Catia Car Design (Audi R8)

CATIA V5R19 - surface modeling Rebuild Audi R8
www.dicksonsham.com
CATIA V5 Surface-modeling
(Tutorial 8- Rebuild Audi R8)
Not For Commercial Use

Surface-modeling Design with a Master Model Design in Context
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Version 1a- Oct 2010 Non-Commercial Use Written by Dickson Sham
www.dicksonsham.com
Design Intent
Hard fillet Hard fillet PictureSource: www.audi.com/r8
Fillet disappears
Fillet disappears
soft fillet Hard fillet
Grab photos from internet (in different views)
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Wheelbase = 2650 Length = 4431 Width, Max w/o mirrors = 1904 Height = 1249 Tread Width, Front = 1632 Tread Width, Rear = 1595
Front Wheel Size (in) = 19 x 8.5 Rear Wheel Size (in) = 19x 11.0 Front Tire Size = P235/ 35R19 Rear Tire Size = P305 / 30R19
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Surface-modeling
Tutorial 8A
Insert 2d pictures and reposition them on offset planes Create 3D control curves
Design with a Master model
Tutorial 8B,C, D
Create the front body of the master model Create the middle body of the master model Create the rear body of the master model Create parting surfaces
Tutorial 8E
Split the finished (master) model into separate parts Build more details on each part
Tutorial 8F
Reassemble them together
Please be reminded that this series of tutorials is designed to demonstrate a design approach with CATIA, rather than the command itself.
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Tutorial 8A
Create a new project folder (e.g. C:\Car_R8)
Pic1.jpg Pic2.jpg
Before Start: http://models.audiusa.com/r8 Crop the picture (972.jpg) into two jpeg files in a square size (just extracting four views: front, left, top & back) Save the files into the project folder
Start CATIA File/New/ Part DO NOT SELECT Hybrid Design Switch Workbench to Generative Shape Design Insert a geometrical set reference Create 4 offset planes
3500mm 6000mm 3500mm
3500mm
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Tutorial 8A
Create 4 Extruded Surfaces on offset planes (4431mm x 1249mm , start from origin) (2000mm x 1249mm , symmetric) (2000mm x 1249mm , symmetric) (2000mm x 4431mm , start from origin) Apply any material onto each surface, then change the texture to our prepared jpeg files (pic1. jpg or pic2. jpg) Scale & Position the image to match the surfaces size 4431mm 2000mm
1
1249mm 4431mm
1249mm
2000mm
2
2000mm
1249mm
Make them semi-transparent Set the Geometrical set Reference to Unpickable A- 6

Non-Commercial Use Written by Dickson Sham
Version 1a- Oct 2010
www.dicksonsham.com
Tutorial 8A

Switch workbench to Shape/ Freestyle Insert a NEW geometrical set control_curves Set Lock Privileged Plane Orientation Parallel to Screen on compass Create some 3d curves (left side only) No curve blending or trimming Thicken the curves and change color to PINK
Drag a control point to modify the spline
Just create the left

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Version 1a- Oct 2010 Non-Commercial Use
Use minimum number of control points to create a spline

Written by Dickson Sham
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Tutorial 8A
Total 19 curves
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Front Body
(master)

Tutorial 8B
Switch workbench to Generative Shape Design Insert a NEW geometrical set Front_body Make a point on curve Make an point on the neighbor curve Connect curve (curvature continuous, trim elements) Adjust the points to get a smooth trimmed curve Complete the above steps to make two more trimmed curves (as shown)
Result
Create an offset plane (Reference YZ plane, Offset 1495mm) Split the trimmed curve into two Offset plane A- 9
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Front Body
(master)

Tutorial 8B
Create an offset plane from the bottom (Reference xy plane, Offset 232mm) Split the curve by the plane (to remove the bottom portion) Split another curve (to remove the bottom portion)
split
Symmetry Curve
3d spline
Mirror the curve Create a 3d spline (linking 3 endpoints) Create another 3d spline
Create a multi-sections surface
3d spline
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Front Body
(master)
Tutorial 8B
Create a sketch (on XZ plane, right view) (three arcs, tangency continuous)
Create another sketch (YZ plane, front view)

Draw a spline
Create a Combined curve
Combine curves
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Tutorial 8B
Create a Extremum Point on top of combined curve Create a plane (Reference: Yz plane, Point: Extremum point) Create a point on 3d curve Create a point on 3d curve Create a Connect curve (trim elements) Create a sketch on plane (a line, an arc, then fillet) Create another sketch on the offset plane (an arc) Create a multi-sections surface (Coupling Control (optional))
Connect curve
Extremum point
Coincident with the 3d curve
sketch
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Tutorial 8B
Create an extruded surface from a 3d curve (Direction: xy plane; dimension: 50mm)
Create a Swept surface

Profile type: Circle Subtype: 2 guides and tangency surface Swept surface
Create a Blend Surface

Define first curve, first support, second curve Select Curvature Continuity for first support
Join the Swept surface & the Blend Surface
Blend surface
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Tutorial 8B
Create a sketch on XZ plane Project the sketch on the Join Surface (Direction: XZ plane) Split the surface by the projected curve
Create an offset plane (Reference: Xy plane, Point: endpoint ) point Create a point on the combined curve Create another point on the projected curve point
Create two split curves Create a blend surface

plane
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Tutorial 8B
Create a Connect curve (Curvature Continuous at both ends)
Create a point on the edge Create a boundary curve Create a multi-sections surface (2 sections, 2 tangent faces, 1 guide)
Create a Parallel Curve (offset 70mm, upward)

Point
Multi-sections surface
Boundary curve

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Tutorial 8B
Project the parallel curve on the multi-sections surface Split the surface by the projected curve
Create a Fill Surface (Curvature continuous) (Check the resultant surface; if not smooth, modify the corresponding curves/sketches)
Fill surface
Create an offset plane Reference: Yz plane, offset = 1500mm
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Tutorial 8B
Join surfaces Split the join surface into Two (by the offset plane) (Keep both sides)
Split the resultant curve into Two (by the offset plane)
Keep both Create a line (point point)
line
Keep both
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Tutorial 8B
Create a swept surface
Profile : Line Guide Curve: Split Curve Surface: Multi-sections Surface
Multi-sections Surface
Line
Split Curve
Create a boundary curve Create a swept surface

Profile : Line Guide Curve: Boundary Curve Surface: Split Surface
Line
Boundary Curve
Split Surface
Create a blend surface

tangent continuous on both sides tension 0.8, 1.0
Tension 0.8
Tension 1.0
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Tutorial 8B
Create surface-surface fillets (R25mm) twice

Extract two edges (tangency continuity)
fillet
Split the fillet surface into THREE
1 3 2
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Tutorial 8B
Create a sketch (on Yz plane)
Draw a straight line Projected curves
Project the sketch onto the two split surfaces
Create a connect curve (Tangency Continuity on both ends)
Projected curves Projected curves
Connect Curve
(Front view)
Connect Curve
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(Top view)
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Tutorial 8B
Create a sketch (on Xy plane)
Draw a straight line
Project the sketch onto the middle split surface Split the surface by the projected curve
Create a connect curve

Curvature Continuity at both ends Tension 0.5 at both ends
Connect curve
tangent
Create a multi-sections surfaces

3 sections & 2 guides Tangent to surfaces tangent
tangent
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Tutorial 8B
Split surface by XZ plane Join surfaces
Join surfaces
Create a new plane (offset 20mm from the existing plane) Create a boundary curve Old Project it onto the offset plane Parallel curve by 20mm (outward) plane
New plane
Boundary Curve (on old plane)
Parallel Curve (on new plane)
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Tutorial 8B
Create a sketch on XZ plane
Draw an arc
Create a Swept surface Create a shape Fillet (R10mm)
Fillet R10mm
Create a point on the boundary Create a plane at the point
Create an intersection curve Create a connect curve
point plane Connect Curve
Intersection curve
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Tutorial 8B
2 Sections & 2 Guides Tangent to surfaces Multisections surface
Split the Fillet surface by the intersection curve
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Tutorial 8B
Create a sketch on Yz plane
Create 3 projected curves, Create a spline curve Create a fillet R25mm Trim curves to form a closed profile Connect curve 3D curve Projected curves on sketch
3D curve
Spline
R25mm
Create an extruded surface (750mm)
After trimming, a closed profile is formed
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Tutorial 8B
arc
Insert a new geometrical set (name it as parting _surface) Create a sketch on YZ plane Create an extruded surface (350mm) Split surface (by the extruded surface)
line
fillet
arc
fillet
Create a sketch on YZ plane

Projected line
Two straight lines
Create an extruded surface (860mm) Split the surface into Two (keep both sides) A- 26
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Tutorial 8B
Right-click Geometrical set Front Body Select Define in Work Object Create a boundary curve Create a swept surface
Profile Type = Linear Subtype = with draft direction Guide curve = Boundary Draft direction = yz plane Angle = 30 deg Length = 120mm Boundary curve
Swept surface

Profile Type = Linear Subtype = with draft direction Guide curve = Boundary Draft direction = yz plane Angle =8 deg Length = 100mm
Boundary curve
Swept surface
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Tutorial 8B
Profile Type = Linear Subtype = with draft direction Guide curve = Boundary Draft direction = yz plane Angle =10 deg Length = 100mm Boundary curve
Extrapolate the surface by 100mm (assemble result)
Split the extended surface by the parting surface
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Tutorial 8B
Mutual Trim the 3 swept surfaces Join surfaces
Edge fillet 35mm Edge fillet 100mm Edge fillet 5mm

R100 R35
R5
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Tutorial 8B
Create a sketch on YZ plane Project the sketch onto surface Split surface by the projected sketch
Check the finished model with the reference pictures Modify the model if needed Save file R8_master_a.catpart
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Middle Body
(master)
Insert a New geometrical set middle_body
Tutorial 8C
Spline Symmetry curve Spline
Create a symmetry 3d curve Create two 3d spline curves Create a multi-sections surface (3 sections, 2 guides)
Long enough to have a cross here Extrapolate the curve by ~900mm
Extrapolate a curve (900mm, curvature, assemble result)
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Middle Body
(master)

Tutorial 8C
3d Curve (build a boundary curve on this edge)
Join two surfaces Hide the 3d curve Create a boundary curve on the edge Create a blend surface (2 curves, no supports)
Join two surfaces
Create a extremum point (direction: xz plane) Create a plane at the point

Parallel through point Reference: YZ plane Point: Extremum point Extremum point
Create a sketch on the plane (Draw an arc) Create a swept surface (profile, guided curve)
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sketch
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Middle Body
(master)
Tutorial 8C
Swept surface
Create offset surface (15mm, inward)
Project 3d curve on the offset surface (Direction: xz direction)
Offset surface
Projected curve
Split surface by the projected curve
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Tutorial 8C
Create a plane at the endpoint of the projected curve. (Normal to curve)
Split the 3d curve by the plane (into 2)
Split the 3d curve into 2 pieces
Create a blend surface (2 curves, 2 supports, tangency continuity, tension 0.8, 0.5) Create a swept surface
Tension 0.8 Tension 0.5
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Tutorial 8C
Right-Click Geometrical set parting_surface, select Define in work object
Create a sketch on XZ plane (draw a spline) Create an extruded surface (1500mm)
Right-Click Geometrical set middle_body, select Define in work object Split the offset swept surface by the extruded surface
Create an Extruded Surface (Direction: Xz plane, L=200mm)
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Tutorial 8C
Create a sketch on XY plane (Draw a spline) Project it on the extruded surface Create a swept surface (Profile: Projected curve, Guide: Sketch)
sketch
Extruded surface
Projected curve
Project 3d onto this swept surface Split surface by the projected curve Split surface by the extruded surface in the geometrical set parting_surface
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Tutorial 8C
Split the extruded surface (by 2 cutting surfaces)
Cutting surfaces
Extruded surface
Split join surface into 2 (by the parting surface)
Cutting surface
Create an offset plane (Reference: Yz plane, offset 2015mm)

Split into two
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Tutorial 8C
Split surface into 2 by the offset plane
Create a sketch on Xz plane (Draw a spline) Project sketch on the split surface Split surface by projected sketch
Create a Translate Surface

Element: Split surface Direction: XZ plane Distance: -60mm Split surface
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Tutorial 8C
First curve First support, curvature continuity, tension =0.6 Second curve Second support, point continuity tension =1
Second curve Second support, Point continuity, tension =1 First curve First support, curvature continuity, tension =0.6
Create a sketch on Xz plane (Draw a spline) Project sketch onto the blend surface Split the surface by projected sketch
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Tutorial 8C
Create a connect curve (tangent, tangent)
Connect curve
Create a fill surface

4 curves, 3 supports Tangent Continuity
Join surfaces (4 surfaces)
3
2
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Tutorial 8C
Create an offset plane (Reference xy plane, Offset 520mm) Split surface
Make the geometrical set front_body visible Create a connect curve (tangent continuity at point ; point continuity at point ) Create 2 boundary curves Create a multi-sections surface
Section: Boundary Curve#1, Tangent to Surface Section: Boundary Curve#2, No Tangent Support Guide: Boundary Curve#3, Tangent to Surface Guide: Connect Curve
Boundary curve#3
Boundary curve #2
Boundary curve #1
Connect curve
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Tutorial 8C
Create a sketch on xz plane (Draw a spline) Project it onto the surface Split surface
Create a sketch on xz plane (Draw a spline) Project it on the old split surface (which should be located before Translate surface, page 38) Split surface by the projected curve

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Tutorial 8C
Create a connect curve
First Support: tangency, tension 2.9 Second Support: tangency, tension 0.5 Tension 2.9
Tension 0.5

4 curves, 3 supports Tangent Continuity Tangent continuous
Tangent continuous Tangent continuous
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Tutorial 8C
Join Surfaces (Total 4) 4 3 1 2
Split surface
Split the surface into 2 (by parting surface)

Create Shape Fillet (Surfacesurface, R25mm) Create Shape Fillet (Surfacesurface, R20mm)
Fillet R20mm Fillet R25mm
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Tutorial 8C
line
Right-Click the Geometrical set front_body, Select Define in work object Create a sketch on Xy plane
Draw a symmetric arc Draw a line Draw a connect curve
Connect curve
arc
Create an extruded surface (1000mm) Split surface by the extruded surface Save file R8_master_a.catpart
sketch
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Back_body
(master)
Tutorial 8D
Extrapolated curve Symmetry curve
Insert a New geometrical set back_body

Create a symmetry curve Extrapolate the 3d curve (select assemble result) Create a multi-sections surface (3 sections) Split the old multi-sections surface by XZ plane
Create Two Isoparametric curves on the multisections surface
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Isoparametric curves
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Back_body
(master)
Tutorial 8D
Split the multi-sections surface by 2 iso curves & XZ plane
Create isoparametric curve Split surface by this iso curve
Isoparametric curve
Create a blend surface (curvature continuous on both sides, tension 0.8)
Curvature continuous

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Back_body
(master)

Tutorial 8D
Create a point & a plane
Create a point on 3D curve Create a plane at the point Split the old blend surface by the plane
Create a Sketch on XZ plane (Draw a spline) Project sketch Split surface by projected sketch
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Tutorial 8D
Project the same sketch onto the split surface
Direction = XZ plane sketch Projected curve
Create a connect curve (tangent continuous on both ends)
Tangent continuous

2 sections (1 tangent support) 2 guides (2 tangent supports)
Tangent continuous (guide)
Tangent continuous (guide)
Connect curve
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Tutorial 8D
Create a sketch on Xz plane (Draw a spline) Project Sketch on the split surface
sketch
Projected Split surface curve
Create an offset plane (Yz plane, 3100mm) Split surface by projected sketch & offset plane
Create a blend surface (curvature continuous)
Offset plane
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Tutorial 8D
Join two surfaces Create a boundary curve
Join 2 surfaces Create a boundary curve on this edge
Create a point on the boundary curve Split the curve by the point
Create a point on the boundary curve
Create a blend surface (curvature continuous) Create a fill surface (curvature continuous)
Blend surface
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Fill Surface
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Tutorial 8D
Show the multi-sections surface (1st surface in this geometrical set) Show the two isoparametric curves Split the surface by these two curves
Create a point on 3D curve Create a point on another 3D curve
Create a connect curve between the two 3d curves (select trim elements)

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Tutorial 8D
Select an edge of the Join Surface (tip: move the mouse cursor on it, then press key on the keyboard, so that we can select it on a selection list) Create a Boundary curve
Create a Fill surface 5 Curves / but 4 Supports Hide the Join Surface
Surface edge
Boundary curve Surface edge Join surface
Connect curve
Surface edge
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Tutorial 8D
Create a sketch (3 arcs , Dia355mm, 3649mm)
Create an offset plane at the back (Yz plane, 5500mm)

Create a sketch (Draw a spline, 3 points) Create a combined curve (from the above 2 sketches)
Offset plane
Create a extremum point on the combined curve Create a plane at the point
Extremum point Combined curve
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Tutorial 8D
Create a sketch on the plane (Draw a line (15mm), arc, fillet R30mm)
Intersection point (coincident with the endpoint of the arc)
arc fillet
line
Coincident with the point
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Tutorial 8D
Create a sketch on Xz plane (Draw a spline) Project sketch Split the surface by projected sketch
The spline must lie before the endpoint of the connect curve
Create 2 points on the combined curve (as shown) Create another point on the projected curve (as shown)
Make a point on this projected curve
Make two points on this combined curve
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Tutorial 8D
Create a split curve by two points Create another split curve by one point Create a blend surface (Curvature continuous on one end, point continuous on other end)
Point continuous
Create a symmetry curve Create a multi-sections surface (3 sections)

Split the surface by XZ plane
Symmetry curve
3d curve 3d curve
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Tutorial 8D
Create an offset surface (20mm, outward)
Offset surface
Right-Click Geometrical set parting_surface, then select Define in work object Create a sketch on XZ plane (Draw a line) Create an extruded surface (1500mm)
Draw a line
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Tutorial 8D
Right-Click geometrical set backbody, then select Define in work object
Create an offset plane (450mm from XY plane; Move the plane near the rear surfaces)
Create a sketch on XZ plane (Draw a line) Create an extruded surface (1500mm)
Draw a line
Split the offset surface (by the plane & the extruded surface)
plane
Extruded surface
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Tutorial 8D
Split surface by the Extruded Surface
Extruded surface
Extruded surface
Split the 3d curve (by a plane & an extruded surface) Split the combined curve ((by a plane & an extruded surface)
3D curve Plane Combined curve Extruded surface
Create a isoparametric curve

Isoparametric curve
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Tutorial 8D
Create a 3d spline curve (3 points, tangent to the surface edge)
3d spline
Similarly, Create another 3d spline curve (3 points, tangent to the surface edge)
Split surface by the iso curve

Iso curve Iso curve 3d spline

3 Sections, 1 tangent support 2 Guides
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Tutorial 8D
Join 2 surfaces Create a shape (surface-surface) fillet (R35mm)
Join 2 surfaces R35mm
Create a connect curve (tangent continuous on both sides)
Create a boundary curve Create a point on the curve Create a plane at the point Split the fillet surface by the plane
plane point Boundary curve
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Tutorial 8D
Create another boundary curve Create a multi-sections surface
2 sections, 1 tangent support 2 guides, 1 tangent support section guide guide section
Create a connect curve (curvature continuous on both sides)
Split the curve/edge by this connect curve

Show the combined curve
Split curve
Connect curve
Combined curve
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Tutorial 8D
3 Sections, 2 tangent supports 1 guide
Create a parallel curve (~80mm offset from the sketch on XZ plane) Project curve onto the multi-sections surface Split surface
Create a fill surface (curvature continuity) Create a fill surface (curvature continuity)
Fill surface
Parallel curve
Fill surface
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Tutorial 8D
Join surfaces (as shown) Split the surface into 2 (by a parting surface)
Parting surface
Join (top) surfaces (as shown)
Split into 2 surfaces
Create a shape fillet (surface-surface) (R25mm)
Fillet R25mm
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Tutorial 8D
Join surfaces Create a boundary curve
Boundary curve
Create a line (625mm, from end point of the 3d curve; direction: Xz plane)
Create a swept surface

Profile Type: Circular Subtype: Two guides & radius Select the boundary curve as guide1 Select the line as guide 2 Radius =450mm Select the line as the spine
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Tutorial 8D
Create a connect curve Create a fill surface (3 edges, 1 tangent support)
Fill surface Tangent support Join surfaces
Join two surfaces Create an offset surface (10mm) Create an offset surface (-10mm) Split Upper Join surface by the upper offset surface Split Lower Join surface by the lower offset surface Create a boundary curve Create a boundary curve Create a blend surface
(tangent continuous on both sides) Boundary curve blend Boundary curve
Create offset surface +10mm
Create offset surface -10mm
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Tutorial 8D
Create a split curve Create a blend surface (curvature continuous, tangent borders none)
Cutting element Split curve Blend Surface
Create a point on curve Create a point on curve Create a spline (on surface, tangent) Split surface by the spline Join surfaces
point spline point

Profile type = linear Subtype = with reference surface Angle = 45deg Length = 30mm
Boundary curve
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Tutorial 8D
Create another boundary curve Create an extruded surface (170mm, direction: Yz plane)
Extruded surface Boundary curve
Show the old split surface Create an offset surface (20mm inward)
Create a sketch on the back offset plane (Draw a line) Project sketch onto the offset surface Split surface A- 69
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Tutorial 8D
Translate the Untrimmed offset surface (75mm inward) Create a sketch on the back offset plane (Draw a line) Project sketch onto the new surface Split surface
Blend surface Tangent continuous

Point continuous on one side, tangent continuous on other side Trim support (Join them together)
Point continuous
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Tutorial 8D
Split surface by the old parting surface (which is in geometrical set parting_surface)
Parting surface
Result after mutual trimming
Mutual trim surfaces

R30mm R15mm
Edge variable fillet (30mm, 15mm)
Shape Fillet (Surface-surface 10mm) Shape Fillet (Surface-surface 10mm)

R10mm
R10mm
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Tutorial 8D
Create a sketch on the back offset plane (Draw 2 lines) Project sketch Split surface by projected curve
End point coincident with the parting line/surface
Create a sketch on XZ plane (Draw a line) line Create an extruded surface (230mm)

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Tutorial 8D
Create a Blend surface
- First curve, first support, Curvature continuous, Trim support - Second curve Second curve First curve First support If trim support is selected, these two surfaces are joined together
Create an extrude surface (230mm, Direction: Yz plane)

Mutual trim surfaces Join surfaces Edge fillet 15mm Edge fillet 10mm
Join surfaces
Result of Mutual trim
R15mm R10mm
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Tutorial 8D
Create a plane at an endpoint (Reference: YZ plane) Create a sketch on the plane
plane
Create another plane at an endpoint (Reference: YZ plane) Create a sketch
Create a multi-sections surface (select vertices coupling)

Create an edge fillet (20mm) Create a Shape fillet (surface-surface 20mm)
plane
R20mm R20mm
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Tutorial 8D
Create a parallel curve (Reference curve: 3d spline; Offset: 10mm)
spline
Create an extruded surface

Profile: the parallel curve Direction: XY plane Limit 1 = 100mm ; Limit 2 =100mm Extruded surface
Create a sketch on the back offset plane

sketch
Extrude the sketch (1500mm) Create a Shape fillet (surface-surface, 5mm) Create a Shape fillet (surface-surface, 15mm)
Fillet 15mm
Fillet 5mm
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Parting Surfaces
(master)
Tutorial 8D
Up to now, there should have been four surfaces in the geometrical set parting surface
Right Click Geometrical set parting_surface, select Define in work object
(Continue to make the rest)

Create a sketch on XZ plane
Project two 3d curve onto the plane Project the old sketch onto the plane Draw a spline Create two fillets Create a centreline, then quick-trim
Project them onto sketch plane
Draw a spline
Create an extruded surface (1800mm)

Quick trim by a centreline
Fillet Fillet
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Parting Surfaces
(master)
again Create a sketch on XY plane Create an extruded surface
Tutorial 8D
Create a sketch on XY plane Create an extruded surface
Create a sketch on the offset plane at back Create an extruded surface
Create a sketch on the offset plane at back Create an extruded surface
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Parting Surfaces
(master)
Create a sketch on XY plane Create an extruded surface
Tutorial 8D
Projected fillet image from a 3D curve Symmetric arc
Create an extruded surface

Profile: 3d curve Direction: XZ plane
(There should be 10 parting surfaces in the geometrical set parting_surface ) Save file R8_master_a.catpart A- 78
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R8_front body
Tutorial 8E
Start a new part file

Copy three surfaces from the master model (Paste Special, as result with link) Create a join curve (3 edges) Extrapolate the surface from the join curve (850mm)
Join curve
Create an offset surface (Surface: Extrapolated surface; Offset 3mm)
Split surfaces (so that there can be a 3mm gap between two surfaces)
3mm gap
3mm gap
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R8_front body
Tutorial 8E
Make a point and then a plane here
Multi-select three surfaces, then make symmetry
Create a new geometrical set Create a point at endpoint of the edge Create a plane (tangent to surface) Create a sketch (4 circles)
Switch to part design workbench Create a pad (Limit 1= 5mm, Limit 2= 5mm, thickness 1,2 = 3mm)
Apply material Tungsten to Part body Apply material Grey Blue to geometrical set.1
Save File as R8_frontbody_a.catpart
A- 80

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R8_grille
Tutorial 8E
Join surfaces

Copy 3 surfaces from the master model (Paste Special, as result with link)
Join 2 surfaces Create a boundary curve

Boundary curve
Copy the multi-sections surface from the master model (Paste Special, as result with link) (the surface should be the first surface in the master model)
A- 81
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R8_grille
Split the surface by right plane
Tutorial 8E
Offset surface 20mm
Create an Offset surface (20mm inward)
Create another Offset surface (20mm inward) Create an intersection curve (between the above two offset surfaces)
Offset surface 20mm
Offset surface Offset surface
Intersection curve
Create a swept surface - profile: circular - subtype: 2 guides & radius - radius: 50mm Create a symmetry surface
Symmetry
A- 82
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R8_grille

Tutorial 8E
Switch workbench to part design Create a sketch on YZ plane (Draw a few lines as shown)
Create a pad (150mm, thickness1,2 =5mm) Split the solid by XZ plane Create a sketch (a rectangle) Create a pad (5mm) Split solid by the two offset surfaces
A- 83
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R8_grille

Tutorial 8E
Create a new body Thick the offset surface (5mm thick, outward) Create a sketch on Yz plane Pocket (up to last) Add Body Mirror Body
Apply material Tungsten to geometrical set.1
Apply material Plastic to Partbody, Change parameters (as table) to Black

Save File as R8_grille_a.catpart
A- 84

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R8_head light
Tutorial 8E
Projected curve

Copy two surfaces from the master model (Paste Special, as result with link) Create a sketch on XZ plane Project sketch on surface
Create an offset plane (XZ plane, 1300mm) Create a sketch on the offset plane Project sketch on surface
Projected curve
Create a blend surface (tangent continuous on one side, point continuous on other side)
Point continuous Tangent continuous
A- 85
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R8_head light
Tutorial 8E
This edge, offset 0mm This surface, variable offset This edge, offset 15mm
Create a variable offset (edge 0mm, edge 15mm, surface- variable) Extrapolate the offset surface (upper edge) (100mm, assemble result)
Extrapolate the surface (lower edge) again (100mm, assemble result) Create a sketch on YZ plane
Extrapolate from the lower edge
A- 86
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R8_head light

Tutorial 8E
Extract curve (from the surface edge) Project curve onto extrapolated surface Project sketch onto extrapolated surface Split surface
Create a sketch on YZ plane Parallel curve (offset 43mm) Parallel curve (offset 43mm)
sketch
Parallel curve Parallel curve
split
Project curves (3 times)

Create 3 extrude surfaces (Length 150mm)
A- 87
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R8_head light

Tutorial 8E
Fill surface line
Create a boundary curve Create a line (from start point of boundary curve to endpoint of the curve) Create a fill surface Switch workbench to Part Design Thick surface (3mm) Mirror
Mirrored solid
3mm thick
Insert a new body Thick surface (thickness1,2 =8mm) Thick surface (thickness1,2 =8mm) Thick surface (thickness1,2 =8mm) Thick surface (thickness = 3mm) Fillet R8mm Mirror
Apply Material White to Part Body Apply Material Plastic black to Body.2 Save File as R8_headlight_a.catpart A- 88
www.dicksonsham.com
R8_door

Tutorial 8E
Parting surface plane
Start a new part file Copy 3 surfaces & a plane from the master model (Paste Special, as result with link) Create an Offset surface (3mm, parting surface) Split surface (by the offset surface)
Split by 3mm offset plane 3mm gap
Offset plane (3mm, backward) Split surface (by offset plane)
Multi-select the two split surfaces, then Create symmetry
symmetry
A- 89
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R8_door
Tutorial 8E
Insert a new geometrical set

Create symmetry of the surface (window)
Insert a new geometrical set

Offset surface (10mm, outward) Extrapolate the offset surface (~120mm) Create a sketch on XZ plane (Draw two lines) Project the curve on the extrapolated surface Split surface Create symmetry
extrapolate
A- 90
Not For Commercial Use Written by Dickson Sham
www.dicksonsham.com
R8_door

Tutorial 8E
Geometrical.set 3
Apply material Grey blue to geometrical.set.2 Apply material Black to geometrical.set.3 Apply material DS Black to geometrical.set.4 Save File as R8_door_a.catpart
Geometrical.set 4
Geometrical.set 2
A- 91
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R8_side cover
Tutorial 8E
Copy two surfaces from the master model (Paste Special, as result with link) Split surface Create a boundary curve Create an extruded surface (200mm) Create Shape fillet (R10mm) Create a symmetry surface
Boundary curve
Apply material DS black to geometrical.set.2

Save File as R8_sidecover_a.catpart
A- 92
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R8_top cover
Tutorial 8E
Copy three surfaces from the master model (Paste Special, as result with link) Create an offset surface (3mm, forward) Split surface by the offset surface Split surface by the front parting surface
Offset surface
Create a boundary curve Create a swept surface (90deg, 30mm)

Create symmetry surfaces
Boundary curve
Swept surface
Geometrical set.2
Insert a new geometrical set Split surface Create symmetry

Apply material Grey blue to geometrical set.2 Apply material Black to geometrical set.3 Save File as R8_topcover_a.catpart A- 93
Geometrical set.3
Non-Commercial Use
www.dicksonsham.com
R8_rear cover
Tutorial 8E
Copy four surfaces from the master model (Paste Special, as result with link) Split surface
Keep both sides
Cutting element
Split surface into 2 (Keep both sides)
A- 94
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R8_rear cover
Tutorial 8E
Offset surface (25mm downward)
Create an Offset surface (25mm, downward)
Create a boundary curve Create a boundary curve Create a Blend surface

Blend surface
Join 2 surfaces
Join 2 surfaces
Create a sketch on xy plane Project sketch onto the join surface Split surface

A- 95
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R8_rear cover
Tutorial 8E
Copy another four surfaces from the master model (Paste Special, as result with link)
Split surface
Create Offset surfaces (3mm) Split surfaces (so that there can be a 3mm gap between 2 surfaces)
Split by parting surface parting surface
Split by offsetted parting surface

3mm
3mm gap
3mm gap Offsetted parting surface

A- 96
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R8_rear cover

Tutorial 8E
3mm gap extrapolate
Extrapolate the parting surface (3000mm) Create an Offset surface (3mm) Split surfaces Create symmetry surfaces (except the translated surface)
Insert a New Geometrical set Right click the offset surface , select Change geometrical set, select the new one Split the surface by a parting surface Create a symmetry surface A- 97
Non-Commercial Use
Parting surface (cutting element)
Symmetry
Split surface
www.dicksonsham.com
R8_rear cover

Tutorial 8E
Switch workbench to Part Design Create a sketch on XZ plane (Draw a straight line) Create a Pad (limit1 ~550mm, thick~60mm, totally cover the cut) Split by 3 parting surfaces (as shown)
sketch
This solid face is flat
3 parting surfaces to split the solid
A- 98
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R8_rear cover

Tutorial 8E
Draw a line
Shell (8mm, one open end) Create a sketch on the planar face Create a stiffener (16mm thick) Create a rectangular pattern (12 instances, 60mm spacing) Switch workbench to generative shape design Create a boundary curve (whole boundary of the offset surface) Extrapolate the offset surface by 300mm (select assemble result)
Extrapolate surface
Switch workbench to part design Split the solid by the extrapolated surface Mirror

A- 99
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R8_rear cover
Insert a new body (Body.2) Create a point Create a plane Create a sketch on the plane Create a pad (Limit 1= 5mm, Limit 2= 5mm, thickness 1,2 = 3mm)
Tutorial 8E
Make a point, then a plane here
Switch workbench to generative shape design Insert a new geometrical set Create a split surface & symmetry (as shown) Apply material Grey Blue to geometrical set.2 Apply material Black to geometrical set.3 Apply material Black to geometrical set.4 Apply material plastic black to Partbody Apply material tungsten to Body.2
Save File as R8_rearcover_a.catpart

A- 100
Non-Commercial Use
www.dicksonsham.com
R8_tail light

Tutorial 8E
Split surface
Start a new part file Copy 3 surfaces from the master model (Paste Special, as result with link) Split surface by parting surface Symmetry
Symmetry surface
Offset plane
Insert a new geometrical set Create an offset plane Create a sketch on the plane (draw a line) Extract a face Project sketch onto the extract surface Create a plane at the endpoint Create a sketch on the 2nd plane (draw an arc) Create a swept surface
2nd sketch
Extract face Projected curve
Offset plane sketch

A- 101
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R8_tail light

Tutorial 8E
Draw a spline
Create a sketch on the offset plane (draw a spline) Create Parallel curves (spacing 43mm, 3 instances) Project curves on the swept surface Extruded surfaces (x4) 98 mm long Extract a back face
Switch workbench to Part Design Thick surface (thickness1,2 = 8mm) (x4) Fillet R8mm
Thick surface (back extracted face, 2mm) Mirror Apply Plastic black to PartBody Apply DS red to geometrical set.2
Save File as R8_taillight_a.catpart

A- 102
Non-Commercial Use
www.dicksonsham.com
R8_rear body
Tutorial 8E
Copy 3 surfaces from the master model (Paste Special, as result with link) Create an offset top parting surface (3mm) Split surface by the offset surface & the other parting surface
Create a sketch on Yz plane Project sketch onto surface Split surface Symmetry surface
sketch split symmetry
Insert a new geometrical set Show the original copied surfaces from the master model Split surface by a parting surface Symmetry surface A- 103
Non-Commercial Use
www.dicksonsham.com
R8_rear body

Tutorial 8E
Switch workbench to Part Design Create an offset plane (4230mm from YZ plane) Create a sketch (two circles) Pad (190mm, 10mm thick) Create a sketch on XZ plane (a line) Pocket (up to last) Fillet 6mm Create a sketch Pad (5mm) Mirror Apply material grey blue to geometrical set.2 Apply material plastic black to geometrical set.3 Apply material titanium to Partbody
Pad (5mm)
Save File as R8_rearbody_a.catpart

A- 104
Non-Commercial Use
www.dicksonsham.com
R8_dummy chassis
Tutorial 8E
Front_wheel_left
Front_wheel_right
Create 4 points as tables Create an Axis system at each point
Rear_wheel_left
Rear_wheel_right
Save File as R8_dummychassis_a.catpart
A- 105
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Assembly
File new product Insert all part files
Tutorial 8F
Insert front wheels, then locate them onto the Axis systems of dummy chassis Insert rear wheels, then locate them.
Insert mirror part file Locate it by compass

Add 3 coincident constraints (plane to plane)
A- 106
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Assembly
Tutorial 8F
(After the part mirror has been located) Select the part mirror Click Symmetry Under the toolbar Assembly Features Select XZ plane of the part R8_door Highlight keep link with position Highlight keep link with geometry File /Save all (A new part file Symmetry of R8_mirror.CATpart is created)
(Name the assembly as R8_assembly.CATproduct) A- 107

Non-Commercial Use
- END Written by Dickson Sham
www.dicksonsham.com
For enquiries, please contact:
Dickson S.W. Sham

CATIA Certified Professional
Email : [email protected] Website : http://www.dicksonsham.com http://www.youtube.com/dicksham http://www.youtube.com/dickshamold
A- 108

Catia Car Design (Audi R8)

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CATIA V5R19 - surface modeling Rebuild Audi R8

Not For Commercial Use

CATIA V5R19 - surface modeling Rebuild Audi R8

soft fillet Hard fillet

Grab photos from internet (in different views)

CATIA V5R19 - surface modeling Rebuild Audi R8

Not For Commercial Use

CATIA V5R19 - surface modeling Rebuild Audi R8

Design with a Master model

Not For Commercial Use

CATIA V5R19 - surface modeling Rebuild Audi R8

3500mm 6000mm 3500mm

CATIA V5R19 - surface modeling Rebuild Audi R8

Make them semi-transparent Set the Geometrical set Reference to Unpickable A- 6

Version 1a- Oct 2010

CATIA V5R19 - surface modeling Rebuild Audi R8

Drag a control point to modify the spline

Not For Commercial Use

Just create the left

Use minimum number of control points to create a spline

CATIA V5R19 - surface modeling Rebuild Audi R8

CATIA V5R19 - surface modeling Rebuild Audi R8

Version 1a- Oct 2010

Written by Dickson Sham

CATIA V5R19 - surface modeling Rebuild Audi R8

CATIA V5R19 - surface modeling Rebuild Audi R8

Create another sketch (YZ plane, front view)

Create a Combined curve

CATIA V5R19 - surface modeling Rebuild Audi R8

Coincident with the 3d curve

CATIA V5R19 - surface modeling Rebuild Audi R8

Create a Swept surface

Create a Blend Surface

Join the Swept surface & the Blend Surface

CATIA V5R19 - surface modeling Rebuild Audi R8

Create two split curves Create a blend surface

CATIA V5R19 - surface modeling Rebuild Audi R8

Create a Parallel Curve (offset 70mm, upward)

Not For Commercial Use

CATIA V5R19 - surface modeling Rebuild Audi R8

Create an offset plane Reference: Yz plane, offset = 1500mm

CATIA V5R19 - surface modeling Rebuild Audi R8

CATIA V5R19 - surface modeling Rebuild Audi R8

Create a boundary curve Create a swept surface

Create a blend surface

CATIA V5R19 - surface modeling Rebuild Audi R8

Not For Commercial Use

Split the fillet surface into THREE

CATIA V5R19 - surface modeling Rebuild Audi R8

Project the sketch onto the two split surfaces

Create a connect curve (Tangency Continuity on both ends)

Projected curves Projected curves

CATIA V5R19 - surface modeling Rebuild Audi R8

Create a connect curve

Create a multi-sections surfaces

CATIA V5R19 - surface modeling Rebuild Audi R8

Boundary Curve (on old plane)

Parallel Curve (on new plane)