CATIA V5 Basics PDF

Reader AE1111-II
Engineering Drawing
CATIA V5 Basics
June 2016
Aerospace Engineering
Faculty of
Ing. E. J. van den Bos
Delft
University of
Technology
Artikelnummer 06917700050
AE1111-II Engineering Drawing
CATIA V5 BASICS
Ing. E. J. van den Bos

Faculty of Aerospace Engineering
Aerospace Structures
Delft University of Technology
Kluyverweg 1
2629 HS Delft
The Netherlands
Production method information:

Ir. J. Sinke
Aerospace Materials
Own design 2
Ir. G.F. Brouwer
Space Systems Engineering
Own design 3
Ir. Durk Steenhuizen
Systems Engineering and Aircraft Design
English editor: Miranda Aldham-Breary, M.Sc. PGCE
Content editors:
Dawud Hage B.Sc, Aerospace Engineering
Richard Kruithof B.Sc, Aerospace Engineering
Thank you Leonid Pavlov for providing me with feedback from a

student’s point of view.
CATIA® is a registered trademark of Dassault Systèmes.
2
Table of contents
Table of contents ........................................................................................................................3
Part Design .................................................................................................................................4
Introduction .............................................................................................................................4
The Part Design workbench ...................................................................................................4
Sketching basics ....................................................................................................................7
3D Navigation .........................................................................................................................8
Part AE1111-II-01: Actuator Base ..........................................................................................9
Part AE1111-II-02: Actuator Rod ........................................................................................ 11
Part AE1111-II-03: Step sheet ............................................................................................ 16
Part AE1111-II-04: Stairs frame .......................................................................................... 20
Part AE1111-II-05: Stiffener ................................................................................................ 24
Part AE1111-II-06: Longitudinal Rib .................................................................................... 28
Part AE1111-II-07: Door Skin .............................................................................................. 32
Part AE1111-II-08: Door liner .............................................................................................. 36
Part AE1111-II-09: Hinge bracket ....................................................................................... 38
Part AE1111-II-10: Step support ......................................................................................... 41
Part AE1111-II-11: Door Frame .......................................................................................... 44
Part AE1111-II-12: Door seal .............................................................................................. 45
Assembly design ...................................................................................................................... 48
Introduction .......................................................................................................................... 48
Assembly AE1111-II-A: Actuator ......................................................................................... 50
Assembly AE1111-II-B: Step assembly .............................................................................. 53
Assembly AE1111-II-C: Foldable stairs .............................................................................. 55
Assembly AE1111-II-D: Door assembly .............................................................................. 58
Drafting .................................................................................................................................... 63
Drawing AE1111-II-04: Stairs Frame .................................................................................. 64
Drawing AE1111-II-05: Stiffener ......................................................................................... 68
eDrawing AE1111-II-D: Door assembly .............................................................................. 73
Kinematics ............................................................................................................................... 79
Introduction .......................................................................................................................... 79
Foldable stair mechanism ................................................................................................... 79
Own Design ............................................................................................................................. 86
General rules for the assignment ........................................................................................ 86
Own Design 1: AE1111-II-final_A: Space Shuttle Robotic Arm .......................................... 86
Own Design 2: AE1111-II-final_B: Deployable Solar Array ................................................ 87
Own Design 3: AE1111-II-final_C: Dropped Hinge Flap Mechanism ................................. 88
Deliverables for all assignments ......................................................................................... 90
Appendix: Model trees ............................................................................................................. 91
Appendix: 2D drawings ............................................................................................................ 93
Production method information

Machining of Metals ................................................................................................................. 11
Rubber Forming of Metal Sheet .............................................................................................. 25
Manufacturing of Composites .................................................................................................. 34
Injection Moulding of Metals and Polymers ............................................................................. 42
Extrusion of Metals .................................................................................................................. 45
3
Part Design
Introduction
CATIA V5
In modern engineering, a wide number of CAD applications is available. You will be working
with one of these applications during this course: CATIA V5. CATIA V5 is the standard in
aerospace and automotive engineering, because of its wide range of modules, the
“workbenches”. Educational licenses are available for students at the Delft University of
Technology, Faculty of Aerospace Engineering, to acquire skills in CAD engineering. These
licenses contain numerous workbenches for numerous applications. In this course, we will
use the most common workbenches, such as Generative Drafting, Assembly Design, Sheet
Metal Design and Kinematics, but we will start with the most basic workbench, which is the
Part Design workbench. It is recommended to read through this chapter, failing to do this
preparation results in a lot of unnecessary questions for the teacher and student assistants.
Staff members are there to answer specific questions about the assignments and not general
questions concerning the functionality of the application.
The Part Design workbench

The Part Design Workbench is the CATIA V5 module that is used to create solid geometry,
based on parametric feature based modelling. Parametric modelling means the geometry is
defined by keyed in values (parameters), e.g. a length, which can be altered during the design
process to change the geometry. A feature is the smallest building block in a model which can
be modified individually. Intelligent use of features and parameters in a model, and changes
of single parameters result in a new geometry in seconds. A good feature based parametric
model is easy to modify.
The Part Design Workbench is accessed by Start => Mechanical design => Part Design.
Choosing a specific workbench in CATIA V5 leads to a working environment in which
commands are accessible via buttons. In this reader, when a specific function is needed, the
function’s button icon is shown as in the example below.
Edge Fillet
Provide the indicated edges with a 2 mm radius by using the “Edge Fillet” command in the
Dress-Up features toolbox.
Fly-out
Switching workbenches leads to a new
set of buttons. In some cases, extra
buttons can be accessed via the Fly-out.
New buttons are shown by clicking the
little black triangle in the right bottom of
a button.
4
Model Tree
A graphical representation of all operations is also present in
the CATIA V5 interface, and since this representation is
structured in branches, it is called the Model Tree. Different
symbols can be recognized when looking at the model tree of
a CATIA V5 CATPart. The Part Number is displayed at the top,
the principal planes can be found below. Entities called
“Geometrical Sets” and “Bodies” can also be found. In CATIA
V5, Workbenches are available to create specific types of
geometry. Solid geometry is created in the Part Design
workbench, surface and wireframe geometry in the Generative
Shape Design workbench. If the “Hybrid Design” option is used
during part creation, it becomes possible to store wireframe
and surface geometry under bodies such as the PartBody. If
the option is not used, CATIA V5 will automatically store solid
features in bodies and wireframe and surface geometry in
Geometrical sets. The last option can make a model easier to
understand, especially when third parties have to work with the
model. The assignments of this course should be made using
the unchecked “Hybrid Design” option.
Geometrical set
A geometrical set can be seen as a folder to organize the
sketches, lines, points, surfaces, etc. To create a geometrical
set: “Insert Æ Geometrical Set…”. To create a (non-body)
feature in a geometrical set, it must be set to the “In Work
Object”. This can be done by right-mouse-button click on the
geometrical set and press “Define In Work Object”. All new
features will be created in the geometrical set; a warning will be given if a body feature is
created which can only be created inside a PartBody, then CATIA automatically defines the
PartBody as the “In Work Object”.
Hide/Show
A lot of construction elements are created when hen working with large models. When they
are no longer needed, but cannot be deleted these elements can be hidden in order to keep
the working environment clear. Hidden elements exist in a separate space that can be viewed
with the “Swap visible space” command and can be found in the “View” toolbar.
In the tree a transparent square is visible on hidden features, e.g. the principal planes and the
Offset feature in the tree shown above. The Hide/Show command is used to either hide or
show objects, moving them between the hidden and the visible space.
Help sources
The “learning by doing” principle is used to acquire skills in CATIA V5. The only way to
become familiar with the application’s functionality is to model parts and assemblies as you
are required to do for the exercises in this reader. A source of information is the CATIA V5
documentation. It can be found on http://catia.tudelft.nl/b20doc This documentation can be
added to CATIA: Tools Æ Options Æ General Æ (tab) Help, and put the documentation
address in the location field within quotation marks. See the picture on the next page.
5
After doing this, it becomes possible to call the documentation when using CATIA, i.e. when
working in a feature press F1 to open the corresponding page of the documentation.
Production Methods
Due to the strong relation between a CAD construction and production techniques, general
information about production methods is integrated in this reader. An experienced CAD
engineer will build up a model in such a way that production data can easily be distilled from
the model.
Practical Setup
The CATIA V5 practical sessions should be done individually. A specific account with its own
username and password will be made available to each student, so you can work on your
assignments during practical hours. A protected computer environment is created for the
sessions. It is not possible to work on the assignments outside these hours. Use of other
programs than those provided for the practical session is forbidden, as is internet surfing.
Attendance is mandatory for this course. Violating these rules will result in exclusion from the
course, for more detailed instructions please refer to the exam regulations.
General Working Method

Some actions are required for every new model. Each assignment will contain information
about Part Number and nomenclature of the part, assembly or drawing. When you create a
new CATIA V5 file, please use the following routine:
Example: for Part AE1111-II-01, follow the next steps:

x at file creation, key in “AE1111-II-01” in the “Enter part
name” box
x make sure the “Enable hybrid design” box is unchecked
x make sure the “Create a geometrical set” box is checked
Geometrical sets can be used to

organize the Model Tree. Wireframe
and surface features can be stored in
Geometrical Sets, whereas solid
features are stored in “Bodies”. The
PartBody is present by default.
After clicking OK, save the file to your

storage folder. You will see a file
extension appear at the top of the
window after saving.
The CATIA V5 file extensions you will encounter are:

x CATPart for part files
x CATProduct for assembly files
x CATDrawing for 2D drawings
More extensions exist, but these will not be used in this course.
6
After saving the file, access the Properties command by using the right mouse on the top of
the model tree. Choose “Properties” from the contextual menu and select the “Product” tab.
Fill in the nomenclature as stated in the assignment. For the example this is “Actuator Base”.
Please follow these standard steps for every new CATIA V5 file you make.
Prompt Area
The Prompt Area is present in the left bottom
corner of the screen. In this area, during
commands, CATIA V5 will always give
information about the next expected step. In
the example picture, the Sketch button is
clicked. Note the Prompt Area: in this stage
you have to select a plane, a planar face or an
existing sketch to proceed with the Sketch
command.
Sketching basics
Sketches are used to define the geometry of the three dimensional part. They are drawn on a
two dimensional plane, and when finished they can be used in other features like “Pad”, to
make an extrusion, or “Shaft” to revolve the sketch around a given axis. It is thus important to
understand how to make good sketches. This chapter will explain the very basics to get
started with drawing sketches, a more detailed explanation can be found in the CATIA V5
documentation.
Creating a sketch
To create a sketch first a 2D plane needs to be selected on which the sketch
will be drawn. This can be any flat surface, or a plane. Every part has an xy,
yz and zx plane (the principal planes) by default, as shown in the model tree.
After the correct plane (or face) is selected by clicking on it, a sketch can be
created by clicking on the sketch command:
Now the workbench is automatically switched to the “Sketcher workbench”. The

“Profile” tools are used to make the actual sketch.
Tip: Do not close the “Sketch tools” toolbar, but dock it, with the other toolbars on the
top, bottom or side. Also the snap to grid can be turned off here, which might make
sketching easier. If you did close the toolbar, select View

ÆToolbarsÆ Sketch tools to reopen it.
Another feature that can be found in the Sketch tools is the

“Construction/Standard Element” toggle button. When drawing a sketch some
elements that are drawn are not part of the actual shape, but will be used as an
element helping to define the shape, those elements are called Construction elements and
can be created from any Standard element (an element that is part of the actual shape) by
toggling this button.
Constraining
If not all dimensions are derivable from the defined dimensions, then a sketch is not
fully defined. Multiple solutions are present in the constraint toolbar to define the
dimensions. Select the lines that need to be constrained (by holding ctrl for multiple
lines) and then click on the “Constraint” button. This will automatically create a distance
or angle constraint. A different type can be selected by pressing the right mouse button
while the constraint feature is still active.
7
Another way of constraining is by clicking the “Constraints defined in dialog box” button after
the selection is made. This opens a dialog box with the possible constraints on the current
selection.
Once an element of the sketch does not have any more degrees of freedom the respective
part changes colour, it will become green.
ISO constrained
If sufficient constraints are given such that there is no degree of freedom on any element in
the sketch, then the sketch is so called ISO-constrained (also known as fully constrained or
well-defined). When this is the case all the lines and point in the sketch are
green. This can be checked by using the “Sketch Solving Status” command:
If to many constraints are given, the sketch is over-constraint and the respective
lines or points will have a purple colour. If too little constraints are given the sketch is under-
constrained and part of the sketch will still be white.
3D Navigation
Controlling the environment is an essential skill you will need in order to efficiently build
models. A very fast way to navigate is by using the different combinations of mouse buttons
in succession to quickly zoom, pan and rotate around the design space.
Centering
Clicking the middle mouse button will center the screen on this point
and set it as the center of rotation of the screen.
Panning
By holding the middle mouse button the model can be dragged
around through a plane in space parallel to the screen.
Zooming
Clicking the right mouse button while the middle mouse button is
held will switch the mouse to zoom functionality. While in zoom
functionality vertical mouse movement allows for control over the
zoom level, allowing for fast and precise control of the viewport.
Rotating
By clicking and holding the right mouse button while the middle mouse button is held the
cursor switches to rotating. This now connects the mouse cursor to virtual sphere in space
and moving the cursor will cause the model to rotate as if it were connected to this sphere.
This sphere is shown in an orange outline while rotating the screen. Use the middle mouse
button to set the rotation center if the point you are looking at is too far from the rotation
center, or it will become hard to control.
Navigating the model tree

You can switch between the model and the tree by clicking on the small axis system in the
bottom left of the screen, or by clicking on a lead in the model tree. If the model tree is
selected pan and zoom operations will work on the tree instead. You can keep the model tree
out of the way of your model and quickly zoom in and out to find parts that are obscured from
view.
Finally
CATIA V5 can be a very powerful tool for engineering. As a student of the Faculty of
Aerospace Engineering you are given a unique opportunity to acquire knowledge about this
tool. The completeness of the educational license is a luxury; industry engineers will in most
cases have to work with more limited possibilities, since what is available to the engineer is
often constrained by cost. We strongly encourage you to explore the possibilities of CATIA V5
outside the course hours. Practice makes perfect.
8
Part AE1111-II-01: Actuator Base
PartNumber Nomenclature
AE1111-II-01 Actuator Base
Sketch.1
On the XY plane, create a sketch for the first
feature. The sketched profile will be used for a
Shaft feature, which revolves the profile about
an axis. An axis will be drawn in the
Sketch using the “axis” command:
CATIA V5 will by default select this axis to
revolve the profile about.
Use Dimensional constraints:

to define width, height, radius and gap
size. Do not forget to make the axis ISO-
constrained by giving it a length dimension
(E.g. 100mm). Use symmetry constraints to
ISO-constrain the geometry. A symmetry
constraint can be made by making a
constraint between the two points you want to
make symmetrical and before confirming the (dimensional) constraint, right-mouse-button
click and select “allow symmetry line”. Now click on the symmetry line, in this case the vertical
axis.
Check the Sketch by using the “Sketch Solving Status” command:

The message “Iso-Constrained” should show up. Exit the Sketcher Workbench after finishing
the sketch by clicking the “Exit workbench” button:
Shaft.1
Create a Shaft by selecting
Sketch.1 as profile. Use a
360º First angle limit to create
a full shaft.
9
Sketch.2
Create a second sketch on the ZX plane. It should be a full circle
with a 25 mm diameter, concentric with the origin. Use the
appropriate constraints to meet these requirements.
Pad.1
Use Sketch.2 to model the rest of the actuator base. The Pad
feature extrudes the sketch normal to the sketch surface. In the
Pad dialog box, check the “Thick” option to create a hollow
cylinder. Notice the dialog box expanding after checking this
button. In the “First Limit” dialog box, use the default
“Dimension” option with a length of 960 mm. In the “Second
Limit” dialog, use the “Up to next” option, this option will
make the cylinder end at the outside of the shaft. Use a 5
mm value for “Thickness2”
Edge Fillet.1
Provide the indicated edges with a 2 mm radius
by using the “Edge Fillet” command in the
Dress-Up features toolbox.
Applying material
Use the “Apply Material” button to invoke the default material library.
Under the “Painting” tab, select the “Fire Red” material and assign it
to the PartBody using a drag-and-drop operation.
Alternatively, the “Apply Material” button can be

used. Using this option, the material will be
assigned to the current selection. Materials can be
assigned to parts, bodies but also to individual
features. Close the Material Library. The material
will be shown in the model tree.
Application of material is useful for analytical

purposes or, in this case for visual properties. In
the “View” toolbar, the option “Shading with
material” can be chosen.
Try the different view options to review the results.
10
Part AE1111-II-02: Actuator Rod
AE1111-II-02 Actuator Rod
Sketch.1
On the ZX plane, create a sketch for the first
Machining of Metals
feature. Use the Centered Rectangle option by
clicking the little black Machining is the name for a
triangle in the corner of manufacturing category, covering a
the Rectangle button wide range of chip removing
(the fly-out). The option processes. Common in all these
for a Centered Rectangle is available in the fly-
processes is the removal of (small)
out menu. Use dimensional constraints for the
Width (30mm) and Height (15mm). chips by some kind of chisel. Typical
examples of this category are milling,
drilling, turning and sawing.
30 All materials can be machined,

although the ease with which a material
can be machined depends on its
properties. Ceramics for example are
very hard and brittle, so it is usually
V very difficult to obtain smooth surfaces
using machining operations. Polymers
H are rather soft though and the
15 machining is often temperature
dependent. Weakened material may
adhere to the cutting tools.
Composites, composed of a mixture of
Pad.1 hard and abrasive fibres and rather soft
Create a Pad. Use a 25mm first Limit value. polymers, show polymer behaviour and
Use the “more” button to be able to define the
fibre breakage. Most metals can be
Second Limit with a 15mm Length dimension.
machined very easily. In this section
the focus is on the machining of metals.
Plane.1
Use the Plane command from the reference The figure below presents the
element Toolbar to create a plane with a 60mm principles of machining or chip
offset from the ZX plane (If you don’t see the removing processes. The cutting tool,
plane command button, drag out the bottom called a chisel, just like the tool an artist
toolbars on the right side of the screen by uses creating a sculpture, is moving
selecting the horizontal bar at the top of a
from right to left. The chisel removes a
toolbar and moving it to the left) The reference
elements toolbar, containing the plane layer of the work piece material by
shearing. The chip it creates is moved
11
command button should show up). The plane upwards, and eventually breaks into
should be created in a “Geometrical Set”; either smaller pieces. During this cutting
make use of an empty Geometrical Set if process, at the contact surface
available in the model, or make a new between the chip and the cutting tool,
geometrical Set by
called the rake face, significant friction
Insert => Geometrical
Set. Use the right is created and thereby heat. This also
mouse button on the happens in the shearing zone; where
new Geometrical Set, the metal is sheared into chips, there is
select “Define In Work a significant increase in temperature.
Object”. In the tree, the
Geometrical Set’s
name is underlined.
The underlined item in
the model tree (In Work
Object) is the actual
location in the model
where new features will
be created.
Sketch.2 Control of this heat as well as the

Create a new
reduction of wear is necessary to
sketch on this
new plane. It prolong the lifetime of the cutting tool.
should be a full Cutting fluids are used to cool friction
circle with a 25 heat and to remove chips.
mm diameter,
concentric with the origin. Use the appropriate This principle is valid for a large
constraints to meet these requirements. number of different machining
processes like drilling, milling, turning,
etc. The main difference between
Sketch.3 these processes is in the movements
of the chisel with respect to the work
piece:
- for milling the cutting tool
rotates around its axis but
translates perpendicular to the
axis
- for drilling the cutting tool
rotates too, but the drill bit
translates in the direction of the
axis
- in turning the tool bit slowly
translates along the surface, but
Four points on the circle are needed to be able the work piece rotates around
to define the Multi-sections Solid in one of the its axis
next steps. These points will be created in a The material of the cutting tools
new sketch on the created plane. In the sketch, should be (much) harder/stronger than
use geometrical constraints to make the 4 the material to be machined (work
points coincide with the circle sketch as well as
piece material). Therefore, specific
the rectangle from the first sketch. Use the
“Mirror” command to generate the other three tooling materials or coatings have
points. been developed. When the hardness of
the tooling material is increased,
brittleness also increases, which may
cause premature failure of a cutting
tool. Good lubrication, alignment and
12
preventing of thermal and mechanical
shocks to the tool bit, should reduce
V the risk of brittle fracture of the cutting
Pad.2
Use the circle sketch to model a 930 mm Pad.
Sketch.4
Use the rectangular face from the first Pad,
closest to the cylinder as the support for the
next sketch. In the sketch, use the “Project 3D
elements” option from the “Operations” toolbar.
The rectangle edges are copied to the sketch
tool.
Machining process:
Drilling
by clicking on the rectangle surface,

represented in a yellow colour.
Machining process: Milling
Parts made by turning
Examples of machined parts
J. Sinke, July 2009.
13
Multi-sections Solid.1
Use Sketch.4 to create the Multi-Sections Solid.
This feature, as the name implies, creates a
solid defined by multiple sections and some
guides.
For the second section, the circle used for the

second Pad can be reused (Sketch.2). It can be
found in the Model Tree by expanding the
Pad.2; click on the plus-sign to expand the
feature’s sub-tree; use the right mouse button to
toggle Hide/Show.
After selecting this sketch, select the cylindrical surface of the part to make the Multi-Sections
Solid feature tangent to this surface.
Press the preview button. An update error is displayed; more data is

required to define the feature. CATIA knows which sections are to
be connected, but it does not know how. There are multiple ways to
connect them, and CATIA needs to be told which one is desired.
In the Multi-Sections Solid dialog box, find the tab called “Coupling”
and change the mode to “Ratio”. Coupling curves will tell CATIA V5
how the points that belong to each other will be connected (they are
coupled). They will be defined by selecting the rectangle corner
points and the points on the circle closest to the rectangle points.
Click on the empty coupling list to tell CATIA that you want to create
a new coupling. Select the points one by one, starting with a point
on the rectangular section (sketch 4). When all four couplings are
created, four curves are previewed in the graphic area.
The last action to be performed to make the feature

definition complete is to change the Closing Point on
the circle. Use the right mouse button on the
displayed Closing point, pick the “Replace” option
and select the point on the circle closest to the
rectangle’s closing point.
Sketch.5
On the XY plane, create a sketch with a
30 mm dimension as depicted. Use
geometrical constraints to ISO-constrain
the sketch.
14
TritangentFillet.1
Use the Tritangent Fillet command to
change the rectangular end to a cylindrical
shape (can be found in the fly-out of the
edge filet).
Select the side faces as faces to fillet and
the end surface as face to remove.
Pocket.1
Use Sketch.5 to create a pocket with a 2,5 mm Depth. Check the “Mirrored extent” option to
create a 5 mm wide slot in the part.
Hole.1
Use the control button to multi-select both the top surface of
the rod’s end and the circular surface (or edge) of the face.
With these two items selected, click the “Hole” feature
button. Creating a hole this way automatically makes it
concentric with the circular surface.
In the dialog box, define the parameters for an “Up to last”
hole with a 10 mm diameter.
EdgeFillet.1
Use a 30 mm value to create an edge fillet on the indicated
edges (the red
lines, both on the top
and bottom).
Applying material
Use the “Apply Material” button to invoke the default material library. Under the “Metal” tab,
select the “Chroma” material and assign it to the PartBody by a drag-and-drop operation.
Close the Material Library.
15
Part AE1111-II-03: Step sheet
AE1111-II-03 Step sheet
Sketch.1
Create the sketch on the YZ plane as shown in the figure. Use the Elongated Hole option
from the Profile toolbar, in the Rectangle fly-out. Use a symmetry
constraint with respect to the ZX plane on the arc centers to make the
sketch ISO-constrained. (If you forgot how to make a symmetry
constraint, go back to the explanation at Sketch.1 of Part AE1111-II-01)
Pad.1
Use Sketch.1 to make a 195mm Pad.
Sketch.2
On the XY plane, make a rectangular
sketch, width 20mm, 22,5mm below the
horizontal axis. Now the bottom part of
the rectangle should coincide with the
bottom of the pad. Since this is a curved
surface (3D geometry) it is not possible to
directly select the intersecting line, it
needs to be created. Tools to do this are
available in the Operation toolbar under
“3D Geometry”. Use either the second or
third button to create the yellow line. Have
a close look at the
image of the
buttons for the
functionality of
each of these
options.
Delete the white bottom line of the rectangle, and coincide the bottom points of the vertical
lines with the yellow line.
16
Trim
Use Trim commands to make the yellow line part of
the rectangle. The trim function cuts of part of the
first selected element, the part that is kept is
dependent on the point at which the line is selected.
If the mouse is moved to the left of that point,
everything of the original line that is on the right
side of the current mouse position is kept. if the
mouse is moved to the right of that point,
everything on the left side of the current mouse
position is kept. Try this out for yourself and trim
the yellow line such that it becomes part of the
rectangle.
Pocket.1
Use Sketch.2 for a pocket feature. Use the “Up to last” Type for both the First Limit and the
Second.
TritangentFillet.1
Use the Tritangent Fillet command to
fillet the square end of the solid.
Hole.1 / Hole.2
Make two Hole features with the following
specifications:
Blind, 3mm diameter, 10mm Depth, V-
Bottom (120º), Type Simple.
Review the pictures for the hole location.
The hole should be concentric with the
outer contour arcs. (If you forgot how to
make a concentric hole, go back to the
explanation at Hole of Part AE1111-II-02).
17
Plane.1
Use the Plane command to create a plane with a 5.5mm offset from the outside surface of the
solid towards the inside. There should be 189.5mm distance from this new plane to the YZ
plane.
Draft.1
A Draft tapers faces with a specified angle. Here a Draft feature is used to make part of the
solid fit into one of the upcoming parts, the Step support.
Faces to draft
In other words, a draft feature provides a surface with an angle relative to the selected pulling
direction. For the faces to draft select one of the outside faces (see the picture). CATIA will
use tangency to automatically select the other faces. Use a 2º angle value.
The geometry stays unchanged at the “Neutral Element” location. Use the new plane as
Neutral Element. Click the “More” button to access the hidden options. Check the “Parting =
Neutral” option to tell CATIA that the drafting should stop at the neutral element (see the
picture below).
The pulling direction deter-

mines which side of the part
with respect to the neutral
element will be drafted. Set
the positive X direction as
pulling direction. This can be
done by right-mouse-button
click in the pulling direction
field, select “X axis”. If it is in
the wrong direction
(compare the orange arrow
with the compass in the top
right of the screen), then
click once on the orange
arrow to flip the direction.
18
EdgeFillet.1 / EdgeFillet.2 / EdgeFillet.3
Provide the indicated edges with EdgeFillets. Select edges, not faces. Use three separate
EdgeFillet features:
EdgeFillet.1: select the edge indicated at the picture and use a

5mm radius. Finish the EdgeFillet feature.
EdgeFillet.2: select the edge

indicated at the picture on the
right for the second Edge Fillet
feature. Use the 5mm radius
value again.
EdgeFillet.3: for the third

EdgeFillet use the outer
edge as indicated at the
picture. Use a 2mm radius
value.
If you do not use this sequence of features the resulting

geometry will be incorrect.
Mirror.1
Use the Mirror feature to Mirror the solid about the YZ plane. This is done by clicking on the
Mirror feature first and then select the plane to mirror about, the YZ plane.
Applying material
Use the “Apply Material” button to
invoke the default material library. Under
the “Construction” tab, select the “No
Skid” material and assign it to the
PartBody by a drag-and-drop operation.
19
Part AE1111-II-04: Stairs frame
AE1111-II-04 Stairs frame
10
R 2,8
Sketch.1
On the YZ plane, create a sketch for the first feature: Use the R 2,8
“Profile” option from the toolbar:
Start sketching in the origin to create a
coincident constraint at the bottom point.
The Profile sketch feature makes sketching a lot faster since 5

it is the line and arc tool build into one. To make an arc with the
Profile feature, click and hold on the previous point and drag the mouse pointer
outwards. Release the left mouse button and the line will change into a tangent 40
arc.
Use dimensional constraints for the two arcs. To make designs easily scalable V
dimensional constraints can be linked to each other. Double click on one of the
radii values to enter the Constraint Definition dialog box. Use the Right mouse
H
button on the value and pick “Edit formula”. Select the other radius value.
Choose OK to close the Formula Editor dialog box. Note the field in the Radius
Constraint Definition being greyed out and the new formula button next to the value. Edit the
other radius value to review the result. Use the values in the picture to ISO-constrain the
Sketch.
Pad.1
Use the Sketch.1 for a thick Pad, 545mm Length, Mirrored extend, 1.5mm Thickness.
20
Hole.1
Use the Hole feature to create a 10mm diameter hole.
Click the Positioning Sketch button to edit the positioning
sketch. In this sketch a point is shown where the hole will
be created. This point should be constrained 20mm by
20mm from the corner at the depicted location.
RectPattern.1
A feature that is created can be copied and placed at
other locations with the pattern commands. Use the
rectangular Pattern command to create 4 holes at a
350mm pitch. Use the bottom edge as input for the
Reference Direction. The pattern direction can be
changed by clicking the orange arrow if needed.
Plane.1 / 4mech
Create a plane with a 30mm offset from the XY plane in the positive Z-direction. Change the
plane’s name in the properties menu to “4mech”. (remember, the toolbar containing the
reference geometry feature can be hidden in the lower right corner).
Sketch.3
Create a new Sketch on the solid’s surface, have a careful look which side it is (see also the
figures on the next two pages). Use the Elongated Hole option from the Profile toolbar, in the
Rectangle fly-out. The horizontal center line should be coincident with the new plane.
Pocket.1
Use the new sketch to create an “Up to last” pocket.
21
Chamfer.1
Select the chamfer command from the Dress-Up features toolbar. Select the small corner
edge and create a Length1/Length2 mode chamfer with 10mm by 75mm dimensions. Check
the reverse button if the triangle is projected in the wrong direction.
EdgeFillet.1
Provide the corner edges with a 20 mm radius by using the “Edge Fillet” command.
Sketch.4
On the inside of the part, left from
the hole feature and right from the
elongated hole pocket, create the
sketch as shown in the pictures.
The axis end point is concentric with
the hole; use symmetry constraints
with respect to the axis.
Start this sketch by drawing the axis.

Then constrain the end point to the
hole. After that draw the arrow.
Doing it in this order makes it easier
to get the constraints right. Can you
think of a smart way to draw the
arrow? Making use of symmetry for
instance?
22
Pocket.2
Use the sketch to create a 0,5mm depth pocket feature. The arrow will help you to construct
the assembly later in another assignment.
Applying material
select the “Steel” material and assign it to the PartBody by a drag-and-drop operation. Close
the Material Library.
23
Part AE1111-II-05: Stiffener
AE1111-II-05 Stiffener
The Generative Sheet Metal Design Workbench

Sheet metal parts are very common in aerospace industry. CAD applications often have
dedicated software tools to facilitate design and engineering of these parts. In CATIA V5, we
will use the Generative Sheet Metal Design Workbench to construct two sheet metal parts.
Switch to the Workbench by selecting Start => Mechanical design => Generative Sheet Metal
Design.
Sheet Metal Parameters

Use the Sheet Metal Parameters command to define the parameters. Use a 1 mm Thickness
value and a 2mm Default Bend Radius value.
Sketch.1
Create a sketch on the XY plane. Use
the Centered Rectangle command to
create a rectangle with a 242,5 mm
width and a 92 mm height. In all
corners of the part, except for the
upper right, a joggle will be present.
Adjust the upper left corner of the
rectangle as the pictures show.
Use the Profile command to create the lines and arcs (For the functionality of the profile
command go back Sketch.1 on page 20). The result should be a horizontal line with a tangent
arc connected to it, to which a second straight line is attached, concluded by a second arc.
Drawing of the joggle can be tricky and might snap to the wrong shape when constrained.
Here
are some tips to help you overcome this:
- Draw the lines in their approximate final position before applying constrains.
- Turn off ‘Snap to grid’ to fix inverted tangency constraints.
- Use the Trim command (or “Quick trim”) to remove excess lines.
To create the 8 mm horizontal dimension, select the two end points, create a dimensional
constraint and before confirming the constraint, right-mouse-button click and select
“Horizontal Measure Direction”. Use dimensional constraints with the shown values to create
the exact geometry.
24
Mirror Rubber Forming of Metal
Use the mirror option in the sketch to copy
the adjusted geometry about the horizontal. Sheet
This can be done by selecting the joggle,
press the Mirror option, and select the axis to Rubber Forming (RF) is a manufacturing
mirror about. process for sheet metal parts which is
Use the Trim feature (or “Quick trim”) to typical for the aerospace industry. The
remove the corner lines of the rectangle. process is a press forming technique using
a rigid die and a soft tool (see figure 1). The
rigid tool imposes its geometry onto the sheet
during the forming cycle; the soft or rubber
tool forces the sheet in or over the rigid die.
Trim Upon unloading the soft tool regains its
original shape due to full elastic spring
back. The overall and detail geometry of the
part is formed in one process cycle, the
Do the same with the mirrored geometry sheet metal deforms plastically at room
about the vertical to create the bottom right temperature – see also Figure 2.
geometry do NOT create a joggle in the top
right corner.
It could happen that by trimming the

constraints are removed, if this occurs redo
the constraints to make the sketch Iso-
constrained again.
Figure 1. The principle of Rubber Forming of
metal sheet.
The process is typical for the aerospace

industry, because the soft tool is a universal
tool: it can be used for a large number of
different parts (see figure 3). So, for a wide
range of rubber formed sheet metal parts,
you only need one soft/rubber tool, though
you need a specific rigid tool for each
different part. The universal character of the
Wall.1 rubber tool results in very low tooling costs.
Using the Wall command, create a wall The combination of product diversity and
feature using the created sketch with the low tooling costs results in a cheap
default settings. manufacturing process which is relevant for
the small product series commonly seen in
the aerospace industry.
Flange.1 t/m Flange.4
The flange command can be used on all four
sides to create flanges on the sides of the
part. Select the bottom edges to make the
flanges point towards the positive z-direction.
Use the parameter values shown in the
picture, note that the given flange definition is
only given for one side (in this case the side Figure 2. A metal sheet and tool before (left)
with one joggle) therefore the other sides will and after (right) the forming cycle.
25
have a different amount of Spine edges. In
total four flange features should be created.
Start with the long sides; use the “Propagate”

button to select tangent edges.
Figure 3. Diversity of parts that can be made

on one Rubber Forming press
The rubber forming process enables us to

make deep-drawn parts and flanged parts
(see figure 4). The deep drawn parts are box-
type shapes, although the complexity is not
as high as for deep drawing and hydro
forming. Specific features like conical shape
and details are easily made in rubber
forming. The flanges parts are the most
common parts made by rubber forming.
These parts often have a flat web plate and
flanges at the periphery of the web plate. The
flanges are curved or may have details like
joggles. Typical parts are wing ribs, fuselage
frames, a lot of other flanged parts.
Folding/Unfolding
Use the Fold/Unfold command to review the
shaped and flat geometry. The unfolded
geometry represents a blank used to be
deformed to the final part shape.
Review the picture on the next page. Figure 4. Examples of a flanged part (left)
and a deep drawn part (right).
Note:
Rubber forming can also be applied to Fiber
Reinforced Thermoplastics (not
thermosets!) – see Figure 5. However, there
are a number of differences with respect to
RF of sheet metal:
- deformation mechanism is different
- temperature is applied to the
thermoplastic to soften this material,
and therefore the rubber/soft tool
should be temperature resistant
- soft tool is adjusted to the rigid tool
so the soft and rigid tools are both
product related
26
CornerRelief.1
Enter the Corner Relief command in the
unfolded state. To define the feature, select
the two top faces next to the corner. Use a
3mm Radius value. Do this for all four
corners. After defining the Corner Reliefs, go
back to the folded state using the Fold/Unfold
command.
Figure 5. Wing ribs made of FRTP using the

rubber forming process.
J. Sinke, May 2009
Point.1
Create a point 55mm left of the origin. This option is in the reference elements toolbar
(remember that this toolbar is possibly hidden in the lower right corner, together with the
Plane option).
Flanged Hole.1
Select the point before invoking the Flanged Hole
command, which can be found in the “Stamping
Toolbar” in the fly-out of the surface stamp:
Then click on the surface to create the

flanged hole.
Use the Parameters shown in the picture. The
flanges should be in the positive z-direction.
After completion, mirror the feature about the
YZ plane. Do this by using the mirror option,
The element to mirror the Flanged hole.
Review the part by using the Fold/Unfold command.
Applying material
Use the “Apply Material” button to invoke the default
material library. Under the “Metal” tab, select the
“Aluminium” material and assign it to the PartBody by a
drag-and-drop operation. Close the Material Library.
27
Part AE1111-II-06: Longitudinal Rib
AE1111-II-06 Longitudinal Rib
Open the part “AE1111-II-06” from the shared section. In the file, the sheet Metal Parameters
are set and the first wall feature is present. A geometrical set called “Isolated geometry” is
present, containing an isolated curve. This curve is used in the Wall sketch. Isolated geometry
is non-associative geometry. No parameters are available to change this geometry, but it can
be used as a reference.
Sketch.1 & Sketch.2

First, two separate reference sketches are drawn. Create or use a Geometrical Set for the
Sketches, see page 5 for information about Geometrical sets. The first sketch is a single point,
on the YZ plane, 1510mm to the right from the vertical axis and 750mm below the horizontal
axis (not shown in a picture).
The second reference sketch is

shown in the picture, also created
on the YZ plane. Use the toggle
between Standard and
Construction elements from the
Sketch Tools toolbar to change the
endpoints of the axis line to
standard geometry items (see the
explanation in the Sketching
Basics section on page 7). Doing
this makes the endpoints of the
axis line available outside of the
sketch for feature creation.
Create two extra points on the axis;

coincident constraints will be
created. Use 350mm dimensional
constraints for the spacing of the
points. Position the top point by
applying two dimensional
constraints, 1550mm to the vertical axis and 60mm to the horizontal. Finally, use a 1475mm
dimensional constraint to position the axis end points in space.
28
Corner.1
Use the Corner command
to create rounded
transitions (R10), similar to
the Edge Fillet command
in the Part Design work-
bench. The edges can be
selected automatically by
checking the “Concave
Edges” option and clicking
“Select all”.
Flange.1 t/m Flange.7

Use the Flange command to create the
flanges by selecting the bottom edges as
spine inputs (see the figure). The “Propagate”
option can be used on the outer edge. Do
NOT use the “Propagate” option on the other
edges, but multi-select each part of the edge
to be flanged. The flanges should be
pointing towards the positive x-axis direction.
All edges should have flanges, except for
the corner feature edges and the edges
between two corner edges. The model tree
should contain seven flange features.
Flanged Hole.1
Select the first reference sketch point,
invoke the Flanged Hole command
and select the indicated face of the
part. Define a flanged hole with the
parameters shown.
29
User Pattern.1
Just as the rectangular pattern, the “User Pattern” can copy and place created features at
selected points, this time specified by the user. Select the Flanged Hole and go to the User
Pattern option in the fly-out of the Rectangular Pattern button. Place the cursor in the
Positions field and select the second reference sketch. The Flanged hole will now be
patterned to the sketch point locations. Five flanged holes in total should be present.
Generative Shape Design Workbench (GSD)

From the Start menu, under “Shape”, go to the Generative Shape Design Workbench.
Wireframe and surface geometry can be modelled in this workbench. Make sure a
Geometrical Set is available. Now, you will make some reference geometry so you can make
a second User Pattern for the lightening holes.
Extract.1
Use the “Define In Work” command on the empty
geometrical set (see page 5 if you do not know how to do
this). Select one of the outside edges of the isolated curve
(the isolated curve can be found in the geometrical set
called “Isolated geometry”); the side where no flange
interruptions are present. From the “Operations” toolbar,
use the Extract
command to copy the
geometry. In the dialog
box, select Tangent
continuity as the
Propagation type, this
will propagate the
selection and extract
(copy) all the connecting
lines that are tangent to the selected line.
Parallel.1
Select the Extract and use the Parallel Curve command to create an offset of the Extract, with
a 49mm value. The Parallel Curve should be present in the middle of the intersection
geometry; use the Reverse Direction button if needed.
Point.1 tm Point.8
Create a point on the parallel
curve; use the “On curve” point
type. The point should be
160mm away from the Parallel’s
top point. Change the
parameters to achieve this and
check the “repeat object after
OK” radio button.
In the next dialog, change the

parameters field to “Instances
and spacing”. Number of instances should be 7 and the spacing value 250mm. This creates
in total 8 points on the parallel curve with a spacing of 250 mm along this curve.
30
Sketch.4
On the YZ plane, create a sketch. Use the Project 3D elements
command to copy the points to the sketch. This step is needed to
be able to use the User pattern again, creating the lightening holes
on each of the points.
Flanged Hole.2
Switch back to the generative Sheet metal workbench. Use the
right mouse button on the PartBody and select “Define In Work
Object”. Select the first point; invoke the Flanged Hole command
(remember, this can be found in the Stamping toolbar) to create a
lightening hole. Use the parameters shown in the picture.
User Pattern.2
Select the new flanged Hole and click
the User Pattern button. Select the
reference Sketch with the copied
points to finalize the pattern.
Folding/Unfolding
Use the Fold/Unfold command to review the shaped and flat geometry.
Applying material
select the “Aluminium” material and assign it to the PartBody by a drag-and-drop operation.
31
Part AE1111-II-07: Door Skin
AE1111-II-07 Door Skin
Next the skin of the door will be created by sketching a curve representing the cross section
of the fuselage. This curve will be extended in perpendicular direction to create a curved
surface.
Axis System
Insert an axis system with the default values (Insert => Axis System).
Generative Shape Design Workbench (GSD)

From the Start menu, under “Shape”, go to the Generative Shape Design Workbench.
Wireframe and surface geometry can be modelled in this workbench. Make sure a
Geometrical Set is available. Rename the set to “Reference”.
Sketch.1
On the YZ plane, create a sketch. This sketch will represent the Fuselage contour and will be
used more than once. Make sure the sketch is can be found in the Reference Geometrical
Set in the model tree .
Profile
The contour will be drawn in multiple steps.
First draw the unconstrained line as close
to its final dimensions as possible. Use the
profile command to create a line connected
to three arcs, this will be the top half of the
curve. Start left from the vertical axis; make
sure the first node coincides with the
vertical axis by clicking once. Then hold the
mouse button as you move to the second
location to create an arc. Finish this
process until the the curve looks
approximately like the constrained curve.
Change the horizontal line to become a

construction element using the button in the
Sketch tools menu.
32
Constrain the
curve with the
values shown
in the picture. It
will not be ISO-
constrained as
the endpoint of
the bottommost
curve is still
free to move.
Profile
Use the profile command again to create a
second curve connected to first curve. The first
segment will go straight down from the top left
point, approximately 3000mm long. The next
point should coincide with the vertical axis.
From here, make a final curved segment by
holding the mouse button and releasing it
below the constrained curve. This curve should be constrained with a radius of 3850 mm.
Corner
Use the corner command to create the last arc. After selecting the corner command, click on
two line open ended curves. A corner section that merges these two segments will then be
automatically generated. This segment will be coincident and tangent to both preselected
segments. Then constrain the corner radius to 870mm.
Rename the sketch to “Fuselage contour” by using the right mouse button on the sketch
name, choose “Properties”. Under the “Feature Properties” tab the name can be changed.
33
Extrude.1
Use ‘Fuselage contour’ to create an extrude from the GSD workbench, set both limits to
1000 mm.
Sketch.2
On the ZX plane, create a rectangle with a 1000mm width, a 2000mm height, symmetric
with respect to the vertical axis. This rectangle has a 1200mm distance between the bottom
line of the rectangle and the horizontal axis.
Project.1
Use the Project command from the Wireframe
Manufacturing of
toolbar to project the sketch upon the extrude. Composites
Switch the type to “Along a direction”. In the
direction field, use the right mouse button to be
able to select the Y Axis as the projection Composites are materials made of more
direction. than one constituent. The best examples
are the fiber reinforced composites or
Polymers/Plastics (FRP) which are
Split.1 discussed in this brief note.
Use the Split
command to split FRP consist of fibers and a polymer or
the extrude with resin. The available choices are very
the projection. If large for both constituents. For the fibers
the wrong side of there are different types, i.e. carbon,
the surface is glass, Aramid or Kevlar£, Poly-Amid or
kept, use the Nylon£, etc. Different lengths, from
“Other side” nano-fibers till “continuous” fibers, and
button to correct different architectures or layers like Uni-
this. Directional (UD) layers – all fibers in one
direction, Cross-ply layers – fibers in two
orthogonal directions, where the ratio is
Part Design Workbench a variable.
Switch back to the Part Design Workbench
(Start => Mechanical Design => Part design). The possible variation in the second
element, the applied polymer, is also very
large. In the polymers there are three
main categories: thermosets,
Thick Surface.1 thermoplastics and elastomers. The
In the “Surface Based features” toolbar, use thermosets are the most common
the “Thick Surface” command on the split to polymers used for aerospace
create a solid skin. The arrows should point applications. Thermosets are based on
towards the positive Y direction. Use two components, that are mixed just
“Reverse Direction” if before the impregnation of the fibers. The
needed. thermoset stays liquid for a while, in the
order of one hour, before if solidifies due
to chemical reactions (cross-linking).
Edge Fillet.1
Thermoplastic polymers consist of one
Use a 150 mm value to
component; long molecules with very
create edge fillets on
limited branches. At room temperature
the skin corners.
they are rigid, but above a material
specific temperature, usually in the range
0
of 100-300 C, the material softens and
Thick Surface.1 becomes viscous. At much higher
Double click on the temperature the thermoplastic may melt,
Thick Surface feature to although the viscosity does not become
redefine the thickness as low as for thermosets. The third type
value. Change the First of polymer, elastomers is seldom used in
Offset of the structural composites.
Thicksurface.1 to 1mm.
34
The initial 100mm value is used to make the
edges of the solid easy to select. First creating The following actions need to be taken to
the fillet and afterwards reducing the wall manufacture a composite part:
thickness of the skin facilitates easy creation of the process should create the shape of
the rounded door corners. This is the one of the part (drape)
the benefits of a parametric modelling the fibers and polymer/resin should come
application: the final geometry is the result of together and be mixed thoroughly
the final parameter values. (impregnate)
after impregnation the mixture needs
solidification (cure)
Applying material These steps will be discussed using two
Use the “Apply Material” button to invoke the very common manufacturing processes
default material library. Under the “Painting” for composite parts: lay-up and resin
tab, select the “White” material and assign it to injection moulding.
the PartBody by a drag-and-drop operation.
Lay-up.
In the lay-up process one may use dry fiber preforms or prepregs. Typical dry preforms are
weaves or fabrics (cloth), tapes, and braids. These preforms are placed on the die/mould
(drape) and the dry fibers are impregnated with the resin using brushes and rollers. Today,
prepregs are used more often. Prepregs are pre-impregnated weaves, fabrics, etc. The right
amount of resin is already applied to the fibers. The prepregs only need to be cut to the right
sizes and placed (drape) over the die/mould. Once the package is complete, the stack is
packed in a vacuum bag and cured, e.g. in an oven.
Resin Injection Moulding

In this process, the entire fiber system is placed in the die/mould first (drape). Locally the fiber
package may consist of multiple layers in different orientations. When complete, the fibers are
packed in a vacuum bag and a vacuum is applied. Then a reservoir with resin is opened and
due to the pressure difference, the viscous resin will flow into the mould and impregnate the
fibers. When the impregnation is complete, the composite is cured at room temperature or in
an oven.
Two pictures of composites lay-up of kite-boards:
the prepregs have been laid up in a stack (left), and
one of the stacks is prepared (wrapped in a vacuum
bag) for the curing process (right)
Notes:
x The two processes mentioned here are typical for thermosets. In these processes one
takes advantage of the drapable fiber preforms and the viscosity of the polymer at room
temperature.
x
x In case of thermoplastics the prepregs are often assembled into flat laminates first and in
a second process press formed into its desired shape (see note at “Rubber forming of
Sheet Metal”). Heat is applied in both processes to soften the polymer.
x
x The composite attains its strength and stiffness mainly from the fibers, the resin/polymers
are to support the fiber (buckling!) and is important with respect to environmental loads,
i.e. temperature and moisture.
Two pictures of a resin injection process of a hull for a catamaran: the mould is filled with dry
fibers (left) and the injection process is ongoing (right).
J. Sinke, June 2009
35
Part AE1111-II-08: Door liner
AE1111-II-08 Door liner
The next step is to create a liner for on the door. We will import the door shape drawn in
AE1111-II-07 in order to re-use it. First create part AE1111-II-08, and then open the AE1111-
II-07 part. Enter the Generative Shape Design Workbench and create a new geometrical set
in AE1111-II-07. Use the properties menu to rename the set to “link to AE1111-II-08”.
Extract.1
In the AE1111-II-07 part, use the inside surface of the partbody as input for an extract with
Tangent continuity. Find the extract surface in the model tree and copy it.
Linked Copy: Surface.1

Use paste special in the AE1111-II-08 part (Right mouse button on top of the
model tree => Paste Special => as result with link). In the AE1111-II0-08 part,
use the right mouse button and use “Define In Work Object” on the newly
created Surface.1. Use “Fit All In” from the View toolbar to review the
result. Now the AE1111-II-07 part can be saved and closed.
Update All
If the original is modified, the linked copy will show a red in the assembly, and the icon in the
model tree will change. In order to propagate the changes from the original to the copy,
synchronize the linked copy in the model tree and press the update all button or use the
Ctrl+U key command to update the part geometry.
Generative Shape Design Workbench

Make sure you are in the Generative Shape Design
Workbench for the next steps. Create the next features in a
Geometrical set.
Axis System.1
Insert an axis system with the default values (Insert => Axis System).
Offset.1
Use the linked surface as input for an offset
command. Create the offset at the concave side of
the reference surface, with a value of 98mm. Use
the Reverse Direction button if needed.
36
Extract.1
Use the extract command to create the contour
curve of the new surface. Use one of the
surface’s edges as input, with Tangent continuity
propagation type.
Parallel Curve.1
From the Wireframe toolbar, choose the Parallel
Curve command. The parallel curve command
can create a new line in the same plane as our
original curve Extract 1. Use the contour created
in the last step as input. The parallel curve should be created 55mm to the inside of the
contour, Use Reverse Direction if necessary. Since the Parallel Curve has to lie in the same
curved plane as the original, the support of the contour is this surface.
Plane.1
Create a plane with a 200mm offset from
the YZ plane.
Split.1
Invoke the Split command:
The split command uses two elements to
create a new shape. This shape can be
either be where the two parts intersect or
everything else. By using this feature
consecutively the shape can be reduced
to its final form.
Use the offset surface as element to cut. Select the first cutting element: the parallel curve.
Check the previewed result after selecting; use “Other side” if necessary. The part of the
surface previewed as transparent geometry will be cut off by the feature. Now select Plane.1
as the second cutting element: Clicking Other Side will switch the outcome of the split step
corresponding to the selected cutting element.
Thick Surface.1
Switch back to the Part Design Workbench (Start => Mechanical Design => Part design). In
the Surface Based features toolbar, use the Thick Surface command on the Split Surface.
Use a 4mm First Offset, add material to the inside (concave).
Mirror.1
Use the Mirror feature to Mirror the solid about the YZ plane.
Depending on the workbench, the mirror feature behaves differently.
In the part design workbench it will automatically mirror the entire
PartBody around the selected plane.
Applying material
Use the “Apply Material” button to invoke the default material library.
Under the “Fabrics” tab, select the “Brown Fiber” material and
assign it to the PartBody by a drag-and-drop operation. Close the
Material Library.
37
Part AE1111-II-09: Hinge bracket
AE1111-II-09 Hinge bracket
The next step is creating a hinge that connects the door to the fuselage. This hinge will be
created from multiple pads to create the framework, a stiffener to reinforce the lip and a shaft
to create the cylindrical part on the end.
Pad.1
Create a sketch on the YZ plane and draw a circle with a 10 mm diameter concentric with the
sketch origin. Close the sketch and use it to make a Thick Pad by selecting the pad feature
and selecting ‘thick’ in the options. The pad has a 240 mm Length and a 2 mm Thickness1
and 0 mm Thickness2, indicating that 2 mm of material will be added towards the inside.
Line.1
Switch to the Generative Shape Design Workbench. Check if the Part Document contains a
Geometrical Set or create a new one if it is missing. Use the “Line” command to create a
Point-Direction type line. In the dialog box, use the right mouse button in the “Point” field. Pick
“Create Point” and make a point in the part origin using the Coordinates Point type. Click OK
to return to the line definition. In the “Direction” field, use the right mouse button to pick the X
axis as direction reference. In the “End” field, key in a 250mm value.
Plane.1
Create a plane by choosing the “Angle/Normal to plane” option
in the plane definition dialog box. Use Line.1 as Rotation axis,
the ZX plane as Reference and use an 18º angle value.
Extrude.1
On the new Plane.1, create the sketch according to the picture.
The bottom line should coincide with the end face of the pad.
Use the extrude feature on this sketch, projecting it 20mm in
both directions.
38
Offset.1
Use Extrude.1 to create an Offset at a 2mm distance, away from the solid. For the next
features you should switch back to the Part Design
workbench.
Pad.2
On the bottom part of the extrude, create a Sketch
with the elongated hole profile. The center line should
be coincident with the new Plane.1. It should have a
63mm length between the centers of the holes. The
bottom arc should be coincident with Sketch.1. Create
the pad: First Limit Up to surface with the Extrude as
input; Second Limit Up to surface with the Offset as
input.
Stiffener.1
Make a new sketch on the created plane according to
the picture on the left. Use a Stiffener command; Mode
From Side, 1mm Neutral Fiber.
Pad.3
On the top part of the Offset, create a sketch. It should
be a circle coincident to the top arc of Pad.2. Use it for
a 11,5mm Pad. Check the dimensions with the values
in the drawing.
Pad.4
Make a sketch on the ZX plane
according to the picture for the
next Pad feature. Use the
“3D Geometry” tools to make the
horizontal line exactly on Pad.1’s
contour. Use the sketch to make
a Mirrored extent 1mm Pad.
39
Shaft.1
Make a new sketch on the Plane.1
according to the picture. Make the axis
coincident with the cylindrical Pad. To
generate the diameter constraints, select
the axis first when constraining the bottom
line. Use the right mouse button after
picking the element to constrain and pick
the Radius/Diameter option. This will only
show up if the centerline is of the type axis.
Use the sketch for the shaft feature, 360º
First angle.
Point.1 / 4mech
From the part design workbench: Create a new
Geometrical Set. In the new Set, create a point by choosing
the “Circle / Sphere center” option. Select the indicated circle as input. Rename the created
point to “4mech” by entering the properties menu.
Applying material
select the “Iron” material and assign it to the PartBody by a drag-and-drop operation. Close
the Material Library.
40
Part AE1111-II-10: Step support
AE1111-II-10 Step support
The feature based parametric modelling method allows features to be created in between
features which have already been defined. In a way, you could say that you can “go back in
time”; the most recent feature is not necessarily the last feature in the specification tree. The
benefit of placing new features in between features defined earlier is that all features below
the new feature in the tree will be applied on the new feature as well. In some cases, error
messages will come up after creation of the new feature, but solving these issues is relatively
easy. The result is a far more flexible design compared to adding the features at the bottom of
the tree. In this assignment you will place draft features on an existing part by placing the
features at specific locations in the model tree.
Open the model AE1111-II-10 from the shared section and save it to your account. Unfold the
model tree by clicking on the plus sign at the PartBody. Find the feature EdgeFillet.1, place
the cursor on the feature in the tree and click the right mouse button. Select “Define In Work
Object”.
Notice the following items:

x The feature EdgeFillet.1 is underlined in the tree.
x Only the features up until EdgeFillet.1 are shown in the graphic representation.
The background of this functionality is that new features can be placed in between features
which are already defined. The model is shown in the graphic area as if only the features until
EdgeFillet.1 were present. The other features are present though, but not shown in the
graphic representation of the model. Benefit of this functionality is that all features located
under the underlined one also affect the new feature.
41
Draft.1
The Step support is a plastic part. The production
Injection Moulding of Metals
method for a part like this is injection moulding. The and Polymers
tool used for this method will consist of a core and
a cavity part. To release the part from the mould, all
Injection moulding is a manufacturing
geometry has to have a certain angle relative to the
open-close direction of the mould. Draft features
process in which the material is processed
can be used to provide geometry with such an in the (nearly) liquid state. In that state, the
angle. material fills a cavity where it solidifies and
Select the outer surface of the solid as Face to is retrieved. There are small differences
draft. Select the YZ plane as Neutral Element. between the injection moulding of metals
Make sure the Pulling Direction is pointing towards and the injection moulding of polymers.
the positive X direction. You can change the First, the injection moulding of plastics is
described.
A schematic overview of an injection

moulding machine for plastics or polymers
is presented in the figure below. The
material is fed into the hopper (2) as
powder or as pellets. The screw (1)
transports the material to the die (4, 6).
During this transport the material is mixed or
homogenized and heated by friction,
which is illustrated by the colour in the
direction by clicking the arrow. Use a 20º value. extruder: yellow to red. The fluidized
material is forced into the die cavity (5) via
The feature makes the selected input to have an the nozzle of the extruder (3). Often the die
angle with the selected pulling direction, resulting in halves (4, 6) are cooled so the hot polymer
a geometry which can be released from a tool. The cools down rapidly. Once the rigidity of the
20º value is clearly recognizable, but smaller values parts is sufficient, the die is opened and the
are sufficient for this function. Redefine the feature part is released.
using a 2º value instead of the 20º.
o
20
The principle of injection moulding for

plastics
The injection moulding process is very

popular for many parts made of
thermoplastics. The process is not so
appropriate for thermoset plastics.
In case of thermoplastics small fibres can
be added to the polymer. These fibres have
o a fibre length of a few millimetres and
2
maybe decreased further in size during the
mixing phase in the extruder.
42
Place the cursor on top of the text “PartBody” of The fibre orientation of these fibres in the
the model tree and select the “Define In Work part is random.
Object” option again. You can see the “PartBody”
text being underlined and all the model’s features The injection moulding process for metals is
shown in the graphic area. Now find the feature
almost identical. The only difference is the
“Stiffener.1” and make it the In Work Object.
melting of the metal. For metal injection the
extruder is replaced by a plunger with
Draft.2 heating elements. The molten metal is
The inside geometry of the part needs to be poured into the plunger where the
drafted as well. Select the indicated faces on the temperature is maintained. Then the plunger
inside of the part (11 faces). By selecting a face, forces the molten metal into the die cavity
all tangent faces will also be selected. Use a 2º where it is cooled down below the melt
angle value. Use the YZ Plane as neutral, make temperature. The solidified but still hot part
sure the pulling direction is pointing towards the can be released from the die and further
negative X-direction. processed.
When more than one nozzle is used, e.g. for

large parts, the fusion of flow fronts in the
die cavity will result in knit lines. These
lines are often weak points and should be
located in the less critical areas of the part.
Since the tooling (dies) is rather expensive,
this process is used for large product
Draft.3 series, i.e. of 10.000 or higher.
The boss on the other side of the part also needs
to be drafted, both on the outside as well as the During the design of an injection moulding
inside. Use a 2º angle value again. The face of
die the designer should take care of a
the solid can be used as neutral (Pad.1\Face…).
This time the pulling direction should be in the
number of features: shrinkage of the
positive X-direction. Click on the arrow to flip the material due to temperature differences; the
direction if needed. possibility to release the part i.e. no
undercut geometry; and some dies are
subjected to high pressures when the
polymer or metal is forced into the die cavity.
The last feature also results in injection
moulding machines that should be capable
of high die closing forces.
Make the PartBody the In Work object and save

the part.
Examples of injection moulded parts
J. Sinke, July 2009
43
Part AE1111-II-11: Door Frame
AE1111-II-11 Door Frame
Open the part “AE1111-II-11” from the shared section. This part is used later on in the
Assembly design assignments and in the next Part design assignment, where geometry from
this part will be copied to be reused in the door seal. Looking at the model tree, notice the
Body.5 next to the PartBody. This demonstrates the possibility in CATIA to model multiple
solids within one part.
Save a copy of this part to your storage folder using “save as”.
44
Part AE1111-II-12: Door seal
AE1111-II-12 Door seal
Open the AE1111-II-11 part to create

geometry which can be used as reference in
the Door seal part. Enter the Generative
Shape Design Workbench. Expand the model
Extrusion of Metals
tree at the PartBody “Trim.1” feature. Use the
right mouse button on Body.2. Select “Define Metal Extrusion is a manufacturing process
In Work object”. performed at elevated temperatures. At
these temperatures the metal is much softer
and has a much better formability: the
Extract.1 required forces to deform the metal are
In the AE1111-II-11 part, select one of the reduced and the failure strain has increased,
concave (inside) faces. Then use the extract both significantly. During the process the
command with tangent continuity. Find the material behaves like a thick liquid
extract surface in the model tree copy it, then substance, think about toothpaste, and is
hide the extracted surface. Define the squeezed through a narrow opening.
PartBody as the In Work Object again.
The principle of extrusion is presented in the

picture above. A metal billet, cylindrical metal
block, is preheated and placed in a container.
Linked Copy : Surface.1 On one end the container is closed with an
Use file => new to create the AE1111-II-12 extrusion die, on the other end with the ram.
part. In the AE1111-II-12 document, use When the ram is forced to the left the hot
Paste Special => As Result with Link to metal will be squeezed through the die
create a linked copy of the surface in the file. opening. Outside the container the extruded
Use “Fit All In” from the View toolbar to shape cools down rapidly, sometimes
review the result. artificially cooled with water.
The resulting surface should be a single
surface, consisting of two faces. You can
check this by zooming in very closely on the
edge of the surface:
45
The product resulting from this process is a
profile with a specific cross section. The
length of the profile is “unlimited”, so the
profile can be cut at any length. The shape
of the cross section is constant; the shape
cannot be changed along the length of the
profile, nor can details in transverse direction
be made to these profiles. The cross
sectional shapes however, can be very
complex: look at the examples at the end of
this inset.
The extrusion die can have a simple die
opening or a rather complex one. Enclosed
holes, thickness differences, and/or thin
gauges increase the complexity (and costs)
of an extrusion die. An extrusion die for a
The PartBody should be defined as the in tubular shape is presented In the figure
work object and the AE1111-II-11 part can below. Note the complexity required to create
now be saved and closed. the tube.
Axis System.1
Insert an axis system with the default values
(Insert => Axis System).
Thick Surface.1
Switch to the Part Design Workbench and
make the PartBody the In Work Object. Use
the Thick Surface command on the External
Reference surface to create a solid with an Extrusion die for a tubular shape.
8mm thickness, pointing inwards from the
surface (concave). Hide the external surface
when done. Aluminium is an ideal material for extrusions
and used in many applications (see below).
The temperature required for extrusion is
0
between 300 and 600 C.
Due to the transformation of the billet into the
profile, the microstructure of the material is
oriented in length direction. This texture has
an influence on some properties of the
profile, like a decrease in corrosion or fatigue
resistance in transverse directions.
Shell.1 Since the extrusion is performed at high
Use the shell command. Select both front and temperatures, the slender profile might
back of the solid as faces to be removed, use distort during cool down. So often extra
a 10mm value. Hide the pasted surface stretching (straitening) is performed to get the
Extract.1 to be able to select ThickSurface.1 profile strait.
The extrusion process is a semi-continuous

process and is applied for profiles that are
required in large numbers (lengths). Typical
applications are found in a lot of buildings, i.e.
window frames, fences, structures, aluminium
extrusions for green houses, and also in
Edge Fillet.1 aircraft: i.e. stringers for the fuselage, which
Select the concave surface to provide the are required in large numbers.
edges of the surface with a 3mm EdgeFillet.
46
Note:
Polymers can also be extruded and are used
quite often. Typical examples are window
frames, and profiles used for fences, often
used in areas/environments, i.e. marine
environment, where metals may corrode.
Polymers however, do not have the high
mechanical properties of metals. The density
is often lower. To improve the properties of
Applying material the polymers, they may be reinforced by
Use the “Apply Material” button to invoke the short fibers, with a. length in the order of a
default material library. Under the “Other” tab, mm.
select the “Rubber” material and assign it to
the PartBody by a drag-and-drop operation. For high strength polymer profiles continuous
Close the Material Library. fibers should be embedded. This is possible
using a process called “pultrusion”. However,
this process is different from the extrusion
process described here.
Some examples of extruded profiles
J. Sinke, June 2009.
47
Assembly design
Introduction
Now you have made several 3D components, the next step is to make assemblies out of
these components. In assemblies, components are positioned in space to create a product.
The interaction of created parts, standard catalog parts such as nuts and bolts, parts created
by others and so on can be reviewed. Relations between parts can be defined and changes in
these relations can be analysed. This allows a design to be reviewed in many ways before the
physical parts are produced.
Assemblies in CATIA V5
In CATIA V5 assembly files are called Product files; the file extension of a product file is
“CATProduct”. Similar to part files, Product files contain a model tree. Instead of bodies,
geometrical sets and features, the tree contains components, constraints and applications.
Components are the parts or sub-assemblies available in the product, constraints are the
definitions of geometrical relations between different components. Only links to Part files or
other Product files (sub-assemblies) are stored, as well as the relations between them. When
a part in an assembly is altered it will light up red to indicate the version is out of date. When
you manually update the assembly, the part is updated to its latest definition.
Constraints
Working with the assembly constraints, you will notice some similarity between the assembly
constraints and the constraints you used in the Sketcher Workbench. Data such as measured
dimensions, additional assembly representations etc. can be stored in the applications tree.
There are five main types of constraints. Coincidence constraints

Constraint types
will imply two elements share at least a single position. Contact
constraints also imply lines or surfaces are tangential at the point
Coincidence
of contact. The offset implies a distance between two elements.
Contact Note that the constraint must make sense from a logical point of
view for CATIA to parse it, ie. Trying to define a distance two
Offset surfaces that are under an angle with respect to another, catia
will not give the intended result. Instead a plane and a line, or a
Angle plane and a point should be
selected if planes are not
Fix parallel. The angle constraint
does as it implies, it requires two elements as input and
places them under an angle with respect to each other. The
Fix constraint should only be used once per assembly, and
causes the fixed part no longer to move due to other
constraints. The first part in an assembly is fixed to be used
as a reference part to constrain the rest of the assembly.
The constraints are displayed in the model tree, with the

type of constraint and the elements the constraint applies to.
The value of an existing constraint can be modified by
double-clicking the constraint. The selection elements on
which the constraint is applied can be modified by right
clicking on a constraint and selecting (Coincidence.1 object
=> definition => more”) when dealing with a coincidence. In
this Object menu the constraint can also be temporarily
disabled by select "Deactivate”. Sets can also be added in
the model tree to sort constraints in large models, this does
not affect their interaction with the model.
If an assembly contains subassemblies, all the parts in the subassembly need to be

constrained with respect to themselves. The constraints belonging to the subassembly are
48
displayed one level deeper into the model tree after the subassembly is inserted into the
assembly. This means constraints can only exist between parts or assembly that exist in the
same level of a tree. For example in the example model tree, constraints at the assembly are
made between the Subassemblies and the Part while the parts within Subassembly1 are
constrained with respect to each other to define their relative positions.
The compass
In the right top area of the screen an item is available which is called “the compass”. In the
assembly design Workbench, the compass can be used to manipulate geometry in space.
The red square in the compass is the handle for moving the compass to a desired location.
Snap functionality will position the compass to geometry items, e.g. if the compass is dragged
on top of a cylinder, the compass will line up its Z-direction with the cylinder’s axis. When the
compass is placed over a planar surface, it will line up its XY plane to this surface. When the
compass is moved to a geometric item, this item can be moved by compass manipulation.
Clicking and dragging will have following results:
x click in a privileged plane and drag: translation in the privileged plane
x click on a compass axis and drag: translation along this axis
x click on an arc of the compass and drag: rotation in the arc direction
x click and drag on the free rotation handle: free rotation about the manipulation handle
A contextual menu is available for more precise manipulation. The menu can be accessed by
using the right mouse button on the red square and choosing “Edit”. Options are available in
the menu to key in angles or lengths to manipulate the compass.
Basic Top-down methodology

The following work method is recommended to create a CATIA V5 assembly:
x Create a new assembly file: This is a file with the extension
“CATProduct” (File=>New=>Product)
x Prepare the CATProduct file by filling in the Product’s name,
nomenclature and other properties (if needed) by invoking
the properties menu
x Insert the first component by either (Insert => Existing
component) or (Window => Tile horizontally) followed by
dragging and dropping the desired parts into the assembly
x Use a Fix constraint on the first component to fix its position
in space
x Insert the second Part file
x Use the compass to move the component roughly so it will be close to its desired final
position
x Use other constraints to position the second part precisely. Press Ctrl+U to update.
x Repeat the last three steps for next components
Save Management
Saving assembly files will have other consequences than saving part files. Since Product files
are linked to other files, warning messages will appear when you try to save an assembly.
When saving a Product file the system will assume all changed data linked to the assembly
has to be saved. When a Product file is closed, warning messages will appear to inform the
user which data is saved and which is not. The “Save all” command is available in the file
menu to save all changed data using a single command.
49
Assembly AE1111-II-A: Actuator
AE1111-II-A Actuator
Assembly Design Workbench

Make sure to have read the explanation about Assembly design on page 48-49. Invoke the
Assembly Design Workbench. Make sure an empty Product file document is open. Open the
parts AE1111-II-01 and AE1111-II-02. With the product document active, use Window => Tile
vertically to show all opened documents simultaneously.
Rename the Product document to AE1111-II-A (Product tab under properties), fill in “Actuator”
in the nomenclature field of the product properties.
Use drag-and-drop operations to assemble the parts in the assembly: e.g. with the Product
document active, drag the AE1111-II-01 description (top of the tree), drop on to the AE1111-
II-A description in the tree of the product file, as is done in the picture. Do the same for the
AE1111-II-02 part.
Existing Component
Note: instead of drag-and-drop operations, the existing component command can be used.
After clicking the button, the top line in the assembly model tree should be selected to
assemble the component.
50
Manipulation
Note: instead of using the compass to move parts and
subassemblies it is also possible to use the manipulation tool in the
Assembly Design Workbench. Select an assembly or subassembly
to move parts within this product. A direction of movement can be
selected from the window to move the part along a linear direction,
through a plane, or to rotate it about an axis. Custom directions can
be indicated in the model using the fourth row of buttons.
Fix constraint
Make sure to be in the Assembly Design Workbench. In an assembly file, parts “float in space”
until constraints are used. A fix constraint is used to create a reference in space, preferably
on the first component assembled. Use the Fix constraint button to impose a fix constraint on
the AE1111-II-01 part.
Coincident constraint
Use the compass to position the AE1111-II-02 part roughly (how to use the compass is
explained on page 49). Use the coincident constraint to line up the rod and the base. As
inputs, select the axes by clicking on the outer surface of the cylinders of both parts. CATIA
V5 will select the axis when a cylindrical object is clicked.
Use another coincident constraint to prevent the rod from turning in the base. Use the
AE1111-II-01 and AE1111-II-02 YZ planes as input. You can select them from the model tree
by expanding it.
Input for the constraint definition can be planes, but also axis lines of created geometry. The
system previews items that are selectable as input.
Update
By default, CATIA V5 product files need to be updated manually. This means the
consequences of imposed constraints will only be shown after the “Update All” button is
clicked. The shortcut Ctrl+U can be used for this action. Alternatively, the option for assembly
update can be changed to automatic under Tools => Options => Assembly Design =>
General.
51
Offset constraint
Use an offset constraint to determine
the actuator length; use a value of
1020mm. Use both ZX planes as input.
If constraints are changed the assembly

is changed accordingly. Change the
offset value to 1950mm and update the
assembly to review the result.
52
Assembly AE1111-II-B: Step assembly
AE1111-II-B Step assembly
Create a Product file with the AE1111-II-03 and AE1111-II-10 parts assembled.
Fix constraint
Use the fix constraint on the step sheet (AE1111-II-03). Position
the step support close to the sheet with the compass.
Use other constraints to position the step support (AE1111-II-10).
The step sheet side should fit exactly into the opening of the step
support (remember the drafts that were created).
A good way to
assemble the step
support to the step sheet is to use coincident
constraints on the screw holes and a contact
constraint on the surfaces that should touch. In
reality this would be the way the parts are
assembled: contact is created at the inner
surfaces by screwing the support to the sheet.
If the coincidence constraint does not work, it
could be that the holes that are created in the
step support are not placed at the right spacing,
and cannot be aligned just as in reality. To fix this, part AE1111-II-03 needs to be changed.
Symmetry
The step will be supported by two parts. Since
the second step support is the mirrored image
of the first, there is no need for a separate part
describing the geometry. The symmetry
command is available in the assembly design
Workbench to generate a mirrored component
quickly. A wizard will start after clicking the
symmetry button, showing the following steps.
1. Select the symmetry plane. Use the AE1111-II-03 YZ-plane for this entry.
2. Select the product to be transformed. Select the AE1111-II-10 part.
3. In the next dialog box, choose “Mirror, new component” and “Part Body”.
4. After clicking “finish” a message appears, prompting the Assembly Symmetry Result.
53
A component named “Symmetry of AE1111-II-10” will now be present in the model tree. Open
the part by using the “Open in new window” command in the contextual menu (Right mouse
button =>“Symmetry of AE1111-II-10.object”). Examine the model tree of the symmetry part.
As you can see, the PartBody consists of an Assemble Boolean operation containing a body
called “Body from original PartBody”. The green plus sign in the grey cube at Solid.1 shows
there is a synchronized link between the solid and its parent. Changes in the original part will
also make this part change.
Close the symmetry part and save the AE1111-II-B product file. Note that a new file will now
be present in your storage folder: Symmetry of AE1111-II-10.CATPart.
54
Assembly AE1111-II-C: Foldable stairs
AE1111-II-C Foldable stairs
Create a new product file with the correct name and nomenclature for this assembly. Insert
the AE1111-II-04 stairs frame part and the AE1111-II-B assembly.
Fix constraint
Fix the stairs frame with a fix constraint.
Use the compass to move the step close to its
desired position, at the end of the frame near to
the slotted hole. Review the picture for the
correct position; notice the arrow on the Stairs
Frame. After assembling the arrow should be
visible as depicted.
Use a coincident constraint on the inner pin of
the step support and the hole with the arrow.
Select these
two surfaces
Offset constraint
Use an offset constraint to create a 2mm space between the frame and the step support. As
input surfaces, use the stairs frame outside surface (not the “arrow” side) and the flat surface
on top of the outer flanges on the inside of the support, see the image for clarification. Use the
“Orientation” option to obtain the correct positioning. The assembly should resemble the
picture shown on the next page.
55
Angle constraint
Position the compass on the pin in the hole at the arrow. Select the AE1111-II-B
component from the tree. Use the compass rotation handle to tilt the step. Create an angle
constraint with the step top surface and a surface or plane from the stairs frame as inputs,
with a 45deg value. The angle constraint will make the assembly fully constrained.
Reuse pattern
In assemblies it is very common to
have certain components assembled
more than once. In the Part Design
Workbench patterns can be used to
repeat features without having to
redefine them. In the AE1111-II-08
part, the rectangular pattern feature
is used to create the three extra
holes. Now we can use this pattern
to assemble three extra step
subassemblies. Click the reuse
pattern button in the constraints
toolbar. Keep the default options in
the upper part of the dialog box.
Select the rectangular pattern in the
AE1111-II-04 part as the input
pattern. Select the AE1111-II-B
subassembly from the tree as
component to instantiate. Selecting from the tree assures the complete subassembly is
instantiated instead of just the step or step support.
Change the angle constraint value to 10deg and update the assembly to review the result.
56
Symmetry
Use the symmetry command to generate a second stairs frame, similar to the support in
AE1111-II-B. Use the AE1111-II-03 YZ plane as the symmetry plane. Save the assembly.
57
Assembly AE1111-II-D: Door assembly
AE1111-II-D Door assembly
Open the assembly “AE1111-II-D” from the shared data section. The file is read only, so
make your own copy in your personal account folder.
Three different parts are present in the model tree. The first part, “AE1111-II_SK001” is called
a skeleton part. This kind of part is used in assemblies to give a mutual set of references. A
skeleton part can be introduced instead of creating part to part dependencies, resulting in
complex parent-child relations which can be hard to control. Using the skeleton part
consistently as a reference when new assembly constraints are created, keeps the assembly
structure clear and controllable. In most cases, skeleton parts do not contain solid geometry,
only datum features such as planes, axes and points.
Open the part by using the contextual menu in the tree (right mouse button => open in new
window) and save it to your storage folder.
The second part in the model tree, “AE1111-II_replace_part”, is the rectangular part shown in
the graphic area. In the next step of this assignment you are going to replace this part with
one of your own models. Each part is individually constrained to planes in the skeleton part.
The third part in the tree is the “Symmetry of AE1111-II_replace_part”, this is the result of the
assembly feature “Assembly Symmetry.1”. This part is copied six times and constrained to the
first symmetry part and planes in the skeleton part.
58
Replace Component
Select the “AE1111-II_replace_part.1” from the tree or in the graphics area. After selecting,
click the Replace Component button in the Product Structure Tools toolbar. Use the file
manager to browse to the AE1111-II-05 stiffener part, click “open”. A dialog box will appear
showing the affected constraints. Since we want all instances of the part to be replaced, keep
the “Yes” option under “Do you want to replace all the instances of the selected element?”
As result of this operation, you will see all the “AE1111-II_replace_part” components being
replaced by AE1111-II-05 stiffener parts. The benefit of this command is that both the
geometry and the references for assembly constraints and assembly

features are replaced simultaneously. Using the command causes the
stiffeners to be fully constrained in the assembly. No constraints need to be
redefined. A prerequisite for this is that elements used in the constraint are
present in both replaced and replacement part, e.g. the XY plane.
Update the assembly. When the assembly is updated, the
symmetry part generated by the assembly feature will
automatically change to the symmetry part of the AE1111-II-05
stiffener, this is also a result of using the Replace Component
command.
Now use Replace Component again. Select one of the remaining

rectangular parts. Cancel the next dialog box. In the “Browse”
dialog box, choose “Loaded document”. Select “Symmetry of
AE1111-II-05.CATPart” from the list.
The skeleton part AE1111-II_SK001 contains an axis system. Other
parts that contain axis systems can be constrained by using a
single coincident constraint with both axis systems as inputs. Use the knowledge
from the previous exercises to assemble the following parts:
Undefined Constraint
Unfortunately using the Replace component sometimes breaks the existing constraints when
the elements that were used to constrain the original part can’t be properly matched to the
elements of the replacement part. This can be dealt with by right clicking the constraint, under
“Constraint.## Object”, clicking on “Definition…” and redefining the constraints to repair them.
Another way of dealing with this is to deactivate all the constraints corresponding to these
parts, and replacing them with fix constraints. This only works if the parts are already in the
correct position.
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AE1111-II-07 Door Skin; use a coincident constraint with
both parts axis systems as input. If you have forgotten to create
the axis system in the Door Skin part, please refer to page 32.
AE1111-II-06 Longitudinal Rib; use a surface contact

constraint with the replaced part outer face and the inner face of
the longitudinal rib as inputs. Make sure you select the correct
surfaces of the solids.
Use two coincident constraints. The door skin and stiffener

are both made up of two cylindrical shapes. They can be
constrained with a Coincidence constraint between the axes.
Hovering the mouse over a cylindrical surface will display the axis
while creating coincident constraints. Constrain the two top and bottom axes together to
constrain the stiffener to the door skin.
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AE1111-II-08 Door Liner; use a coincident constraint with both parts axis systems as input.
AE1111-II-11 Door Frame; use a coincident constraint with both parts axis systems as input.
AE1111-II-12 Door Seal; use a coincident constraint with both parts axis systems as input.
AE1111-II-C Foldable Stairs;use three coincident constraints. First the AE1111-II-03 YZ plane
and the AE1111-II_SK001 YZ plane should be aligned. Use a coincident constraint, keep the
orientation “Same”.
Use the right mouse button on the AE1111-II-08 part, choose Hide/Show to hide the Door
Liner. Use the Compass to position the Step Assembly closer to the Longitudinal Rib.
Then, the outer pin of the top step should be aligned with the longitudinal rib hole as depicted.
Finally, one of the bottom step pins should be aligned with a longitudinal rib hole.
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With these three constraints, the stairs are fully
constrained. No degree of freedom should remain
for the parts, with the exception of symmetry parts;
please check this by using the right mouse button
on the components. Choose the *.object line and
“Component Degrees Of Freedom”. The following
message should appear:
Symmetry
Use the symmetry function to create the symmetry part of the Longitudinal Rib, part AE1111-
II-06. Use the right mouse button on the AE1111-II-08 part, choose Hide/Show to show the
Door Liner. Changing the View Mode to Shading with Material should give the following result:
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Drafting
Introduction
We are living in a digital world. Modern production processes are commonly initiated by
programming based on 3D files. It may seem that no human interaction is needed to progress
from CAD data to physical parts.
In the old days, no computers were available for use in design and engineering processes.
Engineers were able to produce high-end solutions for engineering problems, yet they used
hand drawn and calculated data. An essential part of this process is the fact that engineers
throughout the world spoke, and still speak a universal language: the language of engineering
drawings. This is a very useful metaphor to explain some details of engineering drawing: a
language has its grammar. The rules used to produce technical drawings can be seen as the
grammar of engineering drawing. A language has a correct way of spelling. In engineering
drawing, correct representations should be used to indicate certain objects in space. We all
know that incorrect use of spelling or grammar can lead to miscommunication. This also
applies to engineering drawings: use of incorrect line types, projections or dimensioning will
lead to a product that does not comply with the initial idea and or international standards.
Although in the aerospace industry 2D drawings are used less and less, the chance that you
as a professional engineer will have to distil information from such a drawing is close to 100%.
Being able to interpret engineering drawings quickly and correctly will also lead to greater
respect from fellow engineers; you will be seen as professional.
In CATIA V5, the Drafting workbench is used to derive 2D drawings based on 3D models. The
CATIA V5 software includes different standards such as ANSI, JIS and DIN. Drawings can be
generated according to these standards automatically. It might seem CATIA V5 does the work
for you, but beware: without a thorough basic understanding of engineering drawing
conventions it is very well possible to make mistakes. Good understanding of engineering
drawing basics is essential for interpreting engineering drawings.
Using 2D information is still the most common way for an engineer to communicate with other
engineers throughout the world, whether they are tool shop workmen, suppliers, operators,
professors, managers or CEO’s.
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Drawing AE1111-II-04: Stairs Frame
Preparation
Open the AE1111-II-04 part. Invoke the

Drafting workbench (Start => Mechanical
Design => Drafting). In the New Drawing
Creation dialog box choose “Modify”. In
the next dialog, select A2 ISO as Sheet
Style. Select the “Empty Sheet” layout.
Click OK to create the CATDrawing
document. Save the drawing as “AE1111-
II-04”.
Sheet Properties
Go to the Sheet Properties by using the
right mouse button on the “Sheet.1” line in
the model tree. Change the Scale from 1:1 to 1:2. Change the Projection Method to Third
Angle standard (American projection).
View Creation
Front View
To facilitate view creation, you can use the option Window => Tile
Vertically. Create the Front View by clicking the Front View button.
In the AE1111-II-04 Part document window, select a planar face or
a plane. Use the arrows in the upper right corner of the Drawing
document window to change the position if necessary. Click on the
sheet next to the view or in the center of the arrows in the upper
right corner to create the front view.
64
View Properties
Go to the View Properties by using the right
mouse button either on the “Front View” line in
the tree, or on the blue dashed view frame.
Check the “Axis” and “Center Line” Dress-up
boxes.
CATIA V5 will automatically draw the axes and
center lines in the view with these options
checked. Additionally, projection views based on
the front view will inherit the Front View
properties.
The elongated hole is shown with two circle

center marks. Select the right center mark and
drag the white handle while pressing the Ctrl
button on the keyboard as depicted. Repeat this
action with the right hole center mark near the
arrow to make one center line go through all four
holes.
Offset Section View

Create the A-A Section View by clicking the
Offset Section View button in the Sections
toolbar. Position the cursor above the View
origin. Click to create the first point of the
“Callout”. A section callout is the dash-
dotted line with thick ends used to indicate
a section location. Move the cursor down to
position the second Callout point. A plane
is shown in the part document window
indicating the section location in 3D space.
If the Callout is previewed correctly, double
click to exit the Callout definition. Move the
cursor to the left side of the Front View.
The preview of the section is shown; click
to generate the Section View.
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Use the properties menu to
change the view’s scale to 3:1.
Using the right mouse button
clicked on the section view’s
dashed blue view frame,
select View positioning =>
Position Independently of
Reference View. Drag the
view to its desired location on
the sheet. If the option does
not show up, it is already
independent.
Detail View
In the Detail toolbar, click the
Detail View button. Move the
cursor to the arrow and hole
at the right end of the front
view and click to create the
Detail Callout circle. Finish the
circle by clicking again when
the desired size is previewed.
A blue preview of the Detail
View circle is shown; position
the detail on the sheet and click to create the Detail View B.
Elongate the horizontal center line to make it go through the
arrow.
Section view callouts and detail view callouts can be changed

afterwards by double clicking them. If you do so, an environment
similar to the Sketcher workbench is invoked. Callout end points
or center points can be moved by dragging. Buttons are available
for profile replacement and Profile direction inversion.
Offset Section View

Activate the detail view by double clicking either its blue
dashed view frame or its name in the model tree. The
active view can be recognized by the underlined
representation in the tree and the orange color of the
view frame. So to activate a view, double click on its
view frame or its name in the tree. Use the Offset
Section button to create section view C-C. By double
clicking the arrows the image can be flipped.
Isometric View
The Isometric View is created by clicking the Isometric View button
and clicking on the part geometry in the Part document window.
Make sure the position in space is the way you want the view to
appear before view creation. Create the view and change the Scale
in the View properties menu to scale 1:10. Position the view by
dragging the blue dashed view frame to its desired location.
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Sheet Background
In CATIA V5 drawings a distinction is made between ‘Working Views” and the “Sheet
Background". The views created in the last steps are the “Working Views”. All of these views
refer to the geometry of the part. Elements such as the Drawing Frame, Title block and
additional data like the Bill of material (BOM) and notes are placed in the Sheet Background.
The command edit => Sheet Background is selected to create elements in the sheet
background. After the desired elements are created you can switch back to the Working
Views by choosing edit => Working Views. When working on the Sheet Background, the
Working Views can’t be selected and thus cannot be edited. The same applies for
background elements when working in the Working Views.
Frame Creation
The Drawing Frame and Title Block are created by entering the Sheet Background and
clicking the Frame Creation button in the “Drawing” toolbar. Select
‘Drawing_Titleblock_Sample2 from the Frame and Titleblock drop down menu, make sure
“Creation” is selected in the Action field and click OK. Zoom in to the Title Block.
Notice that some fields are filled in automatically, such as “Drawing Number” and “Drawn by”.
The “Drawing Title” field contains a textbox, which might be a little hard to find. Move the
cursor in the field and the textbox will highlight. Enlarge it by dragging one of the handles.
Double click inside the textbox to enter text. Fill in: “Stairs Frame”.
After filling in the field, switch back to the Working Views.
Dimensioning
Dimension the drawing according the example picture. Use the

commands from the Dimensioning toolbar. Use the Right mouse
button during dimension creation to access functionality for
dimension placement.
67
Tips and Tricks
Symmetry symbols can be

added to dimensions using the
Properties command. Use the
right mouse button on the
dimension value, choose
“Properties”. Choose the
“Dimension Texts” tab. Key in a
“=” symbol in the left and right
box under “Associated Texts”.
Once you have added symmetry symbols to a dimension value, you can use the “Copy
Object Format” command to copy symmetry symbols to other dimension values. Select the
dimension without symmetry symbols, click the Copy Object Format button and select the
dimension with symmetry symbols.
The 10 x 75 dimension is a chamfer dimension.

Use the button as indicated in the picture, follow the
instructions in the Prompt Area at the left bottom of the
screen to generate the dimension.
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Drawing AE1111-II-05: Stiffener
Preparation
Open the AE1111-II-05 part. Invoke the Drafting workbench (Start => Mechanical Design =>
Drafting). Choose “Modify” in the New Drawing Creation dialog box. In the next dialog, select
A2 ISO as Sheet Style. Select the “Empty Sheet” layout. Click OK to create the CATDrawing
document. Save the drawing as “AE1111-II-05”.
Sheet Properties
Go to the Sheet Properties by using the right mouse button on the “Sheet.1” line in the model
tree. Change the Projection Method to Third Angle standard.
View Creation
Front View
Create the Front View by clicking the Front View
button. In the AE1111-II-05 Part document window,
select a planar face or a plane. Use the arrows in the
upper right corner of the Drawing document window
to change the position if necessary. Click on the
sheet next to the view or in the center of the arrows
in the upper right corner to create the front view.
View Properties
Go to the View Properties by using the right mouse button either on the “Front View” line in
the tree, or on the blue dashed view frame. Check the “Axis” and “Center Line” Dress-up
boxes.
Projection Views
Use the Projection View button to
create the Bottom view and the
Right view. Position the views on
the sheet; the view will be created at
the left mouse button click location.
Moving the views by dragging the
view frame is possible afterwards.
Notice the projection views moving
along when the front view is
repositioned. Change the Bottom
View properties; check the “Hidden
Lines” box to make hidden geometry visible in the view.
Unfolded View
The creation of an unfolded view is similar to the
creation of the Front View. Simply click the button,
select a planar face or plane in the part document
window and position the view on the sheet with the
arrows and the mouse. Clicking next to the view or
in the middle of the arrows will generate the view.
Just like the unfolded state in 3D in the Sheet
Metal workbench, the unfolded view represents the metal blank before the part is processed
to its final shape. Change the View properties; check the “Axis” and “Center Line” Dress-up
boxes.
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Isometric View
The Isometric View is created by clicking the Isometric View
button and clicking on the part geometry in the Part document
window. Make sure the position in space is the way you want the
view to appear before view creation. Create the view and
change the Scale in the View properties menu to scale 1:2.
Position the view by dragging the blue dashed view frame to its
desired location.
Offset Section View

Make sure the Front View is the
active view in the drawing. Create
the A-A Section View by clicking the
Offset Section View button in the
Sections toolbar. Position the cursor
exactly above the right lightening
hole in the Front View. A
coincidence symbol will show up to
indicate the coincidence with the
vertical circle center line. Click to
create the first point of the Callout.
Move the cursor down to position
the second Callout point. A plane is
shown in the part document window,
indicating the section location in 3D space. If the Callout is previewed correctly,
double click to exit the Callout definition. Move the cursor to the right side of the
Front View. The preview of the section is shown; if the location is correct click to
generate the Section View.
Detail View
Make sure the Front View is still active. In the Detail toolbar, click the Detail View
button. Move the cursor to the right bottom of the front view and click to create the
Detail Callout circle. Finish the circle by clicking again when the desired size is
previewed. Position the detail on the sheet and click to create the Detail View B.
70
Sheet Background
Frame Creation
Similar to the last assignment, create a frame and title block. Select
‘Drawing_Titleblock_Sample2 from the Frame and Title block drop down menu, make sure
“Creation” is selected in the Action field and click OK. Zoom in to the Title Block. At the
Drawing Title field fill in: “STIFFENER”.
After filling in the field, switch back to the Working Views.
Dimensioning
Dimension the drawing according the example picture. Use the Right mouse button during
dimension creation to access functionality for dimension placement.
After creating the dimensions, select them and reduce the accuracy to 0,10000mm using the
function in the Dimension Properties toolbar.
Tolerances
Production techniques are used when a part is produced. For example, to produce a curtain
rail, aluminium can be extruded and cut off at a certain length. In the engineering drawing for
such a curtain rail, the length of the rail will be indicated by a dimension. From your own
experience you can tell it is impossible to make the length exactly the desired dimension. In
all cases, the rail will either be a little bit longer or shorter than the desired exact value. For
the functionality of this rail, this error is absolutely no problem. In engineering drawings such
errors are taken into account in a concept called tolerances. An engineer knows the function
of a dimensioned part. He or she also knows the inaccuracy that comes with production
techniques. To be sure the part will be able to perform its function the engineer applies a
tolerance to functional dimensions on a drawing. Generally, the more exact the dimensions,
the more expensive a part will be.
71
In engineering drawings tolerances are indicated by values next to the main dimension. In the
example above, the value 248.5mm has a negative tolerance. The tolerance value means
that when the parts actual dimensions are between 248,3mm and 248,4mm, the part will
perform its function. The functional background of this tolerance setting is that the part is
assembled between two other parts: if the dimension is bigger than the main dimension
shown, the longitudinal rib will be closer to the foldable stairs, with the danger of creating a
space that is not large enough to assemble the stairs in.
Tool shop workers will always ask for tolerances. Often accuracy costs money, so be sure
you think about this aspect before showing a drawing to a tool shop worker.
To create the dimension

tolerances as shown in the
example, invoke the dimension
properties with the right mouse
button. Choose properties.
Access the tolerance tab, use
“DIN_NUM2” tolerance type. The
tolerance values can be keyed in
at the “Upper value” and “Lower
value” fields.
Tips and Tricks
Similar to the symmetry

symbols, tolerances can be
copied using the “Copy Object
Format” command. Select the
dimension without tolerance, click
the Copy Object Format button
and select the dimension with the
tolerance.
The ႇ50 dimension of the lightening hole in Section View A-A can be generated using the
“Intersection point detection” option in the
“Tools Palette” Toolbar. Click the button
on the right in the toolbar as indicated in
the picture during the creation of the
dimension.
72
e
73
Drawing AE1111-II-D: Door assembly
Preparation
Open the AE1111-II-D assembly. Invoke the Drafting workbench (Start => Mechanical Design
=> Drafting). In the New Drawing Creation dialog box choose “Modify”. In the next dialog,
select A1 ISO as Sheet Style. Select the “Empty Sheet” layout. Click OK to create the
CATDrawing document. Save the drawing as “AE1111-II-D”.
Sheet Properties
Go to the Sheet Properties by using the
right mouse button on the “Sheet.1” line
in the model tree. Change the scale to
1:10. Change the Projection Method to
Third Angle standard.
View Creation
Create the following views: Front, Top
and Right view. As the front view
reference, use one of the skeleton parts
principal planes. In the view properties
menu, choose “Axis” and “Center Line”.
Create section views A-A and B-B.
Isometric views
In the AE1111-II-D CATProduct window,
choose the isometric view button from
the View toolbar. Switch to the Drawing
document and generate the first
Isometric view. Go back to the Part
document and right click the red square
in the compass. Select the “Edit” option from the contextual menu. Fill in a 180 value at the
field under “Rotation increment”, Along W.
Click on one of the rotation buttons next
to this field and watch the model being
rotated 180 degrees exactly. Now, in the
Drawing document, the second Isometric
view can be generated based on the new
model position in space. Change the 180
degree angle value back to 0 before
closing the dialog box.
74
Exploded View
In engineering drawings, a common way to show all components in a product is to use the
exploded view. In such a drawing all parts are shown in space, separated by distance, yet
showing the relationship between the various parts. Parts that are covered by other parts in
the final assembly can be revealed in the exploded view, parts can be numbered, e.g. to refer
to the bill of material. An exploded view of the door assembly will be made in this exercise.
Enhanced scene
To make an exploded view, in the CATProduct file an “enhanced scene” should be created.
An enhanced scene is a way of showing the assembly in another state, without changing the
product structure or product relations. The functionality of the enhanced scene can be very
useful to review products in different modes such as opened-closed, collapsed-expanded or
in this case an exploded view.
First, make sure the stair steps are in vertical position. Change the angle constraint in the
AE1111-II-C assembly if necessary. To create the enhanced scene, click the Enhanced
Scene button. Uncheck the “Automatic naming” box and fill in “exploded view”. Click OK. A
warning will come up, read and close.
Explode
Now the enhanced scene has been created, the position of the assembly components can be
changed without affecting the assembly constraints. Explode functionality is available in the
enhanced scene environment. Feel free to experiment with its function, but in this assignment
we will use the compass to position the parts in space. In this way we have more control over
the positioning of components and the required result can be obtained more quickly.
Drag the compass to one of the stairs steps. Multi-select all AE1111-II-05 parts in the tree.
Now, select the v/X axis of the compass and drag the AE1111-II-05 parts to the right. Next,
multi-select all symmetry parts of the stiffener and use the v/X axis of the compass to move
them to the left.
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Now, select the AE1111-II-07 part and use the compass w axis to position it backwards.
Repeat this step for the other components until all parts have some distance between them.
Some parts can be repositioned to the front or back and other parts to the left or right. Before
leaving the enhanced scene, make sure all parts in the view are visible. The goal is to have a
compact but complete picture.
A button similar to the “Exit Sketch” button is available to exit the scene. In the model tree a
section "Applications" is available. Scenes are stored under this section. The exploded view
can be accessed by double clicking in the tree.
To make the exploded view appear on the drawing, select window => tile vertically. In the
CATDrawing window, from the projections toolbar, select Isometric View. Now, instead of
selecting geometry, select the “exploded view” line in the assembly model tree. Click on a
geometrical element, like a face or plane in the model after selecting this enhanced scene.
Now, the exploded view is generated.
76
Balloons
Generate Numbering
Numbering of the parts needs to be generated in the assembly to have balloons with
numbers present in the exploded view. Go to the AE1111-II-D CATProduct window and click
the “Generate Numbering” button.
Select the upper line in the model
tree (AE1111-II-D). Keep the
default options, Mode: Integer and
Existing numbers: Replace. In the
CATDrawing window, make sure
the exploded view is the active
view. Select Insert => Generation
=> Balloon generation. Reposition
the balloons to tidy up the lay-out.
Sheet Background
Frame and Title Block
Switch to the sheet background and generate the frame and title block. Use sample 2. Fill in
“Aircraft Door with Foldable Steps” in the Drawing Title field.
Bill of Material (BOM)

To create the BOM, first switch back to the assembly document. Select Analyze => Bill of
Material. Click the “Define formats” button. In the next dialog box, select “Number” from the
Hidden properties in the right column of the “Properties for the Bill of Material” and bring it to
the displayed properties by using the arrow button. Reorder “Number” at the top of the list by
selecting it, clicking the reorder button and selecting “Quantity”. Click “OK” to close the dialog,
click “OK” in the “Bill Of Material” dialog. Switch to the CATDrawing again. Make sure you are
still working on the sheet background. Select Insert => Drawing => Bill of Material. Click on
the top of the tree in the CATProduct window and click on the left top corner of the sheet in
the CATDrawing window afterwards. Now, the BOM is generated. Reposition the tables to the
desired location.
The nomenclature of the parts is shown in the BOM. Check whether all parts, except for
symmetry parts, have correct nomenclature. If not, change the nomenclature in the part files.
Do not alter the BOM manually, but update the drawing after correcting the nomenclature in
the parts. It might be necessary to reposition the BOM again after an update.
77
78
Kinematics
Introduction
You have now covered the main CATIA V5 basics since you have modelled parts and
assemblies and created drawings. As stated in the introduction of this reader, CATIA V5 is not
just a drawing tool. Higher level engineering results can be obtained using workbenches like
the Generative Structural Analysis for finite element calculations, the Human Builder for a
review of the ergonomic aspects of a product, or the DMU Kinematics workbench. DMU is the
abbreviation of Digital Mock-up. This term implies the creation of a product in a virtual
environment; the geometry of a design can be created and the functionality of products can
be simulated. Problems can be identified prior to tool production and adjustments can be
implemented in a design before physical parts are made. In this way errors can be prevented
resulting in first-time-right production, thus reducing the need for costly intensive physical
testing.
We will use the DMU Kinematics workbench in this part of the course. Tools like clash
detection and swept volume are present in the workbench. We will use the kinematics
workbench to simulate the foldable stair mechanism. The door assembly will be placed in a
realistic context and joints and commands will be used to make the door open and close.
Foldable stair mechanism

From the shared directory, open the file “AE1111-II-REF.CATProduct”.
The model contains a fuselage section, which will be the reference for the foldable stairs
mechanism. Make sure the Assembly Design workbench is active. Using “Save as”, save the
file to your storage directory under the name “AE1111-II-FINAL.CATProduct”.
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Assemble the actuator to the fuselage
Assemble the AE1111-II-A
CATProduct. Double click the AE1111-
II-A line in the tree to make the
actuator assembly active. Change the
AE1111-II-A Assembly’s Offset
constraint value to 1905mm by double
clicking on the constraint in the tree.
Update the assembly.
Double click on the AE1111-II-REF

line in the tree to make the main
assembly active. Use a coincident
constraint to align the actuator base to
the yellow center line next to the door
opening.
Assemble the hinge bracket to the actuator

Assemble the AE1111-II-09 part. Constrain the hinge bracket to the actuator rod. Use a
coincident constraint to align the holes. Use an offset constraint to position the flange. Use a
1.5mm value from the inside face of the actuator rod. Use a 90 degree angle constraint to
position the hinge bracket perpendicular to the actuator rod.
Assemble the door to the fuselage

Open the “AE1111-II-D.CATProduct” file. Save the file under the new name “AE1111-II-
D4mech”. Delete the AE1111-II-C subassembly from the tree (the stairs will be reassembled
later using the kinematics workbench since it will move when the door moves). Check the
“Delete all children” option to delete the component constraints as well. Save the file and
assemble it to the AE1111-II-FINAL.CATProduct.
Drag the compass to the yellow center line at the door hinge location. From the tree, select
the AE1111-II-D subassembly. Use the compass to rotate the door. Translate the door to
create a small distance to the fuselage section. If you cannot see the hinge on the door, then
the in work object of part AE1111-II-11 in assembly AE1111-II-D is set to Body.2. To resolve
this, expand the assembly D, and part AE1111-II-11, double click on the part to make it active
and set the PartBody to the in work object. Now double click the AE1111-II-REF to make it
active again.
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Use a contact constraint, see the left picture below, two faces selected that should be in
contact, and a coincident constraint on the hinge geometry to position the door.
Assemble the hinge bracket to the door

Use a coincident constraint and a contact constraint to position the hinge bracket relative to
the door. Use the flanges closest to the fuselage. Make sure to rotate the actuator and hinge
bracket assembly so that it is close to the desired position (see picture below). Other ways it
might update to a wrong solution (the door is to wide open). If this does happen, undo the
coincidence constraint and rotate the door assembly and/or the hinge bracket and actuator
until they are close to the desired position.
Create the first phase of the mechanism

Now the components are in the correct position to build the first phase of the mechanism. In
kinematics it is important to start with the different parts or subassemblies in the right position.
This position is the initial position from which the kinematics are defined. Next, the kinematic
counterpart to the assembly constraints, the Mechanism joints will be defined. Assembly
constraints are generated during this process that are linked to the mechanism joints.
In the first phase of the mechanism the door will not contain the stairs assembly. The movable
parts are the complete door assembly with respect to the fuselage and the actuator.
To prepare the assembly for this, select the AE1111-II-01 and AE1111-II-02 parts from the
tree and use copy in the contextual menu. With the cursor on the top line of the tree, use
paste. Now, delete the AE1111-II-A subassembly from the tree. Choose the “Delete all
children” option and click “No" in the warning message. Delete all assembly constraints
except for the Fix.1 and FixTogether.1 constraints. The deletion of the constraints in the last
step prevents over-constraining the assembly.
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Kinematics
Enter the DMU Kinematics workbench by choosing Start => Digital Mockup =>
DMU Kinematics.
Cylindrical Joint
Use the fly-out on the Revolute Joint to access the other Kinematic Joints. Select the
Cylindrical Joint. In the dialog box, click the “New Mechanism” button. Rename to “Foldable
stair mechanism”. Select the actuator rod as first line and the actuator base as second line.
Check the “Length driven” option. Click OK to create the joint.
In the tree, unfold the “Applications”, “Mechanisms” and “Foldable stairs mechanism” lines. A
command is created as result of the length driven option. Double click the Cylindrical.1 Joint
st st
to access the Joint Edition dialog. Set the 1 lower limit to -885mm and the 1 upper limit to
0mm.
Rigid Joint
Create a rigid joint by using the Rigid Joint button.
Select the actuator rod and the hinge bracket.
Revolute Joint
Create a revolute joint. Use the
actuator base head and the yellow
center line next to the door as inputs.
Select both parts YZ planes as Plane
inputs. Select the “Offset” option. A
value of -425mm should appear.
82
Revolute Joint
Use the compass to create some distance
between the door and the fuselage section.
Create a Revolute Joint with the hinge
geometry as input. Use two hinge cylinder
end faces that have to be in contact as plane
inputs.
Revolute Joint
Create another revolute joint with the hinge
bracket cylinder and the flange on the
longitudinal rib as line inputs. Use two planar
surfaces as plane inputs and check the
“Offset” option.
Fixed Part
Use the “Fixed Part” button on the fuselage
section. A message will come up:
Click OK.
Simulation with Commands

Use the “Simulation with Commands” button
to open the dialog box. Check the “On
request” option and move the slider
completely to the left to change the command value to -885mm.
Press the play button to review the simulation. Exit the dialog
with the door in opened position (0mm).
Create the second phase of the mechanism

In this phase the stairs will be added to the door. The steps will
rotate within the door when it is closed and outwards when the
door is opened so they can be used as stairs. Make sure that the
previous simulation is in the 0mm position, since this will be the
initial position for this phase of the mechanism. Also make sure
to save the file at this point to make it easier to recover if
something goes wrong in the next steps.
Open the AE1111-II-C.CATProduct. Expand the model tree and

select all components except for the symmetry part. Use the right
mouse button to copy the parts (or Ctrl-C). Use the right mouse
button on the top line of the AE1111-II-FINAL assembly model
tree and paste the parts into the assembly. Close the AE1111-II-
C assembly without saving.
83
Revolute Joints
Use the compass to move the
Stairs frame from the steps, to
allow you to select the hole
geometry. For all four steps,
create a revolute joint at every
pin and hole combination. Use
faces as in the picture for plane
inputs. Check the “Offset” option
and set the value to 2mm. click
ok to update the assembly and
mechanism.
If you made a mistake making

the offsets, you can update the
offset values (and of course
other constraints) from the
model tree. To do so, expand
the tree to access the Joints
definitions. Double click the
constraint to change the
definition.
Use the compass to move the top step close to the top
position in the door assembly (and simultaneously the
other steps and the stairs frame by multi selecting
them holding Ctrl). In the tree, expand the AE1111-II-D
assembly. Use the right mouse button on AE1111-II-08
to hide the part. Now, the inside plane of the
longitudinal rib can be selected. Create a revolute joint
with the outside pin of the step support and the flanged
hole on the longitudinal rib, closest to the door hinge
as line inputs. Use the outside faces of the step
support and the inside face of the longitudinal rib as
plane inputs. Check the offset function and key in a
1.5mm value.
84
Assembly design
Switch back to assembly design
again. Create a coincident constraint
with the “4mech” point in the hinge
bracket (AE1111-II-09) and the
“4mech” plane in the stairs frame
(AE1111-II-04). Update the
assembly.
Point Surface Joint

Switch back to DMU Kinematics and
define a point surface point with the
4mech point and plane as inputs.
Revolute Joints
Create three more revolute joints,
similar to the last one for the other
steps. Use similar inputs and values.
After creating the last one, the
mechanism can be simulated again.
Update positions
Press the “Update positions” button to make sure that all the constraints are updated to the
current position of the assembly. Make sure the “Take current positions for rigid joints” check
box is unchecked.
Simulation with Commands

Use the “Simulation with Commands” button to open the dialog box. Check the “On request”
option and move the slider completely to the left to change the command value to -885mm.
Press the play button to review the simulation.
Close the dialog box. The fixed part can be found in the model tree under “Mechanisms”.
Delete the part from the tree and use the Fixed Part button to make the stairs frame the fixed
part. The mechanism can be simulated again. Review the change by using the Simulation
with command
function again.
85
Own Design
Three assignments are described in the next part of this reader. Each student must choose to
do one of these three assignments to complete the AE1111-II course.
General rules for the assignment

In your assignment you will have the chance to use your skills with CATIA V5 to model your
own design. The following criteria should be met:
x you must model at least three separate parts. Context part(s) are available in the
shared section (X:\ disk)
x these parts should be used in an assembly with the context parts
x one assembly drawing showing the final design configuration and the context parts
should be present
x one of the designed parts must be documented in a detail drawing
x a higher mark will be given if a working mechanism is incorporated in your design
x your design must be documented in a PowerPoint file, note: you can use the template
from the shared section
Own Design 1: AE1111-II-final_A: Space Shuttle Robotic Arm
Assignment context
Payload bay doors are present in the fuselage middle section of the Space Shuttle Discovery.
A robotic arm is used to manipulate objects in the payload area. This arm should be able to
cover the payload area in a smart way, weight should be as low as possible, the construction
should be compact, the chance of failure should be minimal, so the number of hinges and
pivots should be limited.
The assignment
Design a robotic arm for the Space Shuttle Payload bay which can cover the total bay area.
Use the available fuselage mock-up (1111-II_space_shuttle_ref.CATPart) in the storage area
as the context part; this should also be your first assembled part (fix constraint) in your
CATProduct file.
86
Own Design 2: AE1111-II-final_B: Deployable Solar Array
Assignment context
The Delfi CubeSats, developed by MSc students at the Faculty of Aerospace, require
electrical power to operate their systems. The electrical power is generated by solar cells,
which are body mounted or located on deployable solar panels. A deployable panel needs a
hinge, and, as can be seen from both Delfi satellite pictures, the angle of deployment may
vary. The configurations of the solar panels and the deployment angles depend on the
mission goals of the satellite.
The assignment
Design a hinge for the deployment of a solar panel of a Delfi like CubeSat (body dimensions:
100X100X340 mm) from the short side of the body. The following constraints apply:
x width of the rectangular solar panels is 65 mm and the maximum length is 310 mm,
the panels are made of Carbon Fibre Reinforced Plastic and have a thickness of 1.4
mm, while the cells on top are 1.2 mm thick, the adhesive glue used is 0.2 mm thick
x when stowed against the sidewall, the outer surface of the panel (i.e. the cells) should
remain within 6.5 mm from the sidewall of the CubeSat
x the maximum useable width on the side of the CubeSat body is 74 mm, i.e. the 13
mm at the corners of the satellite are used for the Hold-Down and Release
Mechanism of the solar panels and the interface with the launch canister
x you may choose your own fixed angle of deployment in this assignment, it shall be
chosen between 30 and 90 degrees with respect to the long side of the satellite
x when the solar panel is released by the Hold-Down and Release Mechanism *) (not
part of this assignment) it should swing out to the chosen (fixed) deployment angle;
once deployed the panel shall stay in that position
x the presence of electrical cabling between the solar panel and the body should be
taken into account
x the attachment of the hinge is on the short side of the body on either side of the edge
x the solar panel must always remain detachable during the assembly, integration and
test period: you must also take into account the design, the use and volume of tools
needed for installation
*)
More information on the CubeSat programs of the Faculty of Aerospace can be obtained at the
chair of Space Systems Engineering (J. Bouwmeester, room 8.19 of high-rise building).
87
Own Design 3: AE1111-II-final_C: Dropped Hinge Flap
Mechanism
Assignment context
A common feature of modern transport aircraft is the high-lift system, which boosts the wing’s
maximum lift generating capability for take-off and landing. These high-lift systems are
comprised of slats and flaps.
Over the years, many different layouts of flaps and slats have been investigated and
incorporated into actual aircraft designs. An increase in high-lift system complexity can be
seen from WWII up to the 1970’s, whereby the simple plane flap mechanisms of propeller-
driven bombers gradually evolved into the complex triple-slotted fowler flap of the Boeing 747.
Since then, high-lift systems have been designed to be more simple and, hence, cheaper to
produce and maintain. An example of this trend is seen in the projected single slotted flaps
used for the Boeing 787 and Airbus A350.
The kinematics of the extending flap elements should be kept as simple as possible in order
to reduce the complexity of high-lift systems. In many modern airliners complex guide tracks
can be observed that ensure that the flap elements extend and rotate according to a carefully
determined schedule. These guide tracks are usually heavy, and expensive. Therefore, the
designers of the above-mentioned aircraft types have readopted the old-fashioned dropped
hinge mechanism.
There are two very important

parameters in the aerodynamic
design optimization of the flap-
mechanism: the flap-element’s
gap-size and overhang with
respect to the main wing
element. These parameters are
indicated in the figure below:
88
The lift characteristics of the flapped airfoil-section seem to be very sensitive to a change in
these parameters, a change of only a few tenths of a percent can have a significant influence.
A dangerous result of an incorrect gap-size and overhang, is a hysteresis in the lift
characteristic of the airfoil. This hysteresis manifests when the airfoil experiences an increase
in angle-of-attack past its critical value. When, from this stalled condition, the angle-of-attack
is reduced to below the critical value, the airfoil does not un-stall immediately, it remains
stalled. The airfoil regains it’s original lifting capability only when the angle-of-attack is
reduced considerably below the critical value.
An illustration of the effect of gap-size and overhang on a flapped airfoil’s characteristics is
given in the following figure:
Hysteresis is highly dangerous: the consequences of hysteresis are not difficult to picture if a
pilot needs to correct a stalled aircraft with flaps extended, at low altitude, e.g. when taking off
or landing.
The assignment
For this assignment you are provided with predefined parts of a wing-surface and a flap-
element. Your task is to design a dropped-hinge mechanism that connects the wing and flap-
surfaces. In the retracted state the flap element should be flush with the main wing-element.
In the extended state, the flap should be rotated over an angle of 40 degrees and should be
positioned in such a fashion that the gap-size is 1,2 % of the retracted wing’s chord and that
the overhang is 1 % of this chord.
The mechanism should be placed at both sides of
the flap to ensure a rigid connection.
89
Deliverables for all assignments
To understand what is expected from you in the own design phase, please read the following
summarized requirements:
One of the three assignments must be chosen. Several digital files need to be produced for
the assignment. All files need to be present in your storage directory, in a subfolder called
“own design”. You have to use the available context files in your design.
x Part files (3): at least three files with name and nomenclature should be present in
the subfolder. Sketches should be fully constrained in the files. The context files do
not count as own design files, so next to the context files at least three part files
should be made.
x Assembly (1): the CATProduct file needs to be present in the directory with name
and nomenclature. Don’t forget to use a fix constraint to prevent your design from
“floating in space”.
x Drawings (2): one assembly drawing containing views, BOM, Balloons and fame/Title
block should be present. One of the part files needs to be documented in a detail
drawing. A sufficient amount of views should be present, i.e. at least the minimum
required to document the part fully. Use at least one section view at a logical location.
Detail views can be used if needed.
x Rendering: a rendering of your own design including the context models should be
made.
x Powerpoint: a PowerPoint file is available in the shared area
(1107_own_design_template.ppt). Review the file and save a copy to your storage
directory. Follow the instructions in the PowerPoint file.
Grading
All Part Design, Assembly Design and Drafting assignments should be complete and correct.
If you do not meet this requirement, you fail the course. The Kinematics assignment will give
you a bonus: one full point will be added to your CATIA grade if you finish the assignment
successfully. Your Own Design work will be graded. The Own Design deliverables should be
complete in order to receive a sufficient grade! The focus in this course in on CATIA. This
means that you should come up with a complete and good set of deliverables rather than a
brilliant design solution. For this course you won’t be penalised for design mistakes, but your
CATIA files have to be good.
x Make sure your sketches are ISO-constrained
x Make sure to use a fix constraint in your assembly; subassemblies should also have a
fix constraint
x Make sure your 2D drawings comply with the common conventions for technical
drawings
x If you have the time, try to incorporate a kinematics mechanism in your own design
Timeframe
Two CATIA V5 sessions are available for this assignment. Files can only be accessed during
practical hours. Since this is a limited amount of time, try to limit the complexity of your design
to something you truly believe you can achieve.
90
Appendix: Model trees
91
92
Appendix: 2D drawings
AE1111-II-01
AE1111-II-02
93
AE1111-II-03
AE1111-II-06
94
AE1111-II-07
AE1111-II-08
95
AE1111-II-09
AE1111-II-12
96
AE1111-II-10
97

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Reader AE1111-II

Ing. E. J. van den Bos

Ing. E. J. van den Bos

Production method information:

English editor: Miranda Aldham-Breary, M.Sc. PGCE

Thank you Leonid Pavlov for providing me with feedback from a

Production method information

The Part Design workbench

General Working Method

Example: for Part AE1111-II-01, follow the next steps:

Geometrical sets can be used to

After clicking OK, save the file to your

The CATIA V5 file extensions you will encounter are:

Now the workbench is automatically switched to the “Sketcher workbench”. The

sketching easier. If you did close the toolbar, select View

Another feature that can be found in the Sketch tools is the

Navigating the model tree

Use Dimensional constraints:

Check the Sketch by using the “Sketch Solving Status” command:

Alternatively, the “Apply Material” button can be

Application of material is useful for analytical

30 All materials can be machined,

Sketch.2 Control of this heat as well as the

by clicking on the rectangle surface,

Machining process: Milling

Parts made by turning

Examples of machined parts

J. Sinke, July 2009.

For the second section, the circle used for the

Press the preview button. An update error is displayed; more data is

The last action to be performed to make the feature

The pulling direction deter-

EdgeFillet.1: select the edge indicated at the picture and use a

EdgeFillet.2: select the edge

EdgeFillet.3: for the third

If you do not use this sequence of features the resulting

The Profile sketch feature makes sketching a lot faster since 5

Start this sketch by drawing the axis.

The Generative Sheet Metal Design Workbench

Sheet Metal Parameters

It could happen that by trimming the

The process is typical for the aerospace

Start with the long sides; use the “Propagate”

Figure 3. Diversity of parts that can be made

The rubber forming process enables us to

Figure 5. Wing ribs made of FRTP using the

J. Sinke, May 2009

Then click on the surface to create the

Sketch.1 & Sketch.2

The second reference sketch is

Create two extra points on the axis;

Flange.1 t/m Flange.7

Generative Shape Design Workbench (GSD)

In the next dialog, change the

Generative Shape Design Workbench (GSD)

Change the horizontal line to become a

Resin Injection Moulding

J. Sinke, June 2009

Linked Copy: Surface.1

Generative Shape Design Workbench

Notice the following items:

A schematic overview of an injection

The principle of injection moulding for