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11Assembly ModelingLearning ObjectivesAfter completing this chapter you will be able to: Insert components into an assembly file. Create bottom-up assemblies. Insert components into a product file. Move and rotate components inside an assembly. Add constraints to the individual components. Create top-down assemblies. Edit assembly designs. Create the exploded state of an assemblies.Evaluation chapter. Logon to www.cadcim.com for more detailsChapter

11-2CATIA for Designers (Evaluation Chapter F007/004)Evaluation chapter. Logon to www.cadcim.com for more detailsASSEMBLY MODELINGAssembly modeling is the process of creating designs that consist of two or more componentsassembled together at their respective work positions. The components are brought togetherand assembled in Assembly Design workbench by applying suitable parametric assemblyconstraints to them. The assembly constraints allow you to restrict the degrees of freedom ofcomponents on their respective work positions. The assembly files in CATIA are called Productfiles. There are two methods to invoke the Assembly Design workbench of CATIA. Theprimary method to start a new product file is by selecting File New from the menu bar toopen the New dialog box From this dialog box select Product, as shown in Figure 11-1. Theother method of invoking the Assembly Design workbench is by choosing Start MechanicalDesign Assembly Design from the menu bar.Figure 11-1 The Product optionselected from the New dialog boxA new file is started in the Assembly Design workbench. The screen display of CATIA afterstarting the new file in the Assembly Design workbench is as shown in Figure 11-2. You willnotice that the toolbars related to assembly are displayed. The tools available in these toolbarswill be discussed later in this chapter.Types of Assembly Design ApproachIn CATIA you can create assembly models by adopting two types of approaches. The firstdesign approach is the bottom-up approach, and the second one is the top-down approach.Both these design approaches are discussed below.Bottom-up AssemblyThe bottom-up assembly is the most preferred approach for creating assembly models. Inthis of approach, the components are created in the Part Design workbench as (*.CATPart)file. Then the product (*.CATProduct) file is started and all the previously created componentsare inserted and placed in it using the tools provided in the Assembly Design workbench.After inserting each component, constraints are applied to position them properly in the 3Dspace with respect to other components.Adopting the bottom-up approach gives the user the opportunity to pay more attention tothe details of the components as they are designed individually. Because the other componentsare not present in the same window, it becomes much easier to maintain a relationship between

11-3Figure 11-2 Screen display after starting a new file in the Assembly Design workbenchthe features of the current component. This approach is preferred for large assemblies,especially those having intricate individual components.Top-down AssemblyIn the top-down assembly design approach, components are created inside the AssemblyDesign workbench. Therefore, there is no need to create separate part files of the components.This design approach is completely different from the bottom-up design approach. Here youhave to start the product file first and then, one by one, create all components. Note thateven though the components are created inside the product file, they are saved as individualpart files and can be opened separately later.Adopting the top-down design approach gives the user the distinctive advantage of using thegeometry of one component to define the geometry of the other. Here the construction andassembly of the components takes place simultaneously. As a result of this, the user can viewthe development of the product in real time. This design approach is highly preferred, whileworking on a conceptual design or a tool design where the reference of previously createdparts is required to develop a new part.NoteAn assembly can also be created by using the combination of both the top-down and bottom-upassembly design approaches.Evaluation chapter. Logon to www.cadcim.com for more detailsAssembly Modeling

11-4CATIA for Designers (Evaluation Chapter F007/004)Evaluation chapter. Logon to www.cadcim.com for more detailsCREATING BOTTOM-UP ASSEMBLIESAs mentioned earlier, while creating an assembly using the bottom-up approach, thecomponents are created in separate part files and are then inserted into the assembly file.They are assembled at their working position by applying assembly constraints to them. Tocreate an assembly using this approach, it is recommended to insert the first component andfix its position after properly orienting it in the 3D space. The other components can beinserted and positioned with reference to the first component. The method used for placingcomponents inside the product file is discussed below.Inserting Components in a Product fileMenu:Toolbar:Insert Existing ComponentProduct Structure Tools Existing ComponentTo insert the first component in the product file, choose the Existing Componentbutton from the Product Structure Tools toolbar. You are prompted to select acomponent into which the existing component will be inserted. You need to selectProduct1 from the Specification Tree. After you do so, the File Selection dialog box isdisplayed. Browse the location where the part files are saved and double-click on thecomponent to be inserted; the component will be inserted in the current product file. Youwill notice a new entry in the Specification Tree, which is referred to as Part1. Part1 is adefault part number assigned by the software to the component. A default part number isassigned to each component that is inserted in the assembly, unless it is changed by the user.Inside the assembly, the components are referred to by their part number and not by theirfile name. The process of changing the part number of the component is discussed later inthis chapter. It is always recommended to fix the first component using the Fix constraintafter inserting. The method of applying the Fix constraint to the component is discussedlater in the chapter.The above procedure needs to be repeated for inserting the next component. When youinsert additional components, the Part number conflicts dialog box is displayed, as shownin Figure 11-3. This dialog box is displayed because there is a clash between the part numbersof the previously inserted component and the currently inserted component. Note that inthe selection area of the dialog box, the numbers of both the components are displayed asPart1, but the names of the files are different. You can change the part number of theFigure 11-3 Part number conflict dialog box

Assembly Modeling11-5If you select the component to be renamed and choose the Automatic rename button, thepart number of the selected component is renamed from Part1 to Part1.1. Choose the OKbutton from the Part number conflicts dialog box to insert the second component into theProduct file. Follow the same procedure to rename the part number, while inserting othercomponents. Note that while inserting the third component, the first time when you renamethe component using the Automatic Rename option the part number is changed to Part1.1.Because this part number is already assigned to the second component, the Part numberconflicts dialog box is again displayed after choosing the OK button and shows the conflictbetween the second and third component. You need to choose the Automatic rename buttonagain to change the part number of the third component. Now, the third component will berenamed from Part1.1 to Part1.1.2. Choosing the OK button will insert the third componentinto the product file. This means if you are inserting the nth component, the automatic renamebutton has to be used n-1 times. This way the part number of every new component keeps onchanging in a similar fashion, and the same is represented in the Specification Tree, asshown in Figure 11-4.Figure 11-4 Specification Tree showing four componentsIf you choose the Rename button from the Part number conflicts dialog box, the Part Numberdialog box is displayed, as shown in Figure 11-5.Figure 11-5 The Part Number dialog boxIn this dialog box, you can enter the new part number for the selected component based onyour requirement. After typing the new part number in the text box provided in the dialogbox, choose the OK button to exit the Part Number dialog box. Now, choose the OK fromthe Part number conflicts dialog box to insert the component in the product file. Ideally thepart number entered should be the same as the file name. If you enter the same part numberfor two different components, it will not be accepted by the software, and the Part numberconflicts dialog box will again be displayed. Again choose the Rename button and enter aunique name for that part such that it does not conflict with any other part number. Theadvantage of using this option is that the user can enter the desired part number, which canEvaluation chapter. Logon to www.cadcim.com for more detailscomponent using the options available in this dialog box. There are two active buttons availableon the right of the selection area of this dialog box: Rename and Automatic Rename.

11-6CATIA for Designers (Evaluation Chapter F007/004)Evaluation chapter. Logon to www.cadcim.com for more detailsbe useful especially when the individual components are referred to in the an assembly usingnumber coding. The Specification Tree showing individual part numbers is shown inFigure 11-6.Figure 11-6 Specification Tree showingfour components with unique part numbersNote that in the Specification Tree, the part numbers of each component is suffixed by theinstance number, which is displayed within parenthesis. This instance number is generatedby the software itself and is unique for each component.When a component is inserted into a product file, its placement in the 3D space depends onthe location of its default planes. The default planes of the component are placed over thedefault planes of the product file. The default planes of the product file are not visible, butare present at the center of the screen, unless moved by panning. When more than onecomponents are inserted into the product file, the default planes of all components are placedone over the other hence appearing as one set of default planes. When the components aremoved away, the defaults planes of each component are distinctly visible. You will learn moreabout moving the components later in this chapter.NoteIf the default planes of the inserted components are not visible, this means its visibility is turnedoff in its part file. Therefore, you need to turn on the visibility of the reference planes in the partfile to display them in the assembly file.Tip. You can also insert components in the product file using the Copy and Pastemethod. To insert the components using this method, open the part file of thecomponent that you need to insert. Select the name of the component from top of theSpecification Tree, and choose Copy from the contextual menu. Now, switch tothe product file, and select the name of the assembly on top of the SpecificationTree. Invoke the contextual menu, and choose Paste from it; the component willbe placed in the assembly.Moving Individual ComponentsGenerally, the components when inserted in a product file are overlapped by other componentsplaced earlier. As a result, their visualization is hampered, and it becomes difficult to applyconstraints to them. Therefore, it is necessary to reposition the components in the 3D spacesuch that they are distinctly visible, and the mating references are accessible in the assembly.CATIA allows you to move and rotate the individual unconstrained components inside the

Assembly Modeling11-7product file without affecting the position and location of the other components. Thereorientation of the component can be carried out using three different methods, which arediscussed in the following sections.Toolbar:Menu:Move ManipulationEdit Move ManipulateThe Manipulation tool is used to move or rotate the component freely by draggingthe cursor. To translate or rotate any component, choose the Manipulation buttonfrom the Move toolbar; the Manipulation Parameter dialog box is displayed, asshown in Figure 11-7.Figure 11-7 Manipulation Parameter dialog boxThis dialog box contains buttons arranged in three rows. The currently active button isdisplayed on the top of the dialog box. The buttons in the first row are used to translate thecomponent along a particular direction. There are four buttons in this row, which are discussedbelow:The Drag along X axis button is the first button and is chosen by default. Thisbutton is used to translate the selected component along the X-axis of the assemblycoordinate system. To move the component, select the component to move and thendrag it. After moving the component to the desired location, release the left mouse button.The Drag along Y axis button is used to translate the component along the Y-axis ofthe assembly coordinate system. It works similar to the button discussed above. Afterchoosing the Drag along Y axis button, select the component to move and then drag it.The Drag along Z axis button is used to translate the component along the Z-axis ofthe assembly coordinate system.The Drag along any axis button is used to move the component along a selecteddirection. After choosing the Drag along any axis button, you need to select a directionto define the translation axis. This direction can be a line, an edge, or an axis of aEvaluation chapter. Logon to www.cadcim.com for more detailsMoving and Rotating Using the Manipulation Tool

11-8CATIA for Designers (Evaluation Chapter F007/004)Evaluation chapter. Logon to www.cadcim.com for more detailscylindrical feature. After selecting the axis of translation, drag the selected component alongthe selected direction.The buttons in the second row of the Manipulation Parameter dialog box are used to movethe selected component along a particular plane. These planar translation buttons arediscussed below.The Drag along XY plane button is used to translate the selected component parallelto the XY plane of the assembly coordinate system.The Drag along YZ plane button is used to translate the selected component parallelto the YZ plane of the assembly coordinate system.Drag along XZ plane button is used to translate the selected component parallel tothe XZ plane of the assembly coordinate system.Drag along any plane button is used to move the selected component parallel to aspecified plane. After choosing the Drag along any plane button, you need to selecta plane for planar translation. This plane can be a construction plane, a planar face,or a surface. After selecting the plane for translation, select the component to move and thendrag it on the selected plane.The buttons on the third row of the Manipulation Parameter dialog box are used to rotate theselected component around an axis. These rotation buttons are discussed below.The Drag around X axis button is used to rotate the selected component around theX-axis of the assembly coordinate system.The Drag around Y axis button is used to rotate the selected component around theY-axis of the assembly coordinate system.The Drag around Z axis button is used to rotate the selected component around theZ-axis of the assembly coordinate system.The Drag around any axis button is used to rotate the selected component around aspecified axis. After choosing the Drag around any axis button, you need to select aline to define the rotation axis. This line can be an edge of the component or an axisof a cylindrical feature. After selecting the axis for rotation, select the component to rotateand then drag it.The With respect to constraints check box is selected to move or rotate the componentswithin its available degrees of freedom after applying constraints. You will learn more aboutapplying constraints later in this chapter.

Assembly Modeling11-9Moving Components Using the Snap ToolMove Snap SnapEdit Move SnapThe Snap tool is used to move the component by snapping the geometric element offirst component on the other component or on the same component. The movementof the component depends on the selection of the geometric elements. The elementselected first will move to snap the second element. For example, if you first select a line andthen a point, the line will be reoriented in such a way that it passes through the selectedpoint.To move a component using the Snap tool, choose the Snap button from the Move toolbar.You are prompted to select on a component the first geometric element: an axis system, apoint, a line or a plane. Select a suitable geometrical element that will be projected on thenext selection. In Figure 11-8, the upper right edge of the left component is selected as thefirst geometrical element.Figure 11-8 Geometric elements selected to snapNext, you are prompted to select on the same component or on another component thesecond geometric element: a point, a line or a plane. Select the second geometric element onwhich you need the first selection to be snapped. In Figure 11-8, the upper left edge of theright component is selected as the second geometric element. The first selection will besnapped to the second selection, and a green arrow will be displayed at the snapping location,as shown in the Figure 11-9. You can click on the arrow to reverse the snapping direction, elseclick anywhere in the geometry area to exit the tool. Figure 11-10 shows the components,after the snapping direction is reversed.In some cases the arrows are not displayed when you snap the two elements such as snappinga point to a point, a point to surface, a point to a cylindrical surface or a planar surface, andso on.Evaluation chapter. Logon to www.cadcim.com for more detailsToolbar:Toolbar:

Evaluation chapter. Logon to www.cadcim.com for more details11-10CATIA for Designers (Evaluation Chapter F007/004)Figure 11-9 Position of components aftersnappingFigure 11-10 Position of components aftersnapping direction is reversedMoving Components Using the Smart Move ToolToolbar:Menu:Move Snap Smart MoveEdit Move SnapThe Smart Move tool works as a multipurpose tool. This tool has the capability ofmanipulating and snapping components and can also apply constraints to them, ifrequired. To invoke this tool, choose the down arrow besides the Snap button toinvoke the Snap toolbar. Choose the Smart Move button to invoke the Smart Move dialogbox. Choose the More button to expand it, as shown in Figure 11-11.Figure 11-11 The expanded Smart Move dialog boxIf the Automatic constraint creation check box is selected, a permanent constraint will beapplied between the selected elements of the components to be snapped and the same willbe displayed in the Specification Tree. If this check box is not selected, the components will

Assembly Modeling11-11The Quick Constraint area displays the constraints in a hierarchial order. These constraintswill be applied to the components, while they are being snapped. If more than one constraintcan be applied to the current selection set, then priority will be given to the constraint, whichon the top in the hierarchy. To change the position of a constraint, select it and choose theUp or Down arrows on the right side of the Quick Constraint area.After settings the options in this dialog box, select the first geometric element on a component,which can be a point, line, plane, planar face, or circular face. Now, select the second geometricelement on the other component. The suitable constraint will be applied between the twocomponents, depending on the current selection set. A green arrow may be displayed at theconstraint location. You can click on this green arrow to reverse the orientation of themating components. The component from which the first selection is made will move to snapthe component on which the second element is selected. After the components are reoriented,choose the OK button from the Smart Move dialog box to complete the operation. Figure 11-12shows two cylindrical surfaces to be selected and Figure 11-13 shows the resulting concentricconstraint applied between the two surfaces.Figure 11-12 Surfaces to be selectedFigure 1-13 Resulting constraint appliedThe Smart Move tool can be invoked along with a viewer, which makes the selection ofgeometric elements easier. To invoke the viewer, first select the components that need to bemoved and then choose the Smart Move button from the Snap toolbar. This time the SmartMove dialog box is displayed with a viewer on top of it. The partial view of the Smart Movedialog box is shown in Figure 11-14. The component selected first is displayed in the viewer.The part number of the displayed component is displayed on top of the viewer. Only onecomponent is displayed in the viewer and its geometric element can be easily selected as youcan zoom in and rotate the component in it. This is especially helpful when there are anumber of components in the geometry area and some of the components are fully or partiallyplaced inside another component. After selecting the geometric element of the firstcomponent, choose the Next component button from the Smart Move dialog box. Note thatthis button will not be available if you select only one component before invoking the SmartEvaluation chapter. Logon to www.cadcim.com for more detailsbe repositioned but no permanent constraint will be applied. You will learn more aboutapplying constraints later in this chapter.

Evaluation chapter. Logon to www.cadcim.com for more details11-12CATIA for Designers (Evaluation Chapter F007/004)Figure 11-14 The partial view of the Smart Move dialog boxwith viewerMove dialog box. Now, the other component is displayed in the viewer and you can select itsgeometric element. Note that while you zoom or rotate the component in the viewer, theactual orientation of the component in the geometry area is not changed. After the selectionsare made from the viewer, the components are reoriented in the geometric area. Now, choosethe OK button to close the Smart Move dialog box.Manipulating Components using the CompassThe orientation of the components can also be manipulated using the compass available onthe top right corner of the geometry area. To move a component using the compass, you firstneed to associate it with the component that needs to be moved or rotated. To associate thecompass to a part, move the cursor over the red square displayed on the base of the compass.When the selection cursor is replaced by the move cursor represented by fourdirectional arrows, hold down the left mouse button, and drag the compass on the surface ofthe component to be manipulated. Once the compass is moved, a black dot appears at itsoriginal location. To associate the compass with a component, place it on the surface of thecomponent by releasing the left mouse button. The black dot is no longer displayed. Tomove the component, place the cursor on any of the straight edges of the compass. The edgeare highlighted in orange and the cursor is replaced by the hand symbol. Press and holddown the left mouse button and drag the cursor along the highlighted edge to move thecomponent in that direction. After moving it to the desired location, release the left mousebutton. Similarly, to rotate the component, place the cursor over any of the circular edgesand when the hand symbol is displayed, drag the cursor along that edge.Once the manipulation is over you need to place the compass back at its original position. Todo so, move the cursor on the red square on the base of the compass. Once the move cursorsymbol is displayed, drag the cursor anywhere in the geometry area away from all thecomponents in the assembly and release the left mouse button.

Assembly Modeling11-13Applying ConstraintsAfter placing the components in the product file, you need to assemble them. By assemblingthe components, you will constrain the degree of freedom of the components. As mentionedearlier, the components are assembled using the constraints. Constraints help you to preciselyplace and position the components with respect to the other components and the surroundingsin the assembly. If all degrees of freedom of all components of the assembly are restricted, itis called a fully constrained assembly. Else it is called a partially constrained assembly. Ifsome mechanism needs to be created after assembling the components, some degrees offreedom of the assembly needs to be kept free intentionally, so that movements can be achievedin that direction. Various types of constraints available in CATIA are discussed below.Fix Component ConstraintMenu:Toolbar:Insert FixConstraints Fix ComponentThe Fix Component constraint is used to fix the location of the selected componentin the 3D space. Once the orientation of the component is fixed, its orientationcannot be changed. To invoke this tool, choose the Fix Component button from theConstraints toolbar; you are prompted to select the component to be fixed. You can selectthe component from the geometry area or from the Specification Tree. Once the componentis selected, an anchor symbol is displayed on the component. Now, other components canbe constrained with respect to the fixed component. While doing so, the orientation of thebase component will not be altered and the other components will be reoriented to apply theconstraints. It is always advisable to fix the base component at its default location so that itcan be used as a reference for other components. The Fix Component constraint is displayedin the Specification Tree. To view the applied constraints, expand the Constraints optionfrom the Specification Tree.Coincidence ConstraintMenu:Toolbar:Insert CoincidenceConstraints Coincidence ConstraintThe Coincidence Constraint is applied to coincide the central axis of the cylindricalfeatures that are selected from two different components. This option can also beused to apply Coincident constraint between edges, points, planes or planar faces.To invoke this tool, choose the Coincidence Constraint button from the Constraints toolbar;the Assistant dialog box is displayed that provides information about the selected constraint.You can select the Do not prompt in the future check box, if you do not want to display thisdialog box again. Now, move the cursor over a cylindrical surface to display the central axis.When the preview of the central axis is displayed, as shown in Figure 11-15, click the leftEvaluation chapter. Logon to www.cadcim.com for more detailsNoteWhen the compass is placed back in its original location, the orientation of the compass remainsthe same as it was after manipulating the component. This may lead to confusion. To bring thecompass back to its default orientation, place the compass over a perfectly horizontal surface.Then place the compass back at its default location.

11-14CATIA for Designers (Evaluation Chapter F007/004)Evaluation chapter. Logon to www.cadcim.com for more detailsmouse button to select it. Similarly, select the axis of the second component, as shown inFigure 11-16.Figure 11-15 Central axis of the first componentto be selectedFigure 11-16 Central axis of the secondcomponent to be selectedOnce the two axes are selected, the Coincidence constraint is applied between them and thecoincidence symbol is displayed, as shown in Figure 11-17. You will notice that althoughthe Coincidence constraint is applied between the two components, the components arenot assembled with respect to the constraint applied. Instead, a line connecting the twoconstraint is displayed. To position the components, choose the Update All button from theTools toolbar or press CTRL U from the key board. Now, the components will be placedsuch that the two selected cylindrical surfaces become concentric, as shown in Figure 11-18.Click once in the geometry area to remove the constraint from the current selection set. Thesymbol of the constraint is displayed in green on the assembled components.Figure 11-17 Coincidence constraint appliedbetween two componentsFigure 11-18 Position of the components afterupdatingTip. If you select planar faces or planes to apply the coincident constraint, theConstraint Properties dialog box is displayed. Choose the OK button from thisdialog box. You will learn more about this dialog box later in this chapter.

Assembly Modeling11-15Contact ConstraintInsert ContactConstraints Contact ConstraintThe Contact Constraint is applied to make a surface to surface contact between twoselected elements from two different components. The elements to be selected canbe planes, planar faces, cylindrical faces, spherical faces, conic faces, or circularedges. To invoke this tool, choose the Contact Constraint button from the Constraints toolbar;you are prompted to select the first geometric element of the Contact constraint. Select theelement from the first component. Next, you are prompted to select the geometric elementto place in contact with the first selection. Select the element from the second component. AContact constraint will be applied between the two elements and the component will beplaced with respect to the constraints after updating. The Contact constraint symbol willbe displayed on the assembled components. Figure 11-19 shows the faces to be selected andFigure 11-20 shows the resulting constraint applied to the components.Figure 11-19 Planar faces to be selectedFigure 11-20 Position of components afterconstraint is applied and updatedNoteIf you apply Contact constraint between two cylindrical surfaces or a cylindrical surface and aplanar face or plane, the Constrain

and assembled in Assembly Design workbench by applying suitable parametric assembly constraints to them. The assembly constraints allow you to restrict the degrees of freedom of components on their respective work positions. The assembly files in CATIA are called Product files. There are two methods to invoke the Assembly Design workbench of .

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