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CATIA: Advanced Part Design

Part 1

Version 5, Release 20

Student Guide

Revision 1.0

February 2011


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ASCENT - Center for Technical Knowledge

CATIA:

Advanced Part Design - Part 1Wildfire 5, Release 20, Revision 1.0

ASCENT - Center for Technical Knowledge is a division of RAND Worldwide Inc.,providing custom developed knowledge products and services for leadingengineering software applications. ASCENT is focused on specializing in thecreation of education programs that incorporate the best of classroom learningand technology-based training offerings.

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Table of Contents

2011, ASCENT - Center for Technical Knowledge

Table of Contents

Part 1

Chapter 1 Part Design Overview................................................. 1-1

1.1 Part Design Philosophies ................................................ 1-3

Default Reference Planes .................................................. 1-3Base Feature...................................................................... 1-3

Active Body ........................................................................ 1-3Sketch Support................................................................... 1-3Sketcher References.......................................................... 1-4Positioned Sketch...............................................................1-4Dimensions.........................................................................1-4Parent-Child Relationships................................................. 1-4

Depth Options ....................................................................1-4Formulas ............................................................................ 1-5Feature Order..................................................................... 1-5Multi-body...........................................................................1-5Boolean Operations............................................................1-5

1.2 Maintaining Design Intent................................................ 1-6

Exercise 1a Locking Insert.................................................... 1-7

Exercise 1b Capturing Design Intent in Sketcher............... 1-9

Exercise 1c Sketcher Analysis (Optional) ......................... 1-12

Exercise 1d Sketcher (Optional) ......................................... 1-18

Chapter 2 Advanced Pattern Options......................................... 2-1

2.1 Advanced Pattern Options .............................................. 2-3

Keep Specifications............................................................ 2-6Pattern Formulas................................................................2-7Exploding Patterns ............................................................. 2-8

Exercise 2a Pattern Options ................................................. 2-9

Exercise 2b Simplified Representations............................ 2-22

Exercise 2c Engine Cover ................................................... 2-25Exercise 2d Copying Features Between Models .............. 2-30

Chapter 3 Working with Multi-Profile Sketches.........................3-1

3.1 Multi-Profile Sketches .....................................................3-3

3.2 Creation of Sketch Sub-Elements...................................3-4

3.3 Output Features................................................................3-8
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ii 2011, ASCENT - Center for Technical Knowledge

3.4 Profile Feature ................................................................ 3-10

3.5 Creation of Multi-Pad Features ..................................... 3-12

Exercise 3a Creating a Multi-Pad Feature ......................... 3-14

Exercise 3b Using Sketch Sub-Elements .......................... 3-20

Exercise 3c Engine Block ................................................... 3-26

Exercise 3d Adjustable Bracket ......................................... 3-41

Chapter 4 Advanced Part Design ............................................... 4-1

4.1 Solid Combine Feature .................................................... 4-3

4.2 Creation of Multi-sections Solids ................................... 4-5

Smooth Parameters ......................................................... 4-14

4.3 Creation of Rib and Slot Features ................................ 4-15

Keep Angle....................................................................... 4-17Pulling Direction ............................................................... 4-18

Reference Surface ........................................................... 4-18Exercise 4a Solid Combine................................................. 4-20

Exercise 4b Crane Hook...................................................... 4-27

Exercise 4c Truck Bumper.................................................. 4-34

Exercise 4d Speaker Cover................................................. 4-45

Exercise 4e Turbine Wheel ................................................. 4-51

Exercise 4f Hammer Head................................................... 4-57

Exercise 4g Transition Pipe................................................ 4-67

Chapter 5 Wireframe Lines and Curves..................................... 5-1

5.1 Wireframe Elements......................................................... 5-3

5.2 Points, Lines, and Planes................................................ 5-4

Points ................................................................................. 5-4Lines................................................................................... 5-6Planes ................................................................................ 5-6

5.3 Creating Splines............................................................... 5-7

5.4 Polyline ........................................................................... 5-10

5.5 Helix Curve ..................................................................... 5-11

5.6 Combine Curve............................................................... 5-14

Combine........................................................................... 5-14

5.7 Projection Curve ............................................................ 5-17

5.8 Intersection Curve.......................................................... 5-18

5.9 Operations ...................................................................... 5-19

Join................................................................................... 5-19
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Table of Contents

2011, ASCENT - Center for Technical Knowledge ii

Extract ..............................................................................5-21

5.10 Multi-Result Management.............................................. 5-25

Exercise 5a Spline-Polyline ................................................ 5-28

Exercise 5b Extract Curve................................................... 5-36

Exercise 5c Spline-Polyline ................................................ 5-42

Exercise 5d Handle .............................................................. 5-49

Exercise 5e Sailboat Keel.................................................... 5-69

Chapter 6 Advanced Fillets and Drafts ......................................6-1

6.1 Advanced Fillets............................................................... 6-3

Edge Fillet .......................................................................... 6-4Variable Radius Fillet .........................................................6-7Chordal Fillet ......................................................................6-9Face-Face Fillet..................................................................6-9

6.2 Creating Reflect Line Draft ............................................ 6-116.3 Creating Advanced Draft ............................................... 6-13

6.4 Draft and Fillet Failure Resolution................................ 6-17

Fillet Failure Resolution....................................................6-17Draft Failure Resolution.................................................... 6-19

Exercise 6a Advanced Fillet Creation ................................ 6-20

Exercise 6b Blended Fillets ................................................ 6-31

Exercise 6c Advanced Fillet and Draft............................... 6-39

Exercise 6d Advanced Draft Creation................................ 6-47

Chapter 7 Analysis Tools ............................................................ 7-1

7.1 Draft Analysis ...................................................................7-3

Color Scale......................................................................... 7-6On The Fly..........................................................................7-7

7.2 Threads and Taps...........................................................7-11

7.3 Thread/Tap Analysis ......................................................7-13

7.4 Parameterization Analysis............................................. 7-15

Exercise 7a Draft Analysis .................................................. 7-19Exercise 7b Creating Threads and Taps............................ 7-26

Exercise 7c Thread/Tap Analysis ....................................... 7-32

Exercise 7d Parameterization Analysis ............................. 7-36

Chapter 8 Multi-Model Links .......................................................8-1

8.1 Reuse of Geometry .......................................................... 8-3
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iv 2011, ASCENT - Center for Technical Knowledge

Advantages ........................................................................ 8-3Disadvantages ................................................................... 8-3

8.2 Copy and Paste Special................................................... 8-4

8.3 External Links................................................................... 8-9

Links Tab............................................................................ 8-9Pointed Documents Tab................................................... 8-13

Re-establishing Broken Links........................................... 8-14

8.4 Publications.................................................................... 8-19

8.5 Best Practices ................................................................ 8-22

Link Management............................................................. 8-22

Exercise 8a Paste Special Options .................................... 8-23

Exercise 8b Multi-Model Links ........................................... 8-29

Exercise 8c Managing Multi-Model Links.......................... 8-46

Part 2

Chapter 9 Boolean Operations ................................................... 9-1

9.1 Creation of Bodies ........................................................... 9-3

9.2 Feature Organization ....................................................... 9-6

PartBody ............................................................................ 9-6Geometrical Set ................................................................. 9-6

Axis System ....................................................................... 9-7Design Considerations....................................................... 9-7

Activate and Deactivate ..................................................... 9-7Hide and Show................................................................... 9-7Color................................................................................... 9-7Geometry Display Options ................................................. 9-8

9.3 Boolean Operations ....................................................... 9-10

Assemble ......................................................................... 9-11Add................................................................................... 9-12Remove............................................................................ 9-12Intersect ........................................................................... 9-13Union Trim........................................................................ 9-14

Remove Lump.................................................................. 9-15Boolean Operation Summary........................................... 9-15Naming Conventions........................................................ 9-16

Advantages ...................................................................... 9-17Disadvantages ................................................................. 9-17

9.4 3D Constraints................................................................ 9-18

Constraints Defined in Dialog Box ................................... 9-19Constraint......................................................................... 9-20
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Table of Contents

2011, ASCENT - Center for Technical Knowledge v

Exercise 9a Boolean Operations Overview....................... 9-21

Exercise 9b Boolean Operations........................................ 9-23

Exercise 9c 3D Constraints................................................. 9-40

Exercise 9d RH-LH Part....................................................... 9-47

Exercise 9e Importing Bodies (Optional)........................... 9-56

Chapter 10 Feature Failure Resolution ....................................10-1

10.1 Failures during Feature Creation.................................. 10-3

10.2 Resolution of Update Failures ...................................... 10-6

Update Cycle....................................................................10-8Links ...............................................................................10-10Boundary Representations.............................................10-10

Exercise 10a Update Cycle ............................................... 10-14

Exercise 10b Update Failures ........................................... 10-19

Chapter 11 Additional Features ................................................ 11-1

11.1 Thickness........................................................................ 11-3

11.2 Face Removal .................................................................11-6

11.3 Face Replacement.......................................................... 11-8

Exercise 11a Thickness..................................................... 11-11

Exercise 11b Remove Face............................................... 11-17

Exercise 11c Replace Face ............................................... 11-20

Chapter 12 Knowledge Templates............................................ 12-1

12.1 Knowledge Templates ................................................... 12-3

12.2 Creation of a PowerCopy............................................... 12-4

Preview.............................................................................12-9

12.3 Instantiation of a PowerCopy......................................12-11

12.4 Creation of UserFeatures ............................................ 12-15

Creating a UserFeature..................................................12-15Instantiating a UserFeature ............................................ 12-17

Exercise 12a PowerCopy Creation................................... 12-18Exercise 12b Working with PowerCopies........................ 12-25

Chapter 13 Part Design Tables ................................................. 13-1

13.1 Preparation of a Model...................................................13-3

Rename Parameters ........................................................ 13-3Create Formulas...............................................................13-5
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vi 2011, ASCENT - Center for Technical Knowledge

13.2 Creation of a Part Design Table.................................... 13-6

Create a Design Table With Current Parameters .......... 13-10

Exercise 13a Parameter Setup ......................................... 13-13

Exercise 13b Design Table I ............................................. 13-18

Exercise 13c Design Table II (Optional)........................... 13-26

Chapter 14 Catalogs .................................................................. 14-1

14.1 Catalogs .......................................................................... 14-3

14.2 Creation of a Catalog ..................................................... 14-4

14.3 Cataloging a PowerCopy............................................... 14-9

Instantiate a PowerCopy from the Catalog .................... 14-10

14.4 Creating Part Family Catalogs.................................... 14-11

Exercise 14a Catalogs....................................................... 14-17

Exercise 14b PowerCopy in Catalogs.............................. 14-25

Exercise 14c Using a Catalog........................................... 14-37

Exercise 14d Stator Band (Optional) ............................... 14-46

Chapter 15 Introduction to Automation ................................... 15-1

15.1 Macro Creation ............................................................... 15-3

Macro Commands............................................................ 15-6Macro Libraries ................................................................ 15-7

15.2 Visual Basic (VB) and VBA............................................ 15-9

How Does it Work? .......................................................... 15-9

Object-Oriented Programming ....................................... 15-10Documents ..................................................................... 15-10Windows......................................................................... 15-11Developing New Code ................................................... 15-12VBA Editor...................................................................... 15-12Object Browser............................................................... 15-14Code Window................................................................. 15-15Variables ........................................................................ 15-16

Exercise 15a Selection Automation................................. 15-17

Exercise 15b Editing a Macro ........................................... 15-24

Chapter 16 Projects ................................................................... 16-1

Exercise 16a Bucket ............................................................ 16-3

Exercise 16b Housing Cover .............................................. 16-9

Exercise 16c Landing Gear............................................... 16-21
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Table of Contents

2011, ASCENT - Center for Technical Knowledge vi

Appendix A Feature Recognition............................................... A-1

A.1 Feature Recognition........................................................ A-3

Manual Feature Recognition ..............................................A-3

A.2 Automatic Feature Recognition ..................................... A-5

Local Feature Recognition .................................................A-6Exercise A1 Feature Recognition........................................ A-7

Appendix B Additional Exercises.............................................. B-1

Exercise B1 Re-using Existing Designs ............................. B-3

Exercise B2 Managing Links ............................................. B-17

Appendix C Advanced Exercise Solutions ............................... C-1

C.1 Step by Step Solution for Exercise 1b .......................... C-3
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11

Chapter 1Part Design Overview

Starting with this chapter, you build on the fundamentals of modeling in CATIA. Youlearn new techniques to help create and manage your part designs. These techniqueshelp to ensure that a part design remains flexible and leads to the creation of robustmodels.

This chapter introduces:

Part Design Philosophies

Maintaining Design Intent


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Part Design Overview

2011, ASCENT - Center for Technical Knowledge 13

1.1 Part Design Philosophies

Before creating any part in CATIA, consider the design intent of thepart. By doing so, you can maximize the flexibility of the design.Considering what ifscenarios that might be introduced into the part

helps you to create a robust model that requires minimal effort whenincorporating modifications. Remember that CATIA is a design tool.Consider the following questions when starting a new model:

Default

Reference

Planes

Why use default reference planes? Every part contains three defaultreference planes, as shown in Figure 11. They form a foundation foryour model and cannot be deleted. Reference planes make anexcellent selection as parents for subsequent features, therebyreducing the number of unwanted parent-child relationships.

Figure 11

Base Feature What is the best choice for the Base feature? The Base feature of thepart is the first geometry feature added to the part (e.g., Pad, Spline,or Surface). Select a form that captures the fundamental shape of themodel.

Active Body Which body should be set to the active body in the model? As newfeatures are created, they are added to the active body. These bodiescan be used to perform boolean operations, group features, andseparate model geometry. Features added to one body might not beaccessible to other bodies within the same model. The active body isset by right-clicking it in the specification tree and selectingDefine inWork Object.

Sketch Support What is the best sketch support plane? It is important to carefullyconsider this reference, because it establishes parent-childrelationships. Do not randomly select a sketch support simplybecause you think you must. This might create an unwantedparent-child relationship. Whenever possible, use a default referenceplane to minimize the number of unwanted parent-child relationships.The selection of this reference also affects the default view of themodel.


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Sketcher

References

Which entities should be selected as sketcher references? As youdimension and constrain your sketch, you select references thatdetermine how the sketch reacts to modification. References can beremoved and added as needed in each sketch. Select references thatincorporate your design intent.

PositionedSketch

The use of a positioned sketch is highly recommended. It enables youto locate the origin of the sketch so that it updates correctly.

Standard sketches are also called Slidingsketches. When themodel is modified, it can reposition itself unexpectedly because itsorigin is not constrained.

Positioned sketches enable you to develop the requiredparent-child relationships between features. For example, if thevertical axis of the sketch is constrained to a specific line or edge,the relationship is maintained throughout the design changes.

If you need to translate, copy, or paste the sketch to another

location, it can be done more easily with a positioned sketch.

Dimensions Which dimensions are required to drive the design? CATIA isassociative. You can take advantage of this with an intelligentdimensioning scheme. Place dimensions so that they enablemodifications. The dimensions that are automatically added to thesketch by Auto Constraint are based on the references andsketched geometry that were originally selected. Additionaldimensions can be added as needed to capture the required designintent.

Which dimensions on the part would change? Always check that thedimensioning scheme works correctly by flexing the model. Test asmany what if scenarios as possible.

Parent-Child

Relationships

Which parent-child relationships work the best? Which parent-childrelationships should be avoided? As mentioned earlier, parent-childrelationships are established when selecting the sketch support, aswell as all other references throughout the creation of a feature (e.g.,dimensioning, using or offsetting edges, or the depth option).

Depth Options Which limit type should be used to create features? The selection ofthe limit type affects the feature. Always consider the consequences ifadditional features are added or if other dimensions in the model aremodified. Remember that some depth options result in parent-childrelationships (e.g., Up to next, Up to plane, or Up to surface).


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Formulas Should any formulas be added? Formulas are user-definedmathematical equations used to capture and control design intent in amodel. In CATIA, you can use formulas in features, parts, andassemblies.

Feature Order Which feature order best captures the design intent? The feature

order of a model is important. For example, should a hole be placedbefore or after a Shell feature? Consider this type of question from thebeginning to the end of the modeling process. Use the specificationtree to easily review the feature order at any time during modelcreation.

Multi-body Typically, all of the features that you create are added to the PartBodywithin the specification tree. This linear tree structure is acceptable formodels with a low feature count or simple geometry. CATIA enablesyou to create multiple bodies within a single CATPart model. Thisenables you to structure your model based on your design intent. Animportant reason for creating multiple bodies is to be able to use theBoolean commands.

Using a multi-body approach to create a model provides the followingadvantages:

Update times are reduced.

Features are grouped by function or area, making the model easyto interpret.

Bodies can be shown or hidden independent of each other.

The creation of the part model becomes easier when the model isdivided into smaller, functional areas.

Features (such as a Shell or Fillet) can be restricted to a finite areaof the model.

Boolean

Operations

Boolean operations in CATIA V5 are a powerful design tool. Theability to combine feature-based modeling with boolean operationspermits the creation of robust geometry. Working with various bodieswithin a single part file provides flexibility in design scenarios,promotes concurrent engineering, and enables the display and

manipulation of multiple model states.


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1.2 Maintaining Design Intent

Not all possibilities can be foreseen. CATIA offers tools formanipulating the design when a change is required. They aredescribed in Table 11.

The Feature Definition,Edit Parameters,

Reorder, and Define inWork Objectoptions canalso be accessed byselecting the geometry inthe main window andright-clicking.

Table 11

Option Description

Feature

Definition

Attributes used to create a feature can be modified by

double-clicking on thefeature in the specification tree.

The Feature Definition dialog box opens, enabling you to

modify any aspect of the feature, including the sketch.

Sketch

Definition

A section can be edited directly in the model. The Feature

Definition dialog box does not need to be opened. Expand

the feature in the specification tree and double-click onthe sketch.

Edit

Parameters

Dimensions that are associated with a specific feature

can be modified.

Reorder The feature order can be reordered for any number of

features in the model.

Define in

Work Object

Features can be inserted into the specification tree after

the feature is selected.


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Exercise 1a Locking Insert

In this exercise you will evaluate the level of your knowledge ofCATIA. A proficient CATIA V5 user should be able to create robustmodels that enable design changes to be made quickly and easily,

resulting in predictable changes throughout the model. You will createPads, Holes, Pockets, and Drafts. The completed model is shown inFigure 12.

Figure 12
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Use the drawing shown in Figure 13to create the model.

Figure 13

The part will be molded. To ease the process of removing the partfrom the mold, apply a [0.2deg] draft to the proper faces.
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Exercise 1b Capturing Design Intent in

Sketcher

The intent of this exercise is to demonstrate how design intent can be

captured using sketcher tools and techniques. As with every modelingprocess, you should strive to use the simplest, but most effectivemethods of capturing design intent. A proficient CATIA V5 user cancreate robust models that enable design changes to be made quicklyand easily, resulting in predicable changes throughout the model.

Create the part using the following information:

Figure 14shows an isometric view of the completed pipe model.

Figure 15shows design requirements that must be captured.

Figure 16shows dimensioned drawing views.

Figure 14
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Design

Considerations

Consider the following design requirements, as shown in Figure 15.Note that relations (formulas) cannot be used.

Figure 15

Before you begin modeling, ask the following questions:

What is the best selection for a Base feature?

What will the second feature be?

What will the complete feature order be?

Which references will be used in Sketcher?

The surface of the flange and the end of this pipe segment must remain co-planar.

The outside diameter of both flanges are the same. The pipe segment and flange

outside diameters must automatically update if the inside diameter of the pipe is

changed.Pipe segment FlangeFlange
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How will you incorporate the design requirements outlined inFigure 16?

Which depth options should be used?

Figure 16

When you have completed the Pipemodel, flex it by modifying theinside diameter of the pipe from 30 to [40]. The model updates, asshown in Figure 17.

Figure 17

A step-by-step solution for this exercise can be found in Appendix C.
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Exercise 1c Sketcher Analysis (Optional)

In this exercise, you will create the cooling fins for an aluminium heatsink extrusion. The base geometry has been created for you, as wellas the sketch that defines the cooling fin geometry. Use the Sketch

Analysistool to solve the problem(s) with the sketch. The completedmodel displays as shown in Figure 18.

Figure 18

Goal After you complete this exercise, you will be able to:

Solve sketch problem(s) with minimal instruction
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Task 1 - Open the part.

1. Open HeatSinkExtrusion.CATPart. The model displays asshown in Figure 19.

Figure 19

Task 2 - Create a pad.

1. Attempt to create a Pad feature using Sketch.2.

The sketch cannot be used to create a Pad feature, as shown inthe warning in Figure 110.

Figure 110

2. Click .

3. Click to cancel the creation of the Pad feature.


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Task 3 - Analyze the sketch.

1. Edit Sketch.2 and click (Sketch Solving Status). The sketchstatus indicates that the sketch is fully constrained, as shown inFigure 111.

Figure 111

2. Click (Sketch Analysis).

3. In the Sketch Analysis dialog box, select the Geometrytab. In the

Corrective Actions area, use (Set in Construction Mode) to setthe appropriate sketch geometry in Construction mode, as shownin Figure 112.

Figure 112

Ensure that the Geometry tab is active
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4. Verify that all of the geometry has a status of Isolated, as shown inFigure 113.

Figure 113

Once complete, the sketch displays as shown in Figure 114.

Figure 114

5. Click .
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6. Exit the Sketcher workbench. The model displays as shown inFigure 115.

Figure 115

Task 4 - Create a Pad.

In this task, you will create a Pad feature using the sketch that you justanalyzed. Because the sketch still contains open sections, theapplication continues to display the Feature Definition Error messageuntil the Thickoption is selected in the Pad Definition dialog box.

1. Use the parameters shown in Figure 116to define Pad.2. Select

the back face of the part for the up to plane reference.

Figure 116


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The completed model displays as shown in Figure 117.

Figure 117

2. Save the model and close the file.
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Exercise 1d Sketcher (Optional)

In this exercise, you will create several closed sketches withoutinstructions. Try to complete at least three of the profiles shown inFigure 118, Figure 119, Figure 120, Figure 121, Figure 122,

and Figure 123. Make sure all the sketches are fully constrained,and that no open profiles are in the sketches.

Figure 118


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Figure 119


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Figure 120


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Figure 121

Figure 122


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Figure 123