How to Make an Aeroshell
General Notes
Never directly use one of the reference sketches, always make a new sketch and convert entities
using a reference sketch takes it away from the folder, so making a new sketch each time keeps the Internal References folder as always having all the sketches you will need
NAME ALL OF YOUR FEATURES
You and anyone else should be able to guess what the feature does just from the name
References
External References
Import Frame Reference Sketch
Create Reference Planes
Make planes where the frame begins and ends
Make planes where the shell begins and ends
Make a plane at the bottom of the shell
Create Internal References
Create side view sketch of the middle and bottom shell
Create a top view profile for the middle shell
Convert entities the middle shell profile into a new sketch
In a new sketch, Convert Entities the middle shell profile and then linear sketch pattern it downwards (2 inches), this creates the upper fillet reference
Add 2 points into the same sketch, where the upper fillet intersect with the bottom shell profile
Make a new sketch, and draw an airfoil between the 2 points from the step above.
Make a new sketch, offset the airfoil (2 inches) and cut off the end of the airfoil, using arcs in the nose and lines in the tail to connect the ends to the front of shell and back of shell planes, this is the upper fillet top profile
Make another sketch and offset the bottom shell airfoil inward
Bottom Half of Shell
Middle Shell
Extrude surface with the middle shell side profile
Trim surface with the middle shell top profile
Upper Fillet
Make 2 new sketches, one containing the middle shell profile that had been extruded downward, and one with the one with the bottom shell airfoil
Project curve the bottom shell airfoil onto the offset middle shell profile
Project curve the upper fillet top profile onto the middle shell
Make a set of reference planes in line with the front plane
On each of these planes, make a sketch that has 2 guide curves, with each curve being a spline with one control vertex, with that control vertex being horizontal and vertical to the endpoints
Make a 3D sketch using convert and split entities to make guide curves out of the part of the side profile that is between the 2 curves.
Do a boundary surface between the 2 curves, and using all the guide curves that you made
Bottom Shell
In a 3D sketch, convert entities on the lower edge of the upper fillet
Boundary surface from the 3D sketch to the inward airfoil offset, with the inward airfoil offset on the plane that defines the bottom of the shell
Surface trim the boundary extrude with the front of frame sketch and with the back of frame sketch
Extrude the bottom flat line of the bottom shell side profile
Trim the flat bottom extrude with the remaining part of the bottom shell boundary surface
Knit the flat bottom extrude to the 2 sides of the bottom shell boundary surface
Fillet the edges where the flat bottom extrude and bottom shell boundary meet
Nose/Tail
Make a sketch on the Front of Frame plane and convert entities the edge of the bottom shell
Make a 3D sketch and convert entities the edge of the upper fillet, up until it intersects with the bottom shell
on the right plane convert entities the side profile and use trim entities to cut it down to the part that is between the 2 curves that you converted entities for in 17-18
Add any other guide curves that you need in order to get the profile you want
Boundary surface from the bottom shell to the upper fillet, using the guide curve of the side profile + anything else you made
All the previous steps apply for the tail as well, except you use the the Back of Frame plane and you convert entities the back edge of the upper fillet
Middle Shell Lip
In a sketch on the top plane, convert entities the middle shell top profile
extrude the sketch upward, far past the middle shell
trim surface using the flat part of the middle shell to get rid of the bottom part of the new extrusion
Make a new sketch, convert entities the middle shell lip and linear sketch pattern it upward
Trim the middle shell lip with that sketch
Top Half of Shell
Top Shell Lip
Offset Surface the middle shell lip
Convert Entities on the top edge of the top shell lip
Extrude that sketch out past the top shell lip
Do a surface trim with mutual surfaces of the surface offset and the surface extrude, removing the parts of the extrude that go out past the lip, and removing the part of the surface offset in the tail that goes up past the rest
Do a surface extend, taking the bottom edge of the surface offset near the tail end to match to the rest
Canopy
Draw the right half of the side profile for the canopy in a sketch on the right plane
Draw the right half of the top profile for the canopy in a sketch on the top plane, making sure the ends of the top profile match with the side profile
Project curve the top profile onto the top shell
Make a set of reference planes in line with the front plane along the path of the canopy curve
Draw guide curves on the planes, going from the side to the projected top profile and making sure to avoid the roll cage
Boundary surface from the side profile to the projected top profile, and using all of the guide curves.
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