Académique Documents
Professionnel Documents
Culture Documents
Procedure
SCOPE:
This document is relative to the modeling and know-how rules necessary with CATIAV5 to design a
complex 5 axis machined part, including manufacturing needs.
The guide contains different steps to define specific geometrical machining features as 2.5 axis, 4
axis, and 5 axis pockets, as ribs.
It describes :
- Model organization and structure data
- Rules to follow in case of design changes : How to show and model updated parts.
Date :
Airbus 2002 . All rights reserved. This document contains Airbus proprietary information and trade secrets. It shall at all times
remain the property of Airbus; no intellectual property right or licence is granted by Airbus in connection with any information
contained in it. It is supplied on the express condition that said information is treated as confidential, shall not be used for any
purpose other than that for which it is supplied, shall not be disclosed in whole or in part, to third parties other than the Airbus
Members and Associated Partners, their subcontractors and suppliers (to the extent of their involvement in Airbus projects),
without Airbus prior written consent.
Table of contents
1 Introduction ............................................................................... 3
2 General recommendations....................................................... 4
2.1 Applicable rules ......................................................................................... 4
5 Identifying modifications........................................................ 44
5.1 Differences between solids made by layer ........................................... 44
Approval ................................................................................................................. 46
1 Introduction
The aim being to:
- Obtain exact geometry of the detail part,
- Check and validate assemblies,
- Facilitate modifications to geometry (design and production),
- Avoid recreating additional geometry during the Numerical Control programming
phases (the programmer will as far as possible use the solid defined by the Design
Office as a basis).
2 General recommendations
- When you modify an object (adding a fillet radius to a body), do not forget to
activate the "Define in work object" command (Mouse Key 3).
- When you want to delete an entity, take care not to destroy the parents but only the
element in question. Deleting the parents is to be prohibited when the work of the
definition phase is well under way.
- The fillet radii of the walls of a pocket must not be defined on the sketch but as
"fillet" features.
Prismatic
Stiffener 1-2 Large Pocket
Central Stiffener
Stiffener 3-4
Open Prismatic
2.5 & 5 axis Pocket
Pocket 3
Final solid including Design
Feature identification
Step 1:
Recovery of data on which part design will bear.
Consists in grouping all of the resources used for the definition of the part and the Part,
which will contain the definition of the part itself.
Pipe element
Outside surfaces
Design Resources
Step 2:
Creation of the outside contour of the part directly on a sketch positioned on one of the
main planes of the Part.
External resources
required for the
definition of the
part.
Here, visualisation
of the surfaces is
used only to
correctly position
the contour
Definition of external
contour
Step 3:
Generation of the main solid (pad feature) from the contour.
The fillet radii are created after generation of the prism. Group fillets with same
definition by multi-selection. Prefer edge selection mode.
Sketch
Definition
Step 4: Sculpture (split function, ) the solid by the two surfaces referenced in the
CATPart.
PartBody
The 3 elementary pockets have been assembled to comprise a body in its own right.
The multi-body approach consists in separating the fillet radius entities from the bodies
on which they bear. The aim of this is to facilitate later integration of the pocket bottom
restrictions.
General methodology for defining a pocket in multi-body approach:
a- Insert a body (body1)
b- Define the pocket without its radii (the body contains the sketch of the contour of the
pocket and the resulting pocket feature)
c- Insert a new body (body2)
Step 6:
Subtract the upper section
- Creation of an additional body. Go to main plane YZ to define sketches.
Step 7:
- 2.5 Axis Pockets 1, 2, 3 & 4 creation:
• Create common sketches for 2.5 axis pocket 1&2 and for 2.5 axis pocket 3&4
(identical transversal section) (see paragraph 4.1.1 & 4.2.1)
• Create a new body for each pocket
• Define a pocket for each one
Pocket 4
Pocket 2
Pocket 3
Pocket 1
Step 8:
5 Axis Pockets 1, 2, 3 & 4 creation:
- Create one body for each 5 axis pocket
- Create one sketch for each 5 axis pocket
• Create the cutting tool contour inside the different sketch (see paragraph 4.1.2 &
4.2.2)
- Create the different solid resulting from the cutting tool trajectory with slot features
5 Axis Pocket 2
5 Axis Pocket 4
5 Axis Pocket 1
5 Axis Pocket 3
5 Axis Pocket 2
Step 9:
Top of Stiffeners modelling (Stiffener 1-2, Stiffener 3-4 & Central Stiffener) (see
paragraph 4.3)
- Creation of separate bodies, one for the stiffener 1-2, one for the stiffener 3-4 and
one for the central stiffener
- Create the sketches defining the material to remove on stiffener top
Step 10:
- Open Pocket Modelling
• Create a specific body
• Define the pocket contour sketch (using solid edges to construct it)
• Define the pocket feature
Step 11:
Adding the boss (see paragraph 4.4)
Boss in context
modelling
Boss
Step 12:
Adding the 2.5 axis large pocket.
- Creation of a separate body
- Pocket sketch creation using 3D definition
Sketch Plan :
Z=4mm
Coincidence
constraint
between a 3D
edge and a sketch
line
Feature Pocket
Step 13:
Final solid
Adding the fillet defined on resulting surface or edge coming from boolean operation
Extrude Surface
! The pocket 1 section is the same as the pocket 3 one. By consequence, we are going to
use this sketch for the pocket 1 & the pocket 3 definition. In that way, a modification in
this sketch will impact the 2 pockets
• Creation of fillet radii on the walls and bottoms of the pockets (multi-body
approach: see Step 5)
• Create the various fillet radii.
R=11 mm
R=20 mm
R= 4 mm (bottom of
pocket)
Intersection of pocket
bottom plane with (S):
(Cm)
Intersection curves
- Definition of 5 axis pocket contour without fillets (use of constraints on the sketch)
• On the sketch plane (P), project the curve (C). We will bear on (Cproj) to construct
the line of the tool on this plane.
• Define a line parallel to the reference plane (XY) offset by the value of the thickness
of the pocket bottom + offset of 0.3 mm (D).
• Create a line (C1) parallel to (C) offset by the value of the diameter of the tool + 1
mm.
• Define a circle (Ci1), modelling the tool corner radius, tangent to (C1) and to (D).
- Define a line (D1) modelling the bottom of the tool tangent to (Ci1) and perpendicular to
(Cproj). For an unruled surface, construct the sweep line (Db) from (C1).
(Ci1) (Cproj)
(D1):
- perpendicular to
(Cproj)
- tangent to (Ci1)
Closing of contour
Definition of contour
• From the contour (Cs) on the sketch and the curve (Cm), define a "slot" feature
with:
As guide curve: (Cm)
As profile: (Cs)
Guide curve : Cm
- Relimit the solid including the 0.3 mm offset on the walls (to avoid the tool was in
contact with the.5 axis wall previously machined
5 axis pocket
Split
Surfaces
! Use the "split" function rather than adding a "thickness" operator. Indeed, the
"thickness" operator models a prism from the selected surface. Discontinuities may
appear for solids when the curvature of the guide curve is high.
- Add an over thickness of 0.3 mm to avoid cutting tool contact
• Use an overthickness of 0.3 mm on 2 prismatic sections (as seen on image below)
Surfaces on which
overthickness is
applied
Overthickness
Line of pocket in
this section to be
determined
(4)
L2
L3 0.3
L4
R1
0.3
- Necessary resources to compute the profile (C3) & (L3) (see picture above :
‘SECTION through (P1)
" Indeed, we need to know the (C3) profile and (L3) lines defined in the sketch plan (P1) used to
construct the tool profile
! Use the same sketch plan (P1) as used to define the 5 axis pocket 1
• In a new open body, define the intersection between the (P1) and an offset
surface (Ss1) of the small integral stiffener thickness (see picture below)
• In the same open body, define the intersection between (Ss1) and the plan
Z=4.5mm corresponding to the pocket thickness.(see picture below)
(C3)
(L4)
Sketch plan
(P1)
Resources
L2 parallel to
L5 L5 coincident
with (C3)
Overthickness of
0.3 mm
0.62 mm)
• Compute the intersection between (Ss1’) and the pocket plane Z=4.5 mm
• Construct the extrude surface (Sl) defined by this intersection & Z axis (Z
corresponding to the machining axis)
(Sl)
Y=2mm
limit
Definition: Production of fillet radius R2 between inner profile L1 and 0.3 mm offset in
relation to bottom of pocket L4.
R2
L4
Pocket bottom
plane
0.3
Φ+1
L7 = Other side of
the tool L1 = Inner profile line
Elements to be
constructed
R2
L6 = Line normal to L1
(bottom of tool)
$ Excepted the cutting tool contour, all the geometric elements belonging to this sketch
have to be defined as construction ones.
L6
Z plane
P1
Remark: In cases where angle α of surface has a high variation, construct two
sections at the limits of the pocket to be processed and take plane Z
passing via the highest point.
This is valid for an open or a closed angle.
We will use loft functionality allowing creating rapidly non-constant profile between
several sections.
• In the WireFrame & Surface workbench, inside a new open body, create 2
planes corresponding to the loft feature thickness
• Insert a new body
• In one of the 2 planes, create a sketch defining the loft section
Sketch section
• Duplicate this sketch in a new one (In this case, the profile is constant)
• Change the sketch support and select the second plane
• In the same body, define the loft feature using the 2 sketch
Section 1
Section 2
Sections Definition
Result on part
The aim is to bear using existing resource, the tube, to create and correctly position this
boss.
Intersection curve
between the bottom of
the pocket and the
element
• Once the contour has been correctly positioned, create a 3.2 mm thick "pad".
- Creation of the hole or a pocket associated with the boss
! Create a hole or pocket feature according to the size of the element. This definition is
related to the machining process that used later, adapted to suit a pocket or a hole. On
account of the dimensions, choose to define this feature as a pocket.
• Define the contour of the hole taking position in relation to the previous sketch.
Edge to be
conserved
93 27 44
5 Identifying modifications
New part
The modification is identified on the new solid by an extraction at a specific layer of the
main modified face or faces.
All adjacent faces affected by the movement of the main face are not extracted to
identify the modification.
" CATIAV5 will create “3dmap” file, a CGR file, called 3Added material” and “Removed material”.
- Include these files in the CATProduct
! Change the graphic properties of these files. For example, choose red colour for removed
material and green for added material
Solid comparison
Reference documents
AP 2622 CAD layers organisation
AP 2610 Naming and Numbering for New Projects
AP 2260 Drawing rules for CATIA V5
AP 2255 3D Modelling rules for CATIA V5
ABD 0004 Definition dossier
Group of redaction
Team Members Company / Department Telephone
CANO-RODRIGUEZ Pedro Airbus España +34 916241292
Gilles MERCADIER EMK-T +33 561184933
Approval
This document has been approved on behalf of the following:
(signatures or proof of agreement are archived together with the master document)
Organization Approval
ACE/SPD/Elementary parts/
C .Vergez - OIMM1
Mechanical Parts Generic
CoC Structure H Schnell - ESDS
EM Quality Assurance
Nicole Lamothe - EMZQ
representative
Record of revisions