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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 1
Wildfire 5, Release 20, Revision 1.0

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866-527-2368
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Table of Contents

Table of Contents
Part 1
Chapter 1 Part Design Overview................................................. 1-1

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

Default Reference Planes .................................................. 1-3
Base Feature...................................................................... 1-3
Active Body ........................................................................ 1-3
Sketch Support ................................................................... 1-3
Sketcher References .......................................................... 1-4
Positioned Sketch............................................................... 1-4
Dimensions......................................................................... 1-4
Parent-Child Relationships ................................................. 1-4
Depth Options .................................................................... 1-4
Formulas ............................................................................ 1-5
Feature Order ..................................................................... 1-5
Multi-body ........................................................................... 1-5
Boolean 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 ............................................................ 2-6
Pattern Formulas ................................................................ 2-7
Exploding Patterns ............................................................. 2-8

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

Exercise 2b Simplified Representations............................ 2-22
Exercise 2c Engine Cover ................................................... 2-25
Exercise 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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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

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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....................................................................... 4-17
Pulling Direction ............................................................... 4-18
Reference Surface ........................................................... 4-18
Exercise 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 ................................................................................. 5-4
Lines................................................................................... 5-6
Planes ................................................................................ 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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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

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

Edge Fillet .......................................................................... 6-4
Variable Radius Fillet ......................................................... 6-7
Chordal Fillet ...................................................................... 6-9
Face-Face Fillet.................................................................. 6-9
6.2 Creating Reflect Line Draft ............................................ 6-11
6.3 Creating Advanced Draft ............................................... 6-13
6.4 Draft and Fillet Failure Resolution ................................ 6-17
Fillet Failure Resolution .................................................... 6-17
Draft 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 ......................................................................... 7-6
On 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 .................................................. 7-19

Exercise 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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Advantages ........................................................................ 8-3

Disadvantages ................................................................... 8-3
8.2 Copy and Paste Special................................................... 8-4
8.3 External Links................................................................... 8-9
Links Tab............................................................................ 8-9
Pointed 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

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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 ............................................................................ 9-6
Geometrical Set ................................................................. 9-6
Axis System ....................................................................... 9-7
Design Considerations ....................................................... 9-7
Activate and Deactivate ..................................................... 9-7
Hide and Show................................................................... 9-7
Color................................................................................... 9-7
Geometry Display Options ................................................. 9-8
9.3 Boolean Operations ....................................................... 9-10
Assemble ......................................................................... 9-11
Add................................................................................... 9-12
Remove............................................................................ 9-12
Intersect ........................................................................... 9-13
Union Trim........................................................................ 9-14
Remove Lump.................................................................. 9-15
Boolean Operation Summary........................................... 9-15
Naming Conventions........................................................ 9-16
Advantages ...................................................................... 9-17
Disadvantages ................................................................. 9-17

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

Constraints Defined in Dialog Box ................................... 9-19
Constraint......................................................................... 9-20

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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

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

Update Cycle.................................................................... 10-8
Links ............................................................................... 10-10
Boundary 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 .................................................. 12-15
Instantiating a UserFeature ............................................ 12-17
Exercise 12a PowerCopy Creation................................... 12-18
Exercise 12b Working with PowerCopies........................ 12-25

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

13.1 Preparation of a Model................................................... 13-3
Rename Parameters ........................................................ 13-3
Create Formulas............................................................... 13-5

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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

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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............................................................ 15-6
Macro Libraries ................................................................ 15-7
15.2 Visual Basic (VB) and VBA............................................ 15-9
How Does it Work? .......................................................... 15-9
Object-Oriented Programming ....................................... 15-10
Documents ..................................................................... 15-10
Windows......................................................................... 15-11
Developing New Code ................................................... 15-12
VBA Editor...................................................................... 15-12
Object Browser............................................................... 15-14
Code Window................................................................. 15-15
Variables ........................................................................ 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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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-6
Exercise 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

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

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

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Chapter 1

Part Design Overview

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

This chapter introduces:

9Part Design Philosophies

9Maintaining Design Intent

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Part Design Overview

1.1 Part Design Philosophies

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

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Default
Reference
Planes

Before creating any part in CATIA, consider the design intent of the
part. By doing so, you can maximize the flexibility of the design.
Considering what if scenarios that might be introduced into the part
helps you to create a robust model that requires minimal effort when
incorporating modifications. Remember that CATIA is a design tool.
Consider the following questions when starting a new model:

Figure 11

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

Active Body

Which body should be set to the active body in the model? As new
features are created, they are added to the active body. These bodies
can be used to perform boolean operations, group features, and
separate model geometry. Features added to one body might not be
accessible to other bodies within the same model. The active body is
set by right-clicking it in the specification tree and selecting Define in
Work Object.

Base Feature

Sketch Support

What is the best sketch support plane? It is important to carefully

consider this reference, because it establishes parent-child
relationships. Do not randomly select a sketch support simply
because you think you must. This might create an unwanted
parent-child relationship. Whenever possible, use a default reference
plane to minimize the number of unwanted parent-child relationships.
The selection of this reference also affects the default view of the
model.

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CATIA: Advanced Part Design

Which entities should be selected as sketcher references? As you

dimension and constrain your sketch, you select references that
determine how the sketch reacts to modification. References can be
removed and added as needed in each sketch. Select references that
incorporate your design intent.

Positioned
Sketch

The use of a positioned sketch is highly recommended. It enables you

to locate the origin of the sketch so that it updates correctly.
Standard sketches are also called Sliding sketches. When the
model is modified, it can reposition itself unexpectedly because its
origin is not constrained.
Positioned sketches enable you to develop the required
parent-child relationships between features. For example, if the
vertical 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.

Sketcher
References

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Dimensions

Which dimensions are required to drive the design? CATIA is

associative. You can take advantage of this with an intelligent
dimensioning scheme. Place dimensions so that they enable
modifications. The dimensions that are automatically added to the
sketch by Auto Constraint are based on the references and
sketched geometry that were originally selected. Additional
dimensions can be added as needed to capture the required design
intent.
Which dimensions on the part would change? Always check that the
dimensioning scheme works correctly by flexing the model. Test as
many what if scenarios as possible.

Parent-Child
Relationships

Depth Options

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Which parent-child relationships work the best? Which parent-child

relationships should be avoided? As mentioned earlier, parent-child
relationships are established when selecting the sketch support, as
well as all other references throughout the creation of a feature (e.g.,
dimensioning, using or offsetting edges, or the depth option).
Which limit type should be used to create features? The selection of
the limit type affects the feature. Always consider the consequences if
additional features are added or if other dimensions in the model are
modified. Remember that some depth options result in parent-child
relationships (e.g., Up to next, Up to plane, or Up to surface).

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Part Design Overview

Should any formulas be added? Formulas are user-defined

mathematical equations used to capture and control design intent in a
model. In CATIA, you can use formulas in features, parts, and
assemblies.

Feature Order

Which feature order best captures the design intent? The feature
order of a model is important. For example, should a hole be placed
before or after a Shell feature? Consider this type of question from the
beginning to the end of the modeling process. Use the specification
tree to easily review the feature order at any time during model
creation.

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Formulas

Multi-body

Typically, all of the features that you create are added to the PartBody
within the specification tree. This linear tree structure is acceptable for
models with a low feature count or simple geometry. CATIA enables
you to create multiple bodies within a single CATPart model. This
enables you to structure your model based on your design intent. An
important reason for creating multiple bodies is to be able to use the
Boolean commands.
Using a multi-body approach to create a model provides the following
advantages:

Boolean
Operations

Update times are reduced.

Features are grouped by function or area, making the model easy
to interpret.
Bodies can be shown or hidden independent of each other.
The creation of the part model becomes easier when the model is
divided into smaller, functional areas.
Features (such as a Shell or Fillet) can be restricted to a finite area
of the model.

Boolean operations in CATIA V5 are a powerful design tool. The

ability to combine feature-based modeling with boolean operations
permits the creation of robust geometry. Working with various bodies
within 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 for
manipulating the design when a change is required. They are
described in Table 11.

Table 11
Description

Feature
Definition

Attributes used to create a feature can be modified by

double-clicking on the feature 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 on
the 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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Option

The Feature Definition,

Edit Parameters,
Reorder, and Define in
Work Object options can
also be accessed by
selecting the geometry in
the main window and
right-clicking.

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Part Design Overview

Exercise 1a

Locking Insert

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In this exercise you will evaluate the level of your knowledge of

CATIA. A proficient CATIA V5 user should be able to create robust
models that enable design changes to be made quickly and easily,
resulting in predictable changes throughout the model. You will create
Pads, Holes, Pockets, and Drafts. The completed model is shown in
Figure 12.

Figure 12

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

Figure 13

The part will be molded. To ease the process of removing the part
from the mold, apply a [0.2deg] draft to the proper faces.

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Part Design Overview

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 modeling
process, you should strive to use the simplest, but most effective
methods of capturing design intent. A proficient CATIA V5 user can
create robust models that enable design changes to be made quickly
and easily, resulting in predicable changes throughout the model.

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Create the part using the following information:

Figure 14 shows an isometric view of the completed pipe model.
Figure 15 shows design requirements that must be captured.
Figure 16 shows dimensioned drawing views.

Figure 14

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CATIA: Advanced Part Design

Design
Considerations

Consider the following design requirements, as shown in Figure 15.

Note that relations (formulas) cannot be used.

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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.
Flange
Pipe segment
Flange

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?

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How will you incorporate the design requirements outlined in

Figure 16?
Which depth options should be used?

Figure 16

When you have completed the Pipe model, flex it by modifying the
inside diameter of the pipe from 30 to [40]. The model updates, as
shown 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)

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In this exercise, you will create the cooling fins for an aluminium heat
sink extrusion. The base geometry has been created for you, as well
as the sketch that defines the cooling fin geometry. Use the Sketch
Analysis tool to solve the problem(s) with the sketch. The completed
model displays as shown in Figure 18.

Figure 18

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

9 Solve sketch problem(s) with minimal instruction

Goal

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Part Design Overview

Task 1 - Open the part.

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1. Open HeatSinkExtrusion.CATPart. The model displays as

shown 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 in

the 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.

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1. Edit Sketch.2 and click

(Sketch Solving Status). The sketch
status indicates that the sketch is fully constrained, as shown in
Figure 111.

Figure 111

2. Click

(Sketch Analysis).

3. In the Sketch Analysis dialog box, select the Geometry tab. In the
Corrective Actions area, use
(Set in Construction Mode) to set
the appropriate sketch geometry in Construction mode, as shown
in Figure 112.

Ensure that the Geometry tab is active

Figure 112

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Part Design Overview

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4. Verify that all of the geometry has a status of Isolated, as shown in

Figure 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 in

Figure 115.

Figure 115

Task 4 - Create a Pad.

In this task, you will create a Pad feature using the sketch that you just
analyzed. Because the sketch still contains open sections, the
application continues to display the Feature Definition Error message
until the Thick option is selected in the Pad Definition dialog box.

1. Use the parameters shown in Figure 116 to 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)

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In this exercise, you will create several closed sketches without

instructions. Try to complete at least three of the profiles shown in
Figure 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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Part Design Overview

Figure 121

Figure 122

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Figure 123

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