cover with its asymmetrical features and threaded holes, and blending sketches which required alternative instructions. The assignment took over 15 hours to complete and reinforced modeling discipline.

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Project 03
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Solid Modeling Assignment
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10/1/2009
Andrew Wise
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2. Contents
1 Introduction .......................................................................................................................................... 4
2 Problem Statement ............................................................................................................................... 4
3 Report ................................................................................................................................................... 4
3.1 Part A............................................................................................................................................. 4
3.1.1 Figure 1.................................................................................................................................. 5
3.2 Part B ............................................................................................................................................. 5
3.2.1 Figure 2.................................................................................................................................. 5
3.3 Part C ............................................................................................................................................. 6
3.3.1 Figure 3.................................................................................................................................. 6
3.4 Lens ............................................................................................................................................... 6
3.4.1 Figure 4.................................................................................................................................. 7
3.5 Microphone................................................................................................................................... 7
3.5.1 Figure 5.................................................................................................................................. 7
3.6 Earpiece......................................................................................................................................... 8
3.6.1 Figure 6.................................................................................................................................. 8
3.7 Antenna ......................................................................................................................................... 8
3.7.1 Figure 7.................................................................................................................................. 8
3.8 PC Board ........................................................................................................................................ 9
3.8.1 Figure 8.................................................................................................................................. 9
3.9 The Keypad.................................................................................................................................. 10
3.9.1 Figure 9................................................................................................................................ 10
3.10 Back Cover................................................................................................................................... 11
3.10.1 Figure 10 ............................................................................................................................. 11
3.11 Front Cover ................................................................................................................................. 12
3.11.1 Figure 11 ............................................................................................................................. 12
3.12 The Assembly Model ................................................................................................................... 13
3.12.1 Figure 12 ............................................................................................................................ 13
3.13 2D Assembly Drawing ................................................................................................................. 14
3.13.1 Figure 13 ............................................................................................................................. 14
4 Discussion............................................................................................................................................ 15
5 Conclusion ........................................................................................................................................... 15

3. 6 References .......................................................................................................................................... 15

4. 1 Introduction
Project 03 is the most ambitious modeling assignment to date. The first simple modeling part requires a
newfound mastery of the sweep, blend, and warp commands. The second part is another complex series
of modeling tasks that culminates in an assembly model of an entire cell phone. The class is also tasked
with a 2D drawing of our assembly drawing.
2 Problem Statement
The task is to complete from the textbook Figure 7 on page 11-5, Figure 28 on 11-17, and Figure 9-14
using the toothpaste tutorial. Additional, the class is to complete pages 4-1 to 6-17 in the “getting
Started with Pro Engineer Wildfire 3.0 on the class website.
3 Report
3.1 Part A
Part A is made with an extrusion and a sweep. The sweep was new, but the book’s tutelage was
stalwart. It was created much like the helical sweep from Project 02, with a user defined path and user
defined cross-section. In this case, the cross-section was an I-beam.

5. 3.1.1 Figure 1
(A) (B)
Figure 1(A) is a longitudinal view of the sweep; Figure 1(B) is shows the height.
This command will be useful in modeling smooth objects.
3.2 Part B
Part B is created using three sketches and the blend feature. The book was not as helpful this time. It
took numerous attempts to successfully link the three sketches.
3.2.1 Figure 2
(A) (B)
Figure2 (A) shows the depth and top contours of Part B; Figure 2(B) shows the bottom.

6. The steps for blends are view, but complicated sketching and temperamental inputs made this piece a
hassle.
3.3 Part C
Part C requires both a blend and a warp. However, the online tutorial offered a different method for the
blend. The user can select blend, draw the sketches, and specify the distance between each sketch to
successfully insert a blend. This was much easier from the class than the method offered book the book
3.3.1 Figure 3
(A) (B)
Figure 3(A) depicts the blended aspects of Part C; Figure 3(B) shows the warp.
The warp command is new. It is easy to use, but difficult to master. Essentially, the user defined
something similar to a sine wave then manipulates the peaks and troughs to depress his/her model. This
last part was imprecise.
3.4 Lens
The Lens was the first part completed for the cell phone assembly. It was not complicated. It required
only familiar techniques such as arc and extrusion.

7. 3.4.1 Figure 4
(A) (B)
Figure 4(A) shows the lens; Figure 4(B) shows the lens from another angle
To make the piece more interesting, the class added color to the lens. This is a simple matter done
through the view menu.
3.5 Microphone
The microphone was the next piece. It was a bit more complicated, but it still only require the basics like
extrusion and cut.
3.5.1 Figure 5
(A) (B)
Figure 5(A) shows the depressions in the mic; Figure 5(B) shows the hard edges.

8. 3.6 Earpiece
The earpiece was also fairly simple. It required mostly the basic techniques. However the six holes were
done via a pattern. While this technique gets easier and easier with every project, it is still not quite
mundane.
3.6.1 Figure 6
(A) (B)
Figure 6(A) is the earpiece; Figure 6(B) is the back side. Can the see chamfered edges?
3.7 Antenna
The antenna was also a review of techniques learned earlier this year. Essentially, this part was a couple
of sketches with a couple of revolutions. Nothing earth-shattering.
3.7.1 Figure 7
(A) (B)
Figure 7(A) shows the antenna; Figure 7(B) shows the tip of the antenna.

9. 3.8 PC Board
The PC Board was a little bit trickier than the other parts. The extrusion based on sketches was no
different than the others and the holes have been done many times before, but we did add a datum
plane to this model. Its purpose is to align the keypad in our assembly drawing.
3.8.1 Figure 8
(A) (B)
Figure 8(A) is a view of the PC Board. The cross-hatching represents the datum plane; Figure 8(B) show the back side.

10. 3.9 The Keypad
The keypad was not difficult. The blue color is added for emphasis on the assembly model. The
techniques used were extrusion, round, pattern, and mirror.
3.9.1 Figure 9
(A) (B)
Figure 9(A) is shows the keypad; Figure 9(B) shows its slender figure.
We also used reference dimensions for the first time. Essentially it creates constrains with a CAD model
instead of just in the sketches as we have done before. Instead selecting a numerical offset, one can
constrain feature locations using other dimension and will change accordingly with said dimensions.

11. 3.10 Back Cover
The back cover was the most difficult piece conceived for this phone. It required the creation of several
model datum planes (easy in creation but confusing in application), countersunk and threaded holes,
asymmetrical features, and uneven surfaces as references. On top of the new techniques, familiar but
difficult techniques like draft and shell were also used.
3.10.1 Figure 10
(A) (B)
Figure 10(A) is shows the cell and the creator’s name; Figure 10(B) shows the inside parts; Pictures don’t do this piece justice.
This is piece probably took the class longer to complete than the rest of the pieces combined.

12. 3.11 Front Cover
The front cover had some of the difficult feature used in the back cover, but it was not as complicated.
The threaded holes were easier and the piece is more symmetrical as a whole.
3.11.1 Figure 11
(A) (B)
Figure 11(A) shows the front of the front cover; Figure 11 (B) shows the inside part of the cover.
The button holes were not actually done in the part file. They are a carryover from the assembly model.
ProE cut the holes once the keypad was properly in place. The holes are made directly from the keypad.

13. 3.12 The Assembly Model
All went pretty smoothly with the Assembly Model. It was a review of techniques learned for last week’s
Project 02.
3.12.1 Figure 12
(A) (B)
Figure 12(A) shows an exploded view of the cell phone; Figure 12(B) shows a non- exploded view.
The color and amount of pieces are the only differences from last week. This model is more complex,
but the color helps differentiate the different parts nicely.

14. 3.13 2D Assembly Drawing
The 2D Drawing was also mostly a review from last week. We did however learn that all drawings need a
title and how to let ProE do a Bill of Materials for the user. All the user needs to do is create a table and
repeat region and ProE takes care of the rest. Balloons make finding each piece a snap.
3.13.1 Figure 13
Figure 14 shows my drawing. This is how folks on the floor would know how the parts go together.
Experience made this 2D much easier than last time.

15. 4 Discussion
No one thing in Project 03 really gave the class much trouble. The threaded holes were tricky and the
class still is not sure why it couldn’t dimension to the axes of the screw posts, but we eventually worked
it out. Project 03 was really more of a grind than anything. It was a lot mind-numbing work. The class
estimates that this project took upwards of 15 hours on average. No one feature was extraordinarily
difficult to conceive and model, but the whole is always greater than the sum of its parts.
The one feature that left me stumped was the blend. The way our ProE 4.0 textbook instructed me to
complete it didn’t work, perhaps more accurately, I couldn’t make it work. I tried everything and kept on
getting the insipid error message about my “unclosed” figure. I thought my goose was cooked until the
instructions for Part C showed an alternate blend method which seemed a lot easier. Again, there was
no one part the class could not understand, just a lot of headaches and combinations that made for a
slow go.
The threaded holes also made Project 03 a time-consuming ordeal. The class could not get the radial
dimension to work. Also, on some edges, the holes were crooked or upside down. Eventually, the class
made it work, but it took a couple of hours at least.
5 Conclusion
The class learned a lesson in discipline in Project 03. The techniques learn were almost trivial. The most
important thing the class got out of this assignment was staying with a challenge.
6 References
Toogood, Roger. Pro Engineer Wildfire 4.0. Edmonton, Alberta: ProCAD Books Ltd, 2006.