MSRSAS - CAE

MSRSAS - Postgraduate Engineering and Management Programme - PEMP

<Computer Aided Engineering>

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ASSIGNMENT

Module Code AME2501

Module Name Computer Aided Engineering

Course M.Sc [Engg] in Advanced Manufacturing Technology

Department Mechanical and Manufacturing Engg.

Name of the Student Shanmuga Raja .B

Reg. No BVB0192004

Batch Full-Time 2012.

Module Leader Mr. Monish Gowda M.H

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M.S.Ramaiah School of Advanced Studies Postgraduate Engineering and Management Programmes(PEMP)

#470-P, Peenya Industrial Area, 4th

Phase, Peenya, Bengaluru-560 058

Tel; 080 4906 5555, website: www.msrsas.org



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Declaration Sheet Student Name Shanmuga Raja .B

Reg. No BVB0912004

Course M.Sc [Engg] in Advanced

Manufacturing Technology Batch Full-Time 2012 .

Batch FT 2012

Module Code AME2501

Module Title Computer Aided Engineering

Module Date 01-10-2012 to 03-11-2012

Module Leader Mr. Monish Gowda M.H

Declaration

The assignment submitted herewith is a result of my own investigations and that I have

conformed to the guidelines against plagiarism as laid out in the PEMP Student

Handbook. All sections of the text and results, which have been obtained from other

sources, are fully referenced. I understand that cheating and plagiarism constitute a

breach of University regulations and will be dealt with accordingly.

Signature of the student Date

Submission date stamp (by ARO)

Signature of the Module Leader and date Signature of Head of the Department and date



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Abstract

____________________________________________________________________________

Product lifecycle management, a culminating approach, which aids in managing the product

from scratch to its expiry. Through subsets which complacent the total lifecycle of the product.

PDM plays an important role in product development and is one of the critical success factors

of the product. On other hand ERP approach impetus a strong and transparent manufacturing

practice sharing, data across all domain, which has become more like a mandate. The

capabilities of both need to fully utilized to attain a balanced harmony in manufacturing.

Geometric modeling is an act of constructing three dimensional models with multiple

approaches; CATIA V5 is a PLM tool which offers wide range of functions peculiar to the

engineering requirement. Modeling of parts of Lever Safety valve is performed in stages. The

parts are finally assembled to check the functionality of the mating condition. Analysis is

carried out to check interferences. Drafting is a means of communicating the idea behind

designing, to down the line departments such as manufacturing, planning, quality. Drafting is

performed for each individual components and the assembly is drafted showing the fit and form

of the relative components.

Surface modeling is a process of creating complex curvature and qualitative blending between

the congruent surfaces. Wireframe is the base to generate the surfaces. The relative juncture

between the surfaces is addressed through geometric and parametric continuities. CATIA

excels in the stream of surface modeling, a holistic and more user friendly interface enhanced

the objective modeling to fine new level. A wireframe entity of Motorman seat, is imposed with

surface modeling process and the product is analyzed for its various parameters. The product is

rendered and blended to a real image to get an aesthetic appeal.



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Contents ____________________________________________________________________________

Declaration Sheet ........................................................................................................................ ii

Abstract ....................................................................................................................................... iii

Contents ........................................................................................................................................iv

List of Tables ................................................................................................................................. v

List of Figures ..............................................................................................................................vi

List of Symbols .......................................................................................................................... vii

1.PDM, ERP and Product Lifecycle Management...................................................................1

1.1 Introduction………………………………………………………….…………………….…1

1.2 Role of PDM in Product lifecycle…………………………………………….…………..1

1.3 Role of ERP in Product lifecycle……………………………………………………..…..2

1.4 Need for integration of PDM and ERP…………………………………….…….……….2

1.5 Integration of PDM and ERP, a Case study……………………………….…….……….3

2. Chapter 2: Geometric modeling of Lever safety valve……………………………………4

2.1 Overview…………………………………………………………………………………4

2.2 CAD modeling development cycle………………………………………………………4

2.2.1 Body……………………………………………………………………..……5

2.2.2 Valve Seat…………………………………………………………………….6

2.2.3 Valve……………………………………………………………………….…6

2.2.4 Cover………………………………………………………………………….7

2.2.5 Cover Bush……………………………………………………………………7

2.2.6 Spindle………………………………………………………………………...8

2.2.7 Toggle………………………………………………………………………....8

2.2.8 Toggle pin, Fulcrum pin, Lever pin…………………………………………..9

2.2.9 Lever Guide…………………………………………………………………...9

2.2.10 Lever………………………………………………………………………...10

2.2.11Weight……………………………………………………………………….10

2.2.12 M20 Stud and Nut…………………………………………………………..11

2.3 Assembly of Lever Safety valve………………………………………………..………12

2.3.1 Assembly procedure………………………………………………………..13

2.4 Analysis of assembly……………………………………………………………………15

2.5 Drafting…………………………………………………………………….……...……16

3. Surface Modeling................................................................................................................17

3.1 Overview…………………………………………………………………………...….17

3.2 Surface development……………………………………………….………………….17

3.3 Analysis of surface model……………………………………………………………..21

3.3.1 Connect checker………………………………………………………….…21

3.3.2 Surface curvature analysis………………………………………………….21

3.3.3 Isophotes mapping analysis…………………………………….………..…22

3.4 Product render ………………………………………………………………… …..….23

Learning outcome………………………………………………………………..……..….24

References………………………………………………………………………….…...….25

Bibliography……………………………………………………..………………….……..26

Appendix-1(Title of the Appendix)……………………………………..…………...…….27

Appendix-2 (Title of the Appendix)……………………..…………………………….…..28



v

List of Tables

____________________________________________________________________________

Table No. Title of the table Pg.No.

Table 2.3 Bill of materials for Assembly 12

Table 2.3.1 Assembly constraint table 13



vi

List of Figures

____________________________________________________________________________

Figure No. Title of the figure Pg.No.

Figure 2.1(a) Mechanism of safety valve 4

Figure 2.1(b) Safety valve 4

Figure 2.2.1(a) Sketch of Body 5

Figure 2.2.1(b) Body 5

Figure 2.2.1(c) Section of Body 5

Figure 2.2.2(a) Sketch of Valve Seat 6

Figure 2.2.2(b) Valve Seat 6

Figure 2.2.3(a) Sketch of Valve 6

Figure 2.2.3(b) Valve 6

Figure 2.2.4(a) Sketch of Cover 7

Figure 2.2.4(b) Cover 7

Figure 2.2.5 Cover Bush 7

Figure 2.2.6 Spindle 8

Figure 2.2.7(a) Sketch of Toggle 8

Figure 2.2.7(b) Toggle 8

Figure 2.2.8 Toggle pin, Fulcrum pin, Lever pin 9

Figure 2.2.9 Lever Guide 9

Figure 2.2.10 Lever 10

Figure 2.2.11(a) Weight 10

Figure 2.2.11(b) Section of Weight 10

Figure 2.2.12(a) M20 Stud 11

Figure 2.2.12(b) M20 Nut 11

Figure 2.3 Schematic arrangement of Lever safety valve assembly 12

Figure 2.3.1(a) Assembly of Lever Safety valve 14

Figure 2.3.1(b) Sectional view of Assembly 14

Figure 2.4(a) Clash analysis 15

Figure 2.4(b) Constraint analysis 15

Figure 2.5 Assembly drawing 16

Figure 3.2(a) Wireframe of Motorman seat 17

Figure 3.2(b) Surface modeling of knob 18

Figure 3.2(c) Surface modeling of side cushion 19

Figure 3.2(d) Surface modeling of retractor 19

Figure 3.2(e) Surface modeling of Motorman Seat 20

Figure 3.2(f) Motorman seat with material 20

Figure 3.3.1 Connect checker 21

Figure 3.3.2 Surface curvature analysis 22

Figure 3.3.3 Isophotes mapping analysis 22

Figure 3.4 Motorman Seat rendition 23



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Abbreviation ____________________________________________________________________________

Abbreviation Definition

PLM Product Lifecycle Management

PDM Product Data Management

ERP Enterprise Resource Planning

CAD Computer Aided Designing

NC Numerical Control



PART-A

CHAPTER 1

1. PDM, ERP and Product Lifecycle Management

1.1 Product Lifecycle Management:

A product, tangible or intangible carries a huge set of information related to its definition, design,

maintenance, control and flow of data comprising the whole product cycle processes. A systematic

way of managing the definition data, life cycle data and meta-data can be collectively termed as

Product lifecycle management [1]

. PLM does not represent a software program. But, the concept

which drives the product from conceptualization to realization and its service.

A large the product range of the company, the more the data associated, though the data handling is

by pure electronic means bridging the relations to the attain an effective streamlined process is a

tough endeavor. For example: a change is carried out on a part with reference to change order from

a customer, manual intervention is bid to regulate and carry out the change followed with review,

approval, make old part obsolete, update BOM and communicate. It’s not a question that this could

be appropriate but, the amount of time killed running and chances of undue error. PLM structure

can be configured to automate very most action effectively and efficiently to cope the complexity of

part and process within and external to any organization, where the collaboration facilitated.

PLM is achieved by the functioning of its subset like PDM, ERP, SCM, CRM indigenously or

collectively applied sharing respective attributes complementing product lifecycle.

1.2 Role of PDM in product Lifecycle [2]

:

Every product evolves with the need, then the definition and design, which almost constitutes the

major task. The qualitative output is realized with this true content. Many a times the data involved

with the discrete stages is hard to locate and retrieve leading to frustration. A policy to provide

deliverables is termed with PDM. Some of the major roles of PDM are listed below:

Facilitate product structure, and mechanism to associate the interdependent.

Manage design data and meta data, and allow concurrent engineering.

Facilitate centralized repository (Vault) with access privileges.

Change management and revision control



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1.3 Role of ERP in product life cycle:

As PDM deals the creation and management of design data. ERP focuses as a next lead to the

product manufacaturing and functional management. ERP provides a common database shared

among all the stakeholders. ERP is a philosophy, a standalone could aid the product manufacturing

efficiently. Some of the major role of ERP in product lifecycle is:

Managing men, machine and materials effectively.

Support monetary functions and management.

Can act as tool to perform estimation and sales forecast.

After sales support and customer relationship management and decision support.

1.4 Need for integration of PDM and ERP systems

PDM and ERP contribute respective expertise shouldering efficient product manufacturing, one

cannot substitute the others function. The “product”, which is the critical success factor for any

business is bifurcated between these systems. It is sensed that the two indigenous system need to

interact with each other to have a profound quality output, but the mode acts as a barrier limiting

one’s function and account to conflicting data and its virtue. The design intent from PDM need to

communicated ERP, also the customer feedback or change requests need to be reverted from ERP

to PDM. The commonly called, “Islands of Automation” need to bridge and system independent

information exchange to be built.

Transparency of data from creation of the product to it becoming obsolete is a vital ingredient.

Since, with the global edge and fierce competition the product is short lived, and the variation is

imposed every often and engineering rendition is expected to meet the pace. The integration allows

to excel with an optimized time. The product followed by PDM to manufacture, has some of its

own changes and consideration, which act as the lessons learnt and iterations can be avoided.

1.5 Integration of PDM and ERP Systems a Case study [3]

:

It is worth noting, the integration of these systems could really scale the efficiency. One of the case

study is put forth to see the benefits enjoyed with the scenario of combining PDM and ERP

systems.



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Uljanik shipyard Joint-stock company, located in Pulo, Croatia established in 1856, is considered as

one of the best ship building enterprise of the country. Oil and chemical tankers, pure car carriers,

and wagon carriers are their product profile. It offers a diverse range of products to comply a

considerable share in world market. Optegra PDM, by Parametric Technology Corporation, An in-

house developed ERP application Burin, running from more over three decades and two integrated

CAD modules CADDS and Trident 5I, were their infrastructure.

The integration was initiated by the up gradation of ERP from Burin to MARS provided by Dutch

company Logimatic in 2001, which has a large insight in ship building. PDM, ERP and CAD

database are with Oracle platform. In October 2002, the integration of all three packages was

initialized bringing MARS (ERP) to operational use.

The approach of integration led the company to enhance data integrity and reduce error. The

strategy had a positive impact over its quality of the data made use to produce the required. The

system aided to detect the flaws before hand, hence downsizing the cost incurred and maintain a

very valued relationship with its customers.

The successful integration of utilizing the capabilities PDM, ERP and CAD, served to introduce a

business intelligence solution at Uljanik.

1.6 Conclusion

The topic seemed contradicting, whether or not the, exploration of capabilities of Product Data

Management and Enterprise Resource Planning will term a total product life cycle management. It

can be put to context that it is. Based on the case study it is clear that one can have a single user

window for all the functions on click of a button, and have a vision to pro-act and estimate where

the business is going to be as planned and shaped. Redundancies in data handling can be almost

made obsolete; Pace to the emerging market trend is constantly elevated. Only by, “A unique

product but a common database”.



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PART-B

CHAPTER 2

________________________________________________________________________________

2. Geometric modeling of Lever safety valve

2.1 Overview:

Geometric modeling is an approach to carry out the engineering design intent through mathematical

representation [4]

. Computer graphics cater to stimulate the scope for creation of these geometric

entities at faster, accurate, flexible and unambiguous ways. The relative database can be stored,

retrieved, edited and more elaborative analysis can be performed. In two approach of solid

modeling, Boundary representation (B-Rep) is broadly used concerning the complex rendition. The

other being, Constructive Solid Geometry (CSG) deals with primitive geometry enhancing via

Boolean concepts. CATIA, an extensively known CAD package is used to perform the geometric

modeling. Which, inherits various workbenches to address the engineering need.

Safety valve are used in boilers to expel the steam when, the threshold reaches the safe limit [5].

In a Safety lever valve load is applied by the lever, which is counter-balanced by a weight keyed to

the lever on one end. The weight can be adjusted to suit the blow off pressure requirement. The

silhouette mechanism is shown in Figure 2.1(a) Part picture is shown in Figure 2.1(b).

2.2 CAD modeling Development cycle:

Lever safety valve, is modeled with CATIA V5, which host part and sketcher workbench. Part

design is initiated with drawing a sketch on one of the datum support, followed by applying sketch

based feature, which need to assessed based on geometry and concept of modeling before hand.

Dress-up features can be applied later the body is construed. Transformations are established to

portray the same object with various stances. The successive part model, are narrated with pictures

along with their procedure.

Figure 2.1(a) : Mechanism of safety valve Figure 2.1(b) : Safety valve [1]



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2.2.1Body:

Figure 2.2.1(c): Section of Body

Sketcher workbench is activated selecting the Datum reference and profile is drawn

Geometrical and dimensional constraints are applied.

Sketch solving status is initialized to review constraints

Under constraint status are solved through Sketch analysis

Sketch based feature SHAFT is applied to generate the part.

DATUM offset is used to create bottom port.

HOLE is used as required and THREAD is applied.

MEASURE ITEM tool is used to validate the created surface

Transformation are used to create the hole entities.

CIRCULAR PATTERN is inherited to create hole pattern.

MIRROR is used to create symmetric hole apart those conform pattern.

Material in applied.

Figure 2.2.1(a): Sketch of Body Figure 2.2.1(b): Body



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2.2.2 Valve Seat:

Sketch is created on the datum support.

Geometric and dimensional constraints are applied.

Over constraint is identified by purple line, UNDO is an easy tip to resolve the flaw.

SHAFT command is used to generate the part.

A notch is created selecting the surface as a sketch support and the dimensions are justified.

MIRROR is applied and Material is inherited

2.2.3 Valve:

A Funneled type of profile is created by Sketch and SHAFT applied.

A DATUM is selected to sketch the feather portion of the part.

Project 3D silhouette, is used to constraint the open curve.

STIFFENER command is used to form the feather portion.

Instances are created using CIRCULAR Pattern.

Material is appended.

Figure 2.2.2(a): Sketch of Valve seat Figure 2.2.2(b): Valve seat

Figure2.2.3(a): Sketch of Valve Figure 2.2.3(b): Valve



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2.2.4 Cover:

The base geometry is created through a sketch and SHAFT is applied.

To create the wedge with a hole in it, a sketch is created in the normal plane.

PAD, mirror extent is applied to get the symmetry.

POCKET is applied with a sketch.

HOLE command is applied to create it on the flange.

CIRCULAR Pattern is then applied specifying the axis as the rotation element.

Two symmetric holes are created by HOLE command and MIRRORing.

One hole with Thread is created for successive assembly.

2.2.5 Cover Bush:

Figure 2.2.5: Cover Bush

Sketcher workbench is called upon to draw the bush.

Constraints both geometric and dimensional are applied

SHAFT command is used specifying the axis centre.

Figure 2.2.4(a): Sketch of Cover Figure 2.2.4(b): Cover



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2.2.6 Spindle:

Figure 2.2.6: Spindle

Sketch is drawn conforming the required dimensions.

An axis line is appended, SHAFT is used to form the part

Material is inherited.

2.2.7 Toggle:

Open sketch made to revolve, along the axis using SHAFT.

Material is applied.

MEASURE ITEM is used to validate the geometry creation.

The flange with eye section is drawn in sketcher.

PAD, mirror extent is applied.

POCKET is made to create a slot in flange with sketch-aid.

Secondary open sketch created.

Figure 2.2.7(a): Sketch of Toggle Figure 2.2.7(b): Toggle



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2.2.8 Toggle-pin, Fulcrum-pin, Lever-Pin:

Figure 2.2.8: Toggle-pin, Fulcrum-pin, and Lever-pin

The pins used, are similar in construction only with varying parametric dimensions.

A sketch is created with Datum support.

SHAFT is applied to the sketch selecting the axis.

POCKET is applied to the sketch for hole.

SAVE as is given, just varying the dimensions by clicking in 3D environment.

2.2.9 Lever Guide:

Figure 2.2.9 : Lever Guide



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A PAD, and a POCKET is created to make the slot.

A sketch containing both the rectangle dimension could have been used to make the

consolidate.

PAD is applied over a sketch to create the boss on the bottom.

THREAD is applied to the boss.

CHAMFER is amended to the bottom edge of the boss.

2.2.10 Lever

Figure 2.2.10: Lever

Sketch is created to define the slender section of the lever.

PAD is applied to extrude the sketch.

POCKET is used instead of a hole, as a single datum could be enough to draw all three.

EDGE FILLET is applied to one end of the lever.

2.2.11 Weight:

Figure 2.2.11(a): Weight Figure 2.2.11(b): Section of Weight



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A section is drawn in sketcher and SHAFT is applied along the axis.

As an alternate, a sphere could have been created and truncated offsetting the DATUM and

applying SPLIT command.

A sketch is drawn to form the internal pocket, followed by the command.

A similar pocket sketch is created and the limits are specified upto last.

A final sketch is created to revolve the tapered hole, instead which HOLE command could

be applied with taper type if only angle is known.

2.2.12 M20 Stud & Nut:

A stud of M20 is created by making a circle in the sketch.

Applying PAD, based on the height required to fasten both the body and cover with Nut.

Thread is applied on either end, on course on fastening action with threaded Body and a Nut

fastener.

Since, a standard Nut is required to fasten the assembly. Catalog browser is surfed to find

one.

Hexagonal M20 steel Nut is located.

The Nut is copied to the environment for assembling the parts.

Figure 2.2.12(a): M20 Stud Figure 2.2.12(b): M20 Nut



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2.3 Assembly of Lever Safety valve:

Individual parts modeled are assembled to simulate the mating conditions. The working model of

the design intent can only be construed with this performance and any design alternates can be

sought to enhance efficient product realization. The relationship between mating components can

be identified truly based on its fit, form and function and any undue interference can be identified

and resolved. Bottom-Up assembly is used to perform the action. The Body is the base feature

acquainting the related part geometries and their dependencies.

Figure 2.3 shows the schematic arrangement of the parts to form a whole assembly.

Figure 2.3: Schematic arrangement of Lever safety valve assembly

The table 2.3 gives the bill of material meant for the assembly.

Part Number Description Qty Part Number Description Qty

1 Body 1 8 Toggle – pin 1

2 Valve Seat 1 9 Lever Guide 1

3 Valve 1 10 Lever 1

4 Cover 1 11 Fulcrum Pin 1

5 Cover Bush 1 12 Weight 1

6 Spindle 1 13 Lever pin 1

7 Toggle 1 14 M20 Stud + Nut 6

Table 2.3: Bill of Material for Assembly



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2.3.1 Assembly Procedure

The assembly of the components is done by adding individual part to the Assembly workbench and

applying constraints relevant to its fit, function and sequence as which the Figure 2.3 illustrates.

The constraint and the relation to its dependencies is as shown in Table 2.3.1.

Component Constraint From Entity To Entity

Body Fix - -

Valve Seat Coincidence Valve seat axis Body axis

Contact Valve seat fit face Body fit face

Parallel Valve seat notch Body datum plane

Valve Coincidence Valve axis Body axis

Contact Valve fit face Valve seat fit face

Perpendicular Valve feather face Valve seat notch

Cover Coincidence Cover axis Body axis

Coincidence Cover hole axis Body hole axis

Contact Cover fit face Body fit face

Cover Bush Coincidence Cover Bush axis Body axis

Contact Cover Bush fit face Cover fit face

Spindle Coincidence Spindle axis Body axis

Contact Spindle point Valve body

Toggle Coincidence Toggle axis Body axis

Contact Toggle point Spindle notch

Parallel Toggle flange face Cover wedge face

Toggle pin Coincidence Toggle pin axis Toggle eye axis

Contact Toggle pin fit face Toggle flange face

Lever Guide Coincidence Lever Guide axis Cover threaded hole axis

Contact Lever Guide fit face Cover fit face

Parallel Lever Guide face Cover wedge face

Lever Coincidence Lever Hole axis Cover hole axis

Offset Lever face Cover wedge pocket

Fulcrum pin Coincidence Fulcrum pin axis Cover hole axis

Contact Fulcrum pin fit face Cover wedge face

Weight Coincidence Weight hole axis Lever hole axis

Offset Weight pocket face Lever face

Parallel Weight pocket face Lever face

Lever Pin Coincidence Lever pin axis Lever hole axis

Contact Lever pin fit face Weight fit face

M20 Stud Coincidence Stud axis Body threaded hole axis

Coincidence Stud face Body fit face

M20 Nut Coincidence Nut axis Stud axis

Contact Nut face Cover face

Table 2.3.1: Assembly constraint table



14

Once the constrain is updated, the real time view would be rendered and one can view the

functional arrangement. Figure 2.3.1(a) shows the assembly of all the elements of a Lever safety

valve. Figure 2.3.1(b) shows the sectional view created by using SPLIT command to facilitate

intricate viewing.

Figure 2.3.1(a): Assembly of Lever Safety valve

Figure 2.3.1(b): Sectional view of the assembly



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2.4 Analysis of Assembly

Assembled parts are analyzed for the interferences, commonly known as clash. A detailed report is

generated regarding the detection of clash, which in turn can be reviewed and solved. CATIA offers

multiple mode of specification whether, the diagnosis is against all, two selection or within single

selection. The report generated for the assembly is shown in Figure 2.4(a) comments are shown.

Out of 38 interferences, 14 are clashes and the rest are contact. Clashes diagnosed are mainly due to

thread engagement interfaces.

Figure 2.4(a): Clash analysis

Constraint analysis is performed over an assembly. It helps to identify that no part is left in the

environment without the relative bound. Also, it is helpful to detect the unconditional degrees of

freedom, solving which the act appraises as a Rigid assembly. Figure 2.4(b) shows the analysis.

Figure 2.4(b): Constraint analysis



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2.5 Drafting

Drafting is a means to communicate the design intent through a combination of orthographic and

isometric projections over a paper, which is circulated down the line i.e., planning, manufacturing,

quality control, etc., CATIA offers a dedicated workbench for drafting. Where, the modeled 3D

geometry is utilized to generate various perspective. Figure 2.5 shows the assembly drawing.

Figure 2.5: Assembly drawing

Part and assembly drawing showing legible views in order to visual true geometry is cited in

Appendix-A.



PART-C

CHAPTER 3

________________________________________________________________________________

3. Surface Modeling

3.1 Overview:

Surface modeling is an approach of representing complex objects with variable curves and contour.

Surfaces render the detail and a whole appeal which can’t be realized through wireframe due to

more ambiguity. A bound surface model and a solid model may look similar but a fundamental

difference does exist. As, Solids are created based on boundary representations or primitive

modeling, Surfaces do share a wireframe entity adherent to relative entities through point or

tangency thus defining the constitute [6]

.

A wireframe entity of a Motorman seat is modeled for surface, which later can be analyzed for

various criterion. CATIA V5 offers a workbench, Wireframe and Surface design and Generative

shape design in specific to this design need.

3.2 Surface Development:

Geometry of the wireframe need to be studied and the form need to be visualized. Few of the

techniques have to be identified based on the construction. The form of the Motorman seat look

symmetrical on some of the interfaces, so which can be addressed as earlier stages of this build.

The wireframe imported to CATIA environment is shown in the Figure 3.2(a)

Figure 3.2(a): Wireframe of Motorman seat



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The knob of the seat on both side comprise of bit more of a detailed work. It is chosen to create the

surface. Figure 3.2(b) shows the surface modeling of knob.

Since, the knob have notches over the periphery of its cylinder, ROTATE command will be

used, formatting the native element along the axis.

The notch portion is created with EXTRUDE, SWEEP and FILL command.

A CIRCLE command is used to connect three of the points which conform the circle, to

which an AXIS line is drawn normal.

The modeled notch entities are selected to ROTATE about the defined axis and multiple

instances are created.

FILL command is used create the plane face; an alternate to this process could be applying the

JOIN command to all the notches followed by FILL the circle created and TRIM.

The other side planar face is created through applying the TRANSLATE command.

Since, the knob is symmetric; a DATUM is created to lie in as a median.

SYMMETRY is applied to generate the other side of the knob.

Figure 3.2(b): Surface modeling of knob

To create the side cushion on retractor symmetry would a beneficial tool. Figure 3.2(c) and Figure

3.2(d) shows the modeling technique.

The side cushion and retractor below the seat is modeled using SWEEP and FILL.

The side cushion on other side is applied with SYMMETRY with the aid of same datum.

But, for the retractor an offset DATUM is created to compensate its own symmetry.



19

Figure 3.2(c): Surface modeling of side cushion

Figure 3.2(d): Surface modeling of retractor

The head rest, base frame and seat cover are modeled as shown in Figure 3.2(e).

FILL, SWEEP, EXTUDE are used to converge the wireframe geometry.

JOIN command is used to fill the curve splits to do the modeling.



20

Figure 3.2(e): Surface model of Motorman seat

The material is apprehended to the model, to have an aesthetic appeal of the product as shown in

Figure 3.2(f)

The Seat are is inherited with material : LEATHER

The Knob are inherited with material: PLASTIC

The base frame and head extension rod is inherited with material: IRON

Figure 3.2(f): Motorman seat with material



21

3.3 Analysis of Surface model

The surface model needs to be analyzed for discontinuities, curvature mode and quality of the

surface obtained. The following analysis are performed over the surface model, Motorman seat:

Connect checker

Surface curvature analysis

Isophotes mapping analysis

3.3.1 Connect checker

Surface model created is put to analyze the discontinuities or gaps. Geometric continuities are

checked and the blend can be solved. Figure 3.3.1 shows analysis performed over different

interfaces.

The gaps will be notified with the value. HEAL geometry can be applied the resolve the closest

gap.

Figure 3.3.1: Connect checker

3.3.2 Surface curvature analysis

Also called as color plot analysis, aids to distinguish the factor of curvature over the selected

surface. The range of the deviation is depicted through the color scale, which helps to quickly

identify the curvature type. Figure 3.3.2 shows the surface curvature analysis performed on critical

surfaces. A much uniform curvature is observed on seat area, few bad surfaces are found in knob.



22

Figure 3.3.2: Surface curvature analysis.

3.3.3 Isophotes mapping analysis

Commonly called as Zebra plots, lets one to visualize the surface quality through the interference of

light which is projected on defined perspective. Though, the product doesn’t focuses on the need to

do this analysis as only Class-A automotive components can be reviewed under this plot, study is

just put to know the differences. Figure 3.3.3 shows the zebra plot performed

Figure 3.3.3: Isophotes mapping analysis



23

3.4 Product render

The surface model produced can be rendered to the image of choice. CATIA V5 offer workbenches

which stimulate the real time blending and a much more sophisticated enrichment to get an

aesthetic feel. Since, the Motorman seat is a product used in train cab, an applicable image is

rendered with the surface model using Photo easy studio tools. Figure 3.4 shows the rendered image

of Motorman seat.

Figure 3.4: Motorman seat rendition

3.5 Surface model drafting

Product Motorman seat is drafted showing the major dimension, to get an estimate of the floor or

equip space required. The drawing depicted is in A3 ISO format addressed in Appendix-B.



24

Learning Outcome ________________________________________________________________________________

The assignment helped me to assess the practical condition and research by the virtue, the process

to know, what the real criteria entails in gathering the literature and analyzing the data to the right

perspective.

I believed, the statement put forth in PART-A, was contradictory prior to analyzing the topic.

Because, PDM is often implied as PLM, and ERP is just thought as a software program, through the

literature review a sense of understanding is obtained on how each contributes their fair expertise.

How important each resource need to utilized to the fullest, need and benefits through integration of

PDM and ERP is really learnt through various case studies. Modern trend is accessed and their

capabilities are realized.

Knowledge of tool skills is a must for a mechanical engineering outset. Manual designing and

drafting process are becoming obsolete. The capabilities of various workbench offered by CATIA

is explored. The need for assembly and fault detection is learnt. Since, drawing and communicating

the content downstream may deplete some of the design intent, a quest for new age methodology is

explored. Digital product definition (DPD) or Model based definition (MBD), where the model data

set, encompasses all the relevant information like material, dimensions and tolerances, notes for the

manufacturing process, analysis reports, NC programs and many more. The next protocol in the

emerging stages used by many of the aerospace giants is understood.

Surface modeling is an art to produce complex shapes, which is too cumbersome, almost

impossible to depict in manual representation. As and when the technology emerges, the need for

complexity of parts can be produced without resorting to design alterations. CATIA offered a user

friendly environment to create the surface and analyze. The designation and application of the

continuities are learnt in the chapter. Mathematical equation which derive the surface not even

needed to be worried too.

An overview exposure to the fundamentals, which is necessary is learnt in the module CAE, topics

like Reverse Engg and Rapid prototyping which are technical trends are worth learning and

exhibiting in one’s endeavor if it call for. The module personally dragged me to have lot of patience

and commitment, which is indeed a best to happen.



25

References ________________________________________________________________________________

[1] Antii Saaksvuori, Anslemi Immonen. (2008) “Product Lifecycle Management”, 3rd

Edition, pp.

3-7, Springer series.

[2] Peltonen, H.,(ND) Doctorate thesis, “Concepts and an Implementation for Product data

management” pp. 19-20, The Finnish Academy of technology.

[3] e-Business w@tch (ND) “Case study: IT systems integration to create efficiencies in the

production process – ULJanik shipyard, Croatia” (Web publishing)

http://ec.europa.eu/enterprise/archives/e-business-

watch/studies/case_studies/documents/Case%20Studies%202006/CS_SR06_Shipbuilding_6-

Uljanik.pdf Retrieved on 01-11-2012

[4] Zeid, Ibrahim. (1998) “CAD/CAM Theory and Practice”, pp. 153-154, Tata McGraw hill

Publication.

[5] K.L. Narayana (ND) “Machine drawing” pp. 355 (Web publishing)

http://books.google.co.in/books?id=FCelzYBXsSIC&pg=PA318&dq=lever+safety+valve&hl=e

n&sa=X&ei=qcCQUIyLLIKErQerh4GoDg&ved=0CDYQ6AEwAA#v=onepage&q=lever%20s

afety%20valve&f=false Retrieved on 29-10-2012

[6] Zeid, Ibrahim. (1998) “CAD/CAM Theory and Practice”, pp. 259-261, McGraw hill

Publication.

http://ec.europa.eu/enterprise/archives/e-business-watch/studies/case_studies/documents/Case%20Studies%202006/CS_SR06_Shipbuilding_6-Uljanik.pdf



http://books.google.co.in/books?id=FCelzYBXsSIC&pg=PA318&dq=lever+safety+valve&hl=en&sa=X&ei=qcCQUIyLLIKErQerh4GoDg&ved=0CDYQ6AEwAA#v=onepage&q=lever%20safety%20valve&f=false





Bibliography ________________________________________________________________________________

1. Antii Saaksvuori, Anslemi Immonen. (2008) “Product Lifecycle Management”, 3rd

Edition,

Springer series.

2. Avraham Shtub. (1999) “Enterprise resource planning (ERP): The dynamics of operation

management”, Kluwer academic publishers.

3. Ellen Monk, Brett Wagner. (2009) “Concepts in Enterprise resource planning”, 3rd

Edition,

Cengage Learning academic resource center.

4. Zeid, Ibrahim. (1998) “CAD/CAM Theory and Practice”, Tata McGraw hill Publication

5. Mr. Monish Gowda, “Computer Aided Engineering”, session module, MSRSAS.



27

Appendix - A ________________________________________________________________________________

Part drawing and Assembly drawing is drafted in CATIA Drafting workbench, ISO drawing layout

is used. Following are the list of drawing appended:

Drawing Title Drawing Number Sheet size

Lever Safety valve Assembly Assembly .1 A4

Body Part .1 A3

Valve Seat Part .2 A3

Valve Part .3 A3

Cover Part .4 A3

Cover Bush Part .5 A3

Spindle Part .6 A3

Toggle Part .7 A3

Lever Guide Part. 9 A3

Lever Part. 10 A3

Weight Part. 12 A3

Pin Pin.1 A3

Bill of Material:Lever Safety valve AssyPart Number Description Material Qty1 Body CI 12 Valve seat GM 13 Valve GM 1

4 Cover CI 15 Cover bush Brass 16 Spindle MS 17 Toggle MS 18 Toggle-pin MS 19 Lever guide MS 110 Lever FS 111 Fulcrum Pin MS 112 Weight CI 113 Lever pin MS 114 M20 Stud Steel 6

M20 Nut Steel 6

Exploded View withschematics

AH BG

DE CF BG AH

33

22

44

11

DESIGNED BYXXX

DATE

XXX

CHECKED BY

XXXDATE

XXX

DRAWN BYShanmuga

DATE

This drawing is our property.It can't be reproducedor communicated withoutour written agreement.

SCALE 1:4 WEIGHT(kg) XXX SHEET

SIZE

A3DRAWING NUMBER REV

X

DRAWING TITLE

Lever Safety Valve assembly

DASSAULT SYSTEMES

Assembly.11/12

01/11/2012

1

2

3 6

4

5

9

7

11 8 12

1310

AD

BC AD

33

22

44

11

DESIGNED BYXXX

DATE

XXX

CHECKED BY

XXXDATE

XXX

DRAWN BYShanmuga

DATE

01/11/2012


SCALE 1:5 WEIGHT(kg) XX SHEET 2/12

SIZE

A4DRAWING NUMBER

Part .1REV

X

DRAWING TITLE

DASSAULT SYSTEMES

Body

6 HOLES EQUI-SP

M20

230

188

128

60

6 0

210

Note: All dimensions are in "mm".

Previous Assy -Next Assy Valve SeatMaterial CIQty 1

A A

260

140

25

13418

230

230

10050

28

168

292

1 24

100

25

32

18 18

92R

18

10

32

66

M 114

Section view A-A

Isometric viewScale: 1:5

AD

BC AD

33

22

44

11

DESIGNED BYXXX

DATE

XXX

CHECKED BY

XXXDATE

XXX

DRAWN BYShanmuga

DATE

01/11/2012


SCALE 1:2 WEIGHT(kg) XXX SHEET 3/12

SIZE

A4DRAWING NUMBER

Part .2REV

X

DRAWING TITLE

Valve seat

DASSAULT SYSTEMES

2 NOTCHES 6 X 12


Previous Assy BodyNext Assy ValveMaterial GMQty 1

A A

28

621 04

100

M114

Section view A-AIsometric view

AD

BC AD

33

22

44

11

DESIGNED BYXXX

DATE

XXX

CHECKED BY

XXXDATE

XXX

DRAWN BYShanmuga

DATE

01/11/2012



SIZE

A4DRAWING NUMBER

Part .3REV

X

DRAWING TITLE

Valve

DASSAULT SYSTEMES

120

4

3 Feathers Equi-Angle


Previous Assy Valve SeatNext Assy SpindleMaterial GMQty 1

A A

20

5

8

104

8

50

100

50

Section view A-A Isometric view

DESIGNED BYXXX

DATE

XXX

CHECKED BY

XXXDATE

XXX

DRAWN BYShanmuga

DATE

01/11/2012


SCALE 1:4 WEIGHT(kg) XX SHEET 5/12

SIZE

A4DRAWING NUMBER

Cover

REV

X

DRAWING TITLE

DASSAULT SYSTEMES

AD

BC AD

33

22

44

11

Part .4

128

210

68

22

22

M 20

60

60


Previous Assy BodyNext Assy Cover BushMaterial CIQty 1

A A

36

76

140

64

40

25

8

42

10044

94

30

2 60

22 30R

Section view A-A

Isometric view

AD

BC AD

33

22

44

11

DESIGNED BYXXX

DATE

XXX

CHECKED BY

XXXDATE

XXX

DRAWN BYShanmuga

DATE

01/11/2012



SIZE

A4DRAWING NUMBER

Part .5REV

X

DRAWING TITLE

Cover Bush

DASSAULT SYSTEMES

38

36


Previous Assy CoverNext Assy SpindleMaterial BrassQty 1

A A

624

28

Section view A-A

Isometric view

AD

BC AD

33

22

44

11

DESIGNED BYXXX

DATE

XXX

CHECKED BY

XXXDATE

XXX

DRAWN BYShanmuga

DATE

01/11/2012



SIZE

A4DRAWING NUMBER

Part .6REV

X

DRAWING TITLE

Spindle

DASSAULT SYSTEMES

12

6

200

44

Broken view


Previous Assy Valve & Cover BushNext Assy ToggleMaterial MSQty 1


DESIGNED BYXXX

DATE

XXX

CHECKED BY

XXXDATE

XXX

DRAWN BYShanmuga

DATE

01/11/2012


SCALE 1:2 WEIGHT(kg) xx SHEET 8/12

SIZE

A4DRAWING NUMBER

Part.7REV

X

DRAWING TITLE

DASSAULT SYSTEMES

AD

BC AD

33

22

44

11

Toggle

22R

22

32

6R


Previous Assy SpindleNext Assy LeverMaterial MSQty 1

12 1224

36

50

2 85 38

Isometric view

AD

BC AD

33

22

44

11

DESIGNED BYXXX

DATE

XXX

CHECKED BY

XXXDATE

XXX

DRAWN BYShanmuga

DATE

01/11/2012



SIZE

A4DRAWING NUMBER

Part .9REV

X

DRAWING TITLE

Lever Guide

DASSAULT SYSTEMES

28

M20

25


Previous Assy CoverNext Assy LeverMaterial MSQty 1

24

42

124

12

12 Isometric view

AD

BC AD

33

22

44

11

DESIGNED BYXXX

DATE

XXX

CHECKED BY

XXXDATE

XXX

DRAWN BY DATE



SIZE


X

DRAWING TITLE

DASSAULT SYSTEMES

9/12

Lever

Part .10

01/11/2012Shanmuga

32R22

15

64

100


Previous Assy Cover, Toggle & Lever Guide Next Assy WeightMaterial FSQty 1

270

1260

16

22

Isometric view

AD

BC AD

33

22

44

11

DESIGNED BYXXX

DATE

XXX

CHECKED BY

XXXDATE

XXX

DRAWN BY DATE



SIZE


X

DRAWING TITLE

DASSAULT SYSTEMES

9/12

Lever

Part .10

01/11/2012Shanmuga

32R22

15

64

100


Previous Assy Cover, Toggle & Lever Guide Next Assy WeightMaterial FSQty 1

270

1260

16

22

Isometric view

AD

BC AD

33

22

44

11

DESIGNED BYXXX

DATE

XXX

CHECKED BY

XXXDATE

XXX

DRAWN BY DATE



SIZE


X

DRAWING TITLE

DASSAULT SYSTEMES

10/12

Part .12

Weight01/11/2012Shanmuga

82

66222


Previous Assy LeverNext Assy Lever PinMaterial CIQty 1

A

A

40

20

1576

102

1 44

Section view A-A

Isometric view

AD

BC AD

33

22

44

11

DESIGNED BYXXX

DATE

XXX

CHECKED BY

XXXDATE

XXX

DRAWN BYShanmuga

DATE



SIZE

A4DRAWING NUMBER

Part .14REV

X

DRAWING TITLE

M20 Stud and Nut

DASSAULT SYSTEMES

12/12

01/11/2012

25

25

M 20

75

M20 Stud

M20

M20 Nut


Previous Assy Body, CoverNext Assy -Material SteelQty 6

PART NUMBER DESCRIPTION A B C D E8 Toggle pin 26 22 5 60 811 Fulcrum pin 26 22 6 80 813 Lever pin 16 12 3 76 6


AD

BC AD

33

22

44

11

DESIGNED BYXXX

DATE

XXX

CHECKED BY

XXXDATE

XXX

DRAWN BYShanmuga

DATE

11/1/2012



SIZE

A4DRAWING NUMBER

Pin.1REV

X

DRAWING TITLE

Pin

DASSAULT SYSTEMES

11/12

A B

C

E

D



28

Appendix - B ________________________________________________________________________________

Drafting showing major dimensions of Motorman seat is appended, ISO layout is used for drafting

with A3 Sheet size.

Drawing Title Drawing Number Sheet size

Motorman Seat Surface .1 A3

DESIGNED BYXXX

DATE

XXX

CHECKED BY

XXXDATE

XXX

DRAWN BYShanmuga

DATE



SIZE

A3DRAWING NUMBER

Surface .1REV

X

DRAWING TITLE

Motorman seat

DASSAULT SYSTEMES

AH BG

DE CF BG AH

33

22

44

11 01/11/2012

1136.22

5 00

Note: All Dimensions are in "mm".

670.1

443.45

3 50

158.23


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