CETOL 6 O Basic Training Manual V8 1 For ProENGINEER 3 52 MB PDF

Zero Tolerance for Error
Basic Training Manual

Version 8.1
for Pro/ENGINEER
(2009.0216)
CETOL 6
Version 8.1 for Pro/ENGINEER
Basic Training Manual
Revision History
Rev. No. Date Description
20080602 2 Jun. 2008 Beta version
20080625 25 June 2008 Initial release
20080703 3 July 2008 Corrections and Revisions
20080723 23 July 2008 Corrections
20080903 3 Sept. 2008 8.1 Production release
20090216 16 Feb. 2009 Corrections and Revisions
Copyright 2009, Sigmetrix, LLC, All Rights Reserved.
Printed in the United States of America. Except as permitted under the United States Copyright Act of
1976, no part of this publication may be reproduced or distributed in any form or by any means, or
stored in a data base or retrieval system, without the prior written permission of the publisher.
The information and/or drawings set forth in this document and all rights in and to inventions disclosed
herein and patents that might be granted thereon disclosing or employing the materials, methods,
techniques, or apparatus described herein are the exclusive property of Sigmetrix, LLC.
No disclosure of information or drawing shall be made to any other person or organization without the
prior consent of Sigmetrix, LLC.
Sigmetrix, LLC
105 West Virginia Street
McKinney, TX 75069
Produced by Sigmetrix, LLC.
Trademarks
CETOL 6 and CETOL Six Sigma are trademarks of Sigmetrix, LLC.
Pro/ENGINEER is a registered trademark of PTC.
Table of Contents
Training Introduction ....................................................................................................... 1-1
Chapter 1. CETOL Overview .......................................................................................... 1-1
Lesson 1-1. The CETOL User Interface............................................................................... 1-2
Starting CETOL & Pro/E ................................................................................................................ 1-2
The CETOL 6 Modeling Interface ................................................................................................ 1-2
Interacting with Pro/ENGINEER .................................................................................................... 1-5
Options ............................................................................................................................................ 1-5
Getting Help .................................................................................................................................... 1-5
Exercise 1-1: CETOL Interface Basics..................................................................................... 1-6
Lesson 1-2. The CETOL Model ......................................................................................... 1-11
Exercise 1-2: Exploring a CETOL Model .............................................................................. 1-12
Lesson 1-3. The CETOL 6 Analyzer ............................................................................... 1-14
Analysis View................................................................................................................................. 1-14
Exercise 1-3: Running an Analysis......................................................................................... 1-16
Chapter 2. Fundamentals.................................................................................................. 2-1
Lesson 2-1. Tolerance Fundamentals ................................................................................... 2-2
Tolerance Design Process............................................................................................................... 2-2
Dimensions, Variations and Tolerances.......................................................................................... 2-2
Causes of Variation ......................................................................................................................... 2-3
Worst-Case Design and Analysis .................................................................................................... 2-5
Exercise 2-1: Worst-Case Analysis of a Shaft.......................................................................... 2-6
Statistical Design and Analysis ....................................................................................................... 2-7
Exercise 2-2: Calculating Part Quality Metrics ...................................................................... 2-12
Exercise 2-3: Analysis of a Shaft............................................................................................ 2-13
Chapter 3. Measurements................................................................................................. 3-1
Lesson 3-1. Measurements ................................................................................................... 3-2
Adding Measurements ..................................................................................................................... 3-2
Measurement Properties ................................................................................................................. 3-3
Exercise 3-1: Defining Measurements...................................................................................... 3-8
Chapter 4. Introduction to Assembly Modeling .............................................................. 4-1
Lesson 4-1. The CETOL Assembly Model .......................................................................... 4-2
Adding Joints ................................................................................................................................... 4-2
Assembly Model Structure............................................................................................................... 4-3
Joint Properties ............................................................................................................................... 4-4
Lesson 4-2. Setting Degrees-of-Freedom............................................................................. 4-6
Setting the Degrees of Freedom ...................................................................................................... 4-6
Degrees-of-Variance ....................................................................................................................... 4-7
Under-Constraints and Over-Constraints....................................................................................... 4-9
Modifying Joint DOFs................................................................................................................... 4-11
Checking the Assembly Constraints .............................................................................................. 4-12
Exercise 4-1: Piston/Cylinder Sub-Assembly .........................................................................4-14
Chapter 5. Introduction to Part Modeling ........................................................................ 5-1
Lesson 5-1. The CETOL Part Model .................................................................................... 5-2
Part Model Structure........................................................................................................................5-3
Lesson 5-2. Features.............................................................................................................. 5-3
Adding Features ...............................................................................................................................5-3
Feature Properties ...........................................................................................................................5-3
Lesson 5-3. Constraints......................................................................................................... 5-4
Constraint types................................................................................................................................5-4
Constrain Feature Wizard ............................................................................................................5-5
Adding Constraints...........................................................................................................................5-6
Constraint Properties.......................................................................................................................5-6
Feature Order ..................................................................................................................................5-8
Lesson 5-4. Variables............................................................................................................ 5-8
Invariant variables ...........................................................................................................................5-8
Variable Properties ..........................................................................................................................5-8
Highlighing Dimensions and Variables ...........................................................................................5-9
Exercise 5-1: Defining a Dimensioning Scheme.....................................................................5-10
Chapter 6. Creating Accurate Assembly Models............................................................. 6-1
Lesson 6-1. More on setting Degrees-of-Freedom ............................................................... 6-2
Modeling Physical Constraints ........................................................................................................6-2
Fixing DOF Problems in the Tolerance Model ...............................................................................6-4
Solving for Closure...........................................................................................................................6-5
Exercise 6-1: Modeling small planar contact ............................................................................6-7
Exercise 6-2: Modeling thin cylindrical contact......................................................................6-10
Lesson 6-2. Assembly Variation ......................................................................................... 6-12
Assembly Process Variables...........................................................................................................6-12
Lesson 6-3. Dealing with Assembly Clearance .................................................................. 6-13
Fastened Interfaces ........................................................................................................................6-13
Exercise 6-3: Modeling Fastened Interfaces ...........................................................................6-15
Exercise 6-4: Changing Fastener Joint Bias Condition ...........................................................6-20
Exercise 6-5: Modeling Fastener Float....................................................................................6-23
Lesson 6-4. Basic Fit Analysis............................................................................................ 6-24
Exercise 6-6: Modeling for Assembly Fit .................................................................................6-1
Lesson 6-5. Multi-level Assemblies...................................................................................... 6-3
Exercise 6-7: Medical Sprayer Assembly .................................................................................6-4
Lesson 6-6. Configurations ................................................................................................... 6-9
Exercise 6-8: Configurations for Sprayer Assembly ...............................................................6-10
Chapter 7. Creating Accurate Dimensioning Schemes.................................................... 7-1
Lesson 7-1. Defining an Accurate Part Overlay Model........................................................ 7-2
Dimension Types ..............................................................................................................................7-2
Defining the Topology of the Part....................................................................................................7-2
Relating Datums to Geometry Features .......................................................................................... 7-7
Lesson 7-2. Checking the Dimensioning Scheme ................................................................ 7-8
DOF states....................................................................................................................................... 7-8
Constraint Order ............................................................................................................................. 7-8
Exercise 7-1: Defining Dimensions and Topology................................................................. 7-10
Lesson 7-3. Applying Geometric Tolerances ..................................................................... 7-16
Adding Geometric Tolerances....................................................................................................... 7-16
Datum Reference Frames .............................................................................................................. 7-16
Geometric Tolerance Properties ................................................................................................... 7-17
Constraint Order ........................................................................................................................... 7-17
Exercise 7-2: Adding Geometric Tolerances to a Part ........................................................... 7-19
Exercise 7-3: Overlay Model for a Plate ................................................................................ 7-22
Chapter 8. Defining Dimensional Variation .................................................................... 8-1
Lesson 8-1. Tolerances & Distributions ............................................................................... 8-2
Component Variation Rules ............................................................................................................ 8-2
Invariant Variables.......................................................................................................................... 8-3
Exercise 8-1: Defining Tolerances and Variation..................................................................... 8-4
Chapter 9. Reviewing and Interpreting Results ............................................................... 9-1
Lesson 9-1. Reviewing Results of Derivative-based Analysis............................................. 9-2
Variation Plots................................................................................................................................. 9-2
Quality Metrics................................................................................................................................ 9-3
Sensitivities ...................................................................................................................................... 9-3
Contributions................................................................................................................................. 9-10
Modifying Analyzer Layouts.......................................................................................................... 9-13
Reports........................................................................................................................................... 9-16
Exercise 9-1: Reviewing and Interpreting Results in the Modeler ......................................... 9-17
Exercise 9-2: Reviewing and Interpreting Results in the Analyzer........................................ 9-19
Chapter 10. File Management and Data Reuse.............................................................. 10-1
Lesson 10-1. Data Management ........................................................................................... 10-2
Exercise 10-1: Importing CETOL models from .cxm files .................................................... 10-3
Chapter 11. Applying CETOL 6.................................................................................. 11-1
Lesson 11-1. Gaining Confidence in your Results ............................................................... 11-2
Exercise 11-1: Complex Part Overlay .................................................................................... 11-4
Exercise 11-2: Cam-Rocker Mechanism ................................................................................ 11-6
Completing Basic Training.......................................................................................................... 11-11
Applying CETOL 6 to Your Models .......................................................................................... 11-11
Training Introduction
This training manual is intended to be used as a Basic Training Guide for a user who is new to
CETOL 6 Version 8.1. It has been written with enough completeness and detail to be used as a
self-paced training manual.
This manual has been written in modular format. Each chapter has been written to teach a specific
aspect of the software. The chapters are broken down into one or more lessons. Most lessons have
exercises to complete.
In order to get the most out of this training manual, please read each lesson carefully before going on
to the exercise. Take your time as you are going through the exercises. Make sure that you
understand each step before going on to the next.
This training guide does not serve as complete documentation of the CETOL software. Although the
most important functionality of the software is covered here, certain aspects of the software are not.
You should familiarize yourself with the content of the CETOL 6 User Reference Manual and refer
to it when seeking more detailed information.
Downloading Training Files
In order to complete the exercises in this manual, you must first obtain the related files. You can
download these files from the Sigmetrix Support Center web site (http://support.sigmetrix.com). A
simple registration is required in order to access this web site.
The act of downloading the training files registers you as CETOL self-paced training customer and
qualifies you for Sigmetrix training support. These files are protected by copyright and are not to be
shared with anyone. Do not distribute these files anyone else, even others who are also going
through this same training. Each trainee must personally download the training files in order to
register as a training customer and be eligible for Sigmetrix training support.
The file that you download from Sigmetrix is a WinZip archive. You must extract all of the files
from the archive using WinZip (or similar program). When you extract the files, you should select
the 5Use folder names option so that the directory structure is properly preserved.
Sigmetrix Training Support
If you are using this manual for self-paced training, you may need to get help getting through the
exercises or you may need additional explanation about a particular topic. You can submit a
question to Sigmetrix Training Support by submitting a training support ticket on the Sigmetrix
Support Center website. In most cases, you will receive a response within two business hours.
Sigmetrix training support hours are Monday through Friday, 8:00 am until 5:00 pm Eastern
Standard Time.
Reporting Problems
If you encounter any problems related to CETOL 6 Basic Training, please report the problem by
submitting a training support ticket on the support center website. If you find a mistake in this
manual (i.e., typo, grammatical error, etc.), please make a copy of the page, mark it up, and FAX it
to the attention of Sigmetrix Training at (317)818-9195.
Chapter 1.
CETOL Overview
In this chapter, you will learn about the CETOL 6 user interface and how it interacts with
Pro/ENGINEER.
The CETOL User Interface
Starting CETOL & Pro/E
When you want to use CETOL with Pro/Engineer you should launch Pro/E as you normally would
(via a startup icon, startup script, etc).
On Windows systems, you can start CETOL from a desktop icon or from the Sigmetrix program
group in the Start menu.
The CETOL 6 Modeling Interface
The main CETOL window includes a Menu bar, Command Bar, Tree View, Properties View, Graph
View, Advisor view and Status Bar.
Menu Bar
Properties
Command View
Bar
Tree View
Advisor
View
Graph
View
Status Bar
The figure above shows the CETOL 6 Modeler interface on Windows XP. You may notice some
minor differences on other OS versions. In this manual, the figures and icons represent what you
would see on Windows XP.
The Command bar contains a Standard Toolbar, View Toolbar, and Insert Toolbars to aid in CETOL
model creation. The main CETOL window contains Graph View, Advisor View, and Property View
dockable windows. By right-clicking anywhere on the Command bar, the following menu appears:
You can toggle the display of the toolbars and windows in the CETOL interface by selecting the
appropriate item in this menu. Double-clicking on the window handle will peal the window or
toolbar into a separate window.
Interface Icons
The objects in a CETOL model are represented in the interface by the icons shown below.
Assembly Component An instance of an assembly, together with the assembly
placement constraints.
Assembly Represents a CAD assembly.
Part Component An instance of a part in an assembly, together with the assembly
placement constraints.
Part Represents a CAD part.
Feature Represents a geometric feature of a part. Symbol varies based on the feature
type.
Constraint Represents a feature constraint with in a part (e.g., dimension, GD&T).
Symbol varies based on the constraint type.
Variable Represents a direction of variation for a feature. Symbol varies based on the
constraint type.
Configuration Represents a specific constraint state of the assembly.
Joint Represents an assembly constraint. Symbol varies based on the joint type.
Measurement Represents the unknown in the model. Symbol varies based on the
measurement type.
Menus and Toolbars
You can use menus and toolbars to give CETOL 6 instructions about what you want to do.
A menu displays a list of commands. The menus are located on the menu bar at the top of the
window. Shortcut menus are available when you right-click on objects in the Model Tree or Graph
View.
CETOL 6 includes three built-in toolbars: Standard, View and Insert. By default, these toolbars are
docked in the command bar along the top of the CETOL 6 window, but you can easily move them
to another location. Just drag the handle on a docked toolbar, or drag the title bar on a floating
toolbar to another location. If you drag the toolbar to the edge of the program window or to a
location beside another docked toolbar, it becomes a docked toolbar.
The Graph View
As you create a model in CETOL, symbols corresponding to each component, joint, measurement,
feature, constraint, and GD&T callout are added to the Graph View. CETOL automatically arranges
the icons within the Graph View. You can rename any object in place by selecting an icon, clicking
on the name, and entering a new name.
As shown below, the Graph View provides a schematic representation of the CETOL model. It
shows the parts and features included in the model, the joints representing the assembly constraints,
and the measurements that represent the fit or performance requirements of the assembly.
The Advisor View

The Advisor View shown below is a key tool in the analysts
arsenal. This view will guide the analyst to know when the model
is complete or when model changes in the CAD geometry
necessitate modification of the variation model. It will tell you
when features lack necessary dimensions, which joints are over-
constraining the assembly model, which parts are under-
constrained, if a measurement is discontinuous or if certain
elements need repair and so on. If an element needs repair it will
be superimposed by a yellow warning triangle: .
Interacting with Pro/ENGINEER
One of the primary advantages of CETOL is its integrated two-way communication with Pro/E.
With the Pro/E geometry loaded, CETOL has direct access to the geometry and is able to recognize
changes almost instantaneously.
CETOL communicates with Pro/E asynchronously. Asynchronous communication allows the user
to access all the functionality of Pro/E even while CETOL is running.
The icons in the status bar, shown in the figure below, indicate the status of the connection to Pro/E.
The Connect icon indicates whether a communication link is established. The Synchronized
icon indicates whether the current CETOL model is synchronized with the active Pro/ENGINEER
model.
Connected Not Connected
Synchronized Not Synchronized
When you select the Read from Pro/E menu command or the toolbar icon, CETOL will first
ensure that a connection to Pro/E has been established. If not, CETOL will initiate a connection
synchronizing to Pro/E requires that CETOL is first connected to Pro/E. If there is a part or
assembly in the active window, CETOL will read all existing CETOL data in the model (or models
in the case of an assembly) and display the data in the CETOL window.
Whenever you change active models in Pro/E, CETOL will lose synchronization with the Pro/E
model. You must click on in order to resume work in CETOL.
Maintaining a connection with Pro/ENGINEER requires some system resources. If you plan on
doing a significant amount of work in Pro/ENGINEER you should select Disconnect from Pro/E in
order to improve system performance.
Options
You can define your CETOL preferences by selecting Tools > Options. The options define
default tolerance values, the model graph spacing, the display settings for the Pro/E window, etc.
Refer to the CETOL 6 User Reference Manual for specific information.
Getting Help
There are a number of ways of getting help in CETOL 6.
If you pass the mouse over any menu item or toolbar icon, a one-line description of that item will
pop up in the view. The one-line help is also displayed in the status bar.
The complete CETOL 6 User Reference Manual is available on-line. Selecting Help > CETOL
Reference Manual will start up Adobe Acrobat Reader and open the reference manual. You can
use the tools available in Adobe Acrobat Reader to navigate the help file to easily find what you
are looking for. Refer to Chapter 2: CETOL 6 Overview in the CETOL 6 User Reference
Manual for information about how to navigate and search this document.
Exercise 1-1CETOL Interface Basics
In this exercise, you will learn how to connect CETOL 6 to Pro/ENGINEER. You will also learn
the basics for using the CETOL interface, how to set options, and how to access the online help.
Task 1. Startup Pro/E and CETOL.
1. Start up Pro/ENGINEER as you normally would.
2. Start up CETOL. (Refer to Chapter 4: User Interface Basics in the CETOL 6 User Reference
Manual for specific information about how to launch CETOL on supported platforms.) The
CETOL window will open up. At this point, CETOL and Pro/ENGINEER are running
independently with no communication between them.
Task 2. Connect CETOL to Pro/ENGINEER.
1. Click in the CETOL toolbar. When you select this button, CETOL attempts to do two things:
1) Establish a connection to Pro/E (if CETOL is currently not connected); 2) Synchronize the
CETOL model to the active Pro/E model. Since a connection has not yet been established the
Version Selection dialog will be displayed.
This panel appears whenever you attempt to establish a connection to Pro/ENGINEER. If this is your
very first time running CETOL, you will have to define the Pro/ENGINEER version that you would
like to connect to.
You will only have to define the Pro/E version information once. If you have already done so, you
can skip to Step 4.
2. Select Add from the Select Pro/ENGINEER Connection Versions dialog.
3. Fill out the fields in the Pro/E Connection Version Information dialog.
For the version name, you can give any descriptive name of your version of Pro/ENGINEER. The
Pro/E startup command can be found in the bin directory where Pro/E is installed. When you have
completed all of the fields, click OK .
4. Select the Pro/E version in the Version Selection dialog and click OK .
CETOL will establish a connection with Pro/ENGINEER. Note the indication of the connection in
the status bar. Since there is no model in the active Pro/ENGINEER model for CETOL to
synchronize, the status bar indicates that CETOL is not synchronized.
Task 3. Synchronize CETOL to a Pro/ENGINEER model.
1. In Pro/ENGINEER, change the working directory to \AssemblyModeling\Completed. Open
the assembly called PUMP_MOTOR_.ASM.
2. Click in the CETOL toolbar again to synchronize to the active Pro/E model. When CETOL
synchronizes to Pro/E, it reads all of the CETOL data that has been stored in the active
Pro/ENGINEER model (part or assembly, including all components) and displays the data in the
CETOL window.
3. Since a CETOL model has been created for this assembly, that model is displayed in the CETOL
window.
Task 4. Modify CETOL window layout.

1. The Graph, Advisor and Properties windows are dockable windows within the CETOL main
window. The Tree view is the anchor for the main window. All other views are positioned
relative to it. Double click on the Properties title bar. This will peal the Properties to a separate
floating window.
2. Double-click on the Properties window title bar. This will dock the Properties window back to its
previous location in the CETOL main window.
3. If you click and drag the Graph window title bar, you will see the window become an
independent floating window. As you drag the window around the CETOL main window you
will notice several different behaviors.
Properties
title bar
When a floating window is positioned over another docked window the docked window will shade
blue and a release of the mouse button will cause the floating window to dock over the shaded
window and a tab will be created for each window. A user can switch between the two windows by
clicking on the appropriate tab.
When a floating window is positioned near the border of a docked window you will see the docked
window move to make way for the floating window, if there is sufficient space, and indicate its new
position with a shaded blue area.
1. Click and drag the Advisor view title bar. Place the Advisor window on top of the Properties
window to create a tabbed window for the two views as shown in the figure below.
2. You can resize the Graph, Advisor and Properties views by clicking and dragging the view
borders. Resize the Pro/E window and the CETOL window and views to look similar to the figure
below.
Tip: Toolbar locations
You can control the location of the toolbars in a similar fashion. You can dock
them to different locations around the main window.
Note: Window layout
CETOL stores the window layout automatically. Whenever you startup CETOL,
the windows and views will be restored to their previous configuration.
Task 5. Set user preferences.
User preference settings allow you to define certain defaults of the software.
1. Select Tools > Options from the CETOL menu.
2. Click on the Variation Defaults tab. Set the default tolerances as shown in the figure below.
3. Click on the Graph View tab and select the options indicated in the figure below. These settings
control the display of the CETOL Graph View.
4. Click OK to close the Options dialog.
Task 6. Access on-line User Reference Manual.
1. Select Help > CETOL Reference Manual This will open the CETOL 6 User Reference
Manual.
2. Browse through the online manual by using the scroll bar and find the Table of Contents. The
entries in the Table of Contents are hyperlinks to the corresponding sections in the manual. Click
on an entry in the Table of Contents to jump to the corresponding section.
3. You can also navigate the document using bookmarks. Click on the Bookmarks tab to the left of
the window to view the available bookmarks. The bookmarks are links to all of the section
headings in the manual. Click on a bookmark to jump to the corresponding section in the manual.
You can also search for a particular word or phrase in the document by using the Find function.
Enter lambda in the Find: field and click Search or hit Enter.
The CETOL Model
The purpose of any CETOL model is to determine the variation of a measurement that is otherwise
unknown. The general flow of a CETOL analysis is shown in the figure below.
The CETOL Model Creation Process
Assembly
Add Measurements
Single Part
Assembly Modeling Part Modeling
Add kinematic Constrain
joints Features
Specify
Tolerances
Run Analysis
Review Analysis
and Improve Model
Generate Report
At its most basic level, a CETOL model consists of a single component (a part) and one or more
measurements on the component. In this case there is no need for an assembly model.
Details of each phase of this process are covered throughout this training guide.
Exercise 1-2Exploring a CETOL Model
In this exercise you will explore the various CETOL model objects in a completed model.
Task 7. Open a model.
1. In Pro/E, Open \AssemblyModeling\Completed\PUMP_MOTOR.ASM if it was not left open

from the previous exercise.
Task 8. Explore the CETOL Model Tree
1. Expand all of the Model Tree by clicking the right mouse button in the Tree view and selecting
Tree Level > Variables. Note the various icons in the model tree.
2. Right mouse click in the Tree view area again to open the context menu:
Select Copy Image to Clipboard and paste the image of the Tree view into another program
or select Save Image to File and insert the Tree view into another program.
3. Notice that certain portions of the Tree are grayed out. The portions of the tray will change
depending on what is set as the active object. Grayed out sections of the tree are not displayed in
the Graph window but they may still be selected to view the objects properties.
Task 9. Explore the Graph view
1. Right mouse click in the Graph view area to open the context menu:
2. Notice that the Graph view context menu has the same image capture options as the Tree view.
3. Select Graph Level > Expand All to expand the graph and show all diagram objects.
4. Select Graph Zoom > Auto-fit to scale the graph to fit within the window boundaries.
5. Select Graph Zoom > Reset (1:1) to bring the graph scale back to 100%.
6. Explore the other view controls in the Graph window command bar:
Zoom in
Zoom out
Pan
Task 10. Explore the Properties and Advisor views
1. Select on the Properties tab if the window is not already visible. Then select the Grav Shaft
Alignment1 measurement under the Gravity Biased configuration in the Tree window.
2. Explore the Properties window tabs paying particular attention to the Features, Variation and
Plots tabs. On the Features tab, objects can be redefined without having to recreate the object.
The Variation and Plots tabs show analysis results and are not populated until an analysis has
been run. The Notes tab allows users to store information pertinent to objects and has three
customizable fields.
3. Select on the Advisor tab to display that window.
4. Right mouse click in the Advisor window and notice that it also has the same image capture
options as the Graph and Tree views. Select Expand/Collapse All from the context menu.
Objects in the Advisor window give the user modeling tips and information that may or may not
be acted upon based on their discretion. In general the Advisor gives alerts to warn the user of
potential problems in the model.
The CETOL 6 Analyzer
Once a CETOL model is complete, you are ready to perform a CETOL analysis. All data analysis
operations are performed from the CETOL 6 Analyzer Window. From this window, you can have
CETOL recalculate sensitivities, review results, modify tolerance and distribution parameters, and
generate reports. Certain model modifications can also be made from this window.
The CETOL 6 Analyzer Window includes a Menu bar, Command bar, Data Objects Area, and
Object Properties Area and Layout Tabs.
Analysis View
In the Analyzer, you can review and manipulate your CETOL analysis results and model objects.
There are options for defining what data you would like displayed. You have complete control over
how the data is organized and sorted in this view.
Command
Menu Bar Bar
Layout Tabs
Measurement
Section
Tolerance Tolerance
Measurement Section and Variable
Properties Properties
Area Area
Analyzer Layouts
All data produced by a CETOL analysis is presented in the Analyzer in the form of user
customizable layout views. Data such as sensitivities, quality predictions, contributions, expected
variation, worst-case ranges or necessary tolerance limits are organized according to these user
defined layouts. The Command and Menu bars provide tools for Creating, Editing, Displaying and
Exporting the layout views. Once opened, layout views can be shown by clicking their respective
tabs on the left side of the Analyzer window. Three layouts are provided with the software: Results
List, Variance Contrib List and Sensitivity List. The Results list is predominantly used for reviewing
variation and quality data. The Variance Contrib List is used for reviewing contribution data and the
Sensitivity List is used for examining sensitivity data.
Generating Reports
Automatically formatted reports can be generated from the Command Bar by clicking on or from
the Data menu in the Menu Bar. From the Create Report dialog, shown below, customizable report
templates can be created or selected, titles can be specified, report directories identified and a report
viewer designated.
Exercise 1-3Running an Analysis
In this exercise you will learn the CETOL 6 Analyzer interface and the basics of running an
analysis and reviewing the results. The details of the Analyzer functionality are covered in greater
detail later in this manual. For this exercise we will continue using the Pump_Motor assembly from
the previous exercises.
Task 1. Run an analysis.
1. Run the analysis by clicking from the Command Bar or selecting Tools > Run New Analysis
(All). You can select what type of analysis you want to run and which measurements you want
analyzed from the Run Analysis dialog. Click on OK to accept the defaults.
Task 2. Review the results in the modeler.
1. After the analysis has completed select the Grav Shaft Alignment1 measurement in the Tree
view under the Gravity Biased configuration in the CETOL Modeler.
2. Select on the Variation tab in the Properties view. In the plot on this tab both statistical and
worst-case results are presented. Some measurement options are also presented here.
3. Select the Plots tab in the Properties view. Three plots can be viewed here: Sensitivities,
Statistical Contributions and Worst-Case Contributions.
Task 3. Review quality results in the Analyzer.
1. Select the Open Analyzer Window button in the Command Bar or select View > Analyzer
from the Menu Bar.
2. On the far left margin of the Analyzer window select the Results List tab. In this view
measurements and their quality predictions are listed in the top window, tolerances and variables
are listed in the middle window, measurement properties are shown in the bottom left and
tolerance/variable properties are shown in the lower right window.
3. Select the Grav Shaft Alignment1 measurement in the top window and click through the
measurement property tabs in the lower left window. Notice that the tabs and the window
contents are the same as the properties window in the Modeler.
4. The tolerance limits on this measurement are a little too restrictive. Change the tolerance limit on
this measurement from 0.20 to 0.30 on the variation tab of the Properties view.
Task 4. Review Sensitivity and Contribution results.
1. Select the Variance Contrib List tab on the left margin. This view is useful for identifying major
and minor contributors to the variation of a measurement.
2. Click on the Show Bars button to display numerical data in bar form.
3. Double click on the column heading for one of the measurements. Any of the data columns can
be sorted this way.
4. Select the Sensitivity List tab on the left margin. This view is useful for identifying those
variables that have an influence on the variation of the model measurements.
5. Click on the Show Bars button to display numerical data in bar form.
6. Click on one of the bars under one of the measurement columns. Notice that both the property
windows in the bottom of the window are populated.
Chapter 2.
Fundamentals
In this chapter you will learn fundamental terminology, principles, and analysis techniques.
Regardless of whether you are using a paper and pencil or CETOL 6 to calculate your results you
must understand these fundamentals before performing any tolerance analysis.
Tolerance Fundamentals
Tolerance Design Process
Designers generally interact with tolerances from a top-down perspective. They start with the
system level functional requirements, distribute the system requirements across the sub-systems,
distribute the sub-system requirements across their parts, distribute the part requirements across the
part features, and so on.
Assembly
System
R i
Distribute across Sub-Systems
Sub-Assembly Sub-Assembly
Distribute across Parts

Part Part
Distribute across Features

Feature Feature
Distribute across Manufacturing Steps

Manufacturin Manufacturin
Step Step
Process
Manufacturing personnel generally interact with tolerances from the opposite perspective. They start
with their manufacturing process capability and determine the variation that will occur on individual
features, which determines the variation between features on the part, which determines the variation
in the subsystems, which determines the variation in the system-level functional requirement.
The different perspectives lead to conflicting goals between Design and Manufacturing:
Design wants tight tolerances in order to achieve the system functional requirements.
Manufacturing wants loose tolerances to reduce costs and maximize process capability.
The tolerance design process attempts to find an acceptable balance between these competing
requirements. Tolerance analysis is used to check the design for conformance to the system
functional requirements and the producibility of the parts.
Dimensions, Variations and Tolerances

Tolerance analysis requires information about the dimensions and tolerances of the parts, along with
the variation of the individual variables.
Definitions:
Dimensions Dimensions are the size, location and orientation descriptors of the part features.
Variables Variables represent the potential directions of variation for a feature.
Variation Variation is the expected or measured deviation of feature variables from their
nominal (design) condition. Variability in manufacturing and assembly
processes results in variation of the variables.
Tolerances Tolerances convey design requirements and design intent. They do not define
feature variation. Rather, they define the limits of variation.Be careful with
terminology -- TOLERANCES ARE NOT VARIATIONS! Tolerances convey design
requirements. In order to perform a tolerance analysis, the variation of the variables must be
extracted from historical manufacturing process data, inferred from the tolerance limits, or obtained
some other way.
Causes of Variation
There are three main sources of variation in a design. Each variation source can propagate through
the assembly and degrade system performance and producibility.
Manufacturing process error -- Manufacturing processes are never perfect. Each manufacturing
process type has characteristics that cause variation. For example, setup error, tool deflections,
and inconsistent material properties all cause variation in machining processes. Mold
imperfections, material shrinkage, and debris in the cavities cause variation in injection molding
processes.
Assembly process error -- As parts are assembled, additional variation can be introduced. This
includes error due to fasteners, error in joining methods (welds, glues), kinematic adjustments
between parts to accommodate imperfect part geometry, servo motor errors, etc. The skill of
the assemblers, accuracy of assembly fixtures, welders skill, glue placement, gravity, etc. all
affect how close to perfect location and orientation parts are in their assembly. The fastening
method often produces shifts and rotations between mating parts.
Environmental effects -- The environment the final product is used in can introduce additional
variation effects, such as load deflections, thermal expansion, and vibrations.
Kinematic adjustments between the mating parts in the tolerance model are very important, but are
often overlooked. As parts are assembled together, kinematic variations are introduced into the
assembly. Contact lengths and angles between parts vary from their nominal condition due to
imperfect part geometry. Unless the parts are forced into a specific location and orientation with
each other by deforming them, they will adjust the location and orientation of the contact points to
find their natural location. If kinematic effects are not included in the tolerance model, the parts
cannot adjust their positions relative to each other and the variation in the parts can't propagate
through the assembly correctly.
In the figure below, if the cylinder radius (in this case, a seal) is manufactured over-size, the contact
points adjust to be further out on the seating surfaces. That change represents a kinematic
adjustment.
r+r
r
The variation in a design may be reduced several different ways:

Manufacturing process error -- Improve the dimensioning scheme and choice of datums, use
more capable processes, improve the setup procedures and tooling.
Assembly process error -- Use more accurate fixtures, use more accurate joining processes. In
extreme cases, use shims.
Environmental error -- Isolate the system from environmental effects using insulation and
dampening materials, use materials that will be unaffected by environmental influences.
Changing the tolerances on the drawing will not directly reduce the variation in the system! It
is the manufacturing and assembly processes that determine the variation of the part features and the
systems functional performance. If those manufacturing and assembly processes remain the same,
so will the variation in the system. Reducing the tolerances and then rejecting all of the parts that
fail inspection may reduce the variation of the system but would be very expensive and largely
ineffective way to improve quality.
Play Movie: \Movies\v_block.gif

Small kinematic translations and rotations occur between mating parts due to
manufacturing variation. A kinematic solution method is required in order to
predict how the variation propagates in the assembly.
Worst-Case Design and Analysis
Designing for worst-case means the tolerances on the individual parts of the assembly are assigned
such that if those tolerances are achieved, the functional requirements will always be satisfied. In
other words:
All dimensional and geometric variation is contained within the defined tolerance zones
All the parts are inspected
Only parts that pass inspection are used in the assembly
In worst-case design, tolerances are set and manufacturing processes are selected so that all
functional requirements are met even when part dimensions are at their tolerance limit.
Benefits:
Guarantees 100% of assemblies will function properly
Guarantees 100% interchangeability of parts
Problems:
Results in expensive designs
Doesnt consider manufacturing realities
The benefits are only guaranteed by 100% inspection
Despite the problems, it is frequently used when contracts, failure risks, and litigation concerns
require it.
To perform a worst-case analysis, the part dimensions are changed to the values inside their
tolerance limits that either maximize or minimize the functional requirement (i.e. gap or angle).
Several simple forms of the worst-case analysis function exist.
1D stacks:
n
TASM = Ti
i =1
Ti = equal bilateral tolerance of the " ith" dimension
2D/3D stacks, first-order approximation:

n
U
TASM = Ti
i =1 xi
U
= first partial derivative of the functional requirement to the " ith" dimension
xi
A generic formulation of the worst-case tolerance analysis problem is:

Maximize (or minimize) the assembly function (functional requirement such as a gap or angle) by
changing the variables of the parts, where the changes to the part variables are constrained by the
tolerance limits on the parts.
Exercise 2-1Worst-Case Analysis of a Shaft
For the shaft assembly shown below, there must be clearance between the SNAP-RING and
BEARING for the design to function properly. The nominal clearance between the end of the
BEARING and the SNAP-RING is .060 inch.
Task 1. Calculate the worst-case tolerance for the clearance between the BEARING and SNAP-
RING.
Statistical Design and Analysis
Statistical design and analysis describes the variation of the variables as statistical distributions to
predict the producibility of the parts and the distribution of the assembly function.
Benefits:
Able to design to any quality, not just 100%
Generally allows less expensive designs and wider tolerance limits
Able to account for manufacturing realities
Problems:
Requires manufacturing process data (measured or approximated)
Conceptually more complex than designing to worst case
Statistical design uses a manufacturing view of the design process. It is concerned with parts as they
are actually produced, and predicts how producible the parts are and how well the assembly
functional requirements will be satisfied.
Statistical Distributions
Statistical distributions are functions that describe the probability of a variable taking specific values.
Lets take a look at a sample distribution. This distribution contains a total of 30 samples.
Measured Values Length Tabulation Frequency

1.01 1.03 1.04 1.03 0.98 0.96 l 1
0.97 0
0.99 1.00 1.02 0.96 0.98
0.98 ll 2
0.99 1.01 1.01 1.02 0.99
0.99 llllll 6
1.00 1.01 0.99 1.01 1.00
1.00 llllllll 8
1.00 1.02 1.02 1.00 1.00 1.01 llllll 6
1.01 0.99 0.99 1.00 1.00 1.02 llll 4
1.03 ll 2
1.04 l 1
This distribution can be shown graphically in a histogram, as shown below.
8
7
6
5
Frequency 4
3
2
1
0
0.96 0.97 0.98 0.99 1.00 1.01 1.02 1.03 1.04
Length
This distribution can also be represented with a curve that has been fit through the data. The area
under the distribution represents the entire population.
DISTRIBUTION
0.96 0.97 0.98 0.99 1.00 1.01 1.02 1.03 1.04

Length
Often the curve that is used to fit the data is assumed to be a normal distribution curve. A normal
distribution is characterized by two values, the mean and standard deviation.
n
xi
Mean: x=
i =1 n
1
n ( x x )2 2
Standard deviation: = i
i =1 n
If a normal distribution does not fit the data the statistical distribution can be described in terms of
distribution moments. Using the distribution moments allows all distributions to be treated
generically.
There are several different ways to define moments of statistical distributions:
Central moments (raw moments)
Moments about the mean
Scaled moments
One set of moments useful for statistical analysis follows:
n
xi
1st central moment (mean): x=
i =1 n
n
( x i x )2
2nd moment about the mean (variance): 2 =
i =1 n
n
( xi x )3
3rd moment about the mean: 3 =
i =1 n
n
( x i x )4
4th moment about the mean: 4 =
i =1 n
Where:
xi is the ith value of the population being measured.
n is the size of the population.
Another set of moments useful for statistical analysis follows:
n
xi
1st central moment (mean): x=
i =1 n
2nd scaled moment (standard deviation): = 2

3
3rd scaled moment (skewness): 1 =
3
4
4th scaled moment (kurtosis): 2 =
4
Where:
2, 3 and 4 are the moments about the mean defined previously.
Given one set of moments, it is simple to convert to the other set.
In tolerance analysis, it is common to use the sample standard deviation instead of the population
standard deviation. Usually the true population standard deviation is not known. The sample
standard deviation can be used in place of the population standard deviation to calculate the sample
skewness and sample kurtosis.
1
n ( xi x ) 2 2
Sample standard deviation: s =

i =1 n 1
Most basic statistics textbooks contain comprehensive information about the issues of sample
statistics versus population statistics. Refer to a statistics text for additional study.
Scaled moments are particularly suitable for describing many common distributions. Normal
distributions have a skewness of 0.0 and a kurtosis of 3.0. Uniform distributions have a skewness of
0.0 and a kurtosis of 1.8.
It is possible to characterize manufacturing and assembly processes and their statistical distributions
by extracting the distribution moments from SPC (Statistical Process Control) data or other historical
process data (if the data is gathered with that purpose in mind). Categorizing the various
manufacturing and assembly processes by machine type, material type, feature size, etc may also be
helpful. For example:
Lathe: Aluminum: Diameter: inch: 0.3 - 0.6: 0.0015
may identify a lathe process that turns a diameter between 0.3 and 0.6 inches on aluminum material.
The expected standard deviation (variation) inherent in the process is 0.0015 in.
Producibility Analysis
Producibility analysis is used to determine how well the manufacturing processes generate part
features that satisfy the specified feature tolerance zones.
The formulas for the most common quality metrics are:
UTL LTL
Cp =
6
(UTL LTL) 2 T
C pk =
6
Sigma: Calculate the area in the distribution tails outside the tolerance limits. Sigma (Z-
score) is the number of standard deviations for a standard normal distribution with a
one-sided limit (Z-score) that gives the equivalent tail area.
Where:
UTL: Upper tolerance limit
LTL: Lower tolerance limit
: Standard deviation of the variable
: Mean value for the variable
T: Target (tolerance midpoint) value for the variable
Performance Analysis
Performance analysis is used to determine if the design satisfies the assembly functional
requirements. In other words, given the process variations of the part variables, what is the statistical
variation of the assembly functional requirement?
The most common form of statistical performance analysis is the 1D RSS (Root Sum of Squares)
equation. This equation assumes that all processes have the same distribution type:
1
n 2
2
ASM = i
i =1
= Standard deviation of the "ith" dimension
i
The process standard deviations are often assumed from the tolerance limits (similar to RSS) using:
UTL LTL
=
6Cp
The 1D RSS is often simplified to the following form:
1
n 2
2
TASM = Ti
i =1
Where:
TASM: Assembly measurement tolerance
Ti: Equal bilateral dimension tolerance
This form of the RSS equation assumes the following:
All dimensions have equal bilateral tolerances.
All tolerances and the assembly tolerance have the same quality (Cp).
For 2-D and 3-D analysis, the equation is slightly more complex:
1
n U 2
2
ASM = i
i =1 xi
U
= first partial derivative of the functional requirement to the "ith" dimension
x
i
= standard deviation of the "ith" dimension manufacturing process
i
CETOL uses a more general form of the equation for performing statistical performance analysis,
called the Method of System Moments (MSM). The method of system moments allows the use of
any combination of distribution types to represent the feature manufacturing processes. And the
MSM is able to predict the first four moments of the assembly functional requirement distribution,
not just the standard deviation. The RSS and generalized RSS equations are simplifications of the
general MSM equations.
Exercise 2-2Calculating Part Quality Metrics
You are trying to hold a 0.490 0.020 dimension tolerances using a manufacturing process with the
following characteristics:
= 0.5020
= 0.0060
Task 2. Calculate the following values:
1. Calculate the value for Cp.
2. Calculate the value for Cpk.

Exercise 2-3Analysis of a Shaft
Calculate the statistical variation for the assembly shown below.
Task 3. Calculate the statistical (RSS) tolerance for the clearance between the BEARING and
SNAP-RING.
Assume all individual part tolerances have a Cp of 1.0 with normally distributed
manufacturing processes.
Chapter 3.
Measurements
At a minimum, all CETOL models include one or more parts, measurements, and tolerances. In this
chapter, you will learn how to add measurements and include tolerances of the parts in order to
perform a simple variation analysis.
Measurements
The purpose of any CETOL model is to determine the variation of a measurement. A measurement
represents the value of any unknown dimension in a part or assembly.
The general flow of a CETOL analysis is shown in the figure below.
Assembly
Add Measurements
Single Part
Add kinematic Add feature
joints constraints
Specify
Tolerances
Run Analysis
Review Analysis
and Improve Model
Generate Report
Adding Measurements
You can add a measurement to any assembly configuration or any individual part.
To add a measurement, follow the procedure below:
1. Click in the Command Bar.
2. Select the first feature for the measurement from the Pro/E model. You can select any
vertex, edge, surface, datum point, datum axis, or datum plane.
3. Select the second feature for the measurement from the Pro/E model.
4. Optionally modify the measurement type from the Properties window. CETOL supports
linear and angular measurement types.
5. Optionally define the direction of the measurement by selecting a direction feature.
Volumetric planar features are preferred as direction references (the direction specified
by the feature is the outward normal vector of the plane).
6. Define the target and tolerance values for the measurement.
You can define a measurement between any two features in the CETOL model. The measurement is
assigned to the active configuration or if one doesnt exist CETOL will create one at the lowest level
of assembly that contains the two measurement references. For example, if you select two features
from the same component, the measurement and configuration are added to that component. If you
select features from separate components, the measurement and configuration are added to the
lowest-level assembly that includes both components.
Measurement Properties
The definition of a measurement is controlled in the measurement Property View. Refer to the
CETOL 6 Users Reference Manual for more detailed information about measurement properties.
General
You have control over the measurement type on the General tab. CETOL supports four types of
measurements: Linear, Angular, Gap and Flush. Linear is the default setting for measurements.
As the names imply, a linear measurement represents the linear distance between the selected
features and an angular measurement represents the angle between the selected features.
Gap and Flush Measurements

Gap and Flush measurements are primarily intended as distance measurements on skin geometry
such as the skin of an automobile, a handheld device or a mobile phone.
There are two significant differences between a Gap measurement and a Linear measurement. The
first is that the Gap measurement uses the normal vector of one of its references as the direction
reference for the measurement. The other is that it reports a positive value for a clearance and a
negative value for interference automatically because of the default direction reference. For this type
of measurement the reference features should be approximately opposed to each other.
The Flush measurement is intended to measure between nearly coincident surfaces. It also has an
automatic direction reference that is taken from one of the reference surfaces at the measurement
endpoint. The measurement direction will be the surface normal vector at one of the endpoints.
Features
The Features tab list region shows the defining features for a measurement with definable modifiers
such as Attachment options, Direction references and endpoint Locks.
Attachment
The value in the attachment field is used to determine the location of the measurement endpoints.
For some features (like cylinders), you can control the attachment by clicking on the attachment field
and selecting from the drop-down menu. The figure below illustrates the attachment options for a
measurement between a linear edge (Feature1) and a circular edge (Feature2).
Feature1
Feature2 Near
Center
Far
Attachment
Fields
Direction
Reference
Field
The actual measurement endpoints are updated during sensitivity Feature1

calculations (see the CETOL 6 User Reference Manual) based on the
measurement definition and the variation of the features. For example,
if the angular orientation of Feature1 were to vary, the endpoints of Near
a measurement (shown with a Near attachment) will update to the Feature2
locations representing the minimum distance between the selected
features. (The figure shown is exaggerated for clarity.)
You cannot modify the attachment for angular measurements.
Direction
By default, there is no fixed direction associated with a measurement. For linear measurements, the
value for the measurement is the minimum distance between the feature attachment endpoints.
For angular measurements, CETOL measures the angle between vectors defined by the selected
features. For example, if you define an angular measurement between a plane and a linear edge, the
measurement is actually between a vector along the linear edge and a vector normal to the plane. If
no direction feature is specified, CETOL finds the minimum angle between the specified vectors.
You can specify the direction of a measurement with a direction feature. For linear measurements,
the direction feature defines the vector direction of the measurement. For more information about
specifying the direction of a measurement, refer to Chapter 6: Measurements in the CETOL 6
User Reference Manual.
In the example below, a measurement called Gap is defined by selecting Feature1 and then
Feature2. By definition, the measurement is made from the first feature to the second feature. The
sign of the measurement value is determined by the dot product of the measurement vector (from the
first feature to the second feature) and the direction vector. In other words, if the projection of the
measurement vector onto the direction vector is in the same direction as the direction vector itself,
the measurement value is positive in sign. If the projection of the measurement vector onto the
direction vector is in the opposite direction as the direction vector, the measurement value is negative.
Note: Directionless measurements

If you do not specify a direction feature, the value of the measurement is always
positive and the direction of the measurement may vary during sensitivity
calculations.
When you specify a direction feature, the endpoints of the measurement are recalculated based on
the measurement direction.
No Direction Feature With Direction Feature
Feature1 Feature1
Value of Gap is Value of Gap is

positive! negative!
Feature2 Gap Feature2
Gap
Direction
Vector
The table below shows the features that you can select to define a measurement direction and the
resulting direction.
Feature type Direction Feature example
Axial Along axis of feature Axis, Cylinder, Linear edge
Anchored Axial Along axis of feature Arc, Cone
Planar Outward normal of plane Plane, Datum plane
Prismatic Along axis of feature Slot, Square prism
For angular measurements, if you specify a direction feature, the measurement is taken between the
projections of the feature vectors onto a plane that is perpendicular to the direction vector.
End Point Locking

The Lock check box on the Features tab in the measurement Properties window allows you to lock
one or both endpoints at their default locations. In the following example we have locked the
measurement endpoint on Feature2 at its default location which is the minimum distance point of the
nominal state. Notice also that there is no direction reference specified so the measurement will still
be calculating a minimum distance between the two endpoints.
Lock
Checkbox
In sensitivity calculations the measurement endpoint on Feature1 is free to move along the feature
length to find its minimum distance point to the locked Feature2 endpoint. So as Feature1s
orientation is varied its endpoint is free to move to the minimum distance location.
Feature1
Near
Feature2
Tolerance
By default, the target value of a measurement is equal to its nominal value. You can change the
target value, the tolerance zone type, the tolerance values, and the precision on the Tolerances tab.
Target Value
Tolerance Value
Repairing Measurement Features

If for some reason you want to change one of the features for the measurement it is possible to do that
on the Features tab shown below. A new feature for either measurement endpoint can be defined by
selecting it either from the CETOL Model Tree or from the CAD system. The following figure shows
which buttons to click for repairing the measurement features from either the CAD system or from the
Model Tree.
Click this button
Click this button to pick a new
to pick a new Reference from
Reference from the CAD system.
the Model Tree.
Click this button Click this button

to pick a new to pick a new
Source from the Source from the
Model Tree. CAD system.
You can use a similar process for repairing joints, dimension constraints and GD&T.
Exercise 3-1Defining Measurements
Measurements are a critical part of any CETOL 6 analysis. It is critical that your measurements
represent the actual measurements of interest. In this exercise you will learn how to add
measurements and how to define the measurement direction and other measurement properties.
Task 1. Open Pro/E part and synchronize CETOL.
1. In Pro/ENGINEER, change your working directory to \ModelingBasics. Open the part

BRACKET.PRT. Select the generic instance.
2. Click in the CETOL toolbar to synchronize to Pro/ENGINEER. BRACKET becomes the top-
level component in the CETOL model. Since there is no CETOL model data defined for this part, the
Graph View is empty.
Task 2. Define a measurement for the vertical dimension.
1. Click to add a measurement for the vertical dimension of the bracket.

2. Select the top surface and one of the circular edges from the large hole (select an edge on the
bottom surface).
Pick top surface Pick lower

edge of hole
The measurement and the selected features are added to the CETOL model. Icons representing
the measurement and features are displayed in the Graph View and listed in the Model Tree.
We will take a closer look at features in a later chapter.
3. The measurement that you have added is given a default name of Measure1. You should give
the measurement a more descriptive name. In the Name field of on the General tab of the Property
View, type Vertical.
The measurement is represented in the Pro/E window with a green line with arrowheads. You
can see that the measurement is not exactly as it should be. By default, when you specify a
measurement between two features, CETOL will find the minimum distance between the
features. If you want a measurement in a particular direction, you must define a direction
feature for the measurement.
4. Click on the Features tab of the Property View. Click to add a direction feature.
5. Select Feature1 from the model tree (the same surface that you selected when defining the
measurement). When you select a planar geometry surface, the direction of the measurement is parallel
to the outward normal vector of the selected plane.
Notice that the measurement highlight updates to show that the measurement is in the vertical
direction. The measurement is to the edge of the hole.
6. Underneath the first reference feature on the Features tab, select Center (rather than Curve) from
the dropdown menu to measure to the center of the hole.
Tip: Verifying measurements visually

You should always check your measurements visually to verify that you have
added them correctly.
7. Click on the Variation tab of the Property View. Set the target value for the measurement to 75.5
and the tolerance to 0.3. These values define your design requirements.
Task 3. Define a horizontal measurement between the holes.
1. Click to add a measurement for the horizontal dimension between the holes of the bracket.
2. Select the inner surface of the small hole and the inner surface of the large hole. You can pick
either half of each hole.
Pick inner
hole surface
Pick inner
hole surface
Pick edge for

direction feature
3. Rename the new measurement in place in the Graph View. Click on the new measurement icon
and then click on the name of the icon. Type Horizontal.
4. Click on the Features tab of the Property View. Click next to the Direction field to add a
direction feature.
5. Select the edge indicated in the figure above. When you select a linear edge, the direction of the
measurement is parallel to the selected edge,
Tip: Undo
If you make a mistake, you can click to undo the previous steps. You can
undo an unlimited number of steps.
6. Notice that the measurement is in the horizontal direction, but it is between the edges of the hole
rather than between hole centers. You can modify the measurement attachment location. Underneath
each reference feature on the Features tab, select Axis (rather than Surface) from the dropdown menu to
measure to the center of the hole.
and the tolerance to 0.2. These values define your design requirements.
Task 4. Add an angular measurement between the top and bottom surfaces.
1. Click to add a measurement for the angular dimension between the top and bottom planes of
the bracket.
2. Select the surfaces indicated in the figure (pick the upper-most and lower-most planes of the part).
Pick surfaces
Direction feature
(edge)
3. Rename the new measurement in place in the Graph View. Click on the new measurement icon
and then click on the name of the icon. Type Angle.
4. Change the measurement type by clicking on Linear in the Property View and selecting
Angular from the drop-down menu.
5. Notice that the measurement is now listed in the Advisor window as being discontinuous.
When the selected angular measurement references are nominally parallel (as is the case in this
example), there are an infinite number of 2-dimensional angles that could be measured. In this
case, we are only interested in the angular variation in the bend-angle direction, so you must
define a direction feature for this measurement.
Click on the Features tab of the Property View. Click next to the Direction field to add a
direction feature.
6. Select the edge indicated in the figure above. The direction feature for angular measurements
defines the vector about which the angle is measured. See the CETOL 6 User Reference Manual for
more information.
Note: Direction features
It is usually necessary to define a direction feature for angular measurements
between nominally parallel features.
and the tolerance to 1.0.
Task 5. Save the model.
1. Click to save the Pro/E model with the CETOL data.

Chapter 4.
Introduction to
Assembly Modeling
CETOL 6 allows you to add an assembly overlay in which you define the assembly constraints
with kinematic joints. CETOLs kinematic joints allow you to very precisely represent the physical
constraints of the assembly without redefining the Pro/E assembly and also allow you to introduce
the effects of assembly-level variation.
The CETOL Assembly Model
It is often necessary to define an alternate set of constraints for the assembly. This can be
accomplished in CETOL by adding joints.
Assembly
Add Measurements
Single Part
joints constraints
Specify
Tolerances
Run Analysis
Review Analysis
and Improve Model
Generate Report
Adding Joints
You can add a joint between any two parts in your assembly. You can add a joint on the top-level
assembly or on a sub-assembly.
To add a joint, follow the procedure below:
1. Click in the Command Bar.
2. Select the first feature for the joint from the Pro/E model. You can select any vertex,
edge, surface, datum point, datum axis, or datum plane.
3. Select the second feature for the joint from the Pro/E model.
4. Optionally modify the constrained degrees-of-freedom.
5. Optionally modify the constraint state (e.g., to include assembly variation).
6. Optionally modify the orientation and location of the joint.
The joint-creation process can be summarized by the flowchart below.
Joint type
automatically
determined
Joint location
Modify joint
at center of
location
Select contact
geometry
Start Done
from Pro/E
Joint
parts
orientation Modify
automatically orientation
determined
Default DOFs
assigned to Modify DOFs
joint
You can define a joint between any two features of different components. The location of the joint
within the model tree depends on the active object when the joint is created.
Assembly Model Structure

Parts and subassemblies are structured under the top level assembly according to components.
Recall that a component is an instance of a part or subassembly in an assembly, together with the
assembly constraints that locate and orient that instance.
There are three types of joints: component joints, assembly joints, and configuration joints. The type
of joint is determined by where the joint appears within the assembly structure in the model tree.
These three joints types provide the maximum amount of control and flexibility in defining the
assembly constraint order.
Component Joints
Component joints are children of a component in the tree structure and are intended to define the
placement of a component in the assembly. In general, most of the joints a typical CETOL model
will be component joints. Component joints affect all configurations of the assembly.
to Grip;1, 1 in the figure above is a component joint and is a child of the PistonPin;1 component.
Assembly Joints
Assembly joints are children of the assembly and are functionally similar to component joints and
intended define constraints to a component that are in addition to the placement constraints
represented by the component joints. For example, an assembly joint might be used to define the
final pin constraint in a 4-bar linkage. Assembly joint affect all configurations of the assembly.
In the figure above Arm;1 to PivotPin;1, 1 is an assembly joint and is a child of the Mechanism
assembly.
Configuration Joints
Configuration joints are used to define assembly constraints that are specific to a particular state of
the assembly model. The joints within a configuration have no affect on the assembly constraint state
in other configurations.
PIST_CYL;1 to PIST in the figure above is an example of a configuration joint.
Joint Properties
The definition of a joint is controlled in the joint Property View. Refer to the CETOL 6 Users
Reference Manual for detailed information about joint properties.
General
The General tab shows the joint name, the joint type, and bias options for the joint. It also allows the
analyst to modify the joint DOFs.
Naming Convention
The naming convention depends on the type of joint. Component joint names have the convention
to Reference_Component, #, where # as an index number to differentiate the joint name when there is
more than one joint from the component to the same reference component. Configuration and
Assembly joint names have the convention Source_Component to Reference_Component, #
DOF
Each joint constrains one or more degrees-of-freedom. The default constraint for a joint is based on
the type of features that you select to define the joint and their location and orientation relative to
each other.
Joints in which one of the selected features is inside of the other features are referred to as fastener
joints since this type of joint is used to represent a fastened interface (i.e., a pin in a hole). For
fastener joints you have the option of defining the joint bias. You can select whether you want the
joint to constrain the features to be nominally centered, or in tangential contact. If you select
tangential contact, you must also specify the location of contact by specifying a direction feature on
the Features tab.
DOF Editor
Common
DOF States
There are two ways to modify the constrained DOFs of a joint. You can select a Common DOF
State from the drop-down menu. The most common constraint situations for the selected feature pair
are listed in this drop-down menu. You can also toggle each individual DOF by clicking on the axis
in the DOF editor. Unconstrained DOFs are represented with an arrowhead, while constrained DOFs
are terminated with a T.
Features
The list region on the Features tab lists the defining features for the joint.
The Locate option allows you to specify the location of some types of joints. The Orient option
allows you to modify the orientation of the joint.
Constraint
The list region on the Constraint tab lists the constrained degrees-of-freedom in terms of two-letter
variable names. The first letter indicates the DOF type: T for translations, R for rotations. The
second letter indicates the coordinate direction for the DOF with respect to the joint coordinate
system. The orientation of the joint coordinate system is shown with the joint symbol in the
Pro/ENGINEER window. The axes of the joint symbol are color-coded: X is red, Y is green, and Z
is blue.
The value listed for each constrained variable is the nominal value for the variable. By definition
constrained features are nominally coincident in the direction of constraint and have a zero value
dimension between them, so this value is always zero.
The default state of constrained variables is Invariant, which means that there is no variation
allowed at the joint in that DOF direction. If you change the state to Variant, there will be
variation at the joint in the DOF direction and a dimension will be listed in the Model Tree (under
the associated joint). For Variant joint dimensions, you must define the tolerance limits and
variable distributions just as you would for a part dimension. Joint dimensions are useful for
representing assembly variation, such as servomotor error.
The Apply Automatic Float is used to specify float variation for fastener joints. When this option
is selected, the state of the constrained translation DOFs are changed to Float and corresponding
variables are added to the model. The tolerances and statistical distributions of these variables are
calculated automatically based on the tolerances and distributions of the reference features.
Setting the Degrees of Freedom

Setting the degrees of freedom of the joints is one of the most important tasks of creating a tolerance
model. Together with the kinematic joint definitions, the degree of freedom (DOF) settings
determine how part dimensional variation physically propagates through the assembly.
The generic meaning of a DOF is any translation or rotation of a part. In its free state, each part has
up to 6 degrees of freedom: Tx, Ty, Tz, Rx, Ry, and Rz, as shown below:
Defining joints between parts constrains some of their DOFs, based on the types and orientations of
the surfaces in contact. For example, a plane in contact with a plane is constrained to be in planar
contact, such that the parts cannot translate relative to each other in the direction perpendicular to the
plane of contact and cannot rotate about the in-plane axes. This contact is modeled in CETOL with a
planar joint, which has Ty, Rx, Rz constrained and Tx, Tz, Ry unconstrained.
When a DOF is unconstrained (or free) the two parts in contact can move freely (translate or
rotate) relative to each other in the DOF direction. When a DOF is constrained (or fixed) the
parts cannot move (translate or rotate) relative to each other in the DOF direction.
The constraints on joints can be modified on the General tab of the joint Property View. A joint is
intended to characterize the interaction between the features in contact, and is represented
mathematically at a point on each feature at the location of contact. In order for the contact behavior
to be accurately represented by a joint, the correct DOFs must be set. Often this means modifying
joint DOFs from the default settings.
Degrees-of-Variance
Degrees-of-freedom for a part can be categorized into two categories: degrees-of-variance and
degrees-of-invariance.
Degrees-of-variance are those DOFs which, if varied, would cause the part to change in location or
orientation. Degrees-of-invariance are those DOFs which, if varied, would not cause the part to
change in location or orientation with respect to its reference coordinate system. Degrees of variance
and invariance are only defined by the features that are added to the CETOL model for a given part.
For example, consider the piston part from the Sprayer sub-assembly shown below:
If only the outside diameter of the part were included in the CETOL model, the part would have 4
degrees-of-variance and 2 degrees-of-invariance. In any case where a cylinder is the only defining
feature this will always be true. The DOF circumstance for this part is shown in the two figures
below where the cylindrical reference feature is highlighted. The degrees-of-variance are Tx, Ty, Rx
and Ry. The degrees-of-invariance are Tz and Rz in that the cylinder does not change location or
orientation given variation in those DOFs. Keep in mind that the cylinder, by its definition, has no
endpoints so it is considered an infinitely long cylinder although it is shown with a finite length.
The addition of the pivot hole feature, highlighted in the figure below, to the model adds two
degrees-of-variance to the part model. It adds a depth reference in the Z direction and an orientation
reference about Z. With the addition of the pivot hole as a feature to the parts geometry definition in
CETOL that part model now has 6 degrees-of-variance.
Degrees-of-variance are important because in an assembly model it is only necessary to constrain the
degrees-of-variance of a part with joints. In the example of the Piston part it would only be
necessary to create a cylindrical contact joint ( ) to fully constrain the part if the outside diameter
were the only feature defined for the part.
In prior versions of CETOL it was necessary to constrain all 6 DOFs of a part; which meant that a
user had to constrain both the degrees-of-variance and the degrees-of-invariance for a part to be fully
constrained. In CETOL version 8 and beyond it is no longer necessary to artificially constrain the
degrees-of-invariance of a part.
Under-Constraints and Over-Constraints

Incorrectly set joint DOFs cause mathematical problems when analyzing tolerance models. A
tolerance model with the DOFs set correctly is called exactly constrained. An exactly constrained
assembly has all degrees-of-variance of each part constrained (or fixed) exactly once. A tolerance
model with incorrect DOF settings may have under-constrained parts, over-constraining joints, or
both. A part is over-constrained if a single degree-of-variance is repeatedly constrained by two or
more joints. Likewise, an under-constrained assembly has at least one part that has a degree-of-
variance that is not constrained by any joint.
Over-constraining Joints
Over-constraints (also called redundant constraints) occur when two or more joints constrain the
same degree-of-variance of a part. In the example below, the rotation of the block about its z-axis
(the axis out of the page) is constrained by both joints, and represents a redundant constraint. Only if
the block and base have perfect form can there be planar contact between both the bottom and left
surfaces of the block and the base. If there are any orientation variations, one of the interfaces will
be reduced to line contact. The user must indicate which planar joint actually represents the line
contact by freeing one of its rotational DOFs.
Gap
It is critical that the DOFs are set correctly because they determine how variation propagates through
the assembly. In the block example shown above, if the bottom rotational constraint is fixed, the
perpendicularity error of the base has no effect on the gap. However, if the rotational constraint at
the left constraint is fixed, the perpendicularity of the base will have a large effect on the gap.
.xxx A .xxx A
Gap
Gap
-A- -A-
Play Movie: \Movies\over_constraints.gif
Over-constraints (also called redundant constraints) occur when two or more
joints remove the identical DOF of a part. You must resolve the constraint
redundancy in order to accurately predict the effect of part variation.
Another common example of over-constraint is illustrated in the figure below. In this assembly, a
crank pin inserts into a tight-fitting hole in the base, represented by a cylindrical joint. A planar face
of the crank contacts a planar face of the base, which is represented by a planar joint. The
cylindrical joint and the planar joint constrain the same two rotational degrees-of-variance of the part
with the hole. Physically, if there are any imperfections in any of the features in contact, there
cannot be simultaneous plane contact along the planar face and cylindrical contact along the pin.
There must either be clearance between the pin and hole or point-contact between the planar features.
The planar joint is over-constraining and should be changed to a point contact joint.
Common sources of over-constraint, along with suggested ways of finding and eliminating them, are
listed below:
Real-world physical constraints are actually redundant. Surfaces may fit nominally, but
variation would cause a violation of the constraints.
Assembly order and biasing forces (springs, gravity, etc.) should be considered when
eliminating redundant DOFs.
Over-constraint is due to redundantly constraining the same DOF.
Since the same DOF is constrained at two joints, it can usually be resolved by
releasing the appropriate DOF on either joint.
Rotational DOFs are frequently over-constrained.
The default DOFs for most joints assume maximum rotational constraint.
Under-Constrained Parts
Under-constraints indicate that one or more of the degrees-of-variance of a component has not been
constrained by any of the joints in the model. In the Piston Cylinder subassembly example below, the
Piston is properly constrained by joints constraining 5 DOFs when the assembly model is built at the
subassembly level. Subsequently, a higher level assembly joint adds the pivot hole feature (highlighted)
in order to attach the subassembly. This higher level assembly joint adds another degree-of-variance to
the Piston part by adding the referenced feature and will make the part under constrained at the sub-
assembly level. To resolve the under constraint it is sufficient to add a joint to constrain the additional
degree-of-variance.
Modifying Joint DOFs

When you add a joint, the default DOFs for the joint are determined based on the defining features of the
joint. You can modify the constraints of the joint to change the joint behavior between the features.
There are two ways to change the DOFs of a joint. You can individually toggle the state of each DOF in
the DOF editor or you can select a different preset DOF state from the drop-down menu.
DOF Editor
Common
DOF States
The DOF editor displays an icon corresponding to the current DOF state of the joint, along with axes
representing the coordinate system for the joint. These axes represent the translational DOFs of the
joints. Arcs around each axis represent the rotational DOFs. If a DOF is fixed, it is displayed with a
T termination at the end of the vector. If a DOF is free, it is displayed with a thick line or arc with an
arrowhead. The colors of the lines and arcs correspond to the colors of the axes displayed in
Pro/ENGINEER when you highlight the joint.
You can change the DOFs of the joint by clicking on the Preset DOF State and selecting from the
drop-down menu. The selections in the menu correspond to common DOF states for the joint based
on its defining features. When you select a Preset DOF State, the corresponding DOFs are displayed
in the DOF Editor, along with a representative joint icon.
To change the state of an individual DOF in the DOF Editor, simply click on a line or arc
representing a DOF.
There is a joint icon for each combination of joint DOFs. As you toggle the DOFs in the DOF Editor,
an icon representing the current DOF combination is displayed. If the combination of DOFs matches
one of the preset DOF states in the drop-down list, that DOF state name is shown. If there is not a
match, the DOF state is shown as Custom. A Custom DOF state represents an unusual
combination of DOFs for the selected features and may be an indication of a constraint error.
For example, if you select two coaxial cylindrical surfaces in defining a joint, the default joint type is
cylindrical (Tx,Ty,Rx,Ry). If you toggle the DOFs so that Ty, Rx, and Rz are fixed and the other
DOFs are free, a planar icon is displayed because that DOF combination corresponds to the DOF
state for typical planar contact. However, the DOF State name is Custom because that
combination of constraints is unusual for the selected features (two coaxial cylinders) and probably
indicates an error in the constraints.
Tip: Custom joints

If you select a combination of DOFs that is not common to the selected feature
pair, the Custom joint icon is displayed in the DOF editor. This may be an
indication that you have constrained an invalid combination of DOFs.
Checking the Assembly Constraints
As you make changes to the model, CETOL runs a DOF analysis in the background. In doing so,
CETOL attempts to solve for closure by calculating the location and orientation of each
component in the assembly based on the joints that have been defined. It then checks the constraint
state of each part in the model.
The results of the DOF analysis are shown in the status bar at the bottom of the CETOL window.
The DOF state indicates the number of over-constrained and under-constrained DOFs in the model.
Closed indicates that the closure calculations were successful. If you define an impossible set of
constraints on your joints, CETOL will not be able to assemble the components properly, which will
be indicated with Not Closed in the Configuration Properties window. Not Closed typically
indicates that two or more of your constraints are in conflict and cannot be honored simultaneously.
In addition to the information in the status bar, the constraint state for each part and joint is displayed
to the upper right of each icon in the Graph View. A negative number indicates that the component
is under-constrained. A positive number indicates that the joint is over-constraining.
Over-constraining
joint
Under-constrained
part
Component and Joint Order

For complex assemblies, knowing the order in which the parts are actually assembled helps when
setting the DOFs. The DOF analysis uses component and joint order to solve for the DOF states of
the parts and joints.
When you have an over-constrained DOF in the model, it is because two joints are constraining the
same DOF of a part. The over-constraining joint is identified based on the joint order. Initial joint
order is determined based on the order in which the joints were added. The constraints of the earlier
of the two joints in the Model Tree take precedence and the later joint is considered to be over-
constraining. In order for the results of a DOF analysis to be completely valid you should reorder
the joints in your assembly accordingly. Typically your constraint order should reflect the actual
assembly process that is used in assembling the parts. Loads, such as gravity, may also influence
constraint precedence (and thus joint order) by enforcing contact at a joint.
When your model is under-constrained, the unconstrained DOFs are assumed to belong to the part
that comes later in the Model Tree. For example, in a two-part assembly that is under-constrained
the second part is always shown as the under-constrained part.
Note: Component and joint order

In order for the DOF states indicated by the DOF analysis to be valid, you should
reorder the parts and joints in the Model Tree to reflect the assembly process
order and the desired constraint order respectively.
The initial component and joint sequences correspond to the order in which they are added to the
model. You can reorder components and joints by simply clicking on them in the Model Tree and
dragging them to a new location. In a multi-level assembly, you can only reorder components and
joints within the existing assembly hierarchy you cannot change the parent of a component or joint.
Joints can be dragged to be children of a higher level assembly or of a configuration.
Exercise 4-1Piston/Cylinder Sub-Assembly
In this exercise you will create a simple assembly overlay model. You will define a measurement
and the CETOL joints necessary to characterize the assembly constraints for the model.
1. In Pro/ENGINEER, change your working directory to \Sprayer and open PIST_CYL.ASM.
2. Click in the CETOL toolbar to synchronize to Pro/ENGINEER.
Task 2. Add measurement for compression volume length.
1. Click to add a measurement between the top of the piston and the top inner surface of the
chamber.
In Pro/E, set the view style to TRANSPARENT_CHAMBER. (View > View Manager, click on the
Style tab, double-click on TRANSPARENT_CHAMBER and then click Close ). This display makes it
much easier to select internal features of the assembly.
Select the top inner surface of the cylinder and then the top face of the piston (in that order), as indicated
in the figure below. The measurement and the selected features are added to the CETOL model.
2. Rename the new measurement Volume Length.
3. Click on the Variation tab and set the value to 30.100.20.

Task 3. Add joint between ID of CHAMBER and OD of PISTON.
1. Right-click on Pist_Cyl in the model tree and select Set as Active Object from the context
menu.
2. Click to add a new joint.
3. Select the inner cylindrical surface of CHAMBER and the outer diameter of PISTON. A new
joint is added to the Graph View.
4. Click on the General tab in the Property View. Notice that the bias is set to Centered, meaning
that the selected surfaces are assumed to be coaxial. You could select Tangent if you wanted to
constrain the piston to be pressed against the cylinder surface. Leave the bias set to Centered.
Task 4. Add joint between STOP_PIN and CHAMBER.
2. Select the cylindrical surface of either STOP_PIN and the cylindrical surface of the hole in which
it inserts into the CHAMBER. A new joint is added to the Graph View.
Task 5. Add joint between STOP_PIN and PISTON.
2. Select the cylindrical surface of the STOP_PIN (the same one that you selected in Task 4) and the
underside of the PISTON (you may have to spin the model to make the picks). A new joint is added to
the Graph View.
Since only one stop pin is necessary to constrain the piston, the second stop pin is redundant. There is
no need to add a joint at the other stop pin. Doing so would result in an over-constrained model.
Task 6. Check your constraints.
You can check to see if you have properly constrained the assembly. Review the DOF state in the status
bar at the bottom of the CETOL Main Window. The total constraint state for the assembly is shown in
the status. The DOF state for the model is 1 Over 0 Under. Before you can solve this model, you
should resolve the degrees-of-freedom.
1. The first step in checking the DOF state of the parts is to reorder the components according to the
actual assembly constraint order. You can reorder the components by clicking and dragging in the
Model Tree. Reorder the components as follows: CHAMBER;1,
STOP_PIN;1, and then PISTON;1.
2. In this example to STOP_PIN;1,2 is over-constraining by one DOF. You will see an alert in
the Advisor View indicating this if you expand the Advisor messages. Click on to STOP_PIN;1,2.
The default condition for this joint is a line contact joint between the PISTON and the STOP_PIN.
3. A triad representing the joint location and orientation is displayed on the Pro/E model. The colors
of the axes correspond to the colors in the Joint DOF editor.
4. In reality, since the PISTON fits tightly in the CHAMBER, the only function of the STOP_PIN
is to keep the PISTON from translating out of the CHAMBER.
Click on Rx
DOF to
toggle state
Click on the arc representing the Rx DOF to toggle its state from constrained to unconstrained. This
changes the behavior of the interface from a line contact to point contact.
5. Review the DOF state in the status bar. The assembly is now exactly constrained.
Task 7. Reorder the Configuration to the bottom of the Tree
1. Click and hold the left mouse button on the Configuration Config1.
2. Drag the configuration to the bottom of the Tree.

Chapter 5.
Introduction to
Part Modeling
In previous chapters, you have learned about basic modeling for assemblies. In this chapter, you will
learn how to define an alternate dimensioning scheme for your parts using part overlay mode.
The CETOL Part Model
Assembly
Add Measurements
Single Part
joints constraints
Specify
Tolerances
Run Analysis
Review Analysis
and Improve Model
Generate Report
The modeling process for defining a part dimensioning scheme is shown in the flowchart below.
Add features
Reorder features
to match mfg.
Add constraints
(order matters)
Make appropriate
variables invariant
or equivalent
Set tolerances to
match mfg.
Part Model Structure
In the process of creating CETOL measurements and joints, you select geometry references from the
Pro/ENGINEER model. Those CAD geometry references are automatically added as features in the
CETOL model as children to the parts they were selected from.
Features are orange-colored objects and can have Constraints as children. Constraints can be
thought of as tolerances and represent dimensional or topological relationships between features.
Variables are children of Constraints and are the lowest level of detail in a CETOL model. Variables
represent the directions of variation for a feature.
Features
A CETOL feature represents a single geometric entity of a part. A feature can represent a simple
geometric entity such as a single surface, edge, or vertex. A feature can also, in some cases,
represent a collection of geometric entities, such as a slotted hole or a width. In addition, features
can represent datum planes, datum axes or datum points.
Adding Features
As you have probably already noticed, any time you select geometry from Pro/ENGINEER when
creating a measurement or a joint, features representing the selected geometry are automatically
added. You can also add features manually on any part in the CETOL model.
To add a feature, follow the procedure below:
1. Click or select Insert > Feature from the main menu.
2. Select geometry from the Pro/E model. You can select any vertex, edge, surface, datum
point, datum axis, or datum plane. Some features support more than one selection (e.g., a
slotted hole). Refer to the CETOL 6 User Reference Manual for a list of valid feature
types. When you have picked all of the geometry for the feature, select OK .
Note that you can only select geometry from parts that are within the active scope of the model
(based on the active object) or from a part that has not yet been included in the CETOL model.
Feature Properties
The definition of a feature is controlled in the feature Property View. Refer to Chapter 8: The Part
Model of the CETOL 6 Users Reference Manual for detailed information about feature properties.
General
The feature name, the feature type, and a checkbox to reverse the outward normal are listed on the
General tab along with the geometry references that define the feature.
The list region on the Geometry tab lists the Pro/E reference geometry that defines the feature. You
can click on an item in the list and click to highlight the feature on the Pro/E model.
To add geometry to a feature, click and then select the geometry from the Pro/E part. You can
remove geometry from a feature by selecting an item in the list and then clicking on . In adding
geometry to, or removing geometry from a feature, the resulting list of geometry must define a valid
feature. Refer to the CETOL 6 Users Reference Manual for a list of feature types and geometry
references.
To completely redefine the feature, click and then select the geometry from the Pro/E part.
Constraints
The list region on the Constraints tab lists the size dimensions of the feature if applicable, the
constraints applied to the feature, and the variables related to the constraints along with an indication
of the state of that variable. Constraints will be covered in detail in a later chapter.
Advanced
The advanced tab allows users to specifically determine the origin and size of the feature should it be
necessary for analysis purposes to modify them.
Constraints
The purpose of a constraint is to define the location and/or orientation of one feature relative to
another feature on a part. When you define a constraint for a feature, CETOL generates a set of
variables that control the relative location and orientation of the features.
Constraint types
Size Constraint
A size constraint defines a size tolerance for a feature of size. Features of size may have one or two
size constraints associated with them where each will have its own associated tolerance. A slotted
hole for example will have two size constraints.
Dimension Constraint
A dimension constraint defines a tolerance that may control one or more variables in defining a
linear distance and/or orientation of one feature relative to another. Dimension Constraints assign a
tolerance value for each individual degree-of-variance for a feature.
GD&T Constraint
A GD&T constraint can define both location and orientation for a feature within a single tolerance
zone. Therefore a single geometric tolerance can define the acceptance boundary for many or all of
the degrees-of-variance for a feature.
Constrain Feature Wizard
Constrain Feature Wizard is a utility for constraining features to other reference features. In the
wizard, Dimension and GD&T constraints can be applied to features.
The wizard is opened by first selecting a feature to be constrained either in the Tree, Graph or
Advisor and then selecting from the command bar.
Unconstrained Feature Parameters
Feature degrees-of-variance are listed in the Unconstrained Feature Parameters section. For a feature
to be fully constrained all of these degrees-of-variance need to be constrained. As constraints are
added the degrees-of-variance move down into the Defined Constraints section as children of the
constraints. In this way the user can know which constraints, and the associated tolerance, are
controlling which degrees-of-variance.
Defined Constraints
Constraints can be added to a feature by selecting or in the Defined Constraints section.
Selecting will add a Dimension Constraint and selecting will add a GD&T constraint.
Variables will move from the Unconstrained Feature Parameters section down into the Defined
Constraints section depending on which type of constraint is selected and which references are
selected. A feature is not fully constrained until there are no more degrees-of-variance listed in the
Unconstrained Feature Parameters section. Any degrees-of-variance that remain unconstrained will
be considered invariant with respect to the initial part features.
Changing a Variable State
The state of a variable can be changed in the Constrain Feature Wizard by double clicking on the
variable label in the State column and selecting the appropriate setting in the pull-down menu that
appears. In this way a variable state can be changed between Invariant, Variant and Free.
Adding Constraints
To add a single constraint, follow the procedure below:
1. Click on the feature that you want to constrain in either the Graph View or the Model
Tree.
2. Click on the command bar, in the Constrain Feature Wizard, or select Insert >
Dimension Constraint from the main menu.
3. From the Add Dimension window you may select the geometry from the Pro/E model or
from the CETOL Tree to which you want to constrain the feature. You can select any
vertex, edge, surface, datum point, datum axis, or datum plane that belongs to the part
that you selected in Step 1.
Or:
1. Click (the Dimension Constraint Tool).
2. Click and hold on the feature in the Graph View that you want to constrain. A red arrow
stretching from the selected feature follows the pointer as you drag the mouse. The arrow
turns green when the mouse is pointing to a valid constraint feature.
3. Drag the mouse to another feature in the Graph View to which you want to constrain the
selected feature and release the mouse button when the arrow turns green.
Adding Multiple Constraints Simultaneously
CETOL 6 has the ability of constraining multiple features to multiple references. This is done
through the Right Mouse Button (RMB) context menu. This process is used in cases where a
common dimension scheme is used for most or all features on a part. A good example of when this
would be used is a flat sheet metal plate that has many features that are all dimensioned to the same
horizontal and vertical reference features.
The process for creating multiple constraints is:
1. Click on the feature icons either in the Tree or the Graph using the left mouse button and
while holding down the Ctrl key or by holding down the left mouse button while
dragging a selection window around the features to be constrained.
2. Click on the selections using the right mouse button to open the context menu and select
Constrain Feature(s). This action will open an acceptance window.
3. Multi-select the features, from the Tree or Graph, that will be the constraint references by
using either of the multi selection methods listed in step 1.
4. Select OK from the acceptance window.
Constraint Properties
The definition of a constraint is controlled in the feature Properties view and its own Properties view.
Refer to the CETOL 6 Users Reference Manual for detailed information about constraint properties.
The Constraint Properties window contains these tabs: General, Reference, Tol/Rule and Notes.
The content of these tabs are explained in the following sections.
General
The constraint name, type, attachment options, nominal value and tolerance are listed on the General
tab. The names of constraints are generated automatically, and have the form to Reference Feature
Name. If you change the name of a feature, the related constraints are updated automatically. You
also have option of disabling the Default Name and giving it a custom name.
Attachments
The attachment line on the General tab lists all of the attachment options associated with the selected
constraint. The value in the Feature Attach and Reference Attach pull-down lists show the
attachment options for the constrained feature and the constraint reference feature, respectively.
In some cases, you can change the attachment option by clicking on the attachment option and
selecting another option from the drop-down menu. For example, for cylindrical features, you can
specify that the constraint is attached to the Near tangent, the Center, or the Far tangent of the
feature. Planar features always have a Center attachment.
Far - Center
Center - Center
Near - Center
Reference
The reference Feature section on this tab allows the user to change the reference for the Constraint.
This can be done by either picking a feature in the Tree View (Default) or Pro/E after clicking the
appropriate command button.
Tol/Rule
The Tol/Rule tab has a number of options for defining the tolerance of the selected dimension
constraint.
Tolerance Edit section
You can define the tolerance zone type, the tolerance values, and the dimension precision.
Rule section
The Apply Rule checkbox defines whether a rule is applied to the dimension. The rule that is applied
can come from the parent part, by selecting the Use Part Rule checkbox, or by defining a rule
exclusive to the dimension. A variation rule defines the relationship between the dimension target
value and tolerances, the process distribution parameters, and the part quality metric. The text
window at the bottom provides a description of the contents of the applied rule. For more
information about component variation rules, see Chapter 9 of the CETOL 6 User Reference
Manual.
Feature Order
When you add a constraint between two features, the feature order determines the direction of
constraint, which is indicated in the Graph View by the direction of the constraint arrow. By
convention, a constraint points from the high-numbered feature to the low-numbered feature. The
feature number is determined by the feature sequence, or the order in which the features are listed in
the Model Tree. You can view the feature numbers in the Graph View by selecting Graph Display >
Show Feature Sequence from the Context Menu.
The variables associated with a constraint are always assigned to the feature that is the latter of the
two features in the sequence.
The variation of the location and orientation of a feature could be affected by all features above it in
the feature list, but will not be affected by the features below it in the list. The feature sequence
should reflect the manufacturing sequence of the part. The first features ordered in the list should be
the manufacturing reference datums, and all subsequent features should be ordered according to the
manufacturing process order.
You can reorder the sequence of the features in the Model Tree. To reorder a feature, click and drag
it to a new location in the Model Tree and then release the mouse button to drop it into the new
location. It is a good idea to define the correct feature sequence before adding constraints to your
model.
Variables
For parts, the dimensioning scheme is defined via constraints. When you add a complete set of
constraints for a feature, a complete set of controlling variables is generated. These variables are
automatically included in the model.
Invariant variables
Sometimes you may not need to include the variation of every variable in the model. For example,
the angular variation of a plane may be unknown or unimportant to the measurements of interest.
You can make any variable invariant (held constant) in the following way:
1. Click on a feature icon in the Tree or Graph View.
2. Click on its Constraints tab of the Properties View.
3. Find the variable of interest and double-click its State value to activate its pull-down
menu and toggle it from Variant to Invariant.
Or:
1. Right-click on a variable in the Tree and select Delete from the context menu. To delete
more than one variable, click on the variables while holding down the Ctrl key.
By default, all angular variables with nominal values of 0, 90, or 180 are Invariant. Likewise,
any linear offset variables with a nominal value of zero are Invariant by default. All other
variables have a Variant default state.
Variable Properties
The variation of a variable is controlled in the variable Properties View. A varible Properties View
consists of five tabs: General, Distribution, Equivalent and Notes.
General
The General tab displays general information about the selected variable. The name, type and
nominal value for the variable are shown.
Distribution
The distribution for the variable is shown here. If a rule is applied the parameters will not be
editable from this window. To edit the distribution parameter first uncheck the Apply Rule
checkbox on the parent Constraint Properties Tol/Rule tab.
Equivalent
The Equivalent tab lists the variable that have been designated as equivalent to the selected variables.
When you have two or more features in your model that are necessarily the same size (e.g., a
cylindrical surface and a circular edge of the same surface) you should make the size variable
equivalent. You can make variable equivalent by selecting them in the Model Tree while holding
down the Ctrl key, then right-clicking on one of them and selecting Make Equivalent.
Note: Equivalent Variables
Only size variables with equal nominal values can be made equivalent.
Highlighing Dimensions and Variables
You can click on the dimensions and variables listed in the Model Tree to highlight them in the
Pro/E window. Offset dimensions and variables are shown with a single line that represents the
offset. Angular dimensions and variables are displayed with a solid line that represents each feature,
a dashed line that represents the rotation axis, and an arc representing the angle, as shown below.
Rotation vector Feature vectors
Exercise 5-1Defining a Dimensioning Scheme
In this exercise, you will add constraints to define a dimensioning scheme similar to the one shown
in the figure below.
1. In Pro/ENGINEER, change your working directory to \Sprayer. Open the CHAMBER.PRT

(GENERIC). (Note that you must first complete Exercise 4-1 prior to performing this exercise.)
2. Click in the CETOL toolbar to synchronize to Pro/ENGINEER. CETOL reads all of the model
data from the Pro/E part and displays the data.
Task 2. Set the Tolerance Defaults
1. Select Tools > Options and set the Tolerance Defaults according to the following graphic.
Task 3. Rename the existing features.
1. Right-click on each feature in the model graph or model tree to see them highlighted on the CAD
model. Name the features Top Inner Face, Inner Diam, and Pin Hole on the General tab of the
Properties view. Pay attention to the highlighted surfaces in Pro/E and make sure that you name the
features correctly.
Task 4. Add feature for pivot attachment hole.
1. Click on to add a new feature.

2. Select the surface of the hole indicated in the figure below and then OK. The new feature is added
to the CETOL model.
3. Click on the new feature in the model graph or model tree and rename it Attach Hole.
Task 5. Add width feature.
1. Click on to add a new feature.

2. Select the surfaces indicated in the figure below and then OK. (Hold the Ctrl key when selecting
the second surface). The new feature is added to the model.
3. Click on the new feature ( ) and rename it Width. (Note: This feature is only to illustrate
CETOL functionality it is not necessary to include it in the model.)
Task 6. Examine features in Model Tree.
1. Right-click in the background of the Model Tree and select Tree Level > Tolerances. Notice that
for the cylindrical features and the width feature, the size dimensions are listed.
For features of size, CETOL automatically includes the size dimensions in the model. However, there
are no location or orientation dimensions defined for the features. You will learn how to add these
dimension types later in this exercise.
Task 7. Review dimension types for size dimensions.
1. Click on one Size underneath Inner Diam. The dimension type is controlled on the General
tab of the dimensions Properties View.
2. Click on the Type field and review the options available in the drop-down menu. Leave the
dimension type set to Diameter.
3. Click on Size underneath Width.
4. Click on the Type field and review the options available in the drop-down menu. Leave the
dimension type set to Thickness.
Task 8. Define constraints for Top Inner Face
1. Click on Top Inner Face and then click on (Add Dimension Constraint) in the toolbar.
2. Click on next to the Reference field in the Add Dimension dialog and select the surfaces of
the CHAMBER shown in the figure below. Click OK to close the dialog and complete the dimension
definition.
A new feature and a dimension constraint from Top Inner Face to the new feature are added to the
model.
3. Rename the new feature (not the constraint!) B.
4. Click on Top Inner Face and then on the Constraints tab in the Property View. Click on To B
in the list region. Notice that this constraint includes the following variables:
TY - Offset variable from Top Inner Face to B
RX - Angle from Top Inner Face to B about the x axis of the feature.
RZ - Angle from Top Inner Face to B about the y axis of the feature.
Notice that the state TY is Variant while RX and RZ are Invariant. All angular variables
that are controlled by standard constraints that are 0, 90, or 180 have a default state of Invariant. If
you want to consider the variation of these variables in your analysis you could toggle the state of these
variables to Variant.
5. Right-click on the background of the Model Tree and select Tree Level > Variables. Notice that
B and to B have been added to the model tree, and that a variable called TY is listed underneath
to B. RX and RZ are not listed in the model tree because they are invariant.
Task 9. Define constraints for Attach Hole
1. Zoom out in the Graph View so that all items are visible.
Tip: Viewing controls in the Graph View
The viewing controls are similar to the 2D viewing controls in Pro/E Wildfire.
To zoom, drag the mouse while holding the MMB and the Ctrl key. To pan,
drag the mouse while holding the MMB and the Shift key.
2. Click on , the Dimension Constraint Tool. This will activate the creation tool pointer ().
3. Click and hold on Attach Hole. A red arrow stretching from Attach Hole follows the pointer
as you drag the mouse. The arrow turns green when the mouse is pointing to a valid constraint feature.
Drag the mouse to B and release the mouse button when the arrow turns green.
4. Right-click on the background of the Model Tree and select Tree Level > Variables. If necessary,
scroll in the Model Tree until Attach Hole is visible. Notice that the new constraint and the associated
variables are listed.
Task 10. Define constraints for Pin hole.
1. Repeat the procedure in Task 9 step 3 to define the dimensions from Pin Hole to B. Your
Graph View should look like the figure below.
Tip: Switching to the selection tool pointer
In order to perform certain operations in the Graph View, the selection tool
pointer ( ) must be active. You can quickly switch from the creation tool () to
the selection tool by clicking the middle mouse button in the Graph View.
Task 11. Switch to assembly model.
1. In Pro/E, close out the CHAMBER model (File > Close).

2. Open the PIST_CYL.ASM.
3. Click in the CETOL toolbar to synchronize to Pro/ENGINEER. Click Yes to save the changed
files. In general, it is good practice to save frequently.
Task 12. Include dimensions for the Piston.
1. Right click on Piston in the Tree and select Set As Active Object.
2. Rename the features: Bottom, Top, and OD (for the outside diameter).
3. Right click on Bottom and select Constrain Feature(s).
4. Select Top as the dimension reference and then OK.
Task 14. Run Analysis.
1. Right click on Config1 in the Tree and select Set As Active Object.
2. Run the analysis by clicking from the toolbar or selecting Tools > Run New Analysis (All).
3. Click OK in the Analysis wizard to solve the model using the default settings.
4. Click next to Config1 and then click on Volume Length to see measurement properties. Click
on the Variation tab to see the calculated statistical and worst-case distributions for the measurement.
Chapter 6.
Creating Accurate
Assembly Models
In order to accurately calculate how variation propagates through an assembly, it is critical that you
accurately characterize the assembly constraints. The key to correct assembly definition is setting
the proper degrees of freedom (DOFs) on each joint. In addition, many models also have assembly
clearance that must be accurately accounted for. In this chapter, you will learn how to properly set
DOFs and how to account for assembly clearance.
More on setting Degrees-of-Freedom
Modeling Physical Constraints
For every joint type supported in CETOL, there is a set of assumptions that is used in determining
which DOFs are constrained by default. In many cases the actual condition that you are attempting to
model with a particular joint may not match those assumptions, and thus the default DOF settings
may not be appropriate. The default translational constraints are usually correct for most joints.
However, the rotational constraints on a joint can often lead to an over-constrained condition.
Lets consider a simple example of two rectangular blocks in contact.
This is typical planar contact, and is adequately represented by the default planar joint, which
constrains Y-translation, X-rotation, and Z-rotation.
Now lets look at a similar assembly, which consists of a thin plate whose edge is in planar contact
with a block. The only difference between this example and the previous one is the width of the
planar contact.
Assuming that the plate is not welded to the block, this type of contact would not be physically
capable of constraining Z-rotation (Z-axis is the axis perpendicular to the plane of the figure above).
The rotation of the plate relative to the block would have to be constrained elsewhere in the
assembly. In this case, the appropriate joint is shown. This type of contact is typical of edge contact
of sheet metal components.
If the contact area is small in both directions then neither rotation is likely to be constrained by the
contact. An example of this type of contact is the bottom of a table leg in contact with the floor. Each
leg of the table constrains only the vertical translation. The rotation of the table is controlled by the
combination of translations at 3 of the legs. Note that the fourth leg is redundant (and in fact is
usually not even in contact with the floor at most restaurants. This is the leg that has a couple of
sugar packets underneath it to keep the table from wobbling). This type of contact is best represented
by a point contact joint.
Play Movie: \Movies\planar.gif

A default planar joint constrains the contacting features to remain coplanar.
When one or more dimensions of one of the planes are small, you should consider
unconstraining the related rotational DOF.
Lets take a look at another example:
Y Y
Z X
V
In this example, a shaft is inserted into a block with a hole. This is typical cylindrical contact and is
correctly modeled with a default cylindrical joint in CETOL. The default cylindrical joint constrains
2 radial translations and 2 rotations.
Now consider a similar model, only the block with the hole is actually a thin plate, as shown below:
Y Y
Z X
In this situation, it is unlikely that the rotational motion of the shaft about the X- or Y-axis would be
constrained by this connection. For a case such as this the connection is probably best modeled with
a joint in which only the X-translation and Y-translation are constrained. This type of constraint is
typical of screwed, bolted, or riveted connections of sheet metal components.
Play Movie: \Movies\cylindrical.gif

A default cylindrical joint constrains the axes of the features to be coaxial. When
one of the features is thin, you should typically select the Concentric at Point
common DOF state to allow the rotation shown.
Similar considerations apply to other types of joints. In general, the default constrained rotational
DOFs are selected based on a significantly large length of contact to constrain all possible DOFs. If
the contact length is not large enough, the corresponding rotational DOF should probably be
unconstrained. By removing the constraints on these rotational DOFs, you can avoid much of the
over-constraint that occurs by default in many models.
Fixing DOF Problems in the Tolerance Model

When adding each joint, the user should follow the procedure shown below:
Setting degrees of freedom
Modify DOFs Modify DOFs
to match according to
Create joint
physical DOF decision
constraint tree
DOF Guidelines
Over-constraint is usually due to excess Do DOFs
No
rotational DOFs. accurately
represent the
Translational DOFs which are constrained by contact?
default should usually remain constrained.
Joints should almost always have at least one
Yes
translational DOF constrained.
Done:
To remove under-constrained DOFs (Under >0) from a tolerance model, you can either define
additional joints or constrain additional DOFs of existing joints. To remove redundant constraints
(Over >0), you can either remove redundant joints or unconstrain DOFs of existing joints.
Setting the DOFs of a complex model correctly can be challenging. The DOF Decision Tree shown
below defines a standard process for setting the DOFs of a tolerance model. In this process flowchart,
rectangles represent processes or procedures, diamonds represent decisions, and ovals represent
completion of the DOF setting process. This procedure is written assuming the user is starting with a
blank tolerance model (no parts or joints), and is setting the DOFs as the joints are defined.
DOF Decision Tree
Identify base part Identify next part in Create joint(s) to
sequence realistically represent
assembly constraint(s)
No
All relevant Done: Check DOF state

Yes
parts Under = 0 of assembly
included? Over = 0
Is model Is model
under- over-
constrained? constrained?
No No
Yes
Yes Yes
Ignore
Is the constraint Yes Unconstrain joint in
No Is the
DOF due to direction of clearance or
unconstrained
constrained by clearance or flexibility
DOF trivial? Ye
a later part? flexibility?
No
Yes No
Missing part or Modify joints to reflect

Constrain DOF on Make change in change in design.
inadequate
existing joint design to minimize Delete extra joints and
design over-constraint unconstrain redundant
DOFs
The process of setting DOFs can be summarized as follows:

1. Add a joint. Add joints according to the actual assembly process order.
2. Modify DOFs to match physical constraints.
3. In general, remove the over-constraining DOFs. In some cases, over-constraint is OK
(i.e., for 2D models).
4. Remove the under-constraints that can be removed at this stage of the assembly. Not all
under-constraints can be removed immediately. Many are resolved by the addition of
other parts to the assembly, and must be left until those parts are added.
5. Return to step 1 and repeat for the next joint. Continue until all parts and their joints are
included, and all over- and under-constraints are resolved.
This procedure can be adapted to help set the DOFs after all the parts and joints have been included
in the tolerance model. The same principles apply. Start by identifying and setting the ground part
to be first in the part sequence. Identify and set the next part in the sequence. Set the sequence of
the joints that connect it to the previous parts and edit their DOFs to remove over- and under-
constraints. Repeat for the next part. Continue until all parts and joints have been covered.
Solving for Closure

Whenever you make a change to an assembly constraint (joint) in the model CETOL attempts to
solve for closure. Closure means that CETOL calculates the location and orientation of the parts
in the assembly, based on the surfaces the user has told it are in contact (i.e. by adding kinematic
joints). CETOL does not physically move the parts in the Pro/E assembly window. It stores the
locations internally.
Pro/E Nominal: Solved Nominal:

Gap Gap
Gravity
There are two nominal values for each measurement that are reported on the General tab of
measurement properties. The CAD Nominal is the value of the measurement based on the location
and orientation of the parts as defined in the Pro/E assembly. This value corresponds to the value of
a similar measurement in Pro/E (Analysis > Measurement in Pro/E) as shown in the figure above
on the left.
The Solved Nominal represents the value of the measurement based on the assembly constraints
(i.e., the kinematic joints) defined in the tolerance model. After solving for closure, the value for the
Solved Nominal is updated, as shown in the figure above on the right.
Play Movie: \Movies\closure.gif

Whenever you add, modify, or delete a joint CETOL solves for closure, in
which it attempts to calculate the locations of the parts based on the joints that
you have defined. Since Pro/E constraints often represent an idealized or
approximated assembly, the CETOL closed part locations may differ from the
locations shown in Pro/E.
If the geometry is such that it is physically impossible for a system to close, the DOF state in the
Configuration Properties will indicate that the model is Not closed. If the DOF state is 0 Over 0
Under and Not Closed, it is likely that there is something wrong with either the actual design
(part geometry won't allow closure) or the CETOL model (DOFs set incorrectly).
When a model is Closed, you can visually verify the constraints applied by the joints by selecting
View > Show Part Locations, which will temporarily display the Pro/ENGINEER components in
their positions as defined in the CETOL model.
Tip: Verifying joints and DOFs

It is good practice to visualize the constraints defined by your joints by selecting
Show Part Locations before running an analysis.
Exercise 6-1Modeling small planar contact
In this exercise, you will create a model of a table to determine the angle of the tabletop to the floor
under worst-case conditions.
Task 1. Open Pro/E assembly and synchronize CETOL.
1. In Pro/ENGINEER, change your working directory to \AssemblyModeling and open

TABLE.ASM.
Task 2. Define measurements between the table and the floor.
1. Click to add a measurement. Select the top surface of the floor and the top surface of the table.
2. Name the new measurement Angle1 and change the type to Angular.
A message in the advisor indicates that the measurement may be discontinuous. When measuring an
angle between nominally parallel surfaces, you must define a direction for the angle.
3. Click on the Features tab in Measurement Properties and click on next to the Direction
field. Select the vertical (the wall) surface of the FLOOR part. The direction feature defines the
measurement to be the angle measured about a rotation vector normal to the selected plane.
Angle1 direction
reference
Angle2 direction
reference
4. Click on the Variation tab and modify the tolerance value to 0.1.
5. Repeat steps 1-4, except name this measurement Angle2 and the thin L-shaped plane of FLOOR.
6. Click on next to Table in the model tree. Name the planar table feature Top.
Task 3. Add joints between the legs and the floor.
1. Right-click on TABLE;1 in the model tree and select Set as Active Object from the context
menu. (Make sure the component order is FLOOR;1 then TABLE;1.)
2. Click to add a joint. In Pro/E select the top surface of the floor and the bottom planar surface
of one of the legs.
3. Click on the new feature belonging to the the TABLE part (Not the joint!) and name it Leg1.
4. Click on the new joint in the Model Tree. Although the default DOFs for the joint define planar
contact, in reality the planar contact is so small that this joint is better characterized as point contact.
Click on the General tab of the Property View. Click on Default and select Point Contact from the
drop-down menu.
5. Repeat steps 1 through 4 for the other two legs, naming the new features Leg2 and Leg3.
Task 4. Constrain in-plane motion of the table
In order to analyze a model, the model cannot be under-constrained. So far, you have modeled the
table in contact with the floor, but the table is not constrained from sliding in the plane of the floor.
1. Click to add a joint. In Pro/E select the back side surface of the table and the back wall.
2. On the General tab of this joints Properties, select Line Contact Along Z.
3. Click to add a joint. In Pro/E select the left side surface of the table and the post.
4. On the General tab of this joints Properties select Point Contact.

Task 5. Verify the assembly constraints.
1. Review the DOF state in the status bar. The DOF state should indicate that the model is correctly
constrained.
2. Click on Config1 and verify that the Closure status for the configuration is Closed.
3. Verify that you have correctly constrained the model by selecting Tools > Show Part
Locations or from the Command bar. The Pro/E model will temporarily display the components
in the positions defined by CETOL joints.
4. Inspect the Pro/E model. Click on Close to resume work in CETOL.

Note:
It is generally good practice for the parts to be in their approximately correct
positions in the Pro/E assembly before attempting to add the joints in CETOL.
CETOL is less likely to find a closed solution if the parts have to be moved
significant distances.
Task 6. Define dimensioning scheme for the table.
1. Click on Table in the Graph View and then . In Pro/E select the underside of the tabletop.
Name the new feature Underside.
Notice that when you preselect the component you can only select geometry from that component. This
is sometimes useful in more complex assemblies.
2. Reorder Underside to come before the leg features click on Underside and drag it above
Leg1. It is good practice to reorder features before constraining them.
3. Cltrl-click Leg1, Leg2, and Leg3 in the model tree. Right-click on one of them and select
Constrain Feature(s) from the context menu. Select Underside and then click OK.
4. Click on next to Table in the model graph. Click in the toolbar. Click and drag from
Underside to Top.
5. Right-click in the Model Tree and select Tree Level > Variables. The dimensions underneath the
leg features represent the length of each leg.
Task 7. Define the tolerances.
1. Click on to Underside underneath Leg1 in the Model Tree. Click on the Tol/Rule tab in the
Property View. Modify the tolerance value to 1.0.
2. Repeat step 1 for the dimensions for the other legs.
Task 8. Analyze the model.
1. Run the analysis by clicking from the toolbar and then clicking OK.
2. Click on next to Config1 to reveal the measurements. Click on Angle1. The results are
displayed on the Variation tab of measurement properties.
3. Select File > Exit to close the Analyzer Window.
Exercise 6-2Modeling thin cylindrical contact
Assume that these two parts are part of a larger assembly. Add the appropriate joints and set the
DOFs for this assembly such that the actual physical constraints are properly captured.

HITCH.ASM.
Task 10. Define an angular measurement between the pin and the bracket.
1. Click to add a measurement. In Pro/E select the surfaces indicated in the figure below. Name
the new measurement Pin Angle.
2. Modify the measurement type to Angular on the General tab of the Property View.
Task 11. Add joint between pin and the holes of the bracket.
1. Right-click on HITCH_PIN;1 in the model tree and select Set as Active Object from the
context menu.
2. Click to add a joint. In Pro/E select the cylindrical surface of the pin and the cylindrical
surface of one of the holes.
3. Click on the General tab of the joint Property View. By default, this joint constrains TX, TY, RX,
and RY. However since the sheet metal thickness is fairly thin, this contact is unlikely to constrain the
rotation of the pin about the joints X- or Y-axis. Click on *Coaxial in the Preset DOF State field and
select Concentric at Point from the drop-down menu.
4. Repeat steps 1 through 3 for the other hole.
5. Review the DOF state in the status bar. The model is now fully constrained.

Assembly Variation
Assembly Process Variables
Joint DOFs can be modified to model assembly process variation. Assembly process variables are
used to specify the variation that occurs between mating part interfaces. They simulate variations
associated with assembling the parts, mechanism input errors, or any other situation where the user
wishes to directly specify the variation on a joint degree of freedom. Examples include positioning
error of one part mated to another due to fixture variation or servo motor variation.
Joint
dimension
Change state
to Variant
When you set the constraint state of a joint DOF to Variant, the variant DOF is listed as a
dimension underneath the associated joint in the Model Tree. Joint dimensions represent assembly-
level dimensions, and are treated the same as part-level dimensions. You can specify the dimension
tolerances and distribution parameters the same as for part dimensions.
Dealing with Assembly Clearance
Including the effects of assembly clearance is a critical consideration for many assemblies. Before
including assembly clearance in the model, you must first decide how the clearance affects the
assembly. There are generally three possibilities:
1. There is a force (spring, gravity, etc.) that causes a bias in the assembly positions, thus
effectively eliminating the clearance.
2. A feature of one part is randomly located within the clearance zone of the other part (e.g.,
random float of a pin in a hole).
3. The clearance is used for assembly adjustment (to increase the possibility of fit?).
Each of these conditions requires a different modeling approach.
Fastened Interfaces
When you define a joint by selecting two surfaces in which one of the surfaces is completely
enclosed by the other surface, CETOL creates a special class of joint called a fastener joint. A
typical fastener joint is the case in which there is a pin in a hole. To define a joint between a pin and
a hole you would select a cylindrical surface off of each part. Since the pin is inside the hole, a
fastener joint would be added.
Joint Biasing
There are a number of different possible scenarios that you may want to model with a fastener joint.
For example, in the case of a pin in a hole, if the pin fits tightly in the hole, you may want to assume
that the pin is always perfectly centered.
If the pin fits loosely, then assuming that the pin is always centered in the hole would probably not
be accurate. If there is some force acting on the joint, such as gravity, then you may want to assume
that the pin contacts the hole at a location determined by the direction of the force. When you
specify a tangent joint bias, you should also specify the direction of tangential contact. The point of
tangential contact for a biased pin/hole fastener joint is in the direction defined by the Orient
feature of the joint. For planar orientation features, the direction is the outward normal vector of the
selected plane.
If there is no biasing force, the pin may be randomly located in the hole during assembly. In this
case, you could apply variation to the joint constraints to simulate the float of the fastener in the hole.
When you apply automatic float to a fastener joint, the translational variables for the joint are
changed to Float and those variables are added to the model (and listed under the joint in the
model tree). The tolerance for the float variables is a function of the LMC conditions of the pin and
the hole. The statistical distribution is automatically calculated based on the statistical distributions
for the pin and hole diameters and the float distribution specified on the Constraint tab of the joint
properties.
Exercise 6-3Modeling Fastened Interfaces
The figure below shows part of water pump assembly for washing machine. The motor shaft must
pass through a hole in the pump housing. The shaft must be centered in the hole in order to maintain
a watertight seal and to eliminate unnecessary noise and wear.
In this exercise, you will add the measurements and joints necessary to determine the alignment of
the motor shaft in the hole in the pump housing.

PUMP_MOTOR.ASM.
Task 2. Set tolerance defaults.
1. It is always a good idea to specify the default tolerance values when starting a CETOL model.
Select Tools > Options from the menu. On the Variation Defaults tab, set the default tolerance values as
shown below.
Task 3. Define a measurement between motor shaft and the pump hole.
1. Click to add a measurement for the alignment of the motor shaft to the pump housing hole.
2. Select the inner surface of the hole in the pump housing and the surface of the motor shaft. The
measurement, the pump and motor, and the selected features are added to the model.
3. Rename the new measurement Shaft Alignment1.
4. The default attachment location for both features is Near. Change both the attachment of both
features by clicking on Surface and selecting Axis from the drop-down menu.
A message in the advisor indicates that the measurement may be discontinuous. You will address this
issue next in step 5
5. Click on Shaft Alignment1 in the model tree. Since these features are coaxial (or nearly so), the
measurement direction is ambiguous. You must specify a direction feature in this case in order to get an
accurate solution. Click on the Features tab in the Property View and then click on to add a
direction feature.
In Pro/E, select the surface indicated below (Shaft Alignment1 direction feature). The measurement is
from the first feature to the second feature (in the order listed on the Features tab) in the direction along
a vector normal to the plane selected as the direction feature.
Shaft Alignment2 Shaft Alignment1
direction feature direction feature
6. Click on the Variation tab. Set the target value and tolerances for this measurement to 0.00 0.20.
7. Add another measurement between the same two features, this time along a direction
perpendicular to the direction of the first measurement. Right-click in the Graph View and select
Graph Level > Features. Click on (Add Measurement Tool) and then click and drag from
Feature1 of PUMP to Feature1 of MOTOR. Rename the new measurement Shaft
Alignment2, and then repeat steps 4 through 6, selecting the direction feature (Shaft Alignment2
direction feature) indicated in the preceding figure.
Task 4. Add joint between mounting surfaces.
1. Ensure that the part order in the tree has the MOTOR first and then the PUMP second. Right-
click on PUMP_MOTOR in the model tree and select Set as Active Object from the context menu.
2. Click and in Pro/E select planar surface of one of the feet on PUMP (see figure below) and one
of the planar mounting pads on MOTOR. Change the DOF setting to Point Contact.
Pick planar
mounting surface
Pick planar
surface of
mounting foot
3. Repeat the previous for the other two mounting feet. You should have a point contact joint at
each foot of the pump.
Task 5. Add a joint between pin and hole.
1. In Pro/E set the view to 2 PIN1 and turn off datum plane display.
2. Click and in Pro/E select surfaces indicated below.
3. Click on the General tab of the Pin1 Property View. Note that the Bias option is set to Centered.
Task 6. Add a joint between pin and slot.
1. Click on to add a feature and select the pin surface highlighted in the image below. Name this
feature Pin 1.
2. Click on to add a feature and select the two side planar surfaces of the slot indicated in the
image below. Name this feature Slot. The resultant feature icon should look like .
3. Click and select the Pin 1 and Slot features from the Pro/E window as indicated below.
Task 7. Check DOF settings.
1. In Pro/E set the view to 1 ISO.
2. Review the DOF state. The total constraint of the model is Over: 3 Under: 0. to
MOTOR;1,4 is over-constraining by two DOFs and to MOTOR;1,5 is over-constraining by one
DOF.
3. Click on to MOTOR;1,4. On the DOF state field (*Coaxial), select Concentric at Point
from the Preset DOF State drop-down menu. The default preset DOF state for this joint constrains the
location and orientation of the pin in the hole. However for most fastener situations, there is a small
amount of clearance and flexibility at the joint, allowing a small amount of rotation in all directions.
The Concentric at Point preset DOF state constrains only the translational DOFs.
4. Click on to MOTOR;1,5 and select Aligned at Point from the Preset DOF State drop-down
menu.
5. Review the DOF state in the status bar. The total constraint of the model is Over: 0 Under: 0,
indicating that the model is properly constrained.
Task 8. Check the model and the nominal values of the measurements.
1. Select Tools > Show Part Locations. Visually check the model to make sure that it is correctly
constrained.
2. Set the view in the Pro/E model to BOTTOM and zoom in so that you can see the pins in the
hole and the slot. Notice that both joints are centered on the pins. (This may be easiest to see if you
switch to a No Hidden display.)
3. Click on Close to reset the model.
4. Click on Shaft Alignment1 and then Shaft Alignment2. Note that the nominal values for
both measurements is 0.000, indicating that the shaft is nominally centered in the hole.
2. Continue on to next exercise.

Exercise 6-4Changing Fastener Joint Bias Condition
In reality, there is a small amount of clearance between the pin and hole and between the pin and the
slot in the previous exercise. Since there is some clearance it is unlikely that the pins would always
be centered.
In this exercise, assume that the pump is put together with the shaft in the horizontal orientation, in
which case gravity would pull the pins down to the bottom of the hole and slot.
Gravity
Task 1. Rename configuration and reorder joints.
1. Rename Config1 to Centered.
2. Right-click on Centered in the model tree and select Set as Active Object from the context menu.
3. Reorder to MOTOR;1,4 and to MOTOR;1,5 (the joint between the pin and the slot) to be
configuration joints by selecting each one and dragging them down (or multi-select and drag) the tree till
the green insertion line is just below the measurements in Centered.
Task 2. Create a new configuration by copying and pasting the existing one.
1. Right-click on Centered in the model tree and select Copy from the context menu.
2. Right-click on PUMP_MOTOR in the model tree and select Paste from the context menu.
3. Rename the new configuration Gravity Biased.

4. Prep end Grad to the measurement names in Gravity Biased to distinguish them from the
measurements in the Centered configuration.
5. Right-click on Gravity Biased in the model tree and select Set as Active Object from the context
menu.
Task 3. Change the Bias option for to MOTOR;1,4.
1. In Pro/E set the view to BOTTOM. Zoom in on Pin 1 location and change the display type to
No Hidden.
2. Click on to MOTOR;1,4 and then click on the General tab in the Property View. Change the
Bias option of the joint to Tangent. Notice that the joint icon location changes in the Pro/E model so
that the joint is now on the cylindrical features rather than at the centers, although the exact location is
somewhat arbitrary since the contact could be anywhere around the surface of the features.
Task 4. Specify the tangential contact direction for to MOTOR;1,4.
In order to define the contact direction for a fastener joint, you must select a direction feature. This
defines the direction that the inner feature (the pin) will move to come into contact with the outer feature
(the hole).
1. Click on the Features tab. Click on next to the Orient field. In Pro/E, select the surface
indicated below. When you select a planar surface, the orientation vector is the outward normal of the
selected plane. Note that the joint icon display on the Pro/E model indicates the location of contact
between the two features. (In Pro/E set the view to BOTTOM.)
Note: Direction for biased fastener joints.

The point of tangential contact for a biased pin/hole fastener joint is in the
direction defined by the orientation feature of the joint. For planar orientation
features, the direction is the outward normal vector of the selected plane.
Task 5. Change the Bias option for to MOTOR;1,5.
1. Click on to MOTOR;1,5 and then click on the General tab in the Property View. Change the
Bias option of the joint to Tangent.
2. In Pro/E set the view to BOTTOM and zoom in on the slot. Notice that the joint icon display
changes in the Pro/E model so that the joint is now at a point that is tangent to both the pin and one of
the planar surfaces of the slot. You can change the contact to the other plane by selecting Tangent
Opposite. In this case you should select Tangent Opposite.
Task 6. Check the nominal values of the measurements.
1. Review the DOF state in the status bar. The total constraint of the model is Over: 0 Under: 0,
indicating that the model is properly constrained.
2. Select Tools > Show Part Locations.
3. Set the view in the Pro/E model to BOTTOM and zoom in so that you can see the pins in the
hole and the slot. Notice that the pins are biased, just as you defined in the CETOL model. (This may
be easiest to see if you switch to a No Hidden display.)
4. Click on Close.
5. Click on Grav Shaft Alignment1 and then Grav Shaft Alignment2. Note that the nominal
values (shown on the General tab) for Grav Shaft Alignment1 and for Grav Shaft Alignment2 are
0.00 and 0.15, respectively. Changing the joint bias condition to tangent shifted the nominal location of
the shaft in the hole.
Note: Solved Nominal values.

If you make a change to the assembly constraints of a model (by adding or
changing joints), the Solved Nominal is updated automatically. However keep
in mind that if the model is under-constrained, the solved nominal may not be
accurate.

Exercise 6-5Modeling Fastener Float
When there is a clearance fit, rather than a known tangent location for the joint due to a biasing force, as in the
previous exercise, the pin may randomly float within in the clearance of the hole.
In this exercise you will define the pins to be nominally centered but allow them to float within the available
clearance.
Task 1. Create a new configuration by copying and pasting the existing one.
1. Continue from the previous exercise.
2. Right-click on Centered in the model tree and select Copy from the context menu.
3. Right-click on PUMP_MOTOR in the model tree and select Paste from the context menu.
4. Rename the new configuration Floating.
5. Prepend Float to the measurement names in Floating to distinguish them from the
measurements in the Centered configuration.
6. Right-click on Floating in the model tree and select Set as Active Object from the context
menu.
Task 2. Change the Bias option for PUMP;1 to MOTOR;1,1.
1. Click on PUMP;1 to MOTOR;1,1. and then click on the General tab in the Property View.
Ensure the Bias option of the joint is Centered.
2. Click on the Constraint Tab. The list region on this tab shows the constrained DOFs associated
with the joint. These variables correspond to the fixed DOFs specified on the General tab. The State
column indicates the state of the constraint, which is Invariant by default.
3. For centered fastener joints (such as this one) CETOL can automatically calculate the float
distribution between the pin and the hole. Click on 5Apply Automatic Float. Notice that when you
select this option, the states of TX and TY in the list region change to Float. Float is a special case
of a Variant constraint, whereby the distribution of the variables is calculated automatically. The float
distribution is a function of the size dimensions and distribution of the joint reference features and of the
specified float settings. In this case, you can accept the default float settings.
Task 3. Change the Bias option for PUMP;1 to MOTOR;1,2.
1. Click on PUMP;1 to MOTOR;1,2 and then click on the General tab in the Property View.
Change the Bias option of the joint to Centered.
2. Click on the Constraint Tab and toggle 5Apply Automatic Float on.
Task 4. Review the float distribution for both joints.
1. In the Model Tree, click on the next to PUMP;1 to MOTOR;1,1 to reveal the variables
associated with the joint.
2. Click on TX and click on the Tol/Rule tab. Notice that the tolerance value is 0.25. This value
is a function of the LMC conditions of the pin and the hole.
The pin diameter is 3.700.10 and the hole is 4.000.10. The value for the float tolerance associated with this joint is
based on the LMC for both features as follows:
[Radial Clearance] Worst-case = (4.10-3.60)/2 = 0.25
3. Click on TX underneath TX and click on the Distribution tab. This distribution is
automatically calculated based on the statistical distributions for the pin and hole diameters and the float
distribution specified on the Constraint tab of the joint properties.
Notice that you cannot modify float tolerance or distributions. These values are calculated automatically (because you
selected 5Apply Automatic Float). If you make any changes to the pin or hole diameters (nominal, tolerances, or
statistical distributions) the float tolerance and distribution will update automatically.
Basic Fit Analysis
Assembly fit analysis is distinctly different from an assembly performance analysis. In performance
analysis, we look at the variation of some critical measurement after a product is completely
assembled. In this situation, looseness of fit in the assembly generally adds to the part variation. In
performance analysis, assembly looseness is often included in the model through assembly process
variation.
In assembly fit analysis, the looseness in the assembly (sometimes referred to as assembly
allowance), increases the chances that the assembly will fit together. The greater the assembly
allowance, the greater the chances that the assembly will fit together.
For this reason analyzing for fit usually requires a different set of constraints than the constraints
necessary for a performance analysis on the same assembly.
As an example, lets consider the fit of the Block to the Base in the figure below. A protrusion
on the block fits loosely into a cut in the base. The parts will fit if the protrusion will fit into the cut
and there is no interference between the parts at the right-side face of the block.
Block
Base
"Assembly allowance"
While assembling these parts, if interference initially occurs, you would push the block to the left in an
effort to eliminate the interference. In order to set up a fit analysis in CETOL, you would define a gap
measurement as shown in the figure below. A negative value of this gap would indicate an interference
condition. You should define the joints in the model such that the gap is maximized (thus minimizing
the chance for interference). The lower limit of the measurement should be set to zero, while the upper
limit is unimportant (since a large gap is OK in terms of fit).
Gap
Block
Base
A CETOL analysis of the model predicts the quality of fit for this situation. The rejects (area of
curve outside the limits) indicated in the results plot represent the assemblies in which there is an
unavoidable interference.
Note that in fit problems, there is frequently more than one possible location for interference to occur
that would prevent successful fit. In such cases, analyzing for fit can be quite complex.
Exercise 6-6Modeling for Assembly Fit
In this exercise you will analyze the fit of a cylindrical part in a rectangular notch. This is a very
simple fit analysis that involves only 2 dimensions, the diameter of the cylinder and the width of the
notch.

FIT.ASM.
Task 2. Define a measurement for fit.
1. Click to add a measurement for gap between the notch and the rod.
2. Select the cylindrical surface of the rod and the right face of the notch that it fits into.
3. Name the measurement Fit.
4. On the Variation tab, select Limits from the Type pulldown menu. A negative value for this
measurement represents an interference condition, so set the lower limit to 0.00. This gap cannot be too
big, so there is no true upper limit. You should just set it to a value sufficiently large so that there are no
rejects above the specified limit, so set the upper limit to 2.00.
5. Change the component order to be NOTCH;1 and then ROD;1 if that is not already the case.
Task 3. Dimension the NOTCH and ROD parts.
1. Right-click in the Tree view and select Tree Level > Features and DRFs.
2. Select Feature1 under the NOTCH part. On the General tab select the sign and select the
left side of the notch to add another reference to the feature definition. Select OK from the Select box.
This will change the feature type from a planar feature to a width feature after you select Continue to
accept the type change.
3. Rename this new width feature Width. On the ROD part rename the cylindrical feature OD.
4. By creating the width feature we added the necessary dimension for this analysis which is the size
constraint. The other variable we need is the size dimension of the ROD which is already included.
5. Set the width dimension type (on the General tab of the Tolerance Properties view) to be Half-
Thickness and the ROD OD size type to be Radius.
6. Set the tolerance for each of the dimensions to be +/- 0.2

Task 4. Create joint at the bottom of the rod.
1. Right-click on ROD;1 and select Set As Active Object from the context menu.
2. Click on to add a joint.
3. Select the flat surface of the rod and the bottom surface of the notch. A joint is added to the
model.
Task 5. Create a joint at the side of the rod.
The key to successfully analyzing for fit is in correctly defining the constraints. The purpose of
assembly clearance is often to improve the possibility of fit. In CETOL terms, this means avoiding a
negative fit measurement. In general, when analyzing for fit, you should create the joints so that the
measurement is maximized.
1. Click on to add a joint.
2. Select the cylindrical surface of the rod and either side of the notch.
3. On the General tab of the new joints properties select the tangent bias option that causes the ROD
to make contact on the left side (or opposite of the measurement side). Adding a joint on the left side
effectively maximizes the gap that is measured on the right side of the rod.
Task 6. Check and fix the DOFs.
1. Review the DOF state in the status bar. The assembly should be exactly constrained (Under=0,
Over=0).
2. Select Tools > Show Part Locations In Pro/E change the view to Front. Notice that all of
the clearance is on the right side of the notch. Click Close.

1. Run the analysis by clicking from the toolbar or selecting Tools > Run New Analysis (All).
You can select the analysis options from the Run Analysis dialog. Click on OK to accept the defaults.
2. Click on next to Config1 to reveal the measurement if necessary. Click on Fit and click on
the Variation tab in the Properties window to view the distribution curve of the measurement. The fit
quality for this assembly should be 2.39 sigma. Notice the fit is violated in the worst case.
Multi-level Assemblies
CETOL 6 supports whatever assembly structure is defined in the Pro/ENGINEER model. Multi-
level assembly structures are easily modeled in CETOL.
When creating a CETOL model on a multi-level assembly, its usually easiest to define the model on
each subassembly model, making sure that the joints define a properly constrained model. After you
complete the subassembly models, you can move up to the next higher level in the assembly
hierarchy. When you open the higher-level assembly in Pro/E and then synchronize to Pro/E from
CETOL, the model data defined in the lower level parts and assemblies is read into the model. To
complete the CETOL assembly model, you must only add the necessary joints in the top-level
assembly.
You can add a joint to any assembly within the model structure. You can add a measurement to any
component (Part or assembly). To add a joint or measurement to a specific component, first set the
component as the active object in the Model Tree and then select the appropriate icon in the toolbar.
When you set a component as the active object, you can only select features from that component.
If you do not set a component as the active object before adding a joint or measurement, the joint or
measurement is added to a new configuration or to the current active object.
Exercise 6-7Medical Sprayer Assembly
In this exercise you will learn how to add a CETOL model on a multi-level assembly.
1. In Pro/ENGINEER, change your working directory to \Sprayer and open

MECHANISM.ASM.
Task 2. Add a measurement.
1. One of the important requirements of this design is that the RELEASE can swing clear of the tip
of the ARM when the mechanism is in its resting state.
2. Click on to add a measurement. Select the tip of the arm and the surface representing the
swing of the release lever, as shown in the figure below.
Note: Part names

The part names referred to in this exercise correspond to the part names in the
Pro/E model. To identify the parts by name, it might help to turn on the display
of the Pro/E Model Tree.
3. Rename the measurement Reset Gap.
4. On the Variation tab, set the Type to Limits. Set the upper limit to 0.75 and the lower limit to
0.05.
Task 3. Add connection between VALVE and GRIP.
1. In Pro/E, set the view style to CETOL_MODELING (Pro/E Wildfire: View > View
Manager) so that you can more easily see the internal components of the assembly.
2. Right-click on MECHANISM and select Set As Active Object in the context menu.
3. Click to add a joint between the VALVE and the GRIP. Select the planar contacting surfaces.
4. The grip has four molded pins that are used to fasten the valve. The top two holes are used to
locate the valve. The bottom holes have more clearance and are only used to hold the valve tightly to
the grip.
Add a joint at each of the top pins by selecting the cylindrical surfaces of the holes and the pins.
Task 4. Check and modify DOFs.
1. Before checking the DOFs of your assembly, it is always a good idea to make sure that the
component and joint order roughly correspond to the actual assembly order.
Reorder components by clicking and dragging the component icons in the Model Tree.
Change to component order to 1) GRIP;1, 2) VALVE_RELEASE;1, and 3) ARM;1.
2. Review the DOF state in the status bar. The constraint state of each object in the model is
displayed in the model graph, as shown in the figure below.
The values next to the part and assemblies represent the degree of under-constraint for the
component. Since GRIP is the first component in the assembly (see the model tree order), the
grip is considered the ground part, which is by definition fully constrained. The valve_release
subassembly is adequately constrained to the grip by the three joints that connect those
components.
3. The model graph shows that the two fastener joints are over-constraining. TX, TY, RX, and RY
are constrained on both of these joints. However, in general fasteners are not capable of constraining
rotations. Imagine that the only constraint on the valve was one of these fasteners. You would be able
to rotate and twist the valve (to at least a limited extent) about any axis.
Modify each of these joints by selecting Concentric at Point from the Preset DOF State menu on the
General tab.
4. The second fastener is still over-constraining. The fastener joints constrain the pins to be centered
in the holes. In order for both fasteners to be centered in the TY direction, the distance between the pins
and the distance between the holes must always be exactly equal. Any variation in either of these
variables would violate one of the TY constraints.
Toggle the TY DOF to be free (unconstrained) on the second fastener joint. This joint should now be a
custom point contact joint. Review the DOF state and verify that none of the joints are over-
constraining. You will address the under-constraint on ARM later.
Task 5. Define the assembly constraints for the VALVE_RELEASE.
1. Right-click on VALVE_RELEASE in the model tree and select Set as Active Object from the
context menu.
2. Ensure that the part order in the VALVE_RELEASE subassembly is: 1) VALVE,
2) RELEASE.
3. Click on . Select the cylindrical surface of the pin of RELEASE and the hole in VALVE. Note
that the model graph indicates that the assembly is properly constrained.
Task 6. Add the connection between the PISTON and the GRIP.
1. Right-click on MECHANISM in the model tree and select Set as Active Object from the
context menu.
2. Click on . Select the cylindrical surface of PISTON_PIN and the hole in GRIP.
3. Add another joint by clicking on . Select the cylindrical surface of PISTON_PIN and the hole
at the bottom of PISTON.
Task 7. Check DOFs.
1. Review the DOF state in the status bar. The total DOF state of the assembly is displayed in the
status bar (Over: 0 Under: 7).
The constraint state for PIST_CYL is shown as +0, -3. Since this is a subassembly, its constraint
state is a little more complex than a single part. The first number indicates the number of DOFs that the
subassembly is over-constrained. The second number is the number of DOFs that the subassembly is
under-constrained. This subassembly is under-constrained by 3 DOFs.
2. The PISTON cannot translate along the axis of the PISTON _PIN. Click on the joint between
PISTON and PISTON _PIN. On the General tab, toggle the Z-axis translational DOF. The joint
icon will change to a revolute joint.
3. Review the DOF state in the status bar. The total DOF state of the assembly is displayed in the
status bar (0 Over 6 Under). PIST_CYL is under-constrained by three DOFs because it can pivot
about the pin. These DOFs are constrained by constraining the rest of the mechanism.
Note: Component and Joint Order

It is good practice to add your joints in the order that the model would actually be
physically assembled. DOF states depend on the component and joint order. The
initial component order corresponds to the order in which they were added to the
model. The order of joint creation defines the initial joint order. Before
reviewing the DOF state of the model, you should verify that the components and
joints are in the proper order. You can reorder components and joints by dragging
and dropping in the model tree.
Task 8. Add a connection between ARM and VALVE.
1. Click on . Select the cylindrical surface of the round protrusion on the valve and the hole in
ARM as shown in the figure below.
Task 9. Add a connection between ARM and CHAMBER.
1. Add a joint between PIVOT_PIN and CHAMBER. Select the cylindrical surface of PIN and
the hole in CHAMBER.
2. Click on . Select the surface of the PIVOT_PIN and the mating hole in ARM.
3. Click on the joint you just created and while holding down the
left mouse button drag the joint down till a green line appears just
above the Config1 at the bottom of the tree. Release the left mouse
button and select:
4. This joint adds one degree of overconstraint to the model.

This degree of freedom overconstrains the twisting or warping of the
ARM. To remove the overconstraint you need to unconstrain the
RY degree-of-freedom on the ARM;1 to PIVOT_PIN;1, 1 joint that
was moved in the previous step. This action will turn the joint into a
Custom type with 3 constrained degrees-of-freedom.
Task 10. Modify Object Order in the Tree View
1. Once you have built the assembly model its usually a good time to review the component and
configuration order in the Tree. Modify the component and configuration order, and joints if necessary,
to match the figure to the right.

Configurations
For many assemblies, you may want to analyze the assembly in different positions or constraint
states. Mechanisms typically have a range of motion. Some assemblies, such as an electrical switch,
may have two distinct assembly conditions: open and closed. In other cases, differing loads or other
conditions could cause a change in the constraint state in the assembly. In all of these cases you may
want to analyze your assembly in two or more different assembly configurations.
CETOL allows you to define multiple constraint states for your assembly by defining a distinct
configuration to represent each state. A CETOL configuration always includes one or more
measurements. A configuration can also include joints. You can use a configuration joint to
represent an assembly constraint that only applies to a particular assembly condition.
By defining multiple configurations within an assembly you can define a model that represents all of
the critical configurations of your assembly.
When you add measurements and configuration joints to an assembly model, by default they are
added to the active configuration. When you add the first measurement to an assembly model, a
configuration called Config1 is automatically created and the measurement is added to this
configuration.
Exercise 6-8Configurations for Sprayer Assembly
In the previous exercise, you created assembly joints that define the mechanism in a single specific
position. In reality, there are several positions in which it is necessary to perform a variation
analysis on this model.
In this exercise you will create multiple configurations of the model to represent different states of
the assembly.
Task 1. Continue from previous exercise or open Pro/E assembly and synchronize CETOL.
1. Continue from previous exercise or open the model if you closed it.
2. Click in the CETOL toolbar to synchronize to Pro/ENGINEER if necessary.
3. In Pro/E, set the component display to CETOL_MODELING (Pro/E 2001: View > Model
Setup > Component Display... > Set Current; Pro/E Wildfire: View > View Manager) so that
you can more easily see the internal components of the assembly.
Task 2. Recreate the to STOP_PIN;1,2 as a configuration joint.
1. Click on the Config1 in the Model Tree that is a child of the PIST_CYL component. Change
the configuration name to Uncompressed in the Property View.
2. Rename the other Config1 to Uncompressed as well.
3. The to STOP_PIN;1,2 joint represents a constraint that is only applicable in one position for
the assembly. In a previous exercise you created this constraint using an assembly joint. This constraint
would be better modeled as a configuration joint. You should move this joint to the PIST_CYL ;
Uncompressed configuration.
Click on the next to PIST_CYL in the Model Tree to view all of the joints in the subassembly.
Right-click on to STOP_PIN;1,2 and select Cut from the context menu.
4. Right-click on both Uncompressed configurations in turn and select Paste from the context
menu.
5. At this point the PIST_CYL ; Uncompressed configuration is still underconstrained by 1
DOF and therefore will not be included in the analysis. At the subassembly level this degree-of-freedom
was not necessary but when we added the subassembly into the higher level assembly we added a
feature reference that required an additional DOF to completely define the location and orientation of
the assembly. The missing DOF is the rotational orientation of the piston about its major axis. This
rotational DOF is defined at the higher level of assembly by the to PISTON_PIN;1,1 joint. We need
to define this DOF at the subassembly level so we will constrain it with a configuration joint.
Right-click on to CHAMBER;1,1 and select Copy from the context menu.
6. Right-click on the PIST_CYL ; Uncompressed configuration and select Paste from the
context menu.
7. Select on the PISTON; 1 to CHAMBER;1,2 joint you just pasted. Select Free from the joint
DOF pull-down menu and then select on the Z-Rotation DOF to constrain it so that the joint DOF
graphic looks like the picture to the right:
Task 3. Create a new configuration.
In order for this mechanism to work properly, there must be sufficient overlap between the tip
of the Arm and the Release. This overlap condition occurs as the trigger is squeezed, so the
assembly is in a different position than the position in which the Reset Gap is measured.
1. Click on MECHANISM and select Add Configuration.
2. Change the name of the new configuration to Overlap in the Property View. Notice that this new
configuration is now the active configuration for the assembly (designated by the yellow highlighted
configuration icon- ).
Task 4. Create a measurement for the overlap condition.
1. Right-click on Reset Gap and select Copy from the context menu,
2. Right-click on Overlap and select Paste from the context menu.
3. Rename the new measurement Overlap.
4. On the Features tab, uncheck the Lock checkbox for the feature for the Arm if necessary, and
select Far from the drop-down menu. Redo the lock on the feature reference for the Arm by checking
the Lock checkbox if it was locked before. Note that the highlight is a little misleading because the
model is constrained in a different position in CETOL than the position shown in Pro/E.
5. On the Variation tab, set the Zone Type to Limits. Set the upper limit to 1.00 and the lower limit
to 0.10.
Task 5. Create a configuration joint.
1. Click on to create a configuration joint. A configuration joint is a joint that applies only to its
own configuration. It does not affect the DOFs of any other configuration in the assembly.
Select the tip of the Arm and the side surface of the Release, as shown below.
2. The default DOF state for this joint is Line Contact. However, in reality only point contact is
actually constrained at this contact line contact is not enforced. Change the DOF state to Point
Contact.
Task 6. Check DOFs for Overlap and visually check model.
1. Since Overlap is the active configuration, the measurement and joint associated with
Uncompressed are temporarily removed from the Graph View. Only measurements and joints
associated with the active configuration are displayed in the Graph View.
Review the DOF state in the status bar. The total DOF state of the assembly is displayed
(Over=0, Under=1). The DOF analysis only applies to the active configuration ( Overlap).
Prior to Task 5 there was no under-constraint for the configuration. When the joint was
created in Task 5 a new feature was added to the RELEASE part and this additional feature
was a non axi-symmetric feature. The addition of this feature now requires that another DOF
be defined in order to define the orientation of the part.
2. Select the to VALVE;1,1 that is a child of the RELEASE part to view its properties.
Constrain the Z rotation DOF to change the joint to a No Rotation type. Now the DOF state should be:
(Over=0, Under=0).
3. Select (Show Part Locations) in the Analysis toolbar. The assembly model is temporarily
displayed in Pro/E according to the assembly constraints defined in CETOL. Note that ARM is to be
in contact with RELEASE. Also note that PISTON is not in contact with STOP_PIN. When
you select the Show Part Locations function ( ), only the configuration joints for the active
configuration are considered joints for all other configurations are ignored.
Task 7. Check Uncompressed configuration.
1. Right-click on Uncompressed that is a child of MECHANISM and select Set as Active Object
in the context menu.
2. Review the DOF state in the status bar. The total DOF state of the assembly is displayed (Over=1,
Under=0, Closed).
3. Click on in the CETOL toolbar. Change the model display to wireframe in Pro/E so the
piston is visible. Note that in this configuration Piston is in contact with StopPin.
Chapter 7.
Creating Accurate
Dimensioning Schemes
A good overlay part model must accurately capture the feature-to-feature relationships in a part. In
this chapter you will learn how to correctly create an overlay model, even for complex parts. You
will also learn how to apply GD&T to the CETOL 6 model.
Defining an Accurate Part Overlay Model
Dimension Types
The purpose of defining an overlay model for a part is to precisely define the location and orientation
of the critical features of the part. An overlay model defines the relationships of these features to
each other or to manufacturing or inspection datums. In defining these relationships you essentially
define the part dimensioning scheme. In addition to defining the dimensional relationships between
features, the overlay model can also define the topological relationships between individual features
of the part.
Linear dimensions define feature location and angular dimensions define orientation. Some features
also include size dimensions. For example, a cylindrical surface will include a dimension
representing its radius or diameter. Size dimensions are inherent characteristics of the feature and
are not dependent on the part overlay model.
Defining the Topology of the Part

By default, CETOL treats all entities as independent. In addition to representing the dimensional
relationships between features or datums, the overlay model of the part must also represent the
invariant topological relationships as well.
For example, by default CETOL treats edges and faces as being completely independent of each
other. In reality the edge is completely defined by the intersection of the two adjacent surfaces. The
location and orientation of the edge is defined by the location and orientation of the two surfaces.
Face 2
Face 1 Edge F1/F2

The figure below shows a Graph View that captures this relationship.
In this example, the edge is constrained to both faces. The variables controlled by the constraints
between the edge to each face have nominal values of zero and the state of these variables is set to
Invariant, indicating that the edge is always exactly located on both of the faces. The angular
variables are 90 deg because the angle between the edge and the normal vectors of the Faces is 90
degrees.
Lets look at a simple example. The figure below shows a two-part assembly and the associated
CETOL assembly Graph View. The measurement of interest is the relative angle between the top
face of the block and the vertical face of the base.
Block
Base
The figure below shows a detailed drawing for our block. A detailed drawing can be used to identify
the dimensions that control the location and orientation of the critical features of a part.
This drawing indicates a dimension (1.00) between the top and bottom surface. The figure below
shows the part Graph View completed to this point. Since not all of the surfaces are considered
critical for this problem, not all dimensions shown on the drawing have to be included in the part. In
this case, the length and width of the block are unimportant.
At this point, the relationships of the edges to the rest of the part are undefined. The edges are, by
definition, at the intersections of the top face and the bottom face with the left face. In the figure
below, the left face has been included in the model and the edges are constrained to their
corresponding faces.
The last step in the process is to confirm that the variables defined by the constraints between the
edges and the defining faces are invariant, as shown in the figure below.
As another common example, lets take a look at creating a proper overlay model for a cylindrical
feature. A simple cylindrical part is shown below.
Edge
Cylinder
End
The figure below shows the default part Graph View for the cylinder. This Graph View includes all
of the entities that make up one end of a cylinder: a cylindrical surface, a planar end surface, and a
circular edge. Note that in the Pro/E model the cylindrical surface is actually two surfaces. In
CETOL you can define a single feature that includes both of these surfaces. Likewise, in Pro/E the
circular edges are actually two semicircular arcs but in CETOL you can include both as a single
feature. In order to fully focus on part modeling issues, no assembly modeling (joints or
measurements) have been included in this model.
The figure below shows the part Graph View that defines the topological relationship between these
features. Notice that the edge feature is constrained to the end face and the cylindrical feature.
The Model Tree for this model is also shown. Notice that there is a separate size dimension for the
Cylinder and Edge. These dimensions actually represent the same size the diameter of the
cylinder and should be made equivalent. To do so, select the variable controlled by each size
dimension while pressing Ctrl, then right-click and select Make Equivalent from the context
menu. When you make variables equivalent, the first of the variables in the Model Tree remains in
the model and the others are made equivalent to it and removed from the Model Tree. The state of
an equivalent variable is designated as Driven on the Constraints tab of Feature Properties.
To complete the model, the location and orientation variables for the edge should be Invariant (the
default state for these variables) since these features are dependent on the surface geometry. The
figure below shows the constraint state for Edge.
Relating Datums to Geometry Features

When your model includes datum planes and axes, it is important that you properly define the
relationship between the datums and the part geometry. By definition, a datum is a theoretically
exact axis or plane derived from the true geometric counterpart of a specified datum feature.
In general you should avoid including datum planes and axes in your model since they add steps to
the modeling process and unnecessarily complicate the Graph View. When defining measurements
and joints, in most cases it is best to select geometry features rather than datum features.
If you need to include both a datum plane or axis and its corresponding geometric counterpart, you
can include both in a single feature. For example, if you need to include both a plane and the
corresponding datum plane, you can include both in one feature. There are three ways to accomplish
this:
1. When adding a new feature to the model, you can select both the plane and the datum
plane as long as neither has already been added to the model.
2. If the plane and datum plane have been added as separate features, they can be merged
into a single feature.
3. If either the plane or the datum plane has been included in the model but the other has not,
you can add the other to the feature on the Geometry tab of the feature properties.
Checking the Dimensioning Scheme
DOF states
When you select Graph Display > Show DOF states from the Graph View context menu, CETOL
displays the constraint state of each individual feature in the part model as shown in the figure below.
By definition, an unconstrained feature has an under-constrained DOF state. The degree of under-
constraint depends on the feature type, feature order and the number of variant degrees-of-freedom
for the feature.
By definition a feature has a total of 6 degrees-of-freedom, some of which are variant while others
are invariant. The variant DOFs represent the directions of potential variation of the feature these
are the DOFs that matter for the feature. The DOF state of a feature indicates the number of
unconstrained variant DOFs of a feature.
For example, a planar surface has 3 invariant DOFs (two in-plane translations and one in-plane
rotation), and 3 variant DOFs (one out-of-plane translation and two out-of-plane rotations), so an
unconstrained planar surface has a DOF state of -3. In order to fully define the location and
orientation of a plane in three-dimensional space, you need a total of three variables. These variables
correspond to the three variant DOFs of the feature.
An unconstrained cylindrical surface has 4 variant DOFs, so it has an unconstrained DOF state of -4.
Refer to the CETOL 6 Users Reference Manual to a find a table that shows the number of variant
DOFs associated with each feature type.
Some simple parts have less than six invariant DOFs. Axi-symmetric parts (such as pins and rivets)
have total DOF state of -5 since the rotation about the axis of revolution is considered to be invariant.
Spherical parts (such as a ball) have a total DOF state of -3 (three translations).
If the total DOF state for all of the features of a part is less than 0 (i.e., -1, -2, etc.) then the feature
constraints for the part are not fully defined, and the dimensioning scheme that you have defined is
not complete. This does not necessarily mean that the dimensioning scheme is wrong; it simply
means that location and/or orientation of the feature in the unconstrained DOFs will be considered as
constant in the analysis.
Constraint Order
The order of the constraints is important in resolving redundant constraint situations. If the same
DOF of a feature is constrained by two or more constraints, the first constraint in the constraint
sequence is considered active for the DOF in question and the other constraint(s) is (are) considered
redundant.
The constraint order is defined by the order in which the constraints are listed in the Model Tree.
You can reorder the constraint sequence in the Model Tree. To reorder a constraint, click and drag it
to a new location underneath the same feature and then release the mouse button to drop it into the
new location.
If you constrain a particular DOF for a feature with more than one constraint, only one variable
representing that DOF can be considered variant. The other variable is considered redundant and is
not included in the model. In the figure below, the angular variables associated with to End are
redundant because those DOFs are already constrained by to Shaft.
Redundant variables are identified based on the constraint order earlier constraints take precedence
over latter constraints. If you have redundant constraints, changing the constraint order will change
the constraint state of the related variables.
Exercise 7-1Defining Dimensions and Topology
The figure below shows a two-part assembly, which consists of an L-shaped plate, screwed to a shaft
block. A CETOL model has been started for this assembly. There are three assembly measurements
of interest: the relative angle of the shaft to the vertical plane of the plate, and the gap between the
center of the shaft end and the edge of the plate measured in the horizontal and vertical directions.
L_Bracket
Shaft_Block
In this exercise you will create an dimensioning scheme for the shaft block according to the detailed
drawing below.
1. In Pro/ENGINEER, change your working directory to \PartModeling and open

OVERLAY1.ASM.
data from the Pro/E part and displays the data. The assembly modeling for this model has been
completed.
When defining the part overlay, it is often more convenient to work in Pro/ENGINEER part
mode.
1. In Pro/E, click on SHAFT_BLOCK (the green block) and then right-click and select Open from
the context menu. You may want to resize the window so that it does not overlap the CETOL window.
Task 3. Define dimensioning scheme for Hole1.
1. Click on Hole1 in the Graph View. Click on in the CETOL toolbar.
2. Click on the Select Reference from CAD Model button in the Add Dimension dialog.
3. Select the side surface of the part, as shown in the figure below and select OK from the Add
Dimension window. Notice that a dimension is added to the Graph View and Model Tree. There is a
variable listed under the dimension in the Model Tree
Top
Side
4. A new feature related to the constraint is automatically added to the model. Rename the new
feature Side.
5. Click on Hole1 in the Graph View. Click on .
6. Click on the Select Reference from CAD Model button in the Add Dimension dialog.
7. Select the top surface of the part, as shown in the previous figure and select OK from the Add
Dimension window. Notice that a feature, a dimension, and associated variable are added to the model.
(You may have to expand the Model Tree to see these).
8. Rename the new feature Top.
Task 4. Define dimensioning scheme for Hole2.
1. Click on the Dimension Constraint Tool in the Graph view toolbar. Click and hold on Hole2
in the Graph View. Drag the constraint arrow to Hole1.
Task 5. Define dimensioning scheme for Shaft.
1. Click on in the Graph view toolbar. Click and hold on Shaft in the Graph View. Drag the
constraint arrow to Mount.
2. Click and hold on Shaft in the Graph View. Drag the constraint arrow to Side.
Task 6. Define dimensioning scheme for Shaft Upper.
1. Press the middle mouse button to clear the tool selection from the previous task.
2. Click on Shaft Upper in the Graph View. Click on Constrain Feature from the Command
Bar to open the Constrain Feature Wizard.
3. Select Add Dimension Constraint from the Defined Constraints section and then select
Shaft from the Tree then select OK from the Add Dimension window. Notice that the TX and RY
degrees-of-variance have been constrained.
4. Select Add Dimension Constraint from the Defined Constraints section and then select
to pick the dimension reference from the CAD system.
5. Select the end surface of the shaft and select OK from the Add Dimension window. Rename the
new feature End. Notice that the TZ and RX degrees-of-variance have now been constrained.
6. Notice that the TY degree-of-variance remains unconstrained. When creating topological

relationships between features with Dimension Constraints CETOL will only constrain one translational
degree-of-freedom per constraint. In cases where a topological relationship requires constraining more
than one degree-of-freedom its necessary to create more than one Dimension constraint.
7. Repeat step 3 above to finish constraining Shaft Upper. TY has now moved down into the
Defined Constraints section and the Unconstrained Feature Parameters section is empty.
8. Click on in the Graph view toolbar. Click and hold on End in the Graph View. Drag the
constraint arrow to Top.
9. Right-click in the Graph View and select Graph Zoom > Auto-fit in the context menu. Your
Graph View should look similar to the figure below.
10. Click on . Right-click in the Graph View and deselect Graph Display > Show Edge Names in
the context menu. This will turn off the constraint name display so that the Graph View takes up less
horizontal space.
Task 7. Review the dimensions.
1. Right-click in the Model Tree and select Tree Level > Variables.
2. Click on each of the dimensions and look for the corresponding highlight on the Pro/E model.
Task 8. Make size variables equivalent.
1. In the Model Tree, click on next to Shaft and Shaft Upper. Notice that each of these
features has a diameter dimension. These two dimensions both represent the same size the diameter of
the shaft.
2. Click on the Diameter variable underneath Shaft and Shaft Upper while holding down the
Ctrl key. Right-click on one of the highlighted variables and select Make Equivalent from the context
menu. The variable associated with Shaft Upper is removed from the model.
Task 9. Review the Shaft Upper variables.
1. Click on Shaft Upper in the Model Tree. Click on the Constraints tab in the Property View.
2. The list region shows the variables of Shaft Upper related to to End and to Shaft.
The location and orientation of this edge should not vary relative to these features. Since the offset
variables have zero-value nominals and the angles have nominals that are multiples of 90 degrees, they
are set to Invariant by default.
The state of Size is Driven because you have made it equivalent to the shaft size variable. The state
of the angular variable associated with the second constraint is Redundant because the same angular
variables are already constrained by the first constraint. You cannot directly change the state of
Driven and Redundant variables.
Task 10. Modify tolerance values to correspond with the values shown on the drawing.
1. Right-click in the Model Tree background and select Tree Level > Tolerances from the context
menu.
2. The tolerances for the dimensions are all set to the default tolerance value. You should change the
tolerances to correspond with the values specified on the drawing at the beginning of this exercise.
3. Click on each of the size and offset dimensions and enter the tolerances shown on the drawing.
Task 11. Check the DOF states.
1. Right-click on the background of the Graph View and verify that Graph Display > Show DOF
States is selected. The number of under-constrained variables appears to the upper right of each feature.
The DOF states for Mount, Side, and Top are 0, -1 and -2 respectively, indicating that the latter
two are under-constrained by a certain number of DOFs. This value simply reflects the number of
variant DOFs for a planar feature that is considered a datum reference.
Unconstrained DOFs are considered invariant, meaning that these planes will not vary from their
nominal condition, implying that they are essentially perfect. In reality, there would be some angular
variation between these planes. The way that the model is currently constrained, this angular variation is
ignored.
The DOF state of Hole2 is -2, which indicates that it is under-constrained by two Degrees Of Freedom
(i.e., missing two variables). Hole2 has been constrained to Hole1. The offset variable associated
with this constraint does not have a direction associated with it, so this variable essentially represents a
radial dimension from the center of Hole2 to the center Hole1. You must add another constraint to
properly constrain this feature.
2. Click on from the Graph view toolbar. Click and hold on Hole2. Drag the constraint arrow to
Top. Notice that the DOF state for Hole2 indicates that the feature is now fully constrained.
3. Right-click in the background of the Model Tree and select Tree Level > Tolerances from the
context menu.
4. Click on to Top (underneath Hole2). Click on the Tol/Rule tab in the Property View. Enter
0.2 in the Tolerance field. Reduce the Precision to 1 if necessary.

Applying Geometric Tolerances
GD&T can be incorporated into the CETOL variation model through the Modeler.
Adding Geometric Tolerances

To add a geometric tolerance, follow the procedure below:
4. Click on the feature and then click on in the toolbar or select GD&T
Constraint from the Insert menu. The Add GD&T Callout window appears.
5. Define geometric control in the feature control frame that is displayed in the dialog box
(see figure below) and then click OK .
CETOL will only allow you to define syntactically correct geometric tolerances. For this reason,
some options for control type, zone shape, material condition modifier and datum reference frames
are filtered under certain circumstances.
When selecting datum reference frames, you can only select features that appear before the
controlled feature in the Model Tree. If necessary, you should reorder the features in the Model Tree
prior to adding geometric tolerances to place reference datums before the feature to be controlled.
When the geometric tolerance definition is complete, all applicable variables are mapped to the
geometric tolerance. For angular variables, the angular variation is a function of both the geometric
tolerance and the characteristic length. The characteristic length is the length of the feature in the
direction perpendicular to the rotation axis of the angular variables. CETOL automatically
determines the applicable characteristic length for each angular variable and calculates the angular
tolerance limits that correspond to the geometric tolerance value.
Datum Reference Frames

The reference features of a feature control frame collectively define a datum reference frame. Often
a part has more than one feature that has the same datum reference frame. In order to minimize the
complexity of the Model Graph, CETOL adds a single icon ( ) for each datum reference frame.
All geometric tolerances that have the same datum reference frame will point to this single icon in
the model graph.
A datum reference frame (DRF) icon is also added to the part model tree, in order, below the last
datum feature of the DRF. Datum features are shown in the model tree with this icon: . In the
properties view of the DRF the reference datum features can be changed and the degrees-of-freedom
constrained by the DRF are listed. An example of the DRF properties is shown below.
Geometric Tolerance Properties
An example of a GD&T properties window is shown below.
The full specification for the feature-control-frame (FCF) can be edited in this window. Basic
dimensions established by the FCF can be viewed on the Reference tab. The Rule tab allows the
model builder to customize rule based assumptions pertaining to the FCF.
Constraint Order
When more than one constraint is applied to a feature, the order of the constraints is important.
CETOL automatically evaluates the constraints and identifies the redundantly constrained variables
of the feature. When a variable is redundantly constrained, the variable associated with the latter of
the constraints is identified as redundant and is removed from the model.
This is especially important when including GD&T in a model. In general, you should use the
following order when applying constraints:
1. Orientation GD&T
Perpendicularity, Parallelism, Angularity
2. Location GD&T
Position, Concentricity
3. Standard constraints
You can control the order of constraints by dragging and dropping the constraints in the model tree.
Example 1:
In the example below, notice that on the left the angular variables that are controlled by the
perpendicularity are redundant. Thus the perpendicularity would have no effect in this case. On the
right, the order of the constraints is correct and the orientation of the feature is controlled by the
perpendicularity.
Wrong Right
Example 2:
In the example below is similar to the previous example. In the case on the left, the perpendicularity
would have no effect the location and orientation of the feature are completely controlled by the
position tolerance. On the right, the order of the constraints is correct and the orientation of the feature
is controlled by the perpendicularity.
Wrong Right
Exercise 7-2Adding Geometric Tolerances to a Part
In this exercise, you will add geometric tolerances to the part from the previous exercise according
the drawing below.
1. In Pro/ENGINEER, change your working directory to \PartModeling and open

SHAFT_BLOCK.PRT.
Task 2. Rename datum reference features.
1. Rename the datum reference features in the CETOL to correspond with the datum names
indicated in the part drawing. Change the name of Top to A, change Mount to B, and Side to C.
2. Reorder A, B and C so that they are the first three features in the model (in that order) by
dragging the icons in the Model Tree.
Task 3. Define the A|B|C Datum Reference Frame
1. Select Add DRF in the toolbar.
2. Select features A, B and C for the primary, secondary and tertiary datums respectively
Task 4. Add position tolerance for Shaft.
1. Click on Shaft in the Model Graph and then click on in the toolbar.
2. In the Add Geometric Tolerance dialog box, define the position tolerance as shown in the part
drawing.
Task 5. Delete constraints on Shaft, Hole1, and Hole2.
1. Click on Shaft then click on the Constraint tab in the property view. Notice that all of the
variables associated with the position tolerance are redundant because this feature is already fully
constrained by the standard constraints that you created in the previous exercise. There is no need for
these constraints now that you have created a position tolerance.
2. While holding the Ctrl key, click the constraints on Shaft ( to B and to C), Hole1 ( to
A and to C), and on Hole2 ( to A and to Hole1).
3. Right-click on one of the selected constraints and select Delete from the context menu.
Task 6. Add position tolerances for holes.
1. Click on Hole1 in the Model Graph and then click on in the toolbar.
2. Open the pulldown menu in the DRF section of the Add GD&T Callout window and select <New
DRF>. From the pulldown menus select datum feature B as the primary datum, datum feature A and
the secondary datum and datum feature C as the tertiary datum.
3. In the Add GD&T Callout dialog box, define the position tolerance as shown in the part drawing.
4. Repeat for Hole2.
Task 7. Add perpendicularity tolerance for B.
1. Click on B in the Model Graph and then click on in the toolbar.
2. In the Add GD&T Callout dialog box, define the perpendicularity tolerance as shown in the part
drawing.
Your model should now resemble the model shown in the figure below.

Exercise 7-3Overlay Model for a Plate
This exercise is intended to give you an opportunity to apply what you have learned about part
overlay mode to a simple model. There are no step-by-step instructions provided for this exercise.
1. In Pro/ENGINEER, change your working directory to \PartModeling and open PLATE.PRT

and then synchronize to Pro/ENGINEER.
Task 2. Create a dimensioning scheme for the part.
1. Based on the dimensioning scheme shown in the drawing below, create an overlay dimensioning
scheme for the critical features of the part. The part model is white, but the critical surfaces have been
assigned a color: reference surfaces are red and critical features are orange. Note: the model must be
shaded in order to see the colors.
For the purposes of this exercise, the tolerances for each dimension are not important you
can just use default values.
Hint: Use a width feature to define the dimensions for the notch on the right edge of the plate.
Task 3. Check your model
1. Compare your model with the completed model that has been provided in the
\PartModeling\Completed directory. You can find explanations of various aspects of the model on
the Notes tab of the Property View for many of the CETOL objects.
Chapter 8.
Defining Dimensional
Variation
Statistical variation analysis is based on the variation of the model variables while the basis for a
worst-case analysis is the tolerances. In this chapter you will learn how to define the tolerances and
statistical variation of variables.
Tolerances & Distributions
Dimension tolerances can be viewed and modified on the Tol/Distrib tab of Dimension Properties
and variable distribution properties can be viewed on the Distribution tab of Variable Properties.
Component Variation Rules
Variation rules define the relationship between tolerances, variable distributions, and quality metrics.
You can define a default variation rule by clicking on the Edit Rule button on the Variation Defaults tab
of the Options dialog (Tools > Options).
Each component in the model has a variation rule associated with it. When you add a component to
the model, the default rule is assigned to the component. You can view and modify the component
variation rule by clicking on the Edit Rule button on the Rule tab of Component Properties.
Changing the default rule does not change the variation rule for any of the components that already
have their own variation rule. (Any part or assembly that has been included in any CETOL model
has its own variation rule).
The Variation Rule Editor (shown below) is used to define the variation rules.
The Rule Editor allows you to define the relationship between tolerances, distribution parameters,
and quality metrics. For example, when using Cp as the quality metric, quality is calculated
according to the following relationship:
Cp =
(UTL LTL ) Where,
(UTL -LTL) = Tolerance bandwidth
6 = Standard deviation
This equation contains a total of three variables: Cp, (UTL-LTL), and . Given values for any two
of these values, CETOL can calculate the third. The variation rules allow you to define which of
these variables are independent and which one is to be calculated. In the figure above, the tolerance
values are used to determine the distribution parameters. The mean value for the variable is set to be
equal to the CAD Nominal and the standard deviation is a function of the tolerance range and the
specified quality metric (Cp = 1.00).
Invariant Variables
In most cases, there are some variables that are invariant (no variation). An invariant variable is
always equal to its nominal value
For parts, there are two ways in which a feature can be defined to be invariant in a specified direction.
By default, all features are invariant. Since the variation is defined for variables, a feature with no
variables has no variation. As you add constraints to your model, you define the dimensioning
scheme, and thus define the directions of variation. An under-constrained feature is implicitly
invariant in the directions of under-constraint. The DOF state of a feature (Graph Display > Show
DOF states) indicates the number of under-constrained DOFs for each feature, and thus indicates
the number of implicit invariant variables.
You can also explicitly establish a variable to be invariant on the Constraints tab of the feature
Property View. The list region shows all variables associated with the selected feature. The State
column shows the state of the feature. You can toggle the state of a Variant variable to be
Invariant. You can also change a variable state by right-clicking on the variable in the Model Tree
and selecting Delete from the context menu. Deleting a variable in this manner changes the state of
the variable to Invariant.
Exercise 8-1Defining Tolerances and Variation
In this exercise you will learn how to control the dimensional tolerances and variation in your model.
Task 1. Open the CETOL Modeler and run an analysis.
1. Start the CETOL 6 Modeler and open \AssemblyModeling\Completed\PumpMotor.asm.
Select Read from Pro/E and Run New Analysis.
Task 2. View the CETOL analysis in the Analyzer.
1. Select View > Analyzer.
2. Confirm that the Results List tab is selected on the left of the Analyzer window.
3. Note the Sigma quality metric for the two measurements: Shaft Alignment1 = 1.41 and
Shaft Alignment2 = 1.84.
Task 3. Review the component variation rule for Motor.
1. Select Show All Row Types from the Analyzer Command Bar.
2. Expand the assembly tree in the middle section of the Analyzer (Tolerance Section), click on
Motor and then click Edit Rule from the Rule tab in the Analysis Property View.
3. Review the component variation rule using the Rule Wizard.
On the General Settings, the Rule Type is set to Tolerance Drives Distribution. According to this rule, the
user specifies a desired quality metric. The standard deviation is then calculated based on these values.
The Variation Controls section defines the distribution type and the distribution controls. In this case,
the variables for this part are specified to have a normal distribution. A normal distribution requires two
distribution parameters: mean and standard deviation. The default mean value is set to be equal to the
tolerance midpoint (and enforced by the rule). The standard deviation will be calculated based on the
tolerance values assuming that Cpk is equal to 1.0. Click OK to close the window.
Select Tools > Options. The Variation Defaults tab shows the default tolerance values for the model.
These values are applied to new variables that are added to the model. Click OK to close the window.
4. Click on some of the motor Tolerances. Tolerance information is displayed on the Tol/Rule tab.
Notice that for each dimension the only editable field is the tolerance value. The fields that are grayed
out are controlled by the component variation rule.
Click on some of the motor variables. The distribution parameters are displayed on the Distribution tab
in the Analysis Property View.
Also notice that in the Analyzer window the Cpk values for all of the motor tolerances are 1.0. This
value is also controlled by the component variation rule.
Task 4. Change the component variation rule for Motor.
1. Click on Motor and then click Edit Rule on the Rule tab in the Analysis Property View.
2. Change the Metric Value to Cpk = 1.33 and then click OK.
Notice that the quality for all of the motor tolerances immediately updates to 1.33. Also notice the
improvement in the quality metrics for the measurements. By increasing the Cpk quality metric of the
part from 1.0 to 1.33, you effectively put tighter manufacturing requirements on your design. Given a
constant tolerance value, a greater value for Cpk requires a manufacturing process with a smaller
standard deviation according to the equation below:
(UTL LTL) 2 T
=
6 C pk
Task 5. Change a tolerance value.
1. Click on Motor: Hole: to B: TY. Its properties are displayed in the Analysis Property
View. Note that the distribution for the variable has a standard deviation of 0.0501.
2. Click on Motor: Hole: to B. Modify the tolerance value from 0.2 to 0.4. Return to the
Motor: Hole: to B: TY Property view. Notice that the standard deviation for this variable
automatically changes to 0.1003 according to the variation rule. The quality for this tolerance is still
Cpk = 1.33 and the Sigma quality of Shaft Alignment1 is reduced. Shaft Alignment2 is not
affected because it is not sensitive to Hole: to B: TY.
Note: Undo/Redo
When you want to see the affect of a change on the quality metrics, after you
make the change, you can select on the measurement of interest and then click
(Undo) and (Redo) to toggle between the before and after conditions.
Task 6. Turn off variation rule.
1. Select Hole: to B in the Model Tree. Deselect Apply Rule to turn off the variation rule for
Hole: to B. Click on the TY variable controlled by that tolerance and notice that all of the
distribution fields (on the Distribution tab of the variable properties panel) become active because they
are no longer controlled by the rule.
2. Modify the tolerance value back to its original value of 0.2. Notice that the value for the standard
deviation and the quality metrics for the measurements are unaffected. However the Cpk value for
Hole: to B changes from 1.33 to 0.67 (this is displayed in the middle section).
3. Change the Hole: to B: TY standard deviation value to 0.05. Notice that the quality
metrics for Shaft Alignment1 and Hole: to B: TY change.
Task 7. Save the Analysis File.
1. Click on Save to File in the CETOL Analyzer toolbar to save the changes and Exit the CETOL
Analyzer.
Task 8. Read the changed values into the Pro/E model.s
The changes that you have made to the values in the Analyzer are saved in the Modeler.
1. Return to the modeler and expand the Model Tree to view Motor: Hole: to B: TY and
Motor: Hole: to B.
2. Notice that the changes made in the Analyzer are reflected in the modeler.
3. Click on in the CETOL toolbar to save the changed Pro/E models.
Chapter 9.
Reviewing and
Interpreting Results
In this chapter you will learn how to review and interpret your analysis results.
Reviewing Results of Derivative-based Analysis
The content and format of the view in the Analyzer window is controlled by the analysis layout
definition. The application come with four pre-defined layouts: Results List, Results Tree, Variance
Contrib List, and Sensitivity List. You can modify the pre-defined layouts or define your own to suit
your needs.
The data may be sortable (if specified in the layout definition). For sortable layouts, clicking on any
column header will toggle the sort order between ascending and descending order.
You can control the order of the columns by clicking on a column header and dragging it to a new
location.
For more information about layouts, refer to Chapter 12: Reviewing and Interpreting Results in
the CETOL 6 User Reference Manual.
Variation Plots
The variation plot shows a graphical representation of the statistical and/or worst-case distribution of
the measurement. This plot includes the following information:
Upper specification limit
Lower specification limit
Measurement target value
Distribution type
Distribution moments
Graphical statistical distribution plot
Minimum and maximum worst-case measurement values
Graphical worst-case variation plot
Distribution Type
and Moments
Statistical
Distribution
Plot
Worst-Case Worst-Case
Distribution Range
Plot Limits
Upper
Specification
Limit
Lower
Measurement
Specification
Target Value
Limit
The specification limits and the target value are user-specified values. These define the design
requirements for the measurement. The statistical measurements are represented by a statistical
distribution. CETOL supports three distribution types: Normal, Uniform, and Lambda. The
distribution moments depend on the distribution type, which is typically determined based on best-fit
criteria. For most real-life problems, the results will be represented by either a normal or lambda
distribution.
Quality Metrics
You can control the quality metrics that are displayed in the Layout views by editing a layout or
creating a new one. To select the quality metrics to display in the Layout View:
1. Select Data > Edit Layout (in the Analyzer Window menu).
2. Select the Layout you want to edit and then click Next .
3. Select the quality metrics that you would like displayed by clicking on the name of the
metric in the Not Displayed list and select the left arrow button to move them into the
Displayed list. Similarly Displayed data can be moved into the Not Displayed list.
4. This same process can be used for the Measurement region columns as well as the
Tolerance region columns.
5. Click Next and then Finish in the Results Layout dialog.
For more information and mathematical detail about quality metrics, refer to Chapter 12:
Reviewing and Interpreting Results in the CETOL 6 User Reference Manual.
Sensitivities
Sensitivity Calculations
In a derivative-based analysis, CETOL uses sensitivities to predict the measurement variation caused
by dimensional variability. Sensitivities are the partial derivatives of a measurement with respect to
each of the variables in the model. Sensitivity values are calculated based on part geometry and
assembly constraints (joints).
The figure below shows a simple two-part example. a, h, and d represent part dimensions and
F is an assembly measurement.
Measurement h = 30 mm
d = 30 mm
a = 90
F
d
h
a
The assembly function, F, can be calculated in closed-form according to the following equation:
a
F (h, d , a ) =
d d
+ csc h
2 2 2
The first-order partial derivatives (the sensitivities) can be calculated by differentiating the assembly
function with respect to each of the part variables:
F
= 1 mm mm
h
F 1 1 a
= + csc = 1.207 mm mm
d 2 2 2
F d a a
= csc cot = 0.185 mm deg
a 4 2 2
Most real-life assembly functions cannot be expressed in terms of a single closed-form equation as in
this example. CETOL calculates sensitivities numerically using the Central Difference formula:
F F (h + h ) F (h h )

h 2h
The figure below illustrates the central difference formula graphically. The vertical axis on this
graph represents the measurement function and the horizontal axis represents one of the variables.
The curve represents the measurement, F, as a function of the variable, h. The sensitivity is the slope
of this curve evaluated at the nominal variable.
F(hnom+h)
F(hnom)
F(hnom-h)
h h
hnom h
Derivative-based analysis is only valid when the measurement function is continuous at the
evaluation point. In some cases, the measurement function is discontinuous. CETOL will give a
warning in the Advisor view if you create a measurement that may be discontinuous. The most
common situation in which you would get this warning is when you create a measurement that has a
nominal value of zero.
The figure below represents the functional curve for a typical discontinuous measurement, F, as a
function of a variable, h. The value of the measurement is zero when the variable is at its nominal
value. Since the measurement value is always positive, the measurement function is discontinuous at
the nominal value of the variable.
hnom h
In many cases a discontinuous measurement can be made continuous by specifying a direction for
the measurement, in which case the value of the measurement can be negative (see figure below).
hnom h
Second-Order Sensitivities
The preceding discussion applies to first-order sensitivities. When you run a second-order analysis,
CETOL calculates second-order and cross sensitivities in a similar fashion. However the equations
involved in calculating these higher-order sensitivities are more complex.
When you turn on second-order effects, a much larger number of calculations are required. For a
second-order analysis, CETOL calculates the second-order and mixed partial derivatives of each
measurement with respect to each variable, in addition to the first-order sensitivities described above.
Running a second-order analysis will require the following number of evaluations for each
measurement in the model:
First-order sensitivities: 2n+1
Second-order and cross sensitivities: 2n2+1
Where: n = number of variables included in the model for that part.
For example, lets say that you have a single-part model and have included 4 variables on the part.
In order to calculate first-order sensitivities, the part geometry would have to be evaluated 9 times.
In order to calculate second-order and cross sensitivities, the part geometry would have to be
evaluated 33 times, so sensitivity calculations would take almost 4 times as long (33)/9) for a
second-order analysis.
The decision to use second-order sensitivities is an issue of speed versus accuracy. Second-order
sensitivities provide greater accuracy, but they can take much longer to compute.
Following are some basic rules for determining when to use first- and second-order sensitivities.
Cases that may call for calculating first-order sensitivities only:
Many variables included in CETOL model (10+) Large numbers of contributing variables
tend to yield normal distributions.
All linear variables in CETOL model (no angular variation) Linear variables often (but not
always) have small second-order effects.
During the building and verifying states of the CETOL model Allows quick refinement of
CETOL model.
Cases that may call for calculating second-order sensitivities:
Few variables included in CETOL model Non-normal distribution effects may be significant.
Model includes angular Angular variation often results in significant second and cross partials.
CETOL model in finished state Maximum accuracy for analysis.
It is often more efficient to calculate only first-order sensitivities while building and refining the
CETOL model. The extra accuracy provided by second-order sensitivities is usually not needed until
the CETOL model is complete. Calculating second-order sensitivities may cause the modeling and
model refinement process to be unnecessarily slow. Once the CETOL model is complete, the
second-order sensitivities can be calculated and used to optimize the design.
Critical to Quality Dimensions
Often designers and engineers must identify critical-to-quality dimensions (or key characteristic
dimensions) for a particular design. These dimensions must often be designated on a detailed
drawing with a special symbol. There are often special inspection and quality requirements for the
critical-to-quality dimensions.
Sensitivities can be used to identify critical-to-quality variables. For a given measurement, variables
with the highest sensitivity values are the most critical variables for that measurement. Conversely,
sensitivities can also be used to identify non-critical variables. Variables with low or zero sensitivity
values are not critical to the measurement. These variables are possible sources of cost savings. If
all of the critical measurements in an assembly have a low sensitivity to a particular variable, it may
be possible to use a low-cost process to manufacture the feature associated with that variable.
Reviewing Sensitivities in the Modeler
Measurement Properties Window
Sensitivity data can be viewed in the Properties window when a measurement has been selected after
an analysis has been run. Once a measurement has been selected the first-order sensitivity data for
that measurement can be viewed in the Sensitivities sub-tab of the Plots tab of the measurement
Properties window as shown in the following figure. The Right-Mouse-Button in this view has two
commands: Select Item and Copy. Choosing Select Item will cause that variable to be selected in
the Tree and Graph windows, its properties shown in the Properties View and the variable to be
highlighted in the CAD window.
Sensitivity Viewer
CETOL version 8.1 offers a new and very powerful tool for visualizing sensitivities called the
Sensitivity Viewer. The viewer is shown in the graphic below. You can open the viewer by
selecting from the command bar or by selecting Visualize Sensitivity from the Tools menu.
Before selecting these commands, a Configuration must be the active object and a variable must be
chosen from the Model Tree. When the window opens the Graph Area will not show any sensitivity
functions. Set the Scale and Range parameters as desired for the variable and then select the
Recalculate button in the lower left corner of the window. This will populate the Graph Area with
the sensitivity functions for the configuration measurements with respect to the selected variable.
Once the Recalculate operation has completed the Start Animation button at the bottom of the
window becomes active. This button will display an animation in the Sensitivity Viewer window
that is coupled with the geometry in the CAD window. When the animation has begun the geometry
in the CAD window is redisplayed to show the position of the parts in the assembly for the discrete
variable values defined for the animation and given the assembly constraints in the model. For each
discrete variable value a new assembly state is displayed in the CAD window, a point on the
sensitivity functions is highlighted, the variable value is displayed in the middle window of the
Range section and the measurement values are shown in the Value column of the Measurements area.
During the animation the measurement values are also shown graphically in the CAD window with a
bold green vector. To stop the animation select Stop Animation at the bottom of the window.
During the animation the CAD system viewing controls are active and can be used to manipulate the
display of the geometry.
Graph Area
Variable Range
Controls
Variable
Scaling
Measurement
Selections
Reviewing Sensitivities in the Analyzer
There are several ways to view sensitivity data. Whenever you select a measurement in the
Analyzer window, a sensitivity plot for the selected item is shown on the Sensitivities tab of the
Analysis Property View > Plots tab. When a measurement is selected, the plot shows the first-order
sensitivities of the measurement to each of the variables in the model in descending order.
Note that the units of a sensitivity value are related to the units of the measurement and the variable.
Thus the units of a sensitivity of a particular measurement to an angular variable are different than
the units for the sensitivity to a linear variable. Since the units are different, these sensitivity values
cannot be compared. CETOL separates the sensitivities in the Sensitivity Plot into groups with
similar units, which are separated by a dashed horizontal line.
You can also view the entire matrix of first-order sensitivities for all measurements to all variables in
the main Analyzer window by selecting on the Sensitivity List tab at the left margin of the Analyzer
window. You can view sensitivities in either Tree view or List view by toggling the Show All Row
Types button.
You can review the entire sensitivity matrix of first and second order sensitivities for any
measurement. To do so, select a measurement and then select Data > Display Taylor Series.
Contributions
Contribution Calculations
CETOL calculates the percent contribution of each variable in the stackup to the measurement
variation. Percent contributions combine the sensitivity information with the part variable variation
information to show how much of the measurement variation is caused by each part variable.
The first-order contribution of a variable to the variation of a measurement depends on three factors:
The first-order sensitivity of the variable to the measurement
The variation of the variable
The type of analysis performed (worst-case or statistical)
The 1st-order statistical percent contribution formula is:
(
U
x i
xi )
2
contribution xi = 100
U 2
x i = ith part variable in model
U = measurement
xi = standard deviation of x i
U = standard deviation of U
The 1st-order worst-case percent contribution formula is:
U
x i
(
UTL xi LTL xi )
contribution xi = 100
UVLU LVLU
x i = ith part varia ble in model
U = measuremen t
UTL xi = upper tolerance limit of x i
LTL xi = lower tolerance limit of x i
UVLU = upper vari ation limit of U
LVLU = lower variation limit of U
The 2nd-order percent contribution formulas are more complex and are not shown here. When you
run a 2nd-order analysis in CETOL, the contribution values include the effects first-order, second-
order, and cross sensitivities.
Reviewing Contributions in the Modeler
Measurement Properties Window

Contribution data can also be viewed in the Properties window when a measurement has been
selected after an analysis has been run. Once a measurement has been selected the statistical and
worst-case contribution data for that measurement can be viewed in the Stat Contribs and WC
Contribs sub-tabs of the Plots tab of the measurement Properties window as shown in the following
figure. The Right-Mouse-Button in this view has two commands: Select Item and Copy. Choosing
Select Item will cause that variable to be selected in the Tree and Graph windows, its properties
shown in the Properties View and the variable to be highlighted in the CAD window.
Reviewing Contributions in the Analyzer
There are several
ways to view
contribution data.
Whenever you select
a measurement in the
Analyzer window, a
contribution plot for
the selected item is
shown on the Stat
Contribs tab of the
Analysis Property
View > Plots tab.
When a measurement
is selected, the plot
shows the percent
contribution of each
tolerance to the
selected
measurement in
descending order.
Note that
contributions are
unitless values.
You can also view the entire matrix of contributions of all tolerances to all measurements in the main
Analyzer window by selecting the Variance Contrib List on the left margin of the Analyzer window.
You can view contributions in either Tree view or List view by toggling the Show All Row Types
button.
Modifying Analyzer Layouts
Additional custom data layouts can be added to the analyzer interface and the existing ones can be
modified and saved at any time. Layouts can also be opened, exported or removed from the
Analyzer interface as shown in the Data menu shown below.
There are two fundamental data layouts: Results and Cross-Tables. When the New Layout
command is selected the following window opens. The layout creation process begins by giving the
new layout a name and choosing what type of layout is to be created.
Results Layouts
Results layouts have four sections to them: Measurements section, Tolerances and Variables section,
Measurement properties and Tolerance/Variable properties. These sections are identified and shown
in Lesson 1-3. Once that type of layout is selected Step 2 of the setup process makes two tabbed
panels available where the analyst can choose what data columns are desired in the Measurements
and Tolerances sections. There is also a check box for turning sorting functionality on or off. These
panels are shown in the following images.
Step 3 of the setup process allows the analyst to choose what rows are to be shown in these same two
sections. The panels for choosing the row elements are shown in the images below. Notice that
there is a checkbox for filtering these elements. They can be filtered according to 17 different data
types using any of four comparison operators.
Cross-Table Layouts
Cross-Table Layouts do not show the Measurements section but do show all of the others. Column
and Row elements are selected in Steps 2 and 3 as shown in the following images. The same
filtering options that were available for Results Layouts are also available for Cross-Table Layouts.
Reports
CETOL 6 has the ability to generate standardized reports of your analyses. You can generate a
report by clicking on in the CETOL Analyzer toolbar or by selecting Generate Report from
the Data menu, which activates the CETOL 6 Sigma Report Setup dialog. Refer to the CETOL 6
User Reference Manual for more information.
When you complete the report setup and click OK , CETOL generates an HTML report and displays it
in the selected report viewer.
Exercise 9-1Reviewing and Interpreting Results in the Modeler
The CETOL 6 Modeler is an effective environment for reviewing and interpreting basic results of
an analysis. In this exercise you will learn how to use analysis reviewing tools in the Modeler.
Task 1. Start the CETOL Modeler and open the model file.
1. Start the CETOL 6 Modeler and ProEngineer if they are not already running.
2. In Pro/ENGINEER, change your directory to \Sprayer\Completed and open

MECHANISM.asm.
data from the Pro/E part and displays the data. The assembly modeling for this model has been
completed.
Task 2. Review the results displayed in the Modeler.
1. In the Model Tree select the Reset Gap measurement under the Uncompressed configuration.
Select the Variation tab in the measurement properties window.
This view shows a combination plot of both statistical and worst-case results. The statistical results
show that the resultant measurement distribution is slightly skewed within the measurement tolerance
limits. Measurement quality could be improved by centering the distribution within its limits. The
distribution parameters are shown above the distribution as Normal( 0.4894; 0.1179) indicating that it is
normally distributed with a mean of 0.4894 and a standard deviation of 0.1179. The worst case results
are shown by the grey and green horizontal bar. The lower limit of this worst-case range is -0.5132 and
the upper limit is 1.48428.
Task 3. Review the measurement analysis plots.
1. Click on the Plots tab in the Properties View of the Reset Gap measurement.
2. The Sensitivities sub-tab is shown by default. Scroll down the plot to view the sensitivities for
this measurement with respect to the variables in the analysis. Notice that at the bottom of the plot there
is one angular variable that has sensitivity.
3. Click on the Stat Contribs sub-tab. This tab shows the contribution data for the statistical analysis
of this measurement. These contributions are based on the measurement sensitivities and the variation
of each variable. Scroll through the plot to review the statistical contributions.
4. Click on the WC Contribs sub-tab. This tab shows the contribution data for the worst-case
analysis of this measurement. These contributions are based on the measurement sensitivities and the
variable tolerances. Scroll through the plot to review the worst-case contributions. Notice that the top
contributors vary compared to the statistical contributions.
Task 4. View the sensitivity animation for a key variable.
1. Ensure the Sensitivities sub-tab of the Reset Gap properties Plots tab is the active display in the
window and that the Uncompressed configuration is the active object (right click on Uncompressed and
select Set As Active Object if necessary).
2. Right click on the top sensitivity: VALVE_RELEASE/VALVE;1/VALVE/arm pins to A
mount/TY
3. Click on Select Item from the displayed context menu.
4. Select Visualize Sensitivity from the Command Bar or the Tools menu.
5. Notice that the variable selected in step 3 is listed in the Variable section at the top of the window.
The Select Variable button to the upper left can be selected at any time to change that variable selection.
6. Select Recalculate in the lower left of the Visualize Sensitivities window. Notice that the
displayed curve in the upper graph area is V shaped. This is indicative of a saddle point or discontinuity
in the measurement function. As long as the inflection in the curve is not in the neighborhood of the
derivative expansion point for the variable there will be no effect on the measurement results. Notice
that the range of the variable has been scaled by a factor of 5.
7. Change the value of the Scale Factor in the Scale Range Limits section from 5 to 1 and select
Recalculate. Notice that the inflection in the curve is no longer visible and this indicates that the saddle
point is not within the tolerance range for this variable so we should expect there to be no error in the
sensitivities for this variable.
8. Change the value of the Scale Factor back to 5, change the number of Intervals to 15 and select
Recalculate.
9. Select Start Animation at the bottom of the window.
10. In the CAD window change to the Arm-Release Closeup view. In the CAD window there is a
green pair of arrows displayed that highlight the value of the measurement for each variable value being
animated by the sensitivity viewer. There is also a white highlighted arrow that represents the value of
the variable. In this case the variable represents the location of the pin that the ARM rotates about.
Notice that the inflection point in the curve occurs at about the same time that the tip of the Arm part
crosses the boundary of the curved sweep surface of the RELEASE part.
11. Select Stop Animation.
12. Click on the slider bar button and move it to the inflection point. At each position of the slider
button you will see a black square highlighting the point on the curve represented by that slider position.
The black box should be at the inflection point and the variable value should be about 11.4667. Notice
that the measurement value is close to zero and increases as you adjust the slider bar button above and
below the inflection point.
13. Click on Select Variable in the upper left corner and select the RX variable in the CETOL Model
Tree that is just under the TY variable previously selected (these variables are children of the to A
mount tolerance of the arm pins feature. This variable represents an orientation error of the arm pins on
the VALVE.
14. Click on OK in the Select a Variable window and then Recalculate.
15. Select Start Animation and view the CAD window. Notice how this variable causes the ARM to
displace rotationally about the Valve and that one end of the ARM tip crosses through the Release swept
surface before the other.
16. Notice that this sensitivity function is slightly more non-linear that the TY variable and that the
Sensitivity value in the Measurement section changes more drastically for the RX variable.
17. Select Stop Animation and Close to close the Visualize Sensitivities window.
Exercise 9-2Reviewing and Interpreting Results in the Analyzer
The CETOL 6 Analyzer provides a rich environment for reviewing and interpreting the results of
your analysis. In this exercise you will learn how to use some of the tools available.
Task 1. Start the CETOL Analyzer and open analysis file.
1. Continue from the previous exercise or start the CETOL 6 Analyzer. If the CETOL Modeler is
currently running, select View > Analyzer. If CETOL is not running, you can start up the Analyzer
from the OS. (On Windows systems: Start > Programs > Sigmetrix > CETOL 6 Sigma v8 for Pro
ENGINEER > CETOL Analyzer).
2. Select File > Open. Browse the file system and open \Sprayer\Completed\Sprayer.cxm.
Task 2. Set analysis preferences.
1. Select Tools > Options
2. On the Analysis & Reports tab, verify that all the checkboxes are selected.
3. On the Analysis & Report tab, select Specify Application and click on Browse in the Default
Report Viewer section and select Internet Explorer.
4. Click OK to close the Options dialog.
5. Maximize the Analyzer window to full screen.
Task 3. Explore the Results List layout.
1. Make sure that Statistical Plots and Worst Case Plots are selected in the View menu or in
the Command Bar.
2. Select the Results List tab on the far left of the Analyzer window.
3. The data and model inputs can be viewed in either a tree or list format. Click on Show All
Row Types to toggle back and forth from those two formats.
4. Explore the Measurement Quality metrics in the upper window. Select a measurement and view
its quality predictions in the upper window. Upon selecting that measurement notice also that the
Measurement Properties window is populated in the lower left section of the layout. Explore the tabs in
the Measurement Properties window.
Task 4. Explore the Variance Contrib List view.
1. Select the Variance Contrib List tab on the far left of the Analyzer window.
2. click on Show All Row Types to toggle the view to a tree format.
3. The contribution of VALVE_RELEASE to Reset Gap - Uncomp is 75.72%. (When you hold
the mouse pointer over a bar in the Analysis View, the value of the bar is displayed.) Expand
VALVE_RELEASE by clicking on . Notice that as you expand an object, the contribution of each
of its underlying objects is displayed. When you expand VALVE_RELEASE, you will see that its
total contribution is blanked, and the contribution of each of its underlying components is displayed. If
you add up all of these individual contributions, you will find that the total is equal to 75.72%.
4. Explore the Contribution Tree by expanding and collapsing the branches of the Model Tree. View
the data in both numeric and graphic formats by toggling View > Show Bars.
5. Turn on Show Bars and then click on Show All Row Types to toggle the view to a list
format. In this view, all of the tolerances are displayed in a flat list. The Name and Context
columns unambiguously identify each tolerance in the list.
6. You can sort the data by clicking on any column header. A small triangle indicates the sort order:
for ascending order the triangle point is up, for descending order the triangle point is down. Click on the
Reset Gap - Overlap column header until it is sorted in descending order (triangle point is down).
Note that the triangle may not be visible if the column is not wide enough. You can expand the width of
any column by dragging on the edges of the header.
In this view, the top contributors for all measurements are displayed at the top of the list. This is a very
useful view of the data when trying to make decisions about which tolerances might require tighter
values.
You can sort any column in a similar manner.
Task 5. Explore the Sensitivity List view.
1. Select Sensitivity List tab on the far left of the Analyzer window. This view displays the
sensitivities of the measurements to each variable in the model. Sensitivities can be used to determine
the critical-to-quality variables for the design. A variable that the measurements are sensitive to can be
considered critical. These are the variables for which you should consider using precise manufacturing
processes to tightly control variation.
Conversely, a variable that the measurements have no sensitivity to is not important to the design (at
least as it pertains to the defined measurements). You should consider using low-cost manufacturing
processes for these variables.
If you have included a variable that has a sensitivity of zero for all of the measurements, it does not have
any impact on the results but adds to the solution time. You should consider removing (making
invariant) zero-sensitivity variables from the model, especially if you will be reusing the model for
future analyses.
2. You can sort the sensitivities the same way that you sort contributions. Click on the various
column headers to sort the data.
3. Turn off the bar graph display ( View > Show Bars). The numeric values for all sensitivities
are displayed. The units for each sensitivity are also shown. Notice that when you sort the data, the
linear, size and angular variables are sorted separately. Since the units for sensitivities to linear and
angular variables are different, it is not valid to compare these values.
Task 6. Generate a report.
1. Select Data > Generate Report. The Report Setup dialog opens.
2. The Report Template with a Style Sheet defines the format of the report. CETOL comes with two
standard style sheets. Click on New in the top line of the Create Report window.
3. For the Report Template Name enter: Top 20 Contrib & non-zero Sens. Enter your company
name and name in the Company and Analyst fields respectively. You can enter some text in the General
Text Block if you desire. This area is for general background text that would go in the background
section at the beginning of a report. Select Next.
4. The Stylesheet Template Settings window allows you to define data and plot content for the report.
5. Select general.xsl for the XSL Stylesheet in the corresponding pulldown menu.
6. For the Contribution Pareto Settings, specify the following:
7. Mean-Shift, Variance and Worst Case Contributions:

Include Top N contributions = 20
8. For the Sensitivity Tornado Settings, specify the following:

Linear Measure, Linear Vars:
- Include Sensitivities >= Value = 0.1
Linear Measure, Angular Vars:
- Include Sensitivities >= Value = 0.01
There is no need to set the plot settings for sensitivities for angular measurements since there
are no angular measurements in this model.
9. Select Finish.
10. Click OK to generate the report. After a few seconds, the report will be displayed in the selected
viewer.
11. Review the report.

Note: Customizing reports
The report style sheets can be customized to suit your reporting requirements.
Refer to the CETOL 6 User Reference Manual and the comments embedded in
the style sheet file for more information about style sheet customization.
12. Close the report viewer and exit the CETOL Analyzer. There is no need to save the analysis file.
Chapter 10.
File Management
and Data Reuse
Data Management
The figure below shows the relationship of Pro/ENGINEER and CETOL applications and data. The
CETOL Modeler has bi-directional communication with Pro/ENGINEER, but only when CETOL is
synchronized with Pro/ENGINEER. When the applications are synchronized CETOL can read and
write to Pro/ENGINEER. All CETOL model data can be written to Pro/ENGINEER and
permanently stored when the Pro/ENGINEER part and assembly files are saved. Optionally, all
CETOL model data can also be written and read from a standalone file called a .cxm file. These
files can be opened both by the Modeler and the Analyzer independently.
CETOL 6
Pro/Engineer
Analyzer
Modeler
Save
Open
Assembly
Pro/Engineer
Data - Measurements.
- Joints
Save Open
Sub-Assembly Sub-Assembly
- Measurements. - Measurements. CETOL .cxm Model File
- Joints - Joints - Model tree
- Dimensions
- Measurements
Part Part - Sensitivities
- Overlay Info - Overlay Info
- Dimensions - Dimensions
- Measurements. - Measurements. Only available when synchronized
Given the fact that there are two ways to store CETOL data (in the CAD models or in a file) there
are several ways to read data into CETOL applications and then write that data to Pro/E.
If you select Read from Pro/E, CETOL will first establish a connection to Pro/E (if necessary) and
then read any CETOL data that is stored in the active model into the CETOL application memory.
After performing a Read from Pro/E, CETOL and Pro/E will be synchronized.
When you select Open you must select a file from which to read CETOL data. The data is read
from the file into CETOL application memory.
Write to Pro/E will first connect CETOL to Pro/E (if necessary) and then write all of the CETOL
data to the active Pro/E model. In order to write the data to Pro/E, the CETOL model must match
the active CAD model. After performing a Read from Pro/E, CETOL and Pro/E will be
synchronized.
Import File to Pro/E allows you to import data that is stored in an external file into a CAD
model. In order to write the data to Pro/E, the applications must be connected, therefore this
operation establishes a connection if necessary. When you select Import to Pro/E you must
select the file to import into Pro/E. The data contained in the import file must then be mapped to the
CAD model. If the parts and assemblies in the import file match the parts and assemblies in the
CAD model, this mapping is automatic. If not, you must manually map the import data to the
components that are not mapped automatically. This functionality allows you to import the data
from a part or assembly into another similar part or assembly (e.g., a redesigned part).
Exercise 10-1Importing CETOL models from .cxm files
In this exercise you will learn how to import CETOL data from a .cxm file into a Pro/ENGINEER
file that contains no CETOL data. You will also learn how to map data from the .cxm file to
common parts across assembly families and to remap features whose feature definitions have
changed due to part revisions.
Task 1. Open /Seat Latch/seat_latch.asm in Pro/E
1. Start Pro/ENGINEER and CETOL 6 if they are not already running.
2. Open the assembly /Seat LatchV8/seat_latch.asm in Pro/E and synchronize CETOL to the
model. Notice that there is no CETOL data in the Pro/E model.
Task 2. Import the /Seat Latch/Latch_import.cxm CETOL model file
1. In CETOL select File > Import File to Pro/E and select the file /Seat
LatchV8/SeatLatch_v8.1-complete.cxm then select Open from the CETOL External Data File window.
2. The Map Import Models to CAD Models window will open and display the assemblies and parts
found in the Import File on the right and the assemblies and parts contained in the CAD model on the
left. CETOL matches up common components between the import file and the CAD model.
Components it was able to match are displayed in the Data Imported From: column with a icon in
between it and the CAD Model column. If CETOL does not find a matching component it displays a
icon in the same column. If there is a corresponding component to an unmatched CAD model
component you may have to manually map it.
3. For this model only the SPRING_ANCHOR, EXT_SPRING AND TORSION_SPRING parts
were not matched. These parts are not necessary for the CETOL model so we can leave them
unmatched. Select OK to close the Map Import window.
4. Select Yes to agree to overwriting any existing data with the data from the import file.
5. Erase the assembly from Pro/E memory by selecting File > Erase > Current in Pro/E. Select all
items in the Erase dialog window and then select OK.
6. Synchronize CETOL to clear its windows and select No when prompted to save.
Task 3. Open the modified assembly Seat Latch/seat_latch_rev1.asm in Pro/E
As inevitably happens, after completing a tolerance analysis and filing a report, a design
change occurred that has modified a part in the assembly.
1. Open the assembly Seat Latch/seat_latch_rev1.asm in Pro/E and synchronize CETOL to the
model. Notice again that there is no CETOL data in the Pro/E model.
Task 4. Import the /Seat Latch/Latch_import.cxm for the modified assembly.
1. In CETOL select File > Import File to Pro/E and select the file /Seat LatchV8/Seat_Latch-
v8.1-complete.cxm then select Open from the CETOL External Data File window.
Task 5. Map the import file components to the assembly.
1. Right click on SEAT_LATCH_REV1 and select SEAT_LATCH to map the assemblies.
2. Right-click on the following components in the CAD Model column of the import dialog to map
to the specified component from the CXM file:
SIDE_PLATE_REV1 SIDE_PLATE
CLAW_REV1 CLAW
The import dialog should appear as shown below:
3. Click OK to complete the import mapping and then click Yes when asked to continue.
Once the component mapping is complete the CETOL data is read into the Pro/E model.
4. Right-click Closed and select Set as Active Object and review the messages in the Advisor.
5. Click on each invalid component in the CETOL model to see the corresponding geometry
highlighted in the CAD model.
Notice that the data is mapped to the wrong instance of the side plate. That is easily repaired.
6. Click on SIDE_PLATE_REV1;1. Click on in the properties view and select the

appropriate side plate in Pro/E.
Notice that a number of messages remain in the Advisor indicating that there are some
problems that must be addressed before this model is ready to analyze. Many of the problems
listed in the Advisor are related to the fact that the claw and claw pivot have been replaced by
a single piece design. Since the most fundamental change in this design is to the claw that is
probably the best place to start repairing the CETOL model.
7. Right-click on CLAW_REV1 and select Set as Active Object in the context menu and then
expand the part in the model tree.
8. Change View Style in Pro/E to Claw_Only.

Since this part has been redesigned, some of the existing features are marked as invalid.
However, the invalid features from the original part can be mapped to the new geometry.
9. Click on B in the Advisor.

Notice that when an invalid feature is selected a triad appears in the CAD geometry indicating
the location of the original feature. Based on this triad display and the feature name it is easy
to identify the geometry from the new part to associate with the features.
There is no longer a pivot hole in the CLAW_REV1 part. This feature has been replaced by a
pin feature.
10. On the General tab of the feature properties, click on to redefine the feature geometry. Pick
the cylindrical pin surface protruding from the part and then click OK.
Notice that there are no messages left in the Advisor because the part is fully repaired.
11. Right-click on on Closed and select Set as Active Object in the context menu and then expand
the part in the model tree.
12. Click on to CLAW_PIVOT,1 in the Advisor view.

On the Features tab of the joint properties notice that the reference feature is from the
CLAW_PIVOT part which no longer exists in this assembly. Lets redefine the joint to
reference the hole in the side plate.
13. Click on Reference. In the model tree, expand SIDE_PLATE_REV1, and select Claw
Hole.
This joint now defines the assembly constraint between the claw and the side plate. The
CLAW_PIVOT component is no longer necessary in this design so we can delete it from the
analysis model.
14. In the Advisor, right-click on CLAW_PIVOT;1 and select Delete from the context menu.
Click OK to delete the dependent objects.
15. This exercise is now complete.

Basic Training CETOL 6 8.1 for Pro/Engineer
Chapter 11.
Applying CETOL 6
The exercises in this section are intended to give you an opportunity to apply what you have learned
about CETOL to a realistic problem. There are no step-by-step instructions provided for these
exercises. You are required to make modeling decisions similar to the types of decisions that you
will have to make when solving your own problems.
Once you have completed the exercises, compare your analysis results with completed analysis files
that are provided in the \Applying\Completed directory. If your results differ from the results
provided, carefully review your model and try to determine why your results are different.
The completed models are also provided in the \Applying \Completed directory. You can find
explanations of various aspects of the model on the Notes tab of the Property View for many of the
CETOL objects.
Gaining Confidence in your Results
Once you have completed an analysis, how do you know that the results are accurate? This is a
concern for any type of analysis, whether you are doing simple hand calculations, running finite
element analysis software, or using CETOL. Although there is no sure way to guarantee a correct
solution, if you use some common sense and follow the guidelines listed below, you can be confident
that your results are correct.
1. Understand your physical assembly.
Before you can define a CETOL model that is intended to represent the variational behavior of
your assembly, you must understand the physical interaction of the parts in the assembly. The
way that the parts are put together, the assembly order, the loads present during assembly
and/or operation, and other factors may influence the variation of the measurements of interest.
2. Make sure that the joints represent the physical assembly conditions.
When you add a joint between two features, CETOL automatically adds a joint based on some
assumptions about the contact between the selected features. You often have to change the
DOF state of the joint to more accurately represent the actual physical condition. You can do
this on the joint properties General tab by either selecting from the Preset DOF State drop-
down menu or by toggling the state of individual DOFs. As you change the DOF state, the
joint icon updates based on the state of the DOFs. In general, there is a joint icon and a named
DOF state for the most likely DOF states for each joint. If you select an unusual combination
of DOFs, you will get a Custom joint, and the joint will be represented with a generic icon
( ). The number on the generic joint icon represents the number of fixed DOFs for that joint.
A custom joint may be an indication of a bad combination of DOFs on the joint.
As you add joints, you should frequently review the DOF state in the status bar. You should
also periodically select Tools > Show Part Locations to visually validate your constraints.
Do not wait until the model is nearly complete to perform these checks.
3. Check the measurement nominal values.
Before running an analysis in CETOL, you should make sure that all nominal values for
measurements make sense. For assemblies, the value of a measurement may change as you
make changes to the assembly constraints in the model. When you start a new model, if you
add a measurement before adding any joints, the measurement in CETOL should match a
Pro/E measurement value. As you add joints in CETOL, CETOL calculates part positions
based on the joint locations. After defining all of the joints in the model, you should check
your CETOL measurement nominal value and compare it to the measurement value that you
get in Pro/E. The CETOL and Pro/E measurement values may not match (because the
assembly constraint definitions in CETOL and Pro/E may not match), but you should at least
be aware of and understand any differences in the measurement values.
If you select Tools > Show Part Locations the positions of the parts in Pro/E are displayed in
the positions calculated according to the CETOL joint definitions. Measurements that you
make in Pro/E (using Analysis > Measure) while the parts are displayed in this manner
should match the CETOL measurement values.
4. Check your dimension tolerances, distributions and measurement limits.
You have probably heard the old saying about computer analysis: Garbage in Garbage out.
Your results are only reliable if your input values are correct. You should always review your
dimension tolerances and distributions to make sure they are correct. Remember that if Apply
Rule is selected for any tolerance, the variation rule will also influence your results.
You should also make sure that the limits that you have applied to the measurements are
correct.
5. Pay attention to Analyzer errors and warnings.
When you run an analysis, pay attention to any errors or warnings. A common message is X
measurements have derivative failures. Where X represents the number of measurement that
have failed derivatives. The model Advisor will tell you which measurements had derivative
failures. Invalid derivatives will be shown in red text in the Sensitivity List layout in the
Analyzer as shown below. You should investigate and determine the cause of sensitivity
failures of an analysis.
In assemblies, this message is often an indication of over-constraint in the direction of the

listed measurement. If the DOF state of your model is over-constrained, you should either
release the over-constrained DOFs or remove the failed variables from your model. If the
DOF state of your model is not over-constrained, you probably have an incorrectly constrained
model. You should review all of your joints and examine the model with Show Part
Locations
6. Review sensitivities.
It is always good practice to review the sensitivities to make sure that they make sense. Are
the variables with the highest sensitivities the ones that you expected to be the most critical to
the measurement? Does it make sense that variables with sensitivity values of zero have no
effect on the measurement?
7. Review contributions.
Scan the contributions to make sure that they make sense. Keep in mind that for statistical
analysis, there is not a linear relationship between the variation of a variable and its
contribution. In other words, doubling the variation of a variable will not necessarily double
its contribution. Refer to the CETOL 6 User Reference Manual for more detail.
8. Use common sense and engineering judgment.
Take advantage of your experience and judgment. You should be hesitant to believe
unexpected results.
Exercise 11-1Complex Part Overlay
In this exercise, you will create a CETOL model and perform an analysis on the part shown below to
determine the clearance between two holes.

1. In Pro/ENGINEER, change your working directory to \Applying and open
MACHINED_BLOCK.PRT and then synchronize to Pro/ENGINEER.
Task 2. Set preferences.
1. For this part, you can assume that the variation of the variables is driven by the tolerance values
shown on the drawings. Assume that all dimensions are manufactured to a Cp value of 1.0.
2. Set the default linear tolerance to 0.20 and the default angular tolerance to 0.50.
Task 3. Add the clearance measurement.
1. Add a measurement between the holes indicated in the drawing below. Set the tolerances of the
measurement to limit values: Upper = 3.0, Lower = 1.8.
Task 4. Create overlay dimensioning scheme.
1. Define an overlay dimensioning scheme that reflects the dimensioning scheme shown in the
drawing.
1. Run an analysis.
2. Determine the critical-to-quality dimensions for the clearance measurement.
3. Determine which tolerances are the highest contributors to the variation of the clearance
measurement.
Task 6. Verify your results.
1. After you are confident that you have successfully completed the analysis, you can compare the
results to the completed analysis model (...\Applying\Completed\hole_clearance.cxm).
Clearance
Exercise 11-2Cam-Rocker Mechanism
In this exercise, you will create and analyze a CETOL model for a cam-rocker mechanism.
1. In Pro/ENGINEER, change your working directory to \Applying and open

CAM_ROCKER.ASM and then synchronize to Pro/ENGINEER.
Task 2. Set preferences.
1. For all of the parts in this analysis, you can assume that the variation of the variables is driven by
the tolerance values shown on the drawings. Assume that all tolerances are manufactured to a Cp value
of 1.0.
Task 3. Define a measurement.
1. In Pro/E, turn on the display of 3D Notes (Utilities > Environment). Add a measurement
called Gap between the surfaces indicated in the note.
2. Set the tolerance limits for the Gap to 10.400.50.
Task 4. Create assembly model.
1. Most of the assembly constraints in this assembly are fairly intuitive. Apply the following
assumptions to your model.
The CAM_PIN is press fit into the CAM.
The ROCKER_PIN is press fit into the ROCKER.
The SPRING is compressed such that it applies a force to the assembly. The spring force
causes the CAM_PIN and ROCKER_PIN to be in tangential contact with their respective
holes in the HOUSING.
2. Remember, it is generally best practice to create component joints for assembly constraints that
apply for all positions of the mechanism and configuration joints for constraints that apply for a specific
position of the mechanism (i.e., the contact of the cam with the rocker).
Task 5. Define part-dimensioning schemes.
1. Define a dimensioning scheme for each part according to the manufacturing drawings shown on
the following pages.
2. There are no drawings provided for the pins. The only tolerance of interest for both pins is the
diameter. For both pins, the diameter is 5.00 +0.00/-0.10.
3. Apply the tolerances to each dimension as shown on the drawings. Assume that the dimensions
will be manufactured to a Cp value of 1.0.
4. You can omit dimensions from the model that are shown in the drawings without tolerances.
1. Determine the distribution and quality (in terms of Sigma) for the GAP measurement.
2. Determine the critical-to-quality dimensions based on the sensitivity of each dimension to the
GAP measurement.
3. Determine which dimensions are the highest contributors to the variation of the GAP.
Task 7. Optional: Find the position and variation of the pushrod at its maximum offset.
1. Create a new configuration and the necessary joints to define the assembly such that the end of the
pushrod is at its maximum offset from the top of the housing.
2. Add a measurement called Max Gap between the same surfaces as the other measurement.
Task 8. Verify your results.
1. After you are confident that you have successfully completed the analysis, you can compare the
results to the completed analysis model (\Applying\Completed\pushrod_gap.cxm).
Completing Basic Training
In an effort to continuously improve CETOL 6 Basic Training, we ask that you complete the
training evaluation form. An electronic version of the evaluation form is included with the training
files (BT_Eval_Form.doc MS Word form). A printed copy of the evaluation form is also included
at the end of this manual. Please complete the form and email it to training@sigmetrix.com or FAX
it to the number shown on the form. We strongly encourage you to also include your comments and
suggestions.
Applying CETOL 6 to Your Models

You are now ready to use CETOL 6 to solve real-life problems. However, keep in mind that you
have only completed the first step in the process of becoming a proficient CETOL 6 user. Just like
learning anything else, it takes some practice to get good at using CETOL 6. You should start out
by attempting to solve relatively simple problems. Dont try to jump right into complex problems.
Try to limit your first models to three or four parts in which the assembly constraints are well
understood.
Once you are comfortable solving simple models and have gained some confidence in your ability to
use CETOL 6 you can move on to more complex models. At some point in the learning process,
you will probably need some additional technical help. There are a number of possible sources for
CETOL 6 technical help. If there are other more experienced CETOL 6 users in your
organization, you should seek their help and advice as you move up to solving more complex models.
You can also get various types of consulting support from Sigmetrix or a Sigmetrix reseller. For
more information about available consulting services, please refer to the Sigmetrix web site
(www.sigmetrix.com).

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Zero Tolerance for Error

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The Advisor View

Task 4. Modify CETOL window layout.

Task 6. Access on-line User Reference Manual.

Task 7. Open a model.

1. In Pro/E, Open \AssemblyModeling\Completed\PUMP_MOTOR.ASM if it was not left open

Task 8. Explore the CETOL Model Tree

Task 9. Explore the Graph view

Distribute across Parts

Distribute across Features

Distribute across Manufacturing Steps

Dimensions, Variations and Tolerances

The variation in a design may be reduced several different ways:

Play Movie: \Movies\v_block.gif

Ti = equal bilateral tolerance of the " ith" dimension

2D/3D stacks, first-order approximation:

A generic formulation of the worst-case tolerance analysis problem is:

Measured Values Length Tabulation Frequency

0.96 0.97 0.98 0.99 1.00 1.01 1.02 1.03 1.04

2nd scaled moment (standard deviation): = 2

Sample standard deviation: s =

Task 2. Calculate the following values:

1. Calculate the value for Cp.

2. Calculate the value for Cpk.

The CETOL Model Creation Process

Gap and Flush Measurements

The actual measurement endpoints are updated during sensitivity Feature1

You cannot modify the attachment for angular measurements.

Note: Directionless measurements

Value of Gap is Value of Gap is

Feature2 Gap Feature2

End Point Locking

Repairing Measurement Features

Click this button Click this button

Task 1. Open Pro/E part and synchronize CETOL.

1. In Pro/ENGINEER, change your working directory to \ModelingBasics. Open the part

Task 2. Define a measurement for the vertical dimension.

1. Click to add a measurement for the vertical dimension of the bracket.

Pick top surface Pick lower

Tip: Verifying measurements visually

Pick edge for

Task 5. Save the model.

1. Click to save the Pro/E model with the CETOL data.

The CETOL Model Creation Process

Assembly Model Structure

Setting the Degrees of Freedom

Under-Constraints and Over-Constraints

Modifying Joint DOFs

Tip: Custom joints

Component and Joint Order

Note: Component and joint order

Task 1. Open Pro/E part and synchronize CETOL.

1. In Pro/ENGINEER, change your working directory to \Sprayer and open PIST_CYL.ASM.

2. Click in the CETOL toolbar to synchronize to Pro/ENGINEER.

Task 2. Add measurement for compression volume length.

2. Rename the new measurement Volume Length.

3. Click on the Variation tab and set the value to 30.100.20.

2. Click to add a new joint.

Task 4. Add joint between STOP_PIN and CHAMBER.

1. Click to add a new joint.