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Figure 5-70 Model of the Vacuum Cleaner for Tutorial 1

Figure 5-71 Views and dimensions of the Vacuum Cleaner for Tutorial 1

Creating the Base Feature of the Model

The base feature of this model is created by first creating a plane at an angle of 26-degree and then extruding a sketch drawn on that plane. The sketch will be extruded along a selected direction. In this model, you will learn a technique to create the reference sketch first and then follow it to create the model. Therefore, you will first draw the reference sketch.

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Start a new file in the Part workbench. Select the zx plane and invoke the Sketcher workbench.

2. Draw the sketch, as shown in Figure 5-72, and then exit the Sketcher workbench. 3. Select the yz plane and invoke the Sketcher workbench. Place a point colinear to the X-axis at any distance, as shown in Figure 5-73. Exit the Sketcher workbench.

Figure 5-72 Reference sketch

Figure 5-73 Point to be placed

After drawing the reference sketch and placing the point, you need to create a reference plane to create the base feature. 4. Create a plane by selecting three points, as shown in Figure 5-74. 5. Invoke the Sketcher workbench after selecting the newly created plane as the sketching plane and draw the sketch, as shown in Figure 5-75.

Figure 5-74 Points to be selected to create a plane

Figure 5-75 Sketch of the base feature

6. Exit the Sketcher workbench. Choose the Pad button from the Sketch-Based Features toolbar; the Pad Definition dialog box is displayed.

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7. Set the value of the Length spinner to 28. The preview of the extruded feature is displayed in the geometry area. If the sketch is extruded in the downward direction, then choose the Reverse Direction button to flip the direction of the feature creation. 8. Now, choose the More button to expand the Pad Definition dialog box.

10. Choose the OK button from the Pad Definition dialog box to complete the feature creation. The model, after creating the base feature, is shown in Figure 5-76.

Figure 5-76 Model after creating the base feature

Creating the Second Feature

The second feature of this model is a drafted extrude feature created using the Drafted Filleted Pad tool. In this feature, you will extrude the sketch drawn on a plane created normal to the right line of the reference sketch. 1. Invoke the Plane tool and select the Normal to curve option from the Plane type drop-down list. 2. Now, select the right line of the reference sketch as the curve and then select the upper endpoint of the same line as the point on which the plane will be created. The preview of the plane is displayed in the geometry area. 3. Choose the OK button from the Plane Definition dialog box. 4. Use the newly created plane to invoke the Sketcher workbench and draw the sketch, as shown in Figure 5-77. 5. Exit the Sketcher workbench and invoke the Drafted Filleted Pad tool.

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9. Clear the Normal to profile check box provided in the Direction area and select the xy plane as the direction of extrusion.

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6. Set the value of the Length spinner to 85 and select the newly created plane from the geometry area as the second limit. 7. Set the value of the draft angle in the Angle spinner to 2deg. Choose the Reverse Direction button to flip the direction of the feature creation. 8. Clear all the radio buttons in the Fillets area and choose the OK button from the Drafted Fillet Pad Definition dialog box. The model, after creating the second feature, is shown in Figure 5-78.

Figure 5-77 Sketch for the second feature

Figure 5-78 Resulting second feature

Next, you need to create the third feature of the model to remove the unwanted portion of the second feature. 9. Select the zx plane and invoke the Sketcher workbench. Draw the open sketch, as shown in Figure 5-79, and exit the Sketcher workbench. 10. Extrude the sketch using the Pocket tool up to the last on both sides of the sketch. You may have to reverse the direction of material removal. 11. Using the Hide/Show tool, hide Sketch1, Sketch2, Plane1, and Plane2. The model, after creating the third feature, is shown in Figure 5-80.

Filleting the Edges of the Model

Next, you need to fillet two sets of edges of the model. You need to apply the fillet feature twice because the two sets of edges need different fillet radii. First you will fillet the set of edges that needs the fillet radius of 12. 1. Double-click on the Edge Fillet button in the Dress-Up Features toolbar; the Edge Fillet Definition dialog box is displayed. 2. Select the edges, as shown Figure 5-81, and set the value of the Radius spinner to 12.

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Figure 5-79 Sketch for the Pocket feature

Figure 5-80 Model after creating the third feature

3. Choose the OK button from the Edge Fillet Definition dialog box. The model, after creating the first set of fillet, is shown in Figure 5-82.

Figure 5-81 Edges to be selected

Figure 5-82 The model after creating the fillet

Next, you need to apply the fillet to the second set of edges. Because you double clicked on the Edge Fillet button, the Edge Fillet Definition dialog box is again displayed. 4. Select all edges of the model, except the edges that are shown in Figure 5-83. 5. Set the value of the Radius spinner to 3 and choose the OK button from the Edge Fillet Definition dialog box. Cancel this dialog box when it is displayed again. The model, after applying the fillet to the second set of edges, is shown in Figure 5-84.

Creating the Shell Feature

Lastly, you need to create the shell feature. The shell feature will also be used to remove the end faces of the model, leaving behind a thin walled structure.

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CATIA for Designers (Eval Copy CAT 05/06)

Figure 5-83 Edges not to be selected

Figure 5-84 Model after creating the second fillet

1. Choose the Shell button from the Dress-Up Features toolbar; the Shell Definition dialog box is displayed. 2. Select the faces to be removed, as shown in Figure 5-85. 3. Set the value of the Default inside thickness spinner to 2 and choose the OK button from the Shell Definition dialog box. The final model, after creating the shell feature, is shown in Figure 5-86.

Figure 5-85 Faces to be removed

Figure 5-86 Final model after shelling

Saving and Closing the Files

1. Choose the Save button from the Standard toolbar to invoke the Save As dialog box. Create the c05 folder inside the CATIA folder. 2. Enter the name of the file as c05tut1 in the File name edit box and choose the Save button. The file will be saved in the \My Documents\CATIA\c05 folder. 3. Close the part file by choosing File > Close from the menu bar.

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Tutorial 2
In this tutorial, you will create the model of the plastic cover shown in Figure 5-87. Its views and dimensions are shown in Figure 5-88. (Expected time: 30 min)

Figure 5-87 Model of the Plastic Cover for Tutorial 2

Figure 5-88 Views and dimensions of the Plastic Cover for Tutorial 2 The following steps are required to complete this tutorial: a. Create the base feature of the model by extruding the sketch drawn on the zx plane equally to both sides of the sketch plane, refer to Figures 5-89 and 5-90. b. Create the second feature by extruding the sketch drawn on a plane created at an offset distance from the xy plane, refer to Figures 5-91 and 5-92.

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CATIA for Designers (Eval Copy CAT 05/06)

Add the draft feature to all faces of the model except the upper and lower faces, refer to Figure 5-93. d. Fillet the edges of the model, refer to Figures 5-94 through 5-99. e. Shell the model using the Shell tool by removing the bottom face of the model, refer to Figures 5-100 and 5-101. f. Create two pocket features to complete the model, refer to Figure 5-102.

Creating the Base Feature of the Model

First, you need to create the base feature of the model by extruding the sketch drawn on the zx plane. The sketch will be extruded equally to both sides of the sketching plane using the Mirrored extent option. 1. Start a new part file. Select the zx plane as the sketching plane and invoke the Sketcher workbench. 2. Draw the sketch, as shown in Figure 5-89, and exit the Sketcher workbench. 3. Invoke the Pad Definition dialog box and set the value of the Length spinner to 125. 4. Select the Mirrored extent check box and choose the OK button from the Pad Definition dialog box. The model, after creating the base feature, is shown in Figure 5-90.

Figure 5-89 Sketch of the base feature

Figure 5-90 The model after creating the base feature

Creating the Second Feature

The second feature of the model will be created by extruding the sketch drawn on a plane created at an offset distance of 14 from the xy plane. 1. Create a plane at an offset distance of 14 mm from the xy plane. 2. Invoke the Sketcher workbench using the newly created plane as the sketching plane. 3. Draw the sketch, as shown in Figure 5-91, and exit the Sketcher workbench.

Creating Dress-Up and Hole Features 4. Invoke the Pad Definition dialog box and choose the Reverse Direction button.

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5. Select the Up to next option from the Type drop-down list and exit the Pad Definition dialog box. The model, after creating the second feature, is shown in Figure 5-92.

Figure 5-91 Sketch of the second feature

Figure 5-92 The model after creating the second feature

Adding a Draft to the Faces of the Model

Next, you need to add a draft to the faces of the model. The draft angle is added to make sure that the component is smoothly ejected from the die. The draft angle is one of the most important aspects of designing the components to be formed, molded, or cast. 1. Choose the Draft Angle button from the Dress-Up Features toolbar; the Draft Definition dialog box is displayed and you are prompted to select the faces to be drafted. 2. Select all the vertical faces of the base feature and the second feature from the geometry area. 3. Click once in the Selection selection area in the Neutral Element area and select the bottom face of the base feature as the neutral element. Make sure that the pulling direction is in the upward direction. 4. Set the value of the Angle spinner to 3 and choose the OK button from the Draft Definition dialog box. The model, after creating the draft feature, is shown in Figure 5-93.

Filleting the Edges of the Model

Next, you need to fillet the edges of the model. In this model, you need to fillet three separate set of edges using the Edge Fillet tool. 1. Choose the Edge Fillet button from the Dress-Up Features toolbar; the Edge Fillet Definition dialog box is displayed.

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CATIA for Designers (Eval Copy CAT 05/06)

Figure 5-93 The model after drafting all the vertical faces 2. Select the edges shown in Figure 5-94 and set the value of the Radius spinner to 3. 3. Choose the OK button from the Edge Fillet Definition dialog box. The model, after filleting the first set of edges, is shown in Figure 5-95.

Figure 5-94 Edges to be selected

Figure 5-95 The model after filleting the first set of edges

4. Invoke the Edge Fillet Definition dialog box again to fillet the second set of edges. 5. Select the edge shown in Figure 5-96 and set the value of the Radius spinner to 1. 6. Choose the OK button from the Edge Fillet Definition dialog box. The model, after filleting the second set of edges, is shown in Figure 5-97. 7. Invoke the Edge Fillet Definition dialog box again to fillet the third set of edges. 8. Select all the edges of the model, except the edges shown in Figure 5-98, and set the value of the Radius spinner to 5.

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Figure 5-96 Edge to be filleted

Figure 5-97 The model after filleting the second set

9. Choose the OK button from the Edge Fillet Definition dialog box. The resulting filleted model is shown in Figure 5-99.

Figure 5-98 Edges not to be selected

Figure 5-99 Resulting filleted model

Creating the Shell Feature

Finally, you need to shell the model and remove its bottom face. It is always recommended to shell the model after adding the draft angle and the fillet feature to maintain the draft angle and fillet curvature on the inside walls of the shelled model. 1. Choose the Shell button from the Dress-Up Features toolbar; the Shell Definition dialog box is displayed. 2. Select the face to be removed, as shown in Figure 5-100, and set the value of the Default inside thickness to 2.

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CATIA for Designers (Eval Copy CAT 05/06)

3. Choose the OK button from the Shell Definition dialog box. The rotated view of the model, after adding the shell feature, is shown in Figure 5-101.

Figure 5-100 Face to be removed

Figure 5-101 Resulting shelled model

4. Use the Pocket tool to create the two pocket features. The final model, after creating the other two features, is shown in Figure 5-102.

Figure 5-102 Final model after creating the remaining features

Saving and Closing the Files

1. Choose the Save button from the Standard toolbar to invoke the Save As dialog box. 2. Enter the name of the file as c05tut2 in the File name edit box and choose the Save button. The file will be saved in the \My Documents\CATIA\c05 folder. 3. Close the part file by choosing File > Close from the menu bar.

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Exercise 2
Create the model of the Clamp Stop shown in Figure 5-105. Its views and dimensions are shown in Figure 5-106. (Expected time: 1 hr)

Figure 5-105 Model of the Clamp Stop for Exercise 2

Figure 5-106 Views and dimensions of the Clamp Stop for Exercise 2 Answers to Self-Evaluation Test 1. T, 2. T, 3. T, 4. F, 5. T, 6. Draft Reflect Line, 7. Shell, 8. Z, 9. Face-Face Fillet, 10. Chamfering