Surf and Code: Surfacing Mountain Bike Handlebar

In this tutorial you learn:

• How to model a Mountain Bike Handlebar using surfacing commands in Solid Edge.
• How to use the cross-curve command.
• The use of swept surface.
• How to thicken surfaces to make solids.

It is assumed that you are familiar with the basics of Solid Edge Part modeling.

Full index of Solid Edge surfacing tutorials on this blog is here.

Disclaimer:
• This tutorial and the steps illustrated herein are by no means claimed to be the best or the only way to create the given design.
• This tutorial is an attempt to introduce and demonstrate the awesome set of tools that Solid Edge has for curve creation and surface manipulation.

Create Two Planes Start with creating two planes parallel to the y-z plane. The distance between the planes is 50 (see figure)
Drawing the profile - front view In the x-z plane, sketch the front view profile of the handlebar as shown in figure. Keep the profile between the two planes created in the earlier step.
Profile - top view In the x-y plane, sketch the top view profile of the handlebar as shown in figure. Here, the overall dimension of 100 matches with the dimension in the front view profile, as shown in earlier step. Also make sure sure that the two profiles are vertically aligned.
Cross Curve Select the Cross Curve command from the Surfacing toolbar as shown. In the ribbon interface, the Cross Curve command is on the Surfacing panel, Curves group.
First Curve Select the front view curve as the first curve. Click accept on the ribbon bar or command bar.
Second Curve Select the top view curve as the second curve. Click accept
Cross Curve Click Finish on the ribbon bar or command bar. Soon the cross curve is formed. The cross curve is neither in the top plane nor in the front plane. It travels in 3D space, giving us the desired path to create the handlebar.
Normal Plane Create a plane normal to the new cross curve at one of its end. Use the Plane Normal to Curve command.
Plane Created The new plane appears smaller in size than parallel created planes. Your figure should now look as shown.
Sketch the profile Create a sketch (a circle) on the new plane and at the end of the cross curve. See figure.
Extruded Surface Click the Swept Surface tool on the Surfacing toolbar. Complete the extrusion of the circle along the cross curve
Close Ends In the Swept Surface, click the Close Ends option on the ribbon bar. This ensures that the ends of the protrusion are capped or closed.
Surface to Solid Start the Thicken command. Select the swept surface and thicken it by 2. Finally, round the end faces of the solid handlebar.