LHRH Symmetrical castmoulded and machinedtrimmed parts STD 00027

LH/RH Symmetrical cast/moulded and machined/trimmed parts (STD 00027 section 5. 3. 3. 2. 1)

Overview This document will provide step by step instructions of how to create symmetrical handed cast parts. The process can also be adopted for other handed parts that require more than one set of manufacturing operations to produce the finished product such as vacuum formed parts that require post mould machining such as trim operations.

The Components. This process will create the following CAD parts… LH Casting RH Casting This is the master part and the first model to be created. The overall shape and size and shape of all subsequent parts are controlled by this model. The right hand part is a WAVE mirror geometry link of the LH Casting, the only feature in the part navigator will be a linked body. LH Machining RH Machining This is a simple WAVE linked body of the LH Casting as well as the linked body, there will also be all the machining features in the part navigator. These features will be the controlling features for the RH Machining This will be a WAVE linked mirror of the LH Machining but in order to make sure the PSE/BOMS and CAD are all correct, they will require some extra operations

LH as Cast (master)

LH Casting (Master) • • • Create the LH Casting at ABS (0, 0, 0) following CADET standards. Once the model is complete create a new datum plane in a suitable place (NOT THE CENTRE LINE OF THE VEHICLE) which will be used as the mirror plane for the WAVE geometry link mirror process. Re-name the datum plane as detailed in STD 00027 to mirror_link_geo_plane or similar. Datum plane created for the WAVE mirror process Re-name the datum plane to identify it as the mirror plane for the WAVE process.

RH as Cast

RH as Cast WAVE Mirror Geo Link • Create a brand new part (RH as Cast) and add the LH as Cast to it as a child component at ABS (0, 0, 0) Ensure that the LH as Cast reference set is set to Entire Part. (Please be aware the visible part in the image below is the LH part but it is being shown as being added to the newly created RH part) New RH part with the LH added as a child at 0, 0, 0 LH part which will be used to create the RH part Ensure ref set is Entire Part so the mirror plane is shown Mirror plane which is used to create the RH part.

Creating The Wave Linked RH Model • • • Ensure that the new RH part is the work part and that the assemblies license is turned on. Then choose Insert > Associative Copy > WAVE Geometry Linker This will open a sub-menu, make sure the Mirror Body command is selected. Mirror Body

Creating The Wave Linked RH (cont’) • • The first selection step asks you select the body to mirror Select the LH model and press MB 2 (middle mouse button) to move to step 2 Step 2 requires the user to choose the mirror plane Select the mirror plane in in the LH part Select LH model and accept with MB 2 Selection step 2: Select mirror plane Selection step 1: Select body Mirror plane in LH model.

Creating The Wave Linked RH (cont’) • • • The RH part is now created The assembly navigator will show the LH part being a child of the RH part The part navigator will only show one feature, which is Linked Mirror RH Part LH is a child of the RH part. Part navigator contains one feature, the linked mirror

Setting The Assembly and PSE Correctly • • There are now some operations that need to be carried out to ensure the PSE, drawing border and ANT are all set correctly Change the LH parts reference set to Empty. This will ensure that the weight that is displayed in the drawing border is correct for a single part and not the combined weight of both. Empty reference set selected for the LH part will ensure that weight on the drawing border is correct.

Setting The Assembly and PSE Correctly • • At this point (assuming the RH part has been saved) The PSE will be incorrect as it will reflect the structure that is shown in the ANT with the LH part being a child of the RH part. The LH part needs to be set to reference only in CAD. This will ensure that it does not appear in the structure of PSE Reflection of the NX 4 ANT is incorrect for the PSE/BOM

Change the LH Part to Reference only • • • In NX right click on the LH part in the ANT (it will be useful to have the reference only column visible in the ANT) Select the Properties button The properties box will be displayed with assembly as the default screen Right click Reference-only column in ANT is turned on Select properties Properties box

Change the LH Part to Reference only • • Put a tick in the Component is Reference-Only box Press OK An information box will appear. The box states that the part will disappear from the BOM (PSE) in Team Centre Select OK Ensure Component is Reference-Only is ticked

Change the LH Part to Reference only • Look at the ANT and notice that a symbol which looks like a little purple book has appeared in the Component is Reference-Only column • Save the part and then open the BOM view in the PSE in TCEng and see how the LH part is no longer shown as a child of the RH part Reference only symbol LH part has now disappeared.

LH Machining (master)

Creating the LH Machining • This next section is relatively straight forward and will cover the creation of the LH Machined part using the WAVE Geometry and the LH as Cast part. LH As Cast LH Machined

The LH Machined Part • • In NX Create a new part file When filling in the initial attributes the material should be entered as being the part number of the LH as cast part. This will ensure that the drawing border attributes are correct (there is no point typing the full material spec out again as this should have been done in the LH as cast part and is now impossible to change. Any future mod’s to material spec will only need to be done in the LH as cast part) Material attribute Part number of LH as Cast

The LH Machined Part • Add the LH as cast part to the newly created LH machined part at 0, 0, 0. The ANT shows the new structure. LH as cast part added to new LH machined part

Creating The WAVE Geometry Link • • Ensure that the new LH machined part is the work part and that the assemblies license is turned on Then choose Insert > Associative Copy > WAVE Geometry Linker Again will open a sub-menu, this time make sure the Body command is selected and not Mirror Body Select the LH as cast part and press OK to create the linked body Body

Creating the WAVE Geometry Link • • It will appear as though nothing has happened, this is because the new linked body is in exactly the same place as the LH as cast part. Change the Reference Set of the LH as cast part to Empty and the new linked body is the only thing that is left. This also ensures that the weight on the drawing border will be correct. Linked body Reference Set changed to empty

Model the Machining Features. • At this point, the only feature in the Part Navigator should be the newly created linked body • The machining detail can now be added to the linked body Linked body is the first feature Subsequent machining features

Finishing the LH Machining • • • Finally, create a datum plane in a suitable place to use as the mirror plane for future operations Re-name the datum plane as detailed in STD 00027 to mirror_link_geo_plane or similar Save the part when complete Datum plane re-named Mirror plane create in LH Machining.

The PSE and the ANT • In the case of processed parts such as LH As Cast and LH Machined, there needs to be a correctly structured parts list that shows that in order to make the “Machined” part the “As Cast” part is required • Regardless of whether it’s a small business unit buying in the fully finished, machined component, or a big business unit buying in the raw, as cast component and machining it themselves, it is required to show the structure • Do not make the “As Cast” part reference only if you are buying in the fully machined and finished component. Your PI Analyst will ensure that the correct part is ordered and that there is no incorrect ordering of unprocessed parts

The PSE and the ANT • For the LH Machining the ANT and the PSE should be identical. Identical structures in both CAD and Team Centre

RH Machining

The RH Machined Part • The final model to be created is the RH Machining • This is where a mixture of techniques needs to be applied in order to ensure that the CAD model and the PSE are all correct • If a straight WAVE mirror geometry link is created from the LH Machining, then the PSE would be incorrect as the LH Machining is not required to make the RH Machining but the RH As Cast is required • Creating a WAVE geometry link of the RH As Cast part would ensure the PSE/BOM is correct. However, this would mean manually duplicating all the machining features and consequently any future mod’s would require double the amount of work • So a neat integration of both the above last 2 points is required. The following steps will detail the process

Creating the RH Machining • Create a new part file for the RH Machining • Ensure that when filling in the material attribute enter the part number of the RH As Cast part for the same reasons as described earlier Material attribute Part number of RH as Cast

Creating the RH Machining • Add the LH Machining to the newly created RH machining at 0, 0, 0 • Ensure that the reference set for the LH machining is set to Entire Part so the mirror plane is shown. Reference set is Entire Part Mirror plane LH Machining added at 0, 0, 0

Creating The Wave Linked RH Machining Model • • • Ensure that the new RH part is the work part and that the assemblies license is turned on. Then choose Insert > Associative Copy > WAVE Geometry Linker This will open a sub-menu, make sure the Mirror Body command is selected. Mirror Body

Creating The Wave Linked RH (cont’) • • The first selection step asks you select the body to mirror Select the LH model and press MB 2 (middle mouse button) to move to step 2 Step 2 requires the user to choose the mirror plane Select the mirror plane in in the LH part and OK Select LH model and accept with MB 2 Selection step 2: Select mirror plane Selection step 1: Select body Mirror plane in LH model.

Creating The Wave Linked RH (cont’) • • • The RH part is now created The assembly navigator will show the LH part being a child of the RH part The part navigator will only show one feature, which is Linked Mirror RH Part LH is a child of the RH part. Part navigator contains one feature, the linked mirror

Setting The Assembly and PSE Correctly • • There are now some operations that need to be carried out to ensure the PSE, drawing border and ANT are all set correctly Change the LH parts reference set to Empty. This will ensure that the weight that is displayed in the drawing border is correct for a single part and not the combined weight of both. Empty reference set selected for the LH part will ensure that weight on the drawing border is correct.

Change the LH Part to Reference Only • • • Whilst the intention is for the LH Machining to be the master part which will control all the machining features in the RH Machining, we do not want to see the LH Machining in the PSE/BOM so the LH Machining needs to be changed to Reference Only In NX right click on the LH part in the ANT (it will be useful to have the reference only column visible in the ANT) Select the Properties button Right click Reference-only column in ANT is turned on Select properties Properties box

Change the LH Part to Reference only • • Put a tick in the Component is Reference-Only box Press OK An information box will appear. The box states that the part will disappear from the BOM (PSE) in Team Centre Select OK Ensure Component is Reference-Only is ticked

Change the LH Part to Reference only • Look at the ANT and notice that a symbol which looks like a little purple book has appeared in the Component is Reference-Only column • Save the part and then open the BOM view in the PSE in TCEng and see how the LH part is no longer shown as a child of the RH part Reference only symbol LH part is no longer structured

Final Steps - Correcting the PSE • The PSE for the RH Machining now needs to be modified to show the correct structure. At present, it just shows the one part which is the RH Machining. • This is made from the RH as Cast so the structure needs to reflect this. The CAD however, must not show any reference to the RH as Cast part in the ANT • All CAD files should be saved and closed at this point as it is bad practice to modify structures in either CAD or the PSE whilst both are open. So in the case of editing the structure in the PSE, close all CAD files • If editing the structure in CAD, then ensure that the PSE is closed

Final Steps - Correcting the PSE • • • Open the RH Machining in the PSE Click on the RH Machining to highlight the part Select Edit > Add from the drop down menu This will open a sub menu Type the part number of the RH as Cast in the Item ID and press enter Select OK to add the part RH as Cast part no. Highlight RH Machining Select Edit > Add from drop down menu Select OK to add the part. Add sub-menu

Final Steps - Correcting the PSE • • • The PSE will now show the new structure. However the system needs to be told not to open the RH as Cast part in CAD, it is purely there for BOM information Double click on the box under UG Geometry in the PSE A sub-menu will appear, type NO in upper case, select OK. The text will appear in the box Save and close the PSE New structure Double click here Type NO in the UG Geometry sub-menu Text appears in the box

Process Complete. • The CAD models, CAD and PSE structure are now complete • The data and structure of all the parts is correct and will cater for each scenario for both Manufacturing and Purchasing whilst being as streamlined and minimal maintenance as possible for the CAD users who control the models and drawings • The following pages contain a Step Guide and all the CAD drawings for reference • If in doubt, speak to your CADET representative

Step Guide (symmetrically handed processed parts) LH as Cast Charted master drawing LH as Cast (master) Points to Geo Link Mirror Geo Link RH as Cast drawing LH Machining Charted drawing LH Machining Mirror Geo Link Add to RH Machining in PSE with UG Geometry set to NO RH Machining drawing Points to

LH as Cast Charted Drawing All technical specifications such as material and dimensions will be on this drawing There should be a table charting each part number of the LH and RH parts Full JCB STD for material spec Drawings are for illustration purposes only

RH as Cast (referencing drawing) This drawing will contain just one pictorial view. Note pointing to LH part for details. No information in the Material or Finish attribute, this will be detailed in the LH part Drawings are for illustration purposes only

LH Machining Charted Drawing This drawing will have dimensions which only detail the various machining features There should be a table charting each part number of the LH and RH parts The material attribute references the LH as Cast Part number The finish will be the JCB paint spec etc, Drawings are for illustration purposes only

RH Machining (referencing drawing) This drawing will contain a pictorial view only There will be a note pointing back the opposite hand for all dimensions and technical information The material will reference the RH as Cast part number The finish will be blank as it will be the same as the one detailed in the LH machining Drawings are for illustration purposes