FAKULTI TEKNOLOGI DAN KEJURUTERAAN

MEKANIKAL
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
BMKF 1064 AUTOMOTIVE COMPONENT DESIGN & ASSEMBLY

LAB 3

AUTOMOTIVE COMPONENT DESIGN

Learning LO2 Follow the proper procedure in constructing 3D CAD data based on
Outcome (LO): the manufacturing aspect.
Program PO2 Able to suggest and apply latest tools and techniques to solve
Outcome: broadly-defined problems.
Synopsis:
The students will become familiar using CATIA V5 to design basic automotive
component including sketch-based modeling, creating and modifying features.
Related
Chapter 3 Features
Lecture’s Topic:
Prepared by: Dr. Mohd Hisham Bin Nordin Date: 13 March 2024
Approved by
Date
LM/SLM/HOD

QMS : REVISION RECORDS

Date
Revisio Prepared Approved by
Description (DD/MM/YY
n No by : LM/SLM/HOD:
)

1.0 THEORY
In designing basic automotive components, creating and modifying features is
essential for design optimization, refining, customization, and part integration as
well as for prototyping and testing purposes.

In Catia V5, these can be achieved using several operations in toolboxes which
is summarized in Table 1.

Table 1: Toolboxes and their operations

Toolbox Operations
Sketch-Based Features Pad, Pocket, Shaft, Hole, Rib
Dress-Up Features Fillet, Chamfer, Shell, Draft
Transformation Features Translation, Mirror, Pattern, Scale
Boolean Operations Add, Union Trim, Remove Lump
A. Sketch-Based Features

Pad (Extrude boss)

The Pad or Extruded Boss function is used in the Part Design workbench to
create a solid feature by extruding a sketch along a specified direction. This
function is commonly used to add material to a part, such as creating a protrusion
or a raised feature.

Figure 1

Pocket (Cut)
The Pocket or Cut function is used in the Part Design workbench to remove
material from a solid part. It is essentially the opposite of the "Extruded Boss"
function. With the Pocket function, you can create features such as holes,
cutouts, or cavities in part by extruding a sketch inward instead of outward.

Figure 2
Shaft
The “Shaft” function is used in the Part Design workbench to create a cylindrical
feature that extends along an axis. The Shaft feature allows you to define the
diameter, length, and position of the shaft, as well as additional parameters such
as fillets or chamfers at the ends. Shafts are commonly used in mechanical
design for creating axles, shafts, pins, and other cylindrical components.

Figure 3

Hole
The "Hole" function is used to create a hole feature in a solid part. This function
allows you to define the size, shape, and position of the hole, as well as
additional parameters such as counterbore, countersink, or counterdrill. The Hole
function is commonly used in mechanical design to add holes for fasteners or
other purposes.

Figure 4

Rib (Swept / Sweep)

The Rib or Swept/Sweep function is used to create a solid or surface feature by
sweeping a profile along a specified path. The profile can be a sketch, and the
path can be a curve or a combination of curves. This function allows you to
create complex shapes and features by sweeping a profile along a path in a
single operation.
 Figure 5

Figure 6: Helix Curve

Figure 7: Spring
B. Dress-Up Features
Fillet
The Fillet function is used to create a rounded edge along the intersection of two
faces of a solid part. This function allows you to specify the radius of the fillet,
which determines the size of the rounded edge. Edge fillets are commonly used
in design to improve the appearance of parts, reduce stress concentrations, and
make them easier to manufacture.

Figure 8

Chamfer
The "Chamfer" function is used to create a beveled edge along the intersection of
two faces of a solid part. This function allows you to specify the distance of the
chamfer along each face, which determines the size and shape of the beveled
edge. Chamfers are commonly used in design to remove sharp edges, improve
the appearance of parts, and facilitate assembly.

Figure 9
Shell
The Shell function is used in the Part Design workbench to hollow out a solid
part, leaving only a specified thickness of material around the outer surfaces.
This function is useful for creating lightweight parts or parts with complex internal
features. The Shell function allows you to specify the thickness of the shell and
which faces of the part should be removed to create the hollow interior.
 Figure 10

Draft
The Draft (Taper) function is used in the Part Design workbench to add a draft
angle to a part's faces. Draft is the angle by which a side wall of a part is tapered,
which is important for facilitating the removal of the part from a mold during
manufacturing. The Draft function allows you to specify the faces to be drafted
and the draft angle to be applied.

There are three types: Draft Angle, Draft Reflect Line and Variable Angle Draft.

Figure 11

Figure 12
 Figure 13

C. Transformation Features

Translation
The translation function is used to move geometry, features, or entire bodies from
one location to another. This function allows you to specify a distance and
direction for the translation, and the selected objects will be moved accordingly.
Translation is useful for repositioning components within an assembly, aligning
features in a part, or making adjustments to the overall position of a design.

Figure 14

Mirror
The mirror function is used to create a mirrored copy of selected geometry,
features, or bodies across a specified plane or axis. This function allows you to
create symmetrical designs or components quickly and efficiently. Mirroring is
commonly used in CAD design to ensure that changes made to one side of a
design are reflected accurately on the other side.
 Figure 15

Pattern
The Pattern function is used to create multiple copies of a feature or a set of
features in a regular arrangement. There are several types of patterns available,
including linear (rectangle) pattern, circular pattern, and user pattern.

Figure 16

Figure 17
 Figure 18

Scale
The scale function is used to resize selected geometry, features, or bodies
uniformly in all directions. This function allows you to increase or decrease the
size of the selected objects while maintaining their proportions. Scaling is useful
for adjusting the size of components, modifying the overall size of a design, or
preparing a design for different manufacturing processes.

Figure 19

2.0 EQUIPMENT/ EXPERIMENT APPARATUS/ CONSUMABLE MATERIALS

i. CATIA V5 R21 software

3.0 PROCEDURES/ METHODOLOGY

Part A: Sketch-Based Features

1. Select a Y-Z plane and click the sketch icon to begin.

2. Draw a semi circle using the Arc ( ) with 50mm radius as shown in Figure
20.

Figure 20
3. Exit the sketch.
4. Click the Shaft ( ) and set the first angle to 0deg and the second angle to
180deg and then click the vertical axis (z-axis) as shown in Figure 21.

Figure 21

5. Then, click the Reverse Direction button and press the OK button to create a
hemisphere object as shown in Figure 22.

Figure 22

6. Select the even surface (not the yz plane) of the hemisphere and then go
into the sketch mode.
7. Draw a 45mm radius circle with the same centre as the hemisphere (Figure
23).
 Figure 23

8. Exit the sketch.

9. Select the Pad and set the length to be 200mm as shown in Figure 24.

Figure 24

10. Press the OK button.

11. Select the even surface of the rod in Figure 24 and then go into the sketch
mode.
12. Draw a 35mm radius circle sharing the same centre as the hemisphere
(Figure 25).

Figure 25

13. Exit the sketch

14. Select the Pocket ( ) and set the length to be 250mm and then click the OK
button to produce a through hole (Figure 26).
 Figure 26

15. Select the yz plane and go into the sketch mode.

16. Select the inner most circle (Figure 27) and then click the Project 3D Element
( ) in the Operation toolbox.
17. Draw a 30mm radius circle sharing the same centre point as shown in Figure
27.

Figure 27

18. Exit the sketch.

19. Click the Pad button and set the length to 300mm as shown in Figure 28.

Figure 28

20. Select the even surface (Figure 28) and get into the sketch mode. Make sure
you select the surface, not the edges of the tube.
21. Select the outer line of the tube (Figure 29) and click the Project 3D Element
button.
 Figure 29

22. Exit the sketch mode.

23. Select zx plane and go into the sketch mode.

24. Click the axis line ( ) in the profile toolbox and create and axis at the centre
of the tube as shown in Figure 30.

Figure 30

25. Exit the sketch mode.

26. Locate the Reference Element (Extended) toolbox and select the point
button ( ).
27. Place the point on the circular sketch created earlier at the end of the tube as
shown in Figure 31.

Figure 31

28. Go to Start > Shape > Generative Shape Design to begin creating helix
profile.
29. Locate Wireframe toolbox and click the helix button (Figure 32).
 Figure 32

30. For the starting point, click the point created earlier on the circle, while for
the axis, click the Horizontal axis. Set the pitch as 10mm and the height as
100mm. (Figure 33).

Figure 33

31. Click the Plane ( ) button in the Wireframe toolbox, then select Plane type
as Normal to curve. Proceed by selecting the helix and then press the OK
button.
32. Return back to the Part Design environment
33. Click on the created plane and enter the sketch mode.
34. Draw a 5mm equilateral triangle and place it in the middle of the plane,
covering the helix profile as shown in Figure 34.
 Figure 34

35. Exit the sketch.

36. Click on the Rib ( ) button inside the sketch-based feature toolbox.
37. Select the triangle as the profile and click on the helix as the Center Curve.
Set Pulling Direction as the Profile Control and then select the center line
axis. Press OK (Figure 35).

Figure 35

38. Record your result in the report.

39. Select yz plane and enter the sketch mode.
40. Draw a 55mm radius circle sharing the same centre point as other sketches,
then exit the sketch.
41. Place a point (Reference Element Extended Toolbox) anywhere on the circle
line as shown in Figure 36.
 Figure 36

42. Go to Start > Shape > Generative Shape Design to begin creating helix
profile.
43. Click the helix button (Wireframe toolbox).
44. For the starting point, click the point created earlier on the circle, while for
the axis, click the Horizontal axis. Set the pitch as 20mm and the height as
300mm. Press the Reverse Direction button if the helix profile does not cover
the tube (Figure 37).

Figure 37

45. Click the Plane ( ) button in the Wireframe toolbox, then select Plane type
as Normal to curve. Proceed by selecting the helix and then press the OK
button.
46. Return back to the Part Design environment
47. Click on the created plane and enter the sketch mode.
48. Draw an 8mm circle and place it in the middle of the plane, covering the helix
profile as shown in Figure 38.
 Figure 38

49. Exit the sketch.

50. Click on the Rib ( ) button inside the sketch-based feature toolbox.
51. Select the circle profile and select the helix for Center curve. Set Pulling
Direction as the Profile Control and then select the center line axis. Press OK
(Figure 39).

Figure 39

52. The resulting object should look likes Figure 40. Record your results.

Figure 40

53. Expand your PartBody tree (on the left of the Part Design Environment) and
then locate and double click on the Helix profile for the spring.
54. Modify the Pitch distance to 50mm and the Height to 250mm (Figure 41).
Press OK.
 Figure 41

55. Your updated object should now look as in Figure 42. Record your result.

Figure 42

Part B: Dress-Up Features

1. Create a 200mm x 150mm x 50mm block as shown in Figure 43.

Figure 43

2. In the Dress-Up features toolbox, click the Edge Fillet ( ) button and select
2 edges as shown in Figure 44. Set the fillet radius as 20mm.
 Figure 44

3. In the Dress-Up features toolbox, click the Chamfer ( ) button and select
the edge as shown in Figure 45. Set the chamfer length to be 5mm with
45deg. Press OK.

Figure 45
4. In the Dress-Up features toolbox, click the Draft Angle ( ) button and select
face to draft on the unfillet side of the block, Neutral Element as the top face
of the block as in Figure 46. Set the draft angle as 30deg.

Figure 46

5. In the Dress-Up features toolbox, click the Shell ( ) button and select the
faces to remove as the bottom side of the object (Figure 47). Set the Default
 inside thickness as 3mm.

Figure 47

6. The resulting object should look like in Figure 48. Record your result.

Figure 48

Part C: Transformation Features

1. Create a disk object with radius 150mm and 50mm thickness as shown in
Figure 49.

Figure 49

2. Go to Insert > Body to create new body.

Figure 50

3. In the new body, add a 20mm radius cylinder with 50mm in height on top of
the disk at the center (Figure 51).
 Figure 51
4. In the Transformation features toolbox, click the Translation ( ) button.
Just click Yes when a dialog box appeared. Select zx plane as the Direction
for translation and 45mm for the distance (Figure 52).

Figure 52

5. In the Transformation features toolbox, click the mirror ( ) button and click
the zx plane to duplicate the cylinder as shown in Figure 53.

Figure 53

6. Select the top surface of any of the cylinder and go into the sketch mode.
7. Place randomly points (Profile Toolbox) on the disc as shown in Figure 54
and then exit.

Figure 54

8. In the Transformation features toolbox, click the user pattern ( ) button

and click on any of the points (Figure 55). Press OK.
 Figure 55

9. In the Transformation features toolbox, click the scale ( ) button. For the
reference, select the yz plane. Set the ratio to 0.7. The result should look
more or less like in Figure 56.

Figure 56

10. Record your result.