12.06.

2009

Presented by

Paul Rudakov

PowerCopy, Parameters and

Morphing Fundamentals using Catia
V5 R14
 Scope
1.How to create and use a PowerCopy

2.Control Geometry using Parameters

3.Morphing fundamentals

This document assumes that those using it understand the GSD Workbench
and will not include detailed geometry creation

Paul Rudakov 12/06/2009 Page 2

 Create a simple PowerCopy (1)
To Create a Chord Line
Open File : 1 – PCopy - Chord Creation - Start

Create a New Geometrical Set and name it : Output Data

Create a Plane : Through Planar Curve on the Wing
Boundary

Create a Point on both ends of the Upper Trailing Edge

Create a Mid Point between these 2 Points

Create a Polar Extremum of Max Radius

Create a Line from TE Mid Point to Polar Extremum

Name this: Line.Chord

Paul Rudakov 12/06/2009 Page 3

 Create a simple PowerCopy (2)
Select : Insert/Knowledge Templates/PowerCopy :
Select Geometrical Set ‘Output Data ’

From the PowerCopy Dialogue Box we can see that the Input
required is the Airfoil Section Curve

•Save this part

with a new name
locally on your PC
and close the Part

Paul Rudakov 12/06/2009 Page 4

 Instantiate a PowerCopy
• Open File : A30X Input Start Model.CATPart
• Create a Boundary on the Outer Wing
• Create Point/On Curve at the Upper TE
• Create Plane/Parallel through Point
to ZX Plane
• Project Boundary onto Plane
• Select Insert/Instantiate From
Document and navigate to your Chord
Creation PowerCopy
•Select the Projected Boundary Curve
• Select OK to create

• The Chord has been created for you

Paul Rudakov 12/06/2009 Page 5
 Create a Parameter (1)
•Open File : 1 - Start - PCopy Morph Blended Raked
Winglet.CATPart
•Using the ‘fx ‘ Dialogue in the Knowledge Toolbar create
a Parameter of length 2000mm

•Name this
Parameter :
‘Tip Extent’

Paul Rudakov 12/06/2009 Page 6

 Applying a Parameter
• Create a Boundary on the Upper TE
• Create a Point/Distance on Curve Upper TE
•In the Length Dialogue Box Right
Click and Select Edit Formula and
Apply the Parameter Tip Extent

• Create a Plane
parallel through
Point on Upper TE
to Plane XZ and
name it Plane.Tip
Extent
• File Part
Paul Rudakov 12/06/2009 Page 7
 Summary (1)
When creating a Power Copy avoid selecting the vertex of
a Surface or a Curve, create a Point on the Curve or a
Boundary on the Surface to reduce the number of
Selections when Instantiating the Power Copy
When creating Parameters make sure to select the right
type of Parameter i.e. Length, Angle or Real for
Ratio’s
Try to make the PowerCopy robust by allowing for bad
geometry i.e. In slide 5 the Boundary was projected
onto a Plane in case the Curve was non-planar or not
parallel to the ZX Axis
Name geometry and organise your Specification Tree, this
will make debugging the PowerCopy much easier

Paul Rudakov 12/06/2009 Page 8

 Set up a Basic Wireframe Framework
The next stage is to set up a Wireframe
Framework to define the Line of Flight
and Plan Form Sketches

The Plan Form Shape is defined in the flat

to allow for the Tip being very Flat, near
Vertical or anywhere in between

Paul Rudakov 12/06/2009 Page 9

 Create Support Geometry (1)
• Intersect the Wing Surface with the Plane.Tip Extent
• Instantiate your PowerCopy : Chord Creation on the
Wing Intersect
• Create a Plane through 3 Points to define a Tip Mean
Plane (The 2 Polar Extremum and Tip Extent Trailing
Edge Mid Point)
• Create 2 Planes Normal to Curve on the Chord Line at
the Polar Extremum and Mid TE (See Slide 20)
• Create a Plane Parallel to this Plane a distance of
5000mm and name it Plane.Sketch LOF
• Intersect Plane.Tip Mean with Plane.Sketch LOF and
Plane.Tip Extent
• Intersect these 2 Intersects to produce a Point and
name it Intersect.Sketch LOF Origin
Paul Rudakov 12/06/2009 Page 10
 Create Support Geometry (2)
• This gives us 2 Vectors and an Intersect (Point) to
create an Axis System
• Create an Axis system on these Intersects,this will
become the Origin of a Sketch for the LOF shape of
the Winglet Axis.Sketch LOF

Plane.LE
Root Extent

Plane.Mean
Plane
Intersect.Sketch LOF
Plane.TE Origin
Root Extent

Plane.Tip
Extent
Plane.Wing Semi-Span
Paul Rudakov 12/06/2009 Page 11
 Create Support Geometry (3)
• Be aware of the difference between the LOF Axis
system and Absolute Axis System (‘V’)
• The Plane.Tip Extent is True for ‘V’ but considerably
different to the LOF Axis System and is only used as
a starting reference

‘V’ ‘Tip LOF’

Paul Rudakov 12/06/2009 Page 12

 Create Support Geometry (4)
1. Intersect Plane.Wing Semi Span with LOF Axis ‘Y’
vector
2. Translate this Intersect 2000mm in direction LOF Axis
‘Z’ and rename to Translate.Tip Height
3. Translate Translate.Tip Height 500mm in direction LOF
Axis ‘Y’ and rename to Translate.Span Offset
LOF Axis ‘Y’

3-Translate. Span Offset

2-Translate.Tip Height

1-Intersect

Plane.Wing Semi-Span
Paul Rudakov 12/06/2009 Page 13
 Create a Positioned Sketch
• Select and create a Positioned Sketch

• Reference : Plane.Sketch LOF

• Origin : Point : Intersect.LOF Origin
• Orientation : Parallel to Line : Axis.LOF ‘Y’ Vector

• This will throw you into the Sketch

• Project Translate.Span Offset and Intersect.LOF

Origin into the Sketch as reference elements

Paul Rudakov 12/06/2009 Page 14

 Create LOF Spline
• Create a Spline that will represent the Line of Flight
shape of the Winglet applying Tangency Constraints at
both ends
Upper Tangency Constraint

Parameter ‘Cant Angle’

Lower Tangency Constraint
Paul Rudakov 12/06/2009 Page 15
 Creating Parameters in a Sketch
• Whilst in the Sketch create an Angle Parameter of 40
degrees, name it to Cant Angle and apply it to the
Spline Upper Tangent and exit the Sketch

Paul Rudakov 12/06/2009 Page 16

 Creating Parameters in a Sketch
• Create Parameters of Length for ‘Tip Height’ 1500mm
and ‘Span Offset’ 500mm
• Apply the ‘Tip Height’ Parameter to ‘Translate.Tip
Height’ and ‘Span Offset’ to ‘Translate.Span Offset’
• Modify Parameter ‘Cant Angle’ to 60 degrees

Paul Rudakov 12/06/2009 Page 17

 Create Plan Form Sketches (1)
• We need to create a Plan Form Sketch for both the
Leading and Trailing Edges
• The Sketch Support in both cases will be the XY Plane
of the Axis System LOF
• But first we need to Intersect the Wing with the LOF
ZX Plane and run the Power Copy.Chord Creation
• This will be the Start Section for the Tip
Intersection
Wing & LOF
ZX Plane

LOF ZX
Plane

Plane.LE
Root Extent
Plane.LE
Root Extent
Paul Rudakov
Chord 12/06/2009 Page 18
 Create Plan Form Sketches (2)
• Extrude Sketch.LOF 15000mm and Unfold
•The Unfolded Extrusion will be used to define the true
length Leading and Trailing Edges and also to create the
Morphing Data

Paul Rudakov 12/06/2009 Page 19

 Create Plan Form Sketches (3)
• We now have to define the ‘Tip Sweep’ (Degrees) and the
‘TE Offset’ (% Root Chord) from that
• We have the LE & TE Root Extent Plane (See Slide 10)
• Create a Boundary on the Outboard Edge of the Unfolded Extruded
Surface and Intersect it with the LE Root Extent Plane
•Translate the Intersect along the Boundary -500mm and name it
‘Translate.Tip Sweep’
Intersect of LE
Root Extent and
Unfolded Surface
Boundary
Translated Intersect

Boundary Curve

Unfolded Surface

Plane.LE Root
Extent
Plane.TE Root Extent
Paul Rudakov 12/06/2009 Page 20
 Create Plan Form Sketches (4)
Tip Sweep Definition
Translate Distance = Tan (Tip Sweep) x True Length Plan Form

True Length Plan Form

Tip Sweep (Degrees)
Translate
Distance

Unfolded Surface

Paul Rudakov 12/06/2009 Page 21

 Create Plan Form Sketches (5)
• Create an Angle Parameter and name it Tip Sweep (deg)
with a value of 40 degrees
• We now have to apply this to the Translated.Tip Sweep
(Slide 20)
• Double Click the Translate and select Edit Parameter
• Enter the formula as shown below and note the result
(See Addendum A for more information)

Paul Rudakov 12/06/2009 Page 22

 Create Plan Form Sketches (6)

Tip Sweep
(Degrees)

Unfolded Surface

Translated Intersect

Unfolded
Surface
Paul Rudakov 12/06/2009 Page 23
 Create Leading Edge Sketch (1)
•Create a Reflect Line on the Wing
• Create a positioned Sketch on the LOF Axis ‘XY’ at the Tip Root Polar
Extremum with ‘H’ along the LOF Axis ‘X’
• Project as Reference the Root Section Polar Extremum, Translated
Intersect, Reflect Line and the Sweep Definition Line

Projected Tip Sweep Tan Line (Reference)

Definition Line

Projected Translated
Intersect

Projected
Reflect Line Unfolded Surface

Activate this Icon to

Projected Polar make Projected entities
Extremum Reference (Will not
show in 3D Space)
Paul Rudakov 12/06/2009 Page 24
 Create Leading Edge Sketch (2)
• Create an Angle Constraint of 10 degrees and name it ‘TE Tan Angle’
•Create a Spline between the 2 Projected Points with Tangency at both ends
• Constrain the Root Tangency to the Sketch ‘V’ Vector
• Create a Reference Line from the Projected Translate and Angle Constrain it
to the Projected Sweep Reference Line
• Double Click the 5 degree Constraint, Select Edit Parameter and Select ‘TE
Tan Angle’

Tan Reference Line

constrained 5 degrees
Sketch Spline to Projected Sweep
Reference Line

Spline Tangent
Constrained to 5 Degree
Spline Tangent
Tan Reference Line
Constrained to
Projected Reflect Line
Projected Sweep
Reference Line
Paul Rudakov 12/06/2009 Page 25
 Create Trailing Edge Sketch (1)
• Translate ‘Translate.Tip Sweep’ –500 along the Unfold Boundary and
name it ‘TE Offset’
• Create a Real Parameter with a value of 20 and name it ‘TE
Offset(% Root Chord)’
• Apply this Parameter to ‘Translate.Tip Sweep’ with the following
formula and note the result (See Addendum A for more information)

Paul Rudakov 12/06/2009 Page 26

 Create Trailing Edge Sketch (2)
• Create a positioned Sketch on the LOF Axis ‘XY’ at the Tip Root Polar
Extremum with ‘H’ along the LOF Axis ‘X’ as in Slide 24
• Project as Reference the Root Mid TE Point, Upper TE Boundary and the
Translated ‘TE Offset’
•Create a Line from the Projected
Upper TE as a Reference for the TE
TE Tan Reference Line Tan

End of Projected • Draw a Line from the Projected

Upper TE Translated TE Offset and Constrain it
to the Tan Reference Line at 5 Degrees

Projected TE Offset

Line From and Parallel to Projected Upper TE

Projected Upper TE

Projected Root TE Mid Point

Paul Rudakov 12/06/2009 Page 27

 Create Trailing Edge Sketch (3)
• Create an Angle Parameter of 15 Degrees and name it TE Tan Angle
• Create a Spline from Projected Root TE Mid Point to Projected TE Offset
with Tangency at both ends
• Constrain the Root Tangency to the Line Parallel to the Projected Upper TE
and the Outboard Tangency to the TE Tan Reference Line
•Double Click the 5 Degree Angle Constraint and apply the Parameter TE Tan
Angle Spline Tangent
Constrained to 5 Degree
Tan Reference Line

Projected TE Offset

Sketch Spline

Line From and Parallel to

Projected Upper TE
Spline Tangent Constrained to Line
from Upper TE

Projected Root TE Mid Point

Paul Rudakov 12/06/2009 Page 28

 Morphing Plan Form Shape to LOF
• Split the Wing Surface with the LOF Axis ZX Plane
• Split the Unfolded LOF Extruded Surface with the LE and TE Sketches

• This surface will be

morphed to the LOF
Sketch LE Spline Extruded Surface

Split Unfolded LOF Surface

Sketch TE Spline

Paul Rudakov 12/06/2009 Page 29

 Morphing (1)
• Create a Plane parallel to the Plane.Tip Root through Translate.TE Offset
• Create 30 Planes Equally Spaced between these 2 Planes
•Intersect all of these Planes with Extrude.Sketch LOF and Unfold.Extrude
LOF
Extrude.Sketch.LOF Intersect Extrude LOF

Unfold.LOF

Intersect Unfold LOF

Morphing Reference Planes

Paul Rudakov 12/06/2009 Page 30

 Morphing (2)
• Create a Morphed Surface
• Select Shape Morphing Icon
• Select the first Intersect on the Unfolded Surface as Reference and the
first Intersect on the Extrude.LOF as Target
Intersects on Extrude.Sketch LOF

Paul Rudakov Intersects on Unfold.LOF 12/06/2009 Page 31

 Morphing (3)
• Continue Selecting all Intersects for Reference and Target (32 in Total)
• Then OK to create

Morphed Plan Form to LOF

Paul Rudakov 12/06/2009 Page 32
 Testing
• We now have to test the robustness of the geometry process, so change as
many of the Parameters as possible and look at any errors
• A good idea as well is to check dimensional validity, in the picture below we
can see the Length of the Plan Form Sketches compared to the Morphed 3D
shape

Paul Rudakov 12/06/2009 Page 33

 Creating a Power Copy with
Parameters
• When you create and run a Power Copy the Parameters
are not carried into the part
• To enable this the Parameter Tree needs to be selected
when creating the Power Copy

Paul Rudakov 12/06/2009 Page 34

 Summary (2)
How Morphing Works
Morphing ‘Target’

Morphed LE

Intersect Morphing ‘Reference’

and LE Plan Form Point on Intersect Curve
Morphing ‘Target’
Distance 2024.51395727mm
is on Morphed LE

Distance from Reference and

LE Plan Form Intersect to
LOF XZ = 2024.5139527mm

Morphing ‘Reference’

Paul Rudakov 12/06/2009 Page 35