Assembly Modeling 11-37

TUTORIALS

Tutorial 1
In this tutorial, you will create all the components of the Blower assembly and then assemble
them together. The Blower assembly is shown in Figure 11-57. After creating it, you will generate

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the exploded view. The exploded view of the Blower assembly is shown in Figure 11-58. The
dimensions of all components are given in Figures 11-59 through 11-64.
(Expected time: 2.5 hr)

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Figure 11-57 The Blower assembly

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Figure 11-58 Exploded view of the Blower assembly

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Figure 11-59 Views and dimensions of the Upper Housing

Figure 11-60 Views and dimensions of the Lower Housing

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Figure 11-61 Views and dimensions of the Blower

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Figure 11-62 Views and dimensions of the Motor

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Figure 11-63 Views and dimensions of the Cover

Figure 11-64 Views and dimensions of the Motor Shaft

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 Assembly Modeling 11-41

The following steps are required to complete this tutorial:

a. Create all components of the assembly as separate part files in the Part Design workbench.
b. Start a new file in the Assembly Design workbench.
c. Insert the Lower Housing into the assembly as the base component, set its orientation, and
apply the Fix constraint to it at its default location, refer to Figures 11-65 through 11-67.
d. Insert the Upper Housing into the assembly and place it over the Lower Housing by applying

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proper constraints, refer to Figures 11-68 through 11-70.
e. Hide the Upper Housing. Insert and place the blower inside the Lower Housing.
f. Now, insert and constrain the Motor, the Motor Shaft, and the Cover refer to Figures 11-71
through 11-77.
g. Turn on the display of the Upper Housing, refer to Figure 11-78.

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h. Create the exploded state of the assembly, refer to Figure 11-79.
i. Save the assembly file.

Before creating components for this tutorial, create \My Documents\CATIA\c11\Blower Assembly
folder. You will save the parts of the Blower assembly in this folder. Note that you should
change the part number of every component before saving it. The process of changing the
part number of a components has already been discussed earlier in this chapter.

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Creating Components of the Assembly

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The Blower assembly will be created using the bottom-up approach. As mentioned earlier,

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in bottom-up assemblies, all parts are first created as individual part files and then inserted
in the assembly file.

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1. Create all parts of the assembly and save them as separate part files in the above mentioned
folder.

2. Close all the part files, if they are open.

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Starting a New File in the Assembly Workbench
All components that you have created above need to be assembled in an assembly file. The
assembly file has a file extension *.CATProduct. You need to start a new file in the Assembly
Design workbench to assemble the parts.

1. Choose the New button from the Standard toolbar; the New dialog box is displayed.

2. Choose the Product option from the List of Types list box.

3. Choose the OK button to start a new product file. A new file is started in the Assembly
Design workbench, and Product1 is displayed on the top of the specification tree.

Note
If you start a new session of CATIA V5, an assembly file is started automatically. Therefore, if
you start another file, it will be named Product2.

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Inserting the First Component and Fixing it

After the new product file is started, you can insert the base component into the assembly. In
this case, the Lower Housing is the base component. After inserting the Lower Housing, you
need to set the orientation of the Lower Housing and then fix its location.

1. Choose the Existing Component button from the Product Structure Tools toolbar.

2. Select Product1 from the specification tree; the File Selection dialog box is displayed.
From this dialog box, browse to the location of the file of the Lower Housing and open it.

The Lower Housing is displayed in the geometry area and its name is shown in the
specification tree. The current orientation of the isometric view is not the same as that
required in the assembly. Therefore, you need to set the orientation of the model. The
orientation of the model will be set by using the Snap tool.

3. Choose the Snap button from the Move toolbar. Select the first element and the
second element, as shown in Figure 11-65. The orientation of the Lower Housing is
changed and a flip arrow is displayed on it.

4. Click anywhere in the geometry area to exit the Snap tool. Set the orientation of the view of
the assembly to Isometric. The Lower Housing is placed in the correct orientation, as shown
in Figure 11-66.

Figure 11-65 First and second elements to be Figure 11-66 The Lower Housing after modifying its
selected orientation

Next, you need to apply the Fix constraint to lock its position.

5. Choose the Fix Component button from the Constraints toolbar and select the
Lower Housing from the geometry area or from the specification tree.

The symbol of the Fix constraint is displayed on the Lower Housing in the geometry area.
Figure 11-67 shows the Lower Housing after fixing it at its location.

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Inserting the Upper Housing and Constraining it

The sequence, in which the parts should be inserted into the assembly depends on the user.
In this case, the Upper Housing will be the second component to be inserted into the
Blower assembly.

1. Insert the Upper Housing in a similar way, as discussed earlier. Note that the part number of

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all components were modified before saving the part files. Therefore, the Part Number
Conflicts dialog box will not be displayed for any component.

The Upper Housing is placed at its default location, as shown in the Figure 11-68. You
need to apply constraints to place it properly over the Lower Housing.

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The first constraint that will be applied to the Upper Housing is the Contact constraint.
This constraint will be applied between the upper face of the Lower Housing and the lower
face of the Upper Housing.

2. Choose the Contact Constraint button from the Constraints toolbar. Select the two
faces shown in Figure 11-68. You need to rotate the view of the assembly to select the

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surface that is not visible in the current display.

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Figure 11-67 Lower Housing after it is fixed at Figure 11-68 The surfaces to be selected to apply
its default location the Contact constraint

3. Choose the Update All button, if it is active. If this button is not active, the assembly does
not need updation.

The Contact constraint is applied between the two surfaces and its name is displayed in the
specification tree under Constraints.

Next, you need to apply the Coincidence constraint between the cylindrical surfaces of the
two components to make them concentric.

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4. Choose the Coincidence Constraint button from the Constraints toolbar. Now,
select the two cylindrical surfaces, as shown in the Figure 11-69, to select the central
axes of these surfaces.

5. Choose the Update All button to reorient the Upper Housing.

Note
To confirm the presence of the free degree of freedom, double-click on the Upper Housing in the
specification tree. The Upper Housing is activated. Now, choose Analyze > Degree(s) of freedom
from the menu bar. The Degrees of Freedom Analysis dialog box is displayed along with a set
of arrows in the x direction. This set of arrows displays the degree of freedom which is free. Choose
the Close button from the Degrees of Freedom Analysis dialog box.

Next, you need to align the right face of the Upper Housing with that of the Lower Housing.
This can be done by applying the Offset constraint with 0 offset.

6. Choose the Offset Constraint button from the Constraints toolbar, and select the
faces shown in Figure 11-70, to apply the constraint between them.

Figure 11-69 Surfaces on which you need to Figure 11-70 The surfaces to be selected for
click to select the central axes applying the Offset constraint

The Constraint Properties dialog box is displayed. Make sure that the Orientation is set to
Same, and the Offset value is set to 0.

7. Choose the OK button, and then choose the Update All button to apply the Offset constraint.
The Upper Housing is fully constrained.
Tip. To check whether a part is fully constrained, try to reorient it using the
Manipulation tool with the With respect to constraints check box selected. If the
part is fully constrained, it will not move or rotate in any direction.

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Assembling the Blower after Hiding the Upper Housing

The Blower needs to be assembled between the Upper and Lower Housings. To ease the
process of assembling the Blower, you need to hide the Upper Housing.

1. Invoke the contextual menu by right-clicking on the name of the Upper Housing in the
specification tree and choose the Hide/Show option to turn off the display of the selected

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component.

2. Now, insert the Blower in the assembly. Choose the Coincidence Constraints button
and select the faces shown in Figure 11-71, to select the central axes of these faces.

3. Update the assembly, if it is required.

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Next, you need to place the left face of the Blower at an offset distance 0.635 from the inner
left face of the Lower Housing using the Offset constraint.

4. Apply the Offset constraint between the faces shown in Figure 11-72. Enter 0.635 as the
value in the Offset spinner and make sure that the Orientation is set to Opposite in the

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Constraint Properties dialog box. Update the model to bring the Blower to its proper
position.

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Figure 11-71 Faces to be clicked to select the Figure 11-72 Faces to be selected for applying the
central axes Offset constraint

Assembling the Motor Shaft

Next, you need to assemble the Motor Shaft.

1. Insert the Motor Shaft into the assembly file. By default, it is placed in the middle of the
existing assembly, as shown in Figure 11-73. You need to move it out of the assembly to get
a better view of the shaft.

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2. Select the Manipulation button from the Move toolbar. Choose the Drag along X
axis button and drag the Motor Shaft to move it out of the assembly, as shown in
Figure 11-74. Exit the Manipulation Parameters dialog box.

The direction of the Motor Shaft needs to be flipped. This is done because by default, its
orientation is not the same as required. The direction of the Motor Shaft will be flipped,
while applying the constraint.

3. Choose the Offset button and then select the faces shown in the Figure 11-74.
The Constraint Properties dialog box is displayed. Set the Orientation to Same
and the Offset value to 0. Update the model to place the Motor Shaft at its proper
location.

Figure 11-73 Motor Shaft inserted at its default Figure 11-74 Faces to be selected for the Offset
location constraint

Next, you need to apply the Coincidence constraint between the axis of the Motor Shaft
and the Blower hub. You will use the Quick Constraint tool to apply this constraint.

4. Choose the Quick Constraint button from the Constraints toolbar and move the
cursor over the Motor Shaft. The axis of the shaft will be displayed as a center line.
Select the axis by clicking over the center line. The axis will now be highlighted in
orange. Similarly, select the axis of the Blower hub. The Coincidence constraint will be
automatically applied between the two selected axes. Update the model to place the Motor
Shaft inside the Blower hub, as shown in Figure 11-75.

Assembling the Motor

Next, you need to assemble the Motor with the Motor Shaft.

1. Insert the Motor in the Blower assembly. By default, it will be placed in such a way that its
body will overlap the existing assembly parts. Therefore, use the Manipulation tool to move
it out into the open space.

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Figure 11-75 Position of the Motor Shaft with

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respect to the Blower shown from the back side

2. Now apply the Offset constraint between the faces shown in the Figure 11-76. Set the
Orientation to Same and the Offset value to zero.

3. Apply the Coincidence constraint between the axis of the shaft and the axis of the hole on

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the back side of the Motor, refer to Figure 11-76. After applying both the constraints, update
the model.

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You will notice that the base of the Motor and the Lower Housing appear to be parallel, but

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there is no constraint applied to both the faces. Therefore, you need to apply the Angle

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constraint to these two faces.

4. Choose the Angle button from the Constraints toolbar. Select the faces, as shown in
Figure 11-76. Select the Parallelism radio button to make the selected faces parallel.

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Figure 11-76 Elements to be selected for applying various constraints

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Assembling the Cover and Turning on the Display of the Upper

Housing
The last component to be assembled is the Cover. After assembling all components, you
need to turn on the display of the hidden Upper Housing.

1. Insert the Cover into the Blower assembly. By default, it will be placed inside the blower.
Use the Manipulation tool to move the Cover away from the assembly. Next, you need to
apply constraints to the Motor Cover.

2. Apply the Contact constraint between the front face of the Motor and the bottom face of the
Cover.

3. Apply the Coincidence constraint between the central hub of the Cover and cylindrical face
of the Motor.

4. Apply another Coincidence constraint between one of the screw holes in the Cover and
Motor. Various faces to be selected for applying these three constraints are shown in
Figure 11-77. After all three constraints are applied, update the model to properly orient
the cover in the Blower assembly.

Figure 11-77 Various faces to be selected for applying the constraints

Next, you need to turn on the display of the Upper Housing.

5. Select the Upper Housing from the specification tree and choose the Hide/Show option
from the contextual menu. The Upper Housing is displayed in the geometry area.

6. Select all constraints under the Constraints heading in the specification tree and hide
them. The Blower assembly is completed. The final assembly is shown in Figure 11-78.

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Figure 11-78 The final Blower assembly.

Creating the Exploded State of the Assembly

After creating the assembly, you can create its exploded state. In the exploded state, all parts
of the assembly are distinctly visible.

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1. Select Product1 from the specification tree and choose the Explode button from
the Move toolbar; the Explode dialog box is displayed.

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2. Select the All levels option from the Depth drop-down list and select 2D from the Type

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drop-down list. Click in the Fixed product area and then select the Lower Housing as the

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product to remain fixed while exploding the assembly.

3. Choose the Apply button from the Explode dialog box to generate the exploded view. The
Information Box will be displayed. Choose the OK button from the Information Box to
close it. The exploded view of the Blower assembly is shown in Figure 11-79.

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4. Choose the OK button from the Explode dialog box and then choose Yes from the Warn-
ing dialog box. The exploded state of the assembly is displayed in the geometry area.

5. To switch back to the assembled mode, choose the Update button from the Tools toolbar.

Saving the File

1. Choose the Save button from the Standard toolbar; the Save As dialog box will be displayed.

2. Browse for the \My Documents\CATIA\c11\Blower Assembly folder and save the file.

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Figure 11-79 The exploded view of the Blower assembly

Tutorial 2
In this tutorial, you will create some components of the Press Tool Base assembly using the
top-down assembly approach. The Press Tool Base assembly is shown in Figure 11-80. The
exploded state of this assembly is shown in the Figure 11-81. The dimensions of all components
are shown in Figures 11-82 and 11-83. The drawing of the complete assembly is shown in
Figure 11-80. (Expected time: 45 min)

Figure 11-80 The Press Tool Base assembly

Note
The assembly shown in Figure 11-80 is not a complete assembly of the Press Tool Base and is only
created to explain the procedure of the top-down assembly approach.

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Figure 11-81 The exploded state of the Press Tool Base assembly

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Figure 11-82 Views and dimensions of the Top Plate, Guide Pillar, and Guide Bush

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Figure 11-83 Views and dimensions of the Bottom Plate

Figure 11-84 Drawing views of the Press Tool Base assembly

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The following steps are required to complete this tutorial:

a. Start a new product file.

b. Create a new part inside the assembly. Modify its name and create features of the base
component, refer to Figure 11-85. In this assembly, the Bottom Plate will be the base compo-
nent.
c. Create the Guide Bush and Guide Pillar as subsequent components inside the product file,

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refer to Figure 11-86 through 11-88.
d. Guide Pillar and Guide Bush are to be duplicated using the Reuse Pattern tool, refer to
Figure 11-89.
e. Create the Top Plate, refer to Figure 11-90.
f. Finally, save the Product file. The Part files will be saved automatically.

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Before you start creating the top-down assembly, create the \My Documents\CATIA\c11\Press
Tool Base folder. You will save the product file of the Press Tool assembly in this folder. All
the Part files will also be automatically saved in the same folder.

Starting a New Product File

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1. Choose the New button from the Standard toolbar and select the Product option from the
List of Types area of the New dialog box. Choose the OK button to start a new Product file.

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2. Invoke the contextual menu by right-clicking on Product1 in the specification tree. Select

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Properties from the contextual menu to display the Properties dialog box.

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3. Choose the Product tab, if it is not chosen, and change the part number to Press Tool Base in
the Part Number edit box. Choose the OK button from the Properties dialog box. Note
that now Press tool is displayed at the top of the specification tree.

When the Product file is saved, it will automatically assign the name Press Tool.

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Creating a New Part Inside the Assembly
1. Select Press Tool Base from the specification tree and choose the Part button from
the Product Structure Tools toolbar.

A new part is started inside the product file and is represented by Part1 in the specification
tree. Also, default planes are displayed in the geometry area. These are the default planes of
the part and its origin is placed over the origin of the assembly coordinate system.

2. Set the part number and the instance name of the new part to Bottom Plate in the Properties
dialog box invoked by right clicking on Part1 in the specification tree.

3. Choose Tools > Options from the menu bar to invoke the Options dialog box. Select
Infrastructure on the left of this dialog box to expand this branch. Now, select Part
Infrastructure from the Infrastructure branch. Select the Keep link with selected object
check box.

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Creating Features of the Bottom Plate

After a new part file is created inside the assembly, you need to invoke the Part Design
workbench to create the features. Since, the Bottom Plate is the base component, you will
now create its features.

1. Click on the plus sign on the left of Bottom Plate in the specification tree to expand its
branch. Now, double-click on the Bottom Plate, which is displayed inside the expanded
branch to invoke the Part Design workbench.

2. Create the Bottom Plate using the part modeling tools. The final model of the Bottom Plate
is shown in Figure 11-85.

Figure 11-85 The final model of the Bottom Plate

3. Double click on Press Tool Base in the specification tree for switching to the Assembly
Design workbench.

4. Apply the Fix constraint to the Top Plate.

Creating the Guide Pillar

Next, you need to create the Guide Pillar by referring to the geometry of the Base Plate.

1. Choose the Part button from the Product Structure Tools toolbar to insert the
second part in the assembly. The New Part: Origin Point dialog box is displayed.

2. Choose the No button from the New Part: Origin Point dialog box to place the origin of
the second part over the origin of the assembly coordinate system.

3. Rename the second component to Guide Pillar and invoke the Part Design
workbench by double-clicking on it.

4. For creating the Guide Pillar, you need to take the reference of the geometry of the Bottom
Plate. Select the bottom face of the Bottom Plate as the sketching plane and invoke the
Sketcher workbench.

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5. Select the circular edge of the left hole having a diameter of 25 and choose the
Project 3D Elements button from the Operation toolbar. The geometry is extracted
from the selected edge and is projected over the sketch plane.

Note that there is no need to provide any dimension to the circle. The size of the extracted
circle is the same as that of the edge of the hole from which it is extracted.

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6. Exit the Sketcher workbench and extrude the sketch, refer to Figure 11-82 for dimensions.

7. Hide the Bottom Plate and apply chamfer on both the ends of the Guide Pillar. This will
complete the feature creation of the Guide Pillar.

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8. Turn on the display of the Bottom Plate and switch back to the Assembly Design workbench.
The Guide Pillar in the assembly is shown in Figure 11-86.

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Figure 11-86 The final Guide Pillar

Creating the Guide Bush

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It is evident from Figure 11-80, that the Guide Bush will be placed over the Guide Pillar.
Therefore, the geometry of the Guide Pillar will be used to create the Guide Bush.

1. Start another part file inside the assembly file and rename it as Guide Bush. Invoke the Part
Design workbench.

2. Select the top face of the Guide Pillar as the sketching plane and draw two concentric
circles. Make the inner circle coincident with the outer edge of the Guide Pillar and apply
the dimension to the outer circle, as shown in the Figure 11-87.

3. Exit the Sketcher workbench and extrude the sketch to 60 units. Now, apply chamfers at
both the outer edges of the Guide Bush.

4. This completes the feature creation of the Guide Bush as shown in Figure 11-88. Return to
the assembly workbench by double clicking on the Press Tool in the specification tree.

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Figure 11-87 Sketch of the Pad feature for creating Figure 11-88 Final Guide Bush
the Guide Bush

Creating the Second set of Guide Bush and Guide Pillar

In the Press Tool Base assembly, Guide Bush and Guide Pillar are used in pairs. Therefore
to create the second set of the Guide Bush and Guide Pillar, you will use the Reuse Pattern
tool. The advantage of using this tool is that the second set of components will be placed at
the desired location without applying any constraints between them.

1. Expand the branch of the Bottom Plate in the specification tree to display the
Rectangular Pattern used for creating holes.

2. Press and hold the CTRL key. Select the RecPattern2 and Guide Pillar from the
specification tree.

3. Choose the Reuse Pattern button from the Constraints toolbar; the Instantiation
on a pattern dialog box is displayed. Choose the OK button to place another Guide
Pillar in the second hole.

4. Similarly, assemble the second Guide Bush over the newly placed Guide Pillar using the
Resume Pattern tool by selecting the rectangular pattern and Guide Bush from the
specification tree.

Once both the components are duplicated, you can close the expanded branch of the
specification tree. Figure 11-89 shows the assembly model, after placing the second set of
Guide Pillar and Guide Bush.

Creating the Top Plate

Top Plate is the last component that will be created in the Press Tool Base assembly. You will
use the reference of the geometries of Bottom Plate and Guide Bush to draw the sketch for
the Pad feature of the Top Plate.

1. Start another part inside the assembly file and rename it as Top Plate. Invoke the Part
Design workbench.

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2. Select the top face of the Guide Pillar as the sketching plane and invoke the Sketcher
workbench.

3. Extract four side edges of the Bottom Plate and the outer circular edge of the Guide Bush
using the Project 3D Elements tool, as shown in Figure 11-90.

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Figure 11-89 The assembly after placing the Figure 11-90 Sketch of the Pad feature for
second set of the Guide Pillar and Guide Bush creating the Top Plate

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4. Exit the Sketcher workbench and extrude the sketch by 30 units by flipping its direction of

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extrusion. Now, create a hole on the top face of the Top Plate.

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This completes the feature creation of the Top Plate.

5. Switch back to the Assembly Design workbench. The final assembly is shown in the
Figure 11-91.

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Figure 11-91 The final Press Tool Base assembly

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Saving the Assembly File

1. Choose the Save button from the Standard toolbar. You need to make sure that you are in the
Assembly Design workbench before saving the assembly. The Save As dialog box is displayed.

2. Browse to the location of the Press Tool Base folder that you created in the beginning of this
tutorial.

3. Choose the Save button from the Save As dialog box; the Save confirmation box is displayed,
as shown in Figure 11-92.

Figure 11-92 The Save confirmation box

4. Choose the Yes button from this confirmation box to save the assembly file, along with all
the Part files.

5. Close the assembly file by choosing File > Close from the menu bar.

SELF-EVALUATION TEST
Answer the following questions and then compare your answers with those given at the end
of this chapter:

1. In the bottom-up assembly design approach, all parts are created in separate part files and
then inserted in to the product file. (T/F)

2. While creating a top-down assembly in CATIA V5, all individual parts created in the
assembly need to be saved separately, after saving the Product file. (T/F)

3. The Angle constraint can be used to make two surfaces parallel to each other. (T/F)

4. The Manipulation tool is used to move and rotate a part present inside an assembly. (T/F)

5. You cannot select a component to fix it at its original position, while exploding an
assembly model. (T/F)

6. The __________constraint is used to place two planar faces at a specified angle with respect
to each other.

7. You can place multiple instances of a component over a predefined pattern by using the
__________tool.

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8. The __________option is selected from the Type drop-down list in the Explode dialog box
to explode all components of the assembly along the 2D plane, which is currently parallel to
the screen.

9. The edges of a component can be snapped on to an edge of another component by using

the __________ tool.

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10. If two parts having the same name are inserted into the assembly file, then the __________
dialog box is displayed.

REVIEW QUESTIONS

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Answer the following questions:

1. The __________ constraint is used to make two cylindrical surfaces concentric.

2. Select the component and then choose the __________ button to hide it from the geometry

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area.

3. The __________ tool can be used to move a component and also apply a constraint to it.

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4. The cross-section of an assembly model can be viewed using the __________ tool.

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5. An existing part can be inserted into a Product file using the _________ button.

6. Which tool is used to calculate the interference between two mating components?

(a) Measure (b) Clash

(c) Smart Move (d) Snap

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7. Which button is used to replace a constraint by another constraint?

(a) Reuse Pattern (b) Replace Component

(c) Change Constraint (d) Replace Constraint

8. Which button is used to apply the most appropriate constraint to the current selection set?

(a) Quick Constraint (b) Change Constraint

(c) Contact Constraint (d) None of these

9. After selecting the Reuse Pattern button, which dialog box is displayed?

(a) Instantiation on a pattern (b) Reuse pattern

(c) Constraint properties (d) Constraint definition

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10. Which constraint is used to fix the position of a part in 3D space?

(a) Contact (b) Fix

(c) Coincidence (d) Angle

EXERCISE

Exercise 1
Create the assembly of the Radial Engine shown in Figure 11-93. The assembly in the exploded state
is shown in Figure 11-94. Note that this exploded view is provided only for your understanding
and has not been generated using CATIA V5. The dimensions of various parts of this assembly
model are given in Figure 11-95 through Figure 11-99.
(Expected time: 3 hr 30 min)

Figure 11-93 The Radial Engine assembly

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 Assembly Modeling 11-61

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Figure 11-94 Exploded view of the Radial Engine assembly

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Figure 11-95 Positioning of the Articulated Rods

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 11-62 CATIA for Designers (Eval Copy CAT 05/06)

Figure 11-96 Views and dimensions of the Master Rod

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 Assembly Modeling 11-63

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Figure 11-97 Views and dimensions of the Piston

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Figure 11-98 Views and dimensions of the Articulated Rod

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 11-64 CATIA for Designers (Eval Copy CAT 05/06)

Figure 11-99 Views and dimensions of the other components

Answers to Self-Evaluation Test

1. T, 2. F, 3. T, 4. T, 5. F, 6. Angle, 7. Reuse Pattern, 8. 2D, 9. Snap, 10. Part number conflicts

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