Methodology Guide for E&E-CG

Integrated Mechanical product Development Solution

Styled Plastic & Packaging Solution

Industrial Design
Conceptual
Case Study

Version 5 Release 15
September 2005
Hand Tool design
Design Process: Hand tool

1
Insert 2D pictures

Enter the Imagine &

Shape workbench

2
Create Main Body
with IMA
3
Create detailed
design with IMA

4
Finish detailed
design with GSD
Enter the GSD
workbench

3
 Open surfaces

Close surfaces
Open surfaces

4
Inputs

Inputs
Mechanical data (internal mechanism)
2D pictures

5
Inputs

6
Insert 2D picture

Open : …\data\proposition1.CATProduct

Go to Free Style Sketch Tracer (FSK) workbench

Select a view to position the 2D picture

Select Create an immersive sketch icon

Select the Front.jpg 2D picture

Check that you are in Material View Mode

7
Insert 2D picture

Move the axis manipulator in the middle to this location

Move the second manipulator to choose dimensions

8
Insert 2D picture

Position that 2D picture with the mechanical data as is shown

If needed apply transparency on the picture (Properties/Graphical/transparency)
2D picture (blue)

3D component (brown)

Position that picture in the 3D environment

Select picture and use those arrows to slide the picture

9
Insert 2D picture

Redo the same task with these three “2D pictures” to obtain what it is
shown

10
 Create the product

This product is composed by

1-Main body I: cylinder
2-Main body II: 2 big bases
3-Main body III: 1 small base
4-Detailed design 1: face
5-Detailed design 2: cd box
6-Detailed design 3: hp
6
7-Detailed design 4: connector
8-Detailed design 5: aeration 5
7
9-Detailed design 6: buttoms

4
1
8
2 3

11
Recommandations

Create for each element

1 Geometrical Set with the name of each element

1 Geometrical Set for Styling Surfaces

1 Geometrical Set for GSD operations
Built step by step detailed design
IMA shape
GSD operations

12
Create main body I

Double click Industrial Part to activate it

Work in the Geometrical Set : Styling Surfaces
Geometrical Set can be created by using the macro (../Macro/ForStyling.catvba)
Create a close surface
Place it on the origin
Use translate function
Use data definition (x=y=z=0)

13
Create main body I

Create 2 cut lines as it is shown

Refine the shape

Use 2D picture lines

14
Create main body I

Refine the shape as is shown

Add transparency

15
Create main body II

Create a new box surface

Select a bottom and apply attraction=0

16
 Create main body II

Cut the shape: once on X, twice on Y and again on the Z axis

Translate the bottom to reduce the size

z
y x

17
Create main body II

Affect weight on the second group of edges as is shown

18
Create main body II

Use Affinity function to find the good shape

First, scale up the second group of edges
Then, scale down others edges on the bottom
Be careful to press SHIFT to perform a uniform scale

Second Group Edges on the bottom

of edges

19
Create main body II

Translate as is shown

20
Create main body II

Align all the middle points on face view

21
Create main body III

This shape is a copy, but smaller and symmetrical on the Y axis

Use the Affinity function, with Shift button
Use the Alignment function to force symmetry on the Y axis

Big shape
Small shape

22
Create main body III

Check with the technical part.

23
Create main body

See the result. The main volume is validated

24
Create detailed design I

Create a new close surface (TRIM CD)

Erase two faces
Cut once
And apply attraction as is shown

25
Create detailed design I

Define in work object the Geometrical Set : Operations GSD

Show MAIN BODY I.
Create 2 edge fillets 10mm to have the result on the right.
Name it EDGE1

26
Create detailed design I

Work with TRIM CD

Create a 2 edges fillet. The value is 5 mm

27
Create detailed design I

Trim TRIM CD with EDGE1

The front of the product is created and validated

28
Create detailed design II

Create a new close surface (CD)

Scale down in the Z axis

29
Create detailed design II

Place this shape with Technical part

Translate
Use the Affinity function if it is necessary
Trim EDGE1 with CD. Be careful to keep the good area

30
Create detailed design III

Create a new close surface (TRIM HP)

Erase opposites faces

31
Create detailed design III

Place TRIM HP with Technical part by Translation and Affinity

Create 1 fillet between TRIM HP and MAIN BODY II to have emplacement of hp. The
value is 0.5mm

32
Create detailed design III

Create the hp definition

First, create a internal offset to TRIM HP (0.5mm)
After, extract the main surface of MAIN BODY II
Offset this extract to have the external limitation of hp definition
At the end, fillet TRIM HP with extract

offset

extract offset
fillet

33
Create detailed design III

Apply symmetry to DETAILED DESIGN III

34
Create detailed design IV

Create a new close surface (CONNECTOR)

Erase the front face
Create 3 cut lines to modify the shape as is shown
Put attraction on external edges = 0
Translate down

35
Create detailed design IV

Place CONNECTOR with MAIN BODY II

Trim CONNECTOR with MAIN BODY II. Name it connector area

36
Create detailed design IV

Import the connector IGES file.

Place this file with the connector area by translation

37
Create detailed design IV

Use the connector elements to set the distances between the primary
elements

38
Create detailed design IV

Trim the primary elements with the connector area

39
Create detailed design V

Create a new open surface

Place it as is shown

40
Create detailed design V

Create an offset, 0.2mm

Trim twice GSD shape with plan
Fisrt time, keep the top
Second, keep the bottom
Fillet each. The value is 0.2mm

Top

0.2mm

Bottom

41
Create detailed design V

Create a new close surface to build a technical access

Place this shape as is shown
Erase 1 face
Fillet this new shape with the GSD bottom

42
Create detailed design V

Create an area for technical information

Create a plan on the external surface
Create a sketch. So go to Sketch Workbench

43
Create detailed design V

Extrude the sketch to create a surface

Fillet edges to cut in the next operation. The value is 0.2mm

44
Create detailed design V

Create the bottom of this element

Use a primary plan
Place it as is shown
Fillet this plan with the extrusion. The value is 0.2 mm

45
Create detailed design V

At the end, fillet the main element of technical access with the box

46
Create detailed design VI

Build sketches in GSD workbench to create aeration shape

Repeat the first sketch 6 times
Trim the second with the first sketch to have the correct shape for aeration
2

Repetition

2
+
1

47
Create detailed design VI

Exit from the sketch

Create a volume
Trim this volume with the fond part
Fillet the result. The value is 0.2

48
 Create detailed design VI

Perform the same operations with this sketch to create the bottom of the
aeration
Old sketch
New sketch
2

repetition

1
+
2

49
Create detailed design VI

Extrude a volume
At the end, trim and fillet.

50
Create detailed design VII

Use primary elements to create the enter surface for the UDF function

51
Create detailed design VII

Apply UDF to create each button

52
Final product

53