Copyright DASSAULT SYSTEMES Sheetmetal Design CATIA Training Exercises Version 5 Release 8 February 2002 EDU-CAT-E-SMD-FX-V5R8

Copyright DASSAULT SYSTEMES In this exercise you will: Assign Material Parameters Create Walls; Profile, Edge and Extrude Create Bends; Auto/Regular and Flange and Hem Add Cut Outs, Pattern, use Flat Mode and 3D Features Create 2D Flat Pattern drawing Modify; Standard Bend Radii, Wall sizes, Cut Outs, Flanges and Features 70 min Control Bracket : Presentation Exercise

Copyright DASSAULT SYSTEMES The part is not symmetrical 2. The first wall is a profile 3. The Bends are common throughout the part 4. Some Flanges are used in the part 5. Some walls are equal in length and can be extruded from a profile 6. Holes whether they are round or a specific profile are done with wall cuts 7. Specialty features such as extruded hole and strengthening ribs are used 8. All walls, bends and features can be modified 9. A 2D flattened view can be created for the part Design Intent of the exercise The Control Bracket is a sheet metal part used across all six lessons in this course

Copyright DASSAULT SYSTEMES Assign Material Parameters 2. Create Walls, Profile, from edge and extruded from sketch 3. Add Auto Bends and Hem Bends 4. Add Wallcuts and Stamp Features and Pattern them Bracket design process Create 2D Flat Views on Drawings 6. Modify Walls and Bend Radius Design process solution of the exercise

Copyright DASSAULT SYSTEMES Assign Material Parameters Bracket design process... And now practice in the context of the Control Bracket...

Copyright DASSAULT SYSTEMES Defining the Parameters for the Control Bracket 10 min Exercise Control Bracket (1) : Defining the Parameters

Copyright DASSAULT SYSTEMES Do it yourself Load the Catia document CATSMDEXControl-Brkt_step1. CATPart Create Parameters for control bracket:. Use 1 mm for thickness, 1 mm for Bend Radius and Square Relief

Copyright DASSAULT SYSTEMES Create Walls, Profile, from edge and extruded from sketch Bracket design process... Step1 And now practice in the context of the Control Bracket...

Copyright DASSAULT SYSTEMES Defining the walls of the Control Bracket 15 min Exercise Control Bracket (2) : Defining the Walls

Copyright DASSAULT SYSTEMES Do it yourself Load the Catia document CATSMDEXControl-Brkt_step2. CATPart Back walls Right walls Left wall Bottom wall Define the walls of the Control Bracket:. Back walls: 9 mm length. Right walls to be 8 mm length Material side

Copyright DASSAULT SYSTEMES Add Auto Bends and Hem Bends Bracket design process... Step 1 Step 2 And now practice in the context of the Control Bracket...

Copyright DASSAULT SYSTEMES Defining the Bends and Flanges of the Control Bracket 10 min Exercise Control Bracket (3) : Defining the Bends and Flanges

Copyright DASSAULT SYSTEMES Do it yourself (1/2) Load the Catia document CATSMDEXControl-Brkt_step3. CATPart Create bends and flanges for control bracket:. Use standard Bend Radii except where indicated. Use 1 mm radius, and 5 mm length and 90 degree angle for the front Flange. Use 0.5 mm radius and 7 mm length for the Hem Bend 2 mm Radius this wall only Flange edges Hem Bend

Copyright DASSAULT SYSTEMES Select Bend icon and change radii to 2mm and create bend on wall indicated on back of part 2- Select the Automatic Bend icon and create bends for other walls. 3- Select the Flange icon and then the 3 front edges indicated. Key in 1 mm radius, 5 mm length and 90 degree angle. 4- Select the Hem icon and the edge indicated. Key in 0.5 radius and 7 mm length 2 mm Radius this wall only Flange edges Hem Bend Do it yourself (2/2)

Copyright DASSAULT SYSTEMES Add Wallcuts and Stamp Features and Pattern them Bracket design process... Step 1 Step 2 Step 3 And now practice in the context of the Control Bracket...

Copyright DASSAULT SYSTEMES Defining Cut Outs, Patterning them and adding Stamp Features to the Control Bracket 10 min Exercise Control Bracket (4) : Defining Cut Outs, Patterning them and adding Stamp Features

Copyright DASSAULT SYSTEMES Do it yourself (1/2) Load the Catia document CATSMDEXControl-Brkt_step4. CATPart Create Cut Outs, Patterns and Features for control bracket:. Use sketches where provide for cut outs. Holes to be 2 mm diameter on 4 mm horizontal spacing and 3 mm vertical spacing. Cut out in the flat to be centered and be 4 mm from edge of part and be 10 mm long by 2 mm wide. Stiffening Rib located in center of center flange with R1 and R2 equal to 1 mm and angle equal to 80 degrees and 10 mm long. Extruded hole to be 3 mm diameter, 4 mm deep with a 0.5 mm Radius and 85 degree angle, centered in wall Center Flange Edge to locate flat cut out from

Copyright DASSAULT SYSTEMES Using Sketch.21 create a simple hole Up to Next 2- Select Sketch.15 create a more complex cut out using Up to Next 3- Pattern hole created in step 1 with 5 instances, 4 mm apart horizontal and 2 instances 3 mm apart vertical 4- Go to Flatten mode and create rectangular cut out 2 mm wide by 10 mm long 4 mm from main body of part, wall indicated above. Re-fold part. 5- Create Stiffener Rib in center of Back center flange. R1 and R2 should be 1 mm radius, the angel should be 80 degrees and the length should be 10 mm 6- Create an extruded hole with a 3 mm diameter 4 mm deep with 0.5 radii. Do it yourself (2/2)

Copyright DASSAULT SYSTEMES Bracket design process Create 2D Flat Views on Drawings Step 1 Step 2 Step 3 Step 4 And now practice in the context of the Control Bracket...

Copyright DASSAULT SYSTEMES Creating a 2D Flattened View of the Control Bracket 10 min Exercise Control Bracket (5) : Creating a 2D Flattened View

Copyright DASSAULT SYSTEMES Do it yourself (1/2) Load the Catia document CATSMDEXControl-Brkt_step5. CATPart Create a 2D Flattened View for control bracket: Select this Reference plane

Copyright DASSAULT SYSTEMES Start a 2D drawing and then select the Unfolded View icon 2- Select the reference plane indicated above. 3- Now click anywhere on the drawing to create the 2D Flattened View. 4- Add some dimensions Select this Reference plane Do it yourself (2/2)

Copyright DASSAULT SYSTEMES Bracket design process... Step 5 Step 1 Step 2 Step 3 Step 4 6. Modify Walls and Bend Radius And now practice in the context of the Control Bracket...

Copyright DASSAULT SYSTEMES Modifying various features of the part, Wall Size, Bend Radii, Flange size, Cut Outs, and Stamp Features 20 min Exercise Control Bracket (6) : Modifying various features

Copyright DASSAULT SYSTEMES Do it yourself (1/2) Load the Catia document CATSMDEXControl-Brkt_step5. CATPart Modify the following list of items as indicated:. Modify the general bend radius to.5 mm. Modify the Flange height and Hem Bend to 3 mm. Modify the back left wall to 5 mm wide. Modify the back right wall with corner cut out 3 mm by 5 mm. Change the length of the tab to be 1 mm shorter then it currently is and add 2 mm by 45 degrees chamfers on the end.. Change saw tooth cut out in bottom to be 7 mm wide and to have 0.25 mm radius on corner of teeth. Back Right WallBack Left Wall Tab

Copyright DASSAULT SYSTEMES Using Sketch.14 create a simple hole Up to Next 2- Select Sketch.15 create a more complex cut out using Up to Next 3- Pattern hole created in step 1 with 5 instances, 4 mm apart horizontal and 2 instances 3 mm apart vertical 4- Go to Flat mode and create rectangular cut out 2 mm wide by 10 mm long 4 mm from main body of part, wall indicated above. Re-fold part. 5- Create Stiffener Rib in center of Back center flange. R1 and R2 should be 1 mm radius, the angel should be 80 degrees and the length should be 10 mm 6- Create an extruded hole with a 3 mm diameter 4 mm deep with 0.5 radii. Do it yourself (2/2)

Copyright DASSAULT SYSTEMES Creating some simple walls in the context of an assembly 15 min Exercise Walls Recap Exercise (1) : Creating some simple walls

Copyright DASSAULT SYSTEMES You are starting in an Assembly and will be creating the Top Cover in the context of the Assembly. Create the Top Cover wall using Sketch.1. Create the back wall extending 7.5 mm downward. Create two side walls on each side where indicated above 3 mm length Do it yourself (1/2) Load the Catia document CATSMDEXSimple_Wall_start.CATProduct Extrude top wall up from these flanges Back Walll Side Walls

Copyright DASSAULT SYSTEMES Select Sketch.1 and the Wall icon. Make sure material arrow points upward. 2- Select the Wall on Edge icon and then then create the back wall making it 7.5 mm long. 3- Select the inside surface of the side wall and go to the sketcher and sketch the first side wall between the two flanges. Use sketch to create a profile wall extruded inward to the part 4- Select the same surface again and sketch between flange and the back relief on the new cover. Again create a profile wall extruded inward. 5- Repeat the process on the other side of the part. Extrude top wall up from these flanges Back Wall Side Walls Do it yourself (2/2)

Copyright DASSAULT SYSTEMES Adding Bends to the walls already created and adding some Flanges 15 min Exercise Bends and Flanges Recap Exercise (1) : Adding Bends and Flanges

Copyright DASSAULT SYSTEMES Add Bends to the walls created lesson 2 and then add a hem bend to the back wall and an S-Bend to the front edge of the cover: The Hem bend should 5 mm long and a radius of.1 mm on the inside of the back wall. Use Sketch.7 for the S-Bend (Swept Flange) Do it yourself (1/2) Load the Catia document CATSMDEXBends_start.CATProduct Front Edge Back Wall

Copyright DASSAULT SYSTEMES Use the Regular Bend icon and create a bend between wall 1 and walls 2 through Select the Hem icon and then the inside edge of the bottom of the back wall and key in.1 mm radius and 5 mm length. 3- Select the Swept Flange icon and then the bottom front edge of the cover for the spine. Select Sketch.7 for the profile. Front Edge Back Wall Do it yourself (2/2)

Copyright DASSAULT SYSTEMES Adding the mounting holes and a Stamp feature with a hole in it. 10 min Exercise Cut Outs, Flat and Features Recap Exercise (1) : Adding mounting holes and stamp features

Copyright DASSAULT SYSTEMES Using holes from existing part create cover mounting holes and then add a Stamp Feature for the raised area in part: Holes to be 3 mm Diameter Feature to be 2 mm high with 0.5 mm radii and 45 degree angle. Center hole in feature to be 10 mm diameter Do it yourself (1/2) Load the Catia document CATSMDEXCutouts_Features_start.CATProduct Hole in each of these 4 flanges Feature Sketch

Copyright DASSAULT SYSTEMES Use 4 holes on flanges in base part to make new holes concentric with. They will be 3 mm in diameter 2- Select the Feature sketch (Sketch.9) and key in 2 mm for the height, 0.5 mm for the radii and 45 degrees for the angle. 3- Select the surface to the feature and sketch a hole in the center of the feature. The Diameter should be 10 mm. Hole in each of these 4 flanges Feature Sketch Do it yourself (2/2)