EDSGN 497K Design Portfolio

Sponsor: The Boeing Company

EDSGN 497K: Engineering Design and Analysis with Advanced CAD (CATIA)
Section: 905

Submitted by: Alexandria Vivar [atv5046@psu.edu]

Submitted to: Xinli Wu [xinli@psu.edu]

CATIA V5-6R2014 [FEA Model: 17-28 Analysis of a Fastened Assembly]

Submitted: December 6, 2016

Abstract

The following design portfolio highlights some of my key skills and accomplishments while learning
CATIA V5 in EDSGN 497K at Penn State University. Below are practice problems I have completed, a mini-design
project, and a final design project encompassing part design, assembly, shape design and FEA. Enjoy!
Table of Contents
I. Course Syllabus
II. Practice Problems and Exercises
III. Mini-Design Project
IV. Final Design Project
V. Summary and Conclusions
VI. Acknowledgements
VII. References
I. Course Syllabus

EDSGN 497K Engineering Design and Analysis with

Advanced CAD (CATIA) (3.0 Credits)
FALL 2016 (August 22 December 09)
http://www.engr.psu.edu/xinli/EDSGN497K/

Course Professor: Xinli Wu, Ph.D., P.E.

Phone number: 814-863-1537

E-mail address: Xinli@psu.edu

Teaching Assistant: Andrew Bellows afb5124@psu.edu, Michael Orner mzo5092@psu.edu

Course Number, Class Time, and Place: EDSGN 497K: 6:00 9:00 PM, Tuesday and Thursday,
315 Hammond

Office hours & location: 12:20 1:10 PM Wednesday, and/or by appointments,

213-S Hammond

Prerequisites: Junior standing or above in an engineering major with knowledge of

E MCH 210 and 211 or equivalent (or approved by the instructor).

Course overview and objectives:

The course objectives are to understand how engineering design efforts are supported through the use
of advanced Computer Aided Design (CAD). Advanced CAD makes creating rich and complex designs possible.
Advanced CAD (in this offering CATIA V5) is used as a design tool to build parts
and assemblies, and to create drawings of those parts and assemblies. Students will learn basic FEA (Finite
Element Analysis) capabilities to conduct structural analysis and computer simulation of designs. Students
will learn how to generate models, establish meshes, apply boundary conditions, loads, and material
properties to the model for structural analysis, and then generate an FEA report. Through various
exercises, design projects with rapid prototyping models, and building design portfolios, students will
obtain a solid foundation in the use of advanced CAD for their designs and engineering analyses.

Textbook: Richard Cozzens (2013), CATIA V5 Workbook, Release V5-6R2013, SDC Publications. ISBN
978-1-58503-544-1 (Available at Penn State Bookstore or online bookstore:
www.schroff.com).
 Nader G. Zamani (2012), CATIA V5 FEA Tutorials, Release 21, SDC Publications. ISBN: 978-1-
58503-764-3 (Available at Penn State Bookstore or online bookstore: www.schroff.com).
Course Calendar:

Week Day/Date Course content Text

Intro. to the course Cozzens, Chap. 1

Introduction to CATIA V5
Week 1 Tuesday (8/23) Practice Exercises 1-5 on p. 1.16
Navigating the CATIA V5 Environment Cozzens, Chap. 2
Practice Exercises 1-6 on p. 2.40

Sketcher Cozzens, Chap. 3

Practice Exercises 3 on p. 3.47
Week 2 Tuesday (8/30) Part Design Cozzens, Chap. 4
Practice Exercises 3 on p. 4.51

Drafting: creating sheets and views Cozzens, Chap. 5

Practice Exercises 3 on p. 5.42
Week 3 Tuesday (9/6) Drafting: creating text and dimensions Cozzens, Chap. 6
Practice Exercises 3 on p. 6.31

Complex and Multiple Sketch Parts Cozzens, Chap. 7

Practice Exercises 3 on p. 7.40
Assembly Design Cozzens, Chap. 8
Week 4 Tuesday (9/13) Practice Exercises 4 on p. 8.38

Generative Shape Design: creating Cozzens, Chap. 9

surfaces
Practice Exercises 2 on p. 9.47
Week 5 Tuesday (9/20) Generative Shape Design: creating surface Cozzens, Chap. 10
geometry using the sweep tool
Practice Exercises 1-8 on p. 10.26-10.28

DMU Navigator Cozzens, Chap. 11

Practice Exercises 1 on p. 11.29
Week 6 Tuesday (9/27) Real Time Rendering Cozzens, Chap. 12
Practice Exercises 1 on p. 12.27

Parametric Design Cozzens, Chap. 13

Practice Exercises 3 on p. 13.29
Week 7 Tuesday (10/4) Mini Design Project (Due 11/08/2016) Handouts/Online
Advanced CATIA Design Example 1
 Final Design Project (Due 12/12/2016) Handouts/Online
Guidelines for online design portfolio
Advanced CATIA Design Example 2
Week 8 Tuesday (10/11) Introduction to Finite Element Analysis Zamani, Chap. 1
Capabilities and limitations of the FEA in
CATIA

Analysis of a Bent Rod with Solid Zamani, Chap. 2

Elements
Practice Exercises 1 on p. 2-20
Week 9 Tuesday (10/18) Axially Loaded Block with Stress Zamani, Chap. 3
Concentration
Practice Exercises 2 on p. 3-23

Deformation of an I-beam under Self- Zamani, Chap. 5

weight
Practice Exercises 1 on p. 5-13
Week 10 Tuesday (10/25) C-clamp Deformed with Enforced Zamani, Chap. 6
Displacement
Practice Exercises 1 on p. 6-12

FEA Modeling of the Bent Rod with beam Zamani, Chap. 7

Elements
Practice Exercises 1 on p. 7-13
Week 11 Tuesday (11/1) Bending of a Notched Specimen with Zamani, Chap. 9
Smooth Virtual Part
Practice Exercises 1 on p. 9-18

Modeling Mismatch in Shell Thickness Zamani, Chap. 11

and Surface Mesh
Practice Exercises 1 on p. 11-18
Week 12 Tuesday (11/08) FE Model of a Bearing-Shaft Assembly Zamani, Chap. 14
Using Analysis Connection
Practice Exercises 1 on p. 14-28

Analysis of a Tensile Specimen as an Zamani, Chap. 16

Assembly
Practice Exercises 2 on p. 16-28
Week 13 Tuesday (11/15) Analysis of a Fastened Assembly Zamani, Chap. 17
Practice Exercises 1 on p. 17-28

Week 14 Thanksgiving Holidays, No classes.

Week 15 Tuesday (11/29) Working on Design Project

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 Working on Design Portfolio
Week 16 Tuesday (12/6) Design Project Due
Online Design portfolios Due
Class concluded

Class Policies:

The following are some ground rules to help us maintain a steady progress through the semester:

1. Assignments submitted after its due time will receive a 20% deduction. A further 20%
reduction will be applied for every week beyond the first.
2. Punctual attendance is mandatory for all the class periods. Course grade will be dropped to
the next lower grade for every class missed. All excused absences must be supported by
written documentation, such as doctor's receipt, Penn State athletics travel notice, ROTC
notice, etc.

Academic Integrity:

Senate Policy 49-20 Academic Integrity

Definition and expectations: Academic integrity is the pursuit of scholarly activity in an open,
honest and responsible manner. Academic integrity is a basic guiding principle for all academic
activity at The Pennsylvania State University, and all members of the University community are
expected to act in accordance with this principle. Consistent with this expectation, the
University's Code of Conduct states that all students should act with personal integrity, respect
other students' dignity, rights and property, and help create and maintain an environment in
which all can succeed through the fruits of their efforts.

Academic integrity includes a commitment not to engage in or tolerate acts of falsification,

misrepresentation or deception. Such acts of dishonesty violate the fundamental ethical principles
of the University community and compromise the worth of work completed by others.

The Penn State Principles:

1. I will respect the dignity of all individuals within the Penn State community;
2. I will practice academic integrity;
3. I will demonstrate social and personal responsibility;
4. I will be responsible for my own academic progress and agree to comply with all University
policies.

Related sites:
Penn State Principles, http://www.psu.edu/ur/2001/principles.html
Code of Conduct, http://www.sa.psu.edu/ja/codeconduct.html
Academic integrity, http://www.psu.edu/ufs/policies/47-00.html - 49-20
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Grading System:

o Class attendance: 10%

o In-class exercises and homework assignments: 40%
o Mini-Design Project with Rapid Prototyping: 15%
o Final Design Project: 25%
o Online Design Portfolios: 10%

Grades will be determined based your performance on the activities listed above. Final letter grades will
be assigned as follows:
> 93 = A 90-93 = A- 87-89 = B+ 83-86 = B 80-82 = B-
75-79 = C+ 70-74 = C 60-69 = D below 60 = F

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II. Practice Problems and Exercises

Part Design & Assembly: 7-3 & 7-5

Complex and Multiple Sketch Parts

FEA Model: 2-20

Analysis of a foot pedal with solid elements

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 FEA Model: 5-13

Deformation of an I-beam under Self-weight

FEA Model: 6-12

C-clamp Deformed with Enforced Displacement

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 FEA Model: 11-18

Modeling Mismatch in Shell Thickness and Surface Mesh

FEA Model: 16-28

Analysis of a Tensile Specimen as an Assembly

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 III. Mini-Design Project

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 CATIA V5 Model of Perfume Bottle

CATIA V5 Drawing of Perfume Bottle

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 Photos of 3D Printed Perfume Bottle using Maker Bot

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 IV. Final Design Project

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 Isometric view of chair assembly

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 Multiview of Chair Assembly

Isometric view of chair legs (X2)

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 Isometric view of the chair back

Isometric view of the chair seat

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 Drawing view of chair assembly

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 Detailed view of chair seat

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 Detailed view of chair legs

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 Detailed view of chair back

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FEA Report: Displacement (5.87 e-005 in) with a 300 lb load
 FEA Report: Von Mises (38 psi) with a 300 lb load

Main Design Features:

This chair design features an all-aluminum industrial body consisting of an aluminum chair back, legs,
and seat. Rivets in the seat and back are design for optimum comfort.

V. Summary and Conclusions

As you can see from my portfolio, I have a learned a great deal about CATIA during the course of the
semester. Hopefully I can apply my knowledge and skills to my future career in the automotive industry.
Capabilities like finite element analysis and shape design will me excel in starting my career.

VI. Acknowledgements

I would like to thank Professor Xinli Wu as well as the teaching assistants for the help and assistance in
learning CATIA V5.
VII. References

(1) Cozzens, Richard. CATIA V5 Workbook, Release 19. Mission, KS: Schroff Development, 2009. Print.

(2) Zamani, Nader G. CATIA V5 FEA Tutorials: Release 19. Mission, KS: SDC Publications, 2010. Print.