Assembly Design Fundamentals CATIA Training Exercises Assembly Design Fundamentals Version 5 Release 10 December 2002 EDU-CAT-E-ASM-FX-V5R10 Copyright DASSAULT SYSTEMES 2002

Table of Contents Connector Assembly p. 3 Vice Assembly p. 23 Connector Assembly: Presentation p. 4 Connector Assembly (1): Assembling Component p. 8 Connector Assembly (2): Positioning Components p. 11 Connector Assembly (3): Analyzing the Assembly p. 14 Connector Assembly (4): Editing Part p. 17 Connector Assembly (5): Working with Components p. 20 Vice Assembly p. 23 Vice Assembly: Presentation p. 24 Vice Assembly (1): Creating the Structure p. 27 Vice Assembly (2): Positioning Components p. 29 Vice Assembly (3): Editing Parts p. 33 Vice Assembly (4): Inserting Fitting Components p. 36 Flexible sub-assemblies p. 41 Flexible sub-assemblies : Presentation p. 42 Flexible sub-assemblies (1) :Assembling Components p. 45 Flexible sub-assemblies (2) :Constrain Full Assembly p. 47 Flexible sub-assemblies (3) :Change configuration p. 49 Page set up: PPT 97=>>> width=8.87 “ / height=6.51” (for 850x625 pixels) [or width=21,29 cm & height=15,41 cm] PPT 2000=> width=11.81 “ / height=8.68” (for 850x625 pixels) [or width=28,35 cm & height=20,83 cm] Note: To print the document in A4 format do not forget to check the ‘Scale to Fit Paper’ checkbox in the print panel (otherwise you will miss content) Fonts (ratio=1.333): 97=>> 10, 12, [14], [16], 18, 20, 24, [28], [40] 2000=>13, 16, [18-19], [21-22], 24, 27, 32, [37-38], [53-54] Colors: background= 236,219,183 text & lines= 0,0,128 shadows= 255,251,240 title text= 0,0,128 fills= 250,220,150 accent= 153,51,51 accent & hyperlink= 250,220,150. Course overview: Title position=> horizontal=0.75” / color of title & text=background color= 236,219,183 / image on top (resized to fit) All screens except for course overview: Titles position=> Horizontal= 0.54” / vertical= 0.25” with text box margins left & top= 0.12” / blue text & titles Rule: Titles must have capital letter (upper case) for every significant word (first letter) Copyright DASSAULT SYSTEMES 2002

Connector Assembly Connector Assembly : Presentation Connector Assembly (1): Assembling Components Connector Assembly (2): Positioning Components Connector Assembly (3): Analyzing the Assembly Connector Assembly (4): Editing Part Connector Assembly (5): Working with Components Copyright DASSAULT SYSTEMES 2002

Master Exercise : Presentation You will practice concepts learned throughout the course, by building the master exercise and following the recommended process Copyright DASSAULT SYSTEMES 2002

Connector Assembly: Presentation Exercise Connector Assembly: Presentation 60 mn Objectives : In this exercise you will build the Connector Assembly and modify one of its components You will use : - Product Structure Tools - Constraints - Compass - Analyze Clash - Part Design in-context of Assembly - Standard tools This assembly will be built Copyright DASSAULT SYSTEMES 2002

Design Intent: Connector Assembly 2 instances of the Shell contact constraint Connector Card Assembly with fix-in-space constraint opening 2 coincidence constraints Create and name the assembly (Connector Assembly). Add a sub-assembly (Connector Card assembly) and two instances of the same part (Connector Shell). Assign Instance Names to the Connector Shells. Position each Component and Set constraints between them Analyze for interferences between the components and correct the interference by making an opening for the Connector Card Assembly. Add two instances of a Screw. Copyright DASSAULT SYSTEMES 2002

Design Process: Connector Assembly Create and name the assembly, insert components, duplicate the shell , assign Instance Names , and save the assembly 1 2 Position the components using constraints. Check for interference. 3 4 Edit the Shell by designing in-context of the assembly 5 Pattern the Screw. Copyright DASSAULT SYSTEMES 2002

Connector Assembly (1) : Assembling Components Exercise Connector Assembly (1) : Assembling Components 15 mn In this step you create and name an assembly, insert components, duplicate the shell, assign Instance Names, and save the assembly Copyright DASSAULT SYSTEMES 2002

And now practice in the context of the Connector Assembly Create and name the assembly, insert components, duplicate the shell , assign Instance Names , and save the assembly 2 1 Position the components using constraints. Check for interference. 3 4 Edit the Shell by designing in-context of the assembly 5 Pattern the Screw. Copyright DASSAULT SYSTEMES 2002

Do It Yourself Inserted components Duplicate instance of Connector Shell 1- Create a new CATProduct document and set the part number to be Connector Assembly. 2- Add the Connector Card Assembly (CATASMConnector_Card_Assembly.CATProduct) sub- assembly and the Connector Shell (CATASMConnector_Shell.CATPart). 3- Duplicate the Connector Shell component. 4- Assign Instance Names to the Connector Shell components. 5- Save the assembly as Connector Assembly 2.CATProduct. To avoid looking for the correct folder where the inserted components are stored, begin a Save as with the loaded Document , then Cancel it. Load: Mex1/CATASMConnector_Assembly_1.CATProduct Copyright DASSAULT SYSTEMES 2002

Connector Assembly (2) : Positioning Components Exercise Connector Assembly (2) : Positioning Components 20 mn In this step you will Fix-in-Space the Connector Card Assembly and set Coincidence and Contact constraints between the Shells and the Connector Card Copyright DASSAULT SYSTEMES 2002

And Now Practice in the Context Of the Connector Assembly 1 2 Create and name the assembly, insert components, duplicate the shell , assign Instance Names , and save the assembly Position the components using constraints. Check for interference. 3 4 Edit the Shell by designing in-context of the assembly 5 Pattern the Screw. Copyright DASSAULT SYSTEMES 2002

Do It Yourself Inside Face 1- Fix-in-space the Connector Card Assembly. 2- Set an axial coincidence between corresponding holes of the Top Shell and the Connector Card. 3- Set a contact between the top face of the card and the inside face of the Top Shell. 4- Set an axial coincidence between corresponding holes of the Bottom Shell and the Connector Card. 5- Set a contact between the underside face of the card and the inside face of the Bottom Shell. 6- Save the assembly as Connector_Assembly 3.CATProduct. Load: Mex2/CATASMConnector_Assembly_2.CATProduct Copyright DASSAULT SYSTEMES 2002

Connector Housing (3) : Analyzing the Assembly Exercise Connector Housing (3) : Analyzing the Assembly 15 mn In this step you will check for interference between the Connector Card Assembly and Connector Shells Copyright DASSAULT SYSTEMES 2002

And now practice in the context of the Connector Assembly 1 2 Create and name the assembly, insert components, duplicate the shell , assign Instance Names , and save the assembly Position the components using constraints. 3 Check for interference. 4 5 Edit the Shell by designing in-context of the assembly Pattern the Screw. Copyright DASSAULT SYSTEMES 2002

Do It Yourself Connector Card Assembly Connector Shell 1- Analyze for clash between the Connector Card Assembly and Connector Shells. 2- Do not make any changes to the assembly at this time. 3- Save the assembly as Connector Assembly 4.CATProduct for use in the next step. Load: Mex3/CATASMConnector_Assembly_3.CATProduct Copyright DASSAULT SYSTEMES 2002

Connector Assembly (4) : Editing Part Exercise Connector Assembly (4) : Editing Part 30 mn In this step you will eliminate the interference between the Connector Card Assembly and Connectors Shells by editing the Connector Shell in-context of the assembly Copyright DASSAULT SYSTEMES 2002

And now practice in the context of the Connector Assembly 2 Create and name the assembly, insert components, duplicate the shell , assign Instance Names , and save the assembly 1 Position the components using constraints. 3 Check for interference. 4 Edit the Shell by designing in-context of the assembly 5 Pattern the Screw. Copyright DASSAULT SYSTEMES 2002

Do It Yourself Dimensions for the pocket in the Connector Shell Connector Shell showing the new pocket 1- No-show the Bottom Shell. 2- Modify the Connector Shell to suppress the clash with the Connector Card Assembly. 3- Save the Connector Shell as Connector Shell 5. 4- Save the assembly as Connector Assembly 5.CATProduct. Load: Mex4/CATASMConnector_Assembly_4.CATProduct Copyright DASSAULT SYSTEMES 2002

Connector Assembly (5) : Working with Components Exercise Connector Assembly (5) : Working with Components 10 mn In this step you will add and constrain a Screw and duplicate the Screw and its constraints using a pattern Copyright DASSAULT SYSTEMES 2002

And now practice in the context of the Connector Assembly 1 2 Create and name the assembly, insert components, duplicate the shell , assign Instance Names , and save the assembly Position the components using constraints. 3 Check for interference. 4 Edit the Shell by designing in-context of the assembly 5 Pattern the Screw. Copyright DASSAULT SYSTEMES 2002

Do It Yourself Screw Pattern To avoid looking for the correct folder where the inserted components are stored, begin a Save as with the loaded Document , then Cancel it. 1- Add the Screw part. 2- Set an axial coincidence between corresponding hole of the Top Shell and the Screw. 3- Set a contact between the face of the Top Shell and face of the Screw. 4- Use the rectangular pattern in the Connector Shell to duplicate the Screw 5- Save the assembly as Connector Assembly 6.CATProduct. Load: Mex5/CATASMConnector_Assembly_5.CATProduct Copyright DASSAULT SYSTEMES 2002

Vice Assembly Vice Assembly : Presentation Vice Assembly (1): Creating the Structure Vice Assembly (2): Positioning Components Vice Assembly (3): Editing Parts Vice Assembly (4): Inserting Fitting Components from catalogs Copyright DASSAULT SYSTEMES 2002

Vice Assembly: Presentation Exercise Vice Assembly: Presentation 70 mm Objectives : In this exercise you will build the Vice Assembly, modify two of its components and complete the fitting by inserting components from catalogs You will use : - Product Structure Tools - Constraints - Compass - Catalog Browser - Part Design in-context of the assembly - Standard tools This assembly will be built Copyright DASSAULT SYSTEMES 2002

Design Intent: Vice Assembly Movable Jaw FixedComponent RotatingComponent Create and name the root assembly (Vice Assembly) and its sub assemblies (RotatingComponent, FixedComponent and AxisAssembly) Add Components inside appropriate assemblies : - Axis and Axis Nut in AxisAssembly - 2ndStaticJaw, Static Jaw , Jaw Holder Flange (2 ones) and Movable Jaw Holder in FixedComponent - Movable Jaw in Vice Assembly Position the Components (constrain them as shown below) Design holes in both jaws in order to allow fitting Browse GeneralEnd catalog in order to find and insert fitting elements in appropriate assemblies Copyright DASSAULT SYSTEMES 2002

Design Process: Vice Assembly 1 Create and name the assembly, insert components, assign Instance Names, and save the assembly 2 Position the components using constraints 3 Edit both Static Jaws by designing in context of the assembly 4 Insert fitting components from catalog and instantiate and constrain them in appropriate assemblies Copyright DASSAULT SYSTEMES 2002

Vice Assembly (1) : Creating the Structure Exercise Vice Assembly (1) : Creating the Structure 15 mn In this step you create and name a root assembly and its sub-assemblies, insert components, assign Instance Names, and save all the assemblies Copyright DASSAULT SYSTEMES 2002

Do It Yourself New Products New Component 1- Create a new CATProduct document,set the part number to be ViceAssembly and save it. 2- Create the structure above with New Product and New Component commands. 3- Insert following parts in their destination assemblies : in AxisAssembly : CATASMAxisNut + CATASMAxis in RotatingComponent : CATASMBigScrew in FixedComponent : CATASM2ndStaticJaw + CATASMJawHolderFlange (take 2 instances of it) + CATASMMovableJawHolder + CATASMStaticJaw in ViceAssembly : CATASMMovableJaw 4- Set instance names of Jaw Holder Flange to “Right Flange” and “Left Flange” 5- Save the assembly as CATASMViceAssembly 2.CATProduct in StudentFolder. Load: Addex1/CATASMViceAssemblyStep1.CATProduct Copyright DASSAULT SYSTEMES 2002

Vice Assembly (2) : Positioning Components Exercise Vice Assembly (2) : Positioning Components 20 mn In this step you create constraints to position components relatively to each other in the correct active assemblies. Copyright DASSAULT SYSTEMES 2002

Do It Yourself (1/3) 2- In RotatingComponent , create coincidence and contact between highlighted elements and save the active assembly as “RotatingComponent3”in StudentFolder 1- In AxisAssembly , create coincidence and contact between highlighted elements Coincidence Coincidence Contact Line Contact Load: Addex2/CATASMViceAssemblyStep2.CATProduct Copyright DASSAULT SYSTEMES 2002

Do It Yourself (2/3) 3- In FixedComponent,Fix in space MovableJawHolder and constrain geometric elements as shown and save the active assembly as “FixedComponent3” in StudentFolder Fix in space = Offsets of 0mm with same orientation (8) = Contacts (4) Copyright DASSAULT SYSTEMES 2002

Do It Yourself (3/3) 4- In ViceAssembly, constrain geometric elements as shown and save the active assembly as “CATASMViceAssemblyStep3” in StudentFolder Two contacts contact coincidence Copyright DASSAULT SYSTEMES 2002

Vice Assembly (3) : Editing parts Exercise Vice Assembly (3) : Editing parts 20 mn In this step you design two parts in context of the assembly in order to allow the fitting Copyright DASSAULT SYSTEMES 2002

Do It Yourself (1/2) 1- Set wireframe rendering style for transparency “PatternPoints” Sketch Concentricity Concentricity Concentricity Concentricity 2- In 2ndStaticJaw a- create a hole (diameter = 11mm, up to next) in the front face of the Static Jaw (a counterbored one) b- set the hole concentric to one of the holes in parts behind c- create a sketch based on the same front face(name it PatternPoints) and draw 3 points concentric to last 3 holes in parts behind d- create a user pattern of the hole using “PatternPoints” for the Positions and keeping specifications of the object to pattern e- save the new part under another name (CATASM2ndStativJaw4.CATPart) under StudentFolder Load: Addex3/CATASMViceAssemblyStep3.CATProduct Copyright DASSAULT SYSTEMES 2002

Do It yourself (2/2) “PatternPoints” Sketch Concentricity Concentricity Concentricity Concentricity 3- In StaticJaw a- create a hole (diameter = 11mm, up to next) in the front face of the Static Jaw (a counterbored one) b- get it concentric to one of the holes in parts behind c- create a sketch based on the same front face and draw 3 points concentric to last 3 holes in parts behind, rename the Sketch “PatternPoints” d- create a user pattern of the hole using “PatternPoints” for the Positions and keeping specifications for selected object e- save the part under another name (CATASMStaticJaw4.CATPart) 4- Set the FixedComponent active and save it as “FixedComponent4.CATProduct” under StudentFolder 5- set back the “shading with edges”rendering style Copyright DASSAULT SYSTEMES 2002

Vice Assembly (4) : Inserting Fitting Components Exercise Vice Assembly (4) : Inserting Fitting Components 15 mn In this step you will insert fitting elements from a catalog. You will also constrain and instantiate them in their destination assemblies Copyright DASSAULT SYSTEMES 2002

Do It Yourself (1/4) 1- In FixedComponent we want to insert and instantiate screws with fitting dimensions a- To determine diameters and lengths of inserted screws, measure diameters of threaded holes and thickness that screws have to go through Note carefully the measured diameters and distances because you will need them to make queries on the end chapter of a catalog Inserted Screws Crossed thickness Crossed thickness Load: Addex4/CATASMViceAssemblyStep4.CATProduct Threaded Holes Copyright DASSAULT SYSTEMES 2002

Do It Yourself (2/4) b- Browse GeneralEnd.catalog to select and insert Hexagonal Socket Head Screws in FixedComponent : make queries in chapter to get those conditions respected - diameters of selected screws must be equal to diameters of threaded holes they go into - lengths must be superior or equal to (crossed thickness +15mm) Insert the selected screws in FixedComponent c- Instantiate and constrain as many time as needed (reuse Pattern if possible) inserted screws Copyright DASSAULT SYSTEMES 2002

Do It Yourself (3/4) 2- In ViceAssembly we Want to insert Outer Retaining Ring that fit to the big Screw a- to determine what ring you will insert, measure the diameter of the groove Note carefully the measured diameter because you will need it to make a query on the end chapter of the catalog Diameter to measure Groove Diameter of retaining ring Copyright DASSAULT SYSTEMES 2002

Do It Yourself (4/4) b- Browse GeneralEnd catalog to select and insert an Outer Retaining Ring in ViceAssembly : select the ring in order to get this conditions respected - the Groove Diameter of the selected retaining ring must be equal to the measured diameter c- Insert the selected ring in Vice Assembly and constrain it to the Big screw coincidence contact Copyright DASSAULT SYSTEMES 2002

Flexible Assemblies Flexible Assemblies : Presentation Flexible Assemblies (1): Assembling Components Flexible Assemblies (2): Constrain Full Assembly Flexible Assemblies (3): Change Configuration Copyright DASSAULT SYSTEMES 2002

Exercise Flexible Assemblies : Presentation Objectives : In this exercise you will build the Full Assembly and use flexible /rigid sub-assemblies You will use : - Product Structure Tools - Constraints - Use flexible / Rigid sub-assemblies command to create ‘some configurations’ 25 mm Copyright DASSAULT SYSTEMES 2002

Design Intent: Flexible Assemblies Skills needed : Insert existing components to create a assembly Duplicate a sub-assembly Constraint a assembly Making a product flexible in order to drive dimension All elements you need to complete exercise : sub-clamp.CATProduct. Clamp-pad.CATPart. Copyright DASSAULT SYSTEMES 2002

Design Process: Flexible Assemblies. 1 Create and name the assembly, insert components from sub-clamp.CATProduct and clamp-pad Constrain the assembly 2 Change configuration of one sub-assembly 3 Copyright DASSAULT SYSTEMES 2002

Exercise Flexible Assemblies (1) : Assembling Components In this step you create and name an assembly, insert components, duplicate assembly and save the full assembly 3 mn Copyright DASSAULT SYSTEMES 2002

Do It Yourself Create a new assembly: Name it full-clamp Insert components Duplicate sub-clamp Save it Load : sub-clamp.CATProduct clamp-pad.CATPart Copyright DASSAULT SYSTEMES 2002

Exercise Flexible Assemblies (2) : Constrain Full Assembly In this step you constrain full-clamp 15 mn Copyright DASSAULT SYSTEMES 2002

Do It Yourself Constrain the full assembly in design intent: Fix in-space clamp-pad Set surface-contact constraints following the picture Set axial coincidence and points coincidence. Copyright DASSAULT SYSTEMES 2002

Exercise Flexible Assemblies (3) : Change configuration In this step with flexible/Rigid command, you simulate two configurations for sub-clamp assembly - First configuration:’Open’ (value=60 mm) - Second configuration:’Close’ (value=72.7 mm) 7 mn Copyright DASSAULT SYSTEMES 2002

Do It Yourself Make flexible one instance of sub-clamp Edit and change numerical value of the offset constraint Measure the distance to obtain the ‘Close’ configuration Load : full-clamp.CATProduct Copyright DASSAULT SYSTEMES 2002