CATIA V5 Design Portfolio

The Pennsylvania State University

EDSGN 497K: Engineering Design and

Analysis with Advanced CAD

Submitted by: Ian Kopack (​iankopack@gmail.com​)

to: Xinli Wu (​Xinli@psu.edu​)

April 25th, 2017

Abstract
During the spring 2017 semester of my undergraduate mechanical engineering
studies at the Pennsylvania State University, I enrolled in the course EDSGN 497K:
Engineering Design and Analysis with Advanced CAD. Throughout my time in this
course, I followed instructional workbooks to gain a working knowledge of CATIA V5
and completed various practice assignments and projects to exemplify my capabilities
with the software.

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 Table of Contents

1.0 Course Syllabus 2

2.0 Practice Exercises: Basic CATIA Functions 4

2.1 Part Design 4
2.2 Drafting 5
2.3 Complex and Multiple-Sketch Parts 6
2.4 Assembly Design 7
2.5 Generative Shape Design I 8

3.0 Practice Exercise: Advanced CATIA Design 9

3.1 Teapot Design 9

4.0 Practice Exercises: Finite Element Analysis in CATIA 10

4.1 Analysis of a Bent Rod with Solid Elements 10
4.2 Axially Loaded Block with Stress Concentration 11
4.3 Deformation of an I-beam under Self-weight 12
4.4 C-clamp Deformed with Enforced Displacement 13
4.5 FEA Modeling of the Bent Rod with beam Elements 14
4.6 Bending of a Notched Specimen with Smooth Virtual Part 15
4.7 Modeling Mismatch in Shell Thickness and Surface Mesh 16
4.8 FE Model of a Bearing-Shaft Assembly Using Analysis Connection 17
4.9 Analysis of a Tensile Specimen as an Assembly 18
4.10 Analysis of a Fastened Assembly 19

5.0 Mini-Design Project: 3D Printing of a Perfume Bottle 20

5.1 3D Solid Model 21
5.2 Detail and Assembly Drawings 22
5.4 3D-Printed Prototype 24

6.0 Final Design Project: Design and FEA of a Chair 25

6.1 3D Solid Model 26
6.2 Detail and Assembly Drawings 27
6.3 FEA Report 29

7.0 Summary and Conclusions 33

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1.0 Course Syllabus

The course syllabus for this course, EDSGN 497K, can be found at the link below:

http://sites.psu.edu/iak5024/edsgn497_section905_syllabus_sp17-1ihpich/

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2.0 Practice Exercises: Basic CATIA Functions
The following are the topics covered and images and/or renders of the practice
exercises completed from the book: ​CATIA V5 Workbook​ by Richard Cozzens:

2.1 Part Design

Practice exercise 4.3​:

4
2.2 Drafting
Practice exercise 6.3​:

5
2.3 Complex and Multiple-Sketch Parts
Practice exercises 7.3 and 7.5​:

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2.4 Assembly Design
Practice exercise 8.4​:

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2.5 Generative Shape Design I
Practice exercise 9.2​:

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3.0 Practice Exercise: Advanced CATIA Design
The following are images and/or renders captured of the practice exercise completed
from the book: ​CATIA for Designers​ by Sham Tickoo:

3.1 Teapot Design

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4.0 Practice Exercises: Finite Element Analysis in CATIA
The following are the topics covered and images and/or renders of the practice
exercises completed from the book: ​CATIA V5 FEA Tutorials​ by Nader G. Zamani:

4.1 Analysis of a Bent Rod with Solid Elements

Practice exercise 2.1​:

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4.2 Axially Loaded Block with Stress Concentration
Practice exercise 3.2​:

11
4.3 Deformation of an I-beam under Self-weight
Practice exercise 5.1​:

12
4.4 C-clamp Deformed with Enforced Displacement
Practice exercise 6.1​:

13
4.5 FEA Modeling of the Bent Rod with beam Elements
Practice exercise 7.1​:

14
4.6 Bending of a Notched Specimen with Smooth Virtual Part
Practice exercise 9.1​:

15
4.7 Modeling Mismatch in Shell Thickness and Surface Mesh
Practice exercise 11.1​:

16
4.8 FE Model of a Bearing-Shaft Assembly Using Analysis
Connection
Practice exercise 14.1​:

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4.9 Analysis of a Tensile Specimen as an Assembly
Practice exercises 16.2​:

18
4.10 Analysis of a Fastened Assembly
Practice exercise 17.1​:

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5.0 Mini-Design Project: 3D Printing of a Perfume Bottle
As an intermediate design project for this course, I was tasked with designing a
uniquely-shaped perfume bottle. I was required to develop basic drawings for the
product’s components and assembly, and have the bottle design 3D printed by
resources provided by Penn State’s College of Engineering department. Below are the
specific requirements provided by the instructor for this project:

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)
● The maximum size of the bottle should not be greater than 80 x 80 x 80 mm​3

Major Deliverables:
● A 3D solid model generated by CATIA V5
● Detail drawings of the bottle (multiviews with full dimensions)
● Prototype by 3D printing

Comments:
The design I developed was a pyramid-shaped perfume bottle with some decorative
extruded block elements. In the process of designing the perfume bottle to the required
specifications, I discovered some unique tricks that allowed me to monitor the volume of
the internal cavity while modifying other design parameters. This allowed me to get very
close to the exact value of 3.4 fluid ounces required. Drawings and photos of the final
design can be seen in the sections that follow.

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5.1 3D Solid Model

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5.2 Detail and Assembly Drawings

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5.4 3D-Printed Prototype

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6.0 Final Design Project: Design and FEA of a Chair
As a final design project for this course, I was tasked with designing a chair product. I
was required to develop drawings for the product’s components and assembly, and
obtain results from a finite element analysis. Below are the specific requirements
provided by the instructor for this project:

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 (using mcmaster.com for estimation)
● The chair should be safe

Major Deliverables:
A complete design report including the following items:
● A solid model generated by CATIA
● A complete set of working drawings including an assembly drawing and detail
drawings for non-standard parts
● A complete FEA report

Comments:
The chair designed is a simple assembly consisting of four posts, a seat platform, and a
seat back. The entire chair was made out of an Oak wood. The chair is estimated to
cost about $50 in material, using information from Mcmaster-Carr and Woodworker’s
Source. Pictures and information regarding the model and FEA report can be found in
the sections that follow.

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6.1 3D Solid Model

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6.2 Detail and Assembly Drawings

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6.3 FEA Report
The finite element analysis report can be found at the link below:

http://sites.psu.edu/iak5024/fea-report-102uw5f/

Preview images of the results can be viewed below:

(Constraints imposed on the model for the finite element analysis)

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(Displacement experienced by the assembly, with a distributed load of 300lbs on the
seat platform surface of the chair oriented vertically downwards)

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(Stresses experienced by the assembly under the imposed loading)

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(Alternative view of the stresses within the assembly, under the imposed loading)

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7.0 Summary and Conclusions
Overall, the EDSGN 497K course has given me great introductory experience to the use
of the CATIA V5 software. I am now comfortable with designing solid models and
understanding how to perform basic finite element analysis on a part. Having knowledge
of this program is a great addition to my computer-aided drafting skillset.

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