CATIA V5-6R2014 Design Portfolio

Boeing
Engineering Design and Analysis with Advanced CAD (EDSGN 497k)
Daniel Pfeiffer-Kelly
Section 905
Submitted by: Dmp5444@psu.edu
Submitted to: Xinli@psu.edu
Submitted: 12/10/2016

Model Generated Using CATIA V5

1.
Abstract:
The following design portfolio contains some of my CATIA projects produced in EDSGN
497k. The knowledge I have gained using CATIA is highlighted throughout the models
below. I hope you enjoy!
Table of Contents:
1) Course Syllabus: 3-7
2) Practical Problems & Exercises: 8-13
3) Mini Design Project: 14-16
4) Final Design Project: 16-29
5) Summary & Conclusions: 30
6) Acknowledgments: 30

2.
Course Syllabus:
EDSGN 497K Engineering Design and Analysis
with Advanced CAD (CATIA) (3.0 Credits)
FALL 2016 (August 22 December 09)
http://www.engr.psu.edu/xinli/EDSGN497K/

Course Professor: Xinli Wu, Ph.D., P.E.

Phone number: 814-863-1537

E-mail address: Xinli@psu.edu

Teaching Assistant: Andrew Bellows afb5124@psu.edu, Michael Orner mzo5092@psu.edu

Course Number, Class Time, and Place: EDSGN 497K: 6:00 9:00 PM, Tuesday and Thursday,
315 Hammond

Office hours & location: 12:20 1:10 PM Wednesday, and/or by appointments,

213-S Hammond

Prerequisites: Junior standing or above in an engineering major with knowledge of

E MCH 210 and 211 or equivalent (or approved by the instructor).

Course overview and objectives:

The course objectives are to understand how engineering design efforts are supported through
the use of advanced Computer Aided Design (CAD). Advanced CAD makes creating rich and complex
designs possible. Advanced CAD (in this offering CATIA V5) is used as a design tool to build parts
and assemblies, and to create drawings of those parts and assemblies. Students will learn basic FEA
(Finite Element Analysis) capabilities to conduct structural analysis and computer simulation of
designs. Students will learn how to generate models, establish meshes, apply boundary conditions,
loads, and material properties to the model for structural analysis, and then generate an FEA report.
Through various exercises, design projects with rapid prototyping models, and building design
portfolios, students will obtain a solid foundation in the use of advanced CAD for their designs and
engineering analyses.

Textbook: Richard Cozzens (2013), CATIA V5 Workbook, Release V5-6R2013, SDC

Publications. ISBN 978-1-58503-544-1 (Available at Penn State Bookstore or online
bookstore: www.schroff.com).

Nader G. Zamani (2012), CATIA V5 FEA Tutorials, Release 21, SDC Publications.
ISBN: 978-1-58503-764-3 (Available at Penn State Bookstore or online bookstore:
www.schroff.com).

3.
 Course Calendar:

Week Day/Date Course Text

content
Intro. to the course Cozzens, Chap. 1
Introduction to CATIA V5
Week 1 Tuesday (8/23) Practice Exercises 1-5 on p. 1.16
Navigating the CATIA V5 Environment Cozzens, Chap. 2
Practice Exercises 1-6 on p. 2.40

Sketcher Cozzens, Chap. 3

Practice Exercises 3 on p. 3.47
Week 2 Tuesday (8/30) Part Design Cozzens, Chap. 4
Practice Exercises 3 on p. 4.51

Drafting: creating sheets and views Cozzens, Chap. 5

Practice Exercises 3 on p. 5.42
Week 3 Tuesday (9/6) Drafting: creating text and dimensions Cozzens, Chap. 6
Practice Exercises 3 on p. 6.31

Complex and Multiple Sketch Parts Cozzens, Chap. 7

Practice Exercises 3 on p. 7.40
Assembly Design Cozzens, Chap. 8
Week 4 Tuesday (9/13) Practice Exercises 4 on p. 8.38

Generative Shape Design: Cozzens, Chap. 9

creating surfaces
Practice Exercises 2 on p. 9.47
Week 5 Tuesday (9/20) Generative Shape Design: creating Cozzens, Chap. 10
surface geometry using the sweep tool
Practice Exercises 1-8 on p. 10.26-10.28

DMU Navigator Cozzens, Chap. 11

Practice Exercises 1 on p. 11.29
Week 6 Tuesday (9/27) Real Time Rendering Cozzens, Chap. 12
Practice Exercises 1 on p. 12.27

Parametric Design Cozzens, Chap. 13

Practice Exercises 3 on p. 13.29
Week 7 Tuesday (10/4) Mini Design Project (Due 11/08/2016) Handouts/Online
Advanced CATIA Design Example 1

4.
 Final Design Project (Due 12/12/2016) Handouts/Online
Guidelines for online design portfolio
Advanced CATIA Design Example 2
Week 8 Tuesday (10/11) Introduction to Finite Element Analysis Zamani, Chap. 1
Capabilities and limitations of the FEA in
CATIA

Analysis of a Bent Rod with Solid Zamani, Chap. 2

Elements
Practice Exercises 1 on p. 2-20
Week 9 Tuesday (10/18) Axially Loaded Block with Stress Zamani, Chap. 3
Concentration
Practice Exercises 2 on p. 3-23

Deformation of an I-beam under Self- Zamani, Chap. 5

weight
Practice Exercises 1 on p. 5-13
Week 10 Tuesday (10/25) C-clamp Deformed with Enforced Zamani, Chap. 6
Displacement
Practice Exercises 1 on p. 6-12

FEA Modeling of the Bent Rod with beam Zamani, Chap. 7

Elements
Practice Exercises 1 on p. 7-13
Week 11 Tuesday (11/1) Bending of a Notched Specimen with Zamani, Chap. 9
Smooth Virtual Part
Practice Exercises 1 on p. 9-18

Modeling Mismatch in Shell Thickness Zamani, Chap. 11

and Surface Mesh
Practice Exercises 1 on p. 11-18
Week 12 Tuesday (11/08) FE Model of a Bearing-Shaft Assembly Zamani, Chap. 14
Using Analysis Connection
Practice Exercises 1 on p. 14-28

Analysis of a Tensile Specimen as an Zamani, Chap. 16

Assembly
Practice Exercises 2 on p. 16-28
Week 13 Tuesday (11/15) Analysis of a Fastened Assembly Zamani, Chap. 17
Practice Exercises 1 on p. 17-28

Week 14 Thanksgiving Holidays, No classes.

Week 15 Tuesday (11/29) Working on Design Project

5.
 Working on Design Portfolio
Week 16 Tuesday (12/6) Design Project Due
Online Design portfolios Due
Class concluded

Class Policies:

The following are some ground rules to help us maintain a steady progress through the semester:

1. Assignments submitted after its due time will receive a 20% deduction. A further 20%
reduction will be applied for every week beyond the first.
2. Punctual attendance is mandatory for all the class periods. Course grade will be dropped to the
next lower grade for every class missed. All excused absences must be supported by written
documentation, such as doctor's receipt, Penn State athletics travel notice, ROTC notice, etc.

Academic Integrity:

Senate Policy 49-20 Academic Integrity

Definition and expectations: Academic integrity is the pursuit of scholarly activity in an open,
honest and responsible manner. Academic integrity is a basic guiding principle for all academic
activity at The Pennsylvania State University, and all members of the University community are
expected to act in accordance with this principle. Consistent with this expectation, the University's
Code of Conduct states that all students should act with personal integrity, respect other students'
dignity, rights and property, and help create and maintain an environment in which all can succeed
through the fruits of their efforts.

Academic integrity includes a commitment not to engage in or tolerate acts of falsification,

misrepresentation or deception. Such acts of dishonesty violate the fundamental ethical principles of
the University community and compromise the worth of work completed by others.

The Penn State Principles:

1. I will respect the dignity of all individuals within the Penn State community;
2. I will practice academic integrity;
3. I will demonstrate social and personal responsibility;
4. I will be responsible for my own academic progress and agree to comply with all University
policies.

Related sites:
Penn State Principles, http://www.psu.edu/ur/2001/principles.html
Code of Conduct, http://www.sa.psu.edu/ja/codeconduct.html
Academic integrity, http://www.psu.edu/ufs/policies/47-00.html - 49-20

Grading System:

o Class attendance: 10%

o In-class exercises and homework assignments: 40%

6.
 o Mini-Design Project with Rapid Prototyping: 15%
o Final Design Project: 25%
o Online Design Portfolios: 10%

Grades will be determined based your performance on the activities listed above. Final
letter grades will be assigned as follows:
> 93 = A 90-93 = A- 87-89 = B+ 83-86 = B 80-82 = B-
75-79 = C+ 70-74 = C 60-69 = D below 60 = F

7.
Practical Problems & Exercises:

An assembly model generated in CATIA.

8.
Lesson 5 exercise 13, model of beam deflecting

9.
Von mises display in a foot pedal. Concentration of stress can be seen in the
corner.

10.
Von mises display from exercise 11 lesson 18. Stress concentration can be
observed in the central circle.

11.
Lesson 17 exercise 28, bracket deformation from simulated bolt load.

12.
Lesson 16 exercise 28, generative structural analysis of clamped triangular model
with pressure load.

13.
Mini Design Project:
EDSGN 497 K Engineering Design and Analysis with CATIA

Fall
2016

Mini Design Project for 3D Printing Due Date: Nov. 8, 2016

Design Task:

Design and produce a prototype via 3D printing of an innovative perfume bottle.

Design Specifications:

The bottle is used for a volume of 100 mL (or ~ 3.4 FL

OZ). Note: 1.0 FL OZ = 29.5735 mL, and 1000 mm3 = 1.0

mL;

The maximum size of the bottle should not be greater than 80 x 80 x 80 mm3;

The minimum thickness of the perfume bottle should not be less than 2 mm to ensure
a successful rapid prototyping.

Deliverables and Evaluations:

A 3D solid model generated by CATIA V5: 60%

Detail drawings of the bottle (multiviews with full dimensions): 20%

Prototype by 3D printing: 10%

Creativity 10%

Total: 100%

Note: After you finalize your design, please save it as

14.
YourFirstLastName_EDSGN497K_FA16.stl and then email the stl file to
psu3dprinting@gmail.com for 3D printing of your designed perfume
bottle.

The due date is Nov. 8, 2016 for you to email your stl file to psu3dprinting@gmail.com. You
should expect to get your prototype back within two weeks or so after you submit your stl
file.

Detail Drawing View of Perfume Bottle Design.

15.
 3D model of perfume bottle generated in CATIA V5.

3D printed perfume bottle model, image of bottle cap can be seen to the right.
16.
Final Design Project:
EDSGN 497K Engineering Design and Analysis with Advanced
CAD
Design Task:

Design a chair capable of holding a person of 300 lbs and then conduct a finite
element analysis to verify/prove that the chair is safe under such a load.

Design Specifications:

The chair must be able to withhold up to 300 lbs;

The chair should be ergonomically sound;
The chair should be durable;
The chair should be comfortable;
The chair should cost no more than $100 (Note: Use mcmaster.com for estimation);
The chair should be safe.

Major Deliverables:

A complete design report (part of the design portfolio for the course) including the
following items:
o A solid model generated by CATIA;
o A complete set of working drawings including an assembly drawing and detail
drawings for non-standard
parts;
o A complete FE analysis report.

Evaluation:
The total value is 25% of the course

grade. The breakdown is:

Assembly drawing: 40%

Detail drawings: 20%
3-D solid model: 20%
FEA Report: 20%

Total: 100%

17.
The following is an image taken from CATIA of the final chair assembly model.
Main design features include solid legs with central support. The support can be
used for item or book storage. The chair seat is adequately thick, designed to
maintain over 300 pounds of force. Lastly, the chair back is crafted with bright oak
wood, aesthetically cut into a modern, sleek look.

18.
 Drawing view of assembly with bill of materials attached.

19.
 Drawing view of non-standard chair legs.

20.
 Drawing view of non-standard chair base

21.
 Drawing view of non-standard chair back

22.
FEA Analysis: 232323

23.
24.
25.
26.
27.
28.
 Close up screen shot of FEA analysis.

29.
Summary & Conclusions:
As you can see from my portfolio, I have learned a lot about CATIA V5 during the
semester. The broad range of projects exposed me to countless different
capabilities of CATIA. Hopefully I can potentially apply this knowledge to a future
job working with the program!
Acknowledgments:
I would like to acknowledge Xinli Wu as well as the class TAs for their help and
assistance with CATIA V5. It has been a fantastic semester working together and
learning more about CATIA!

30.