Chapter 5: Mechanical Assembly Design

6.1 Introduction

• Most engineered products-from pencil sharpeners to aircraft

engines - are assembled units.

• Engineering products are made of assemblies, sub-

assemblies and components.

• Assembly modeling is an extension of part design.

• During product design and development, designers

traditionally consider not only functionality but also ease of
manufacture of individual components and parts.

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• However, little attention is given to those aspects of design
that will facilitate assembly of parts.
• Assembly-related problems are typically discovered on the
shop floor when its is either too late or too expensive to
remedy them.
• There is a needs of building an assembly model by using
component geometric → product assembly modeling CAD
application tool.
• Typically, it comprises add on modeling capability to describe
the product assembly structure and geometric relationship
(e.g. position and orientation) of individual components in the
context of the assembly.
• Today many CAD systems provide product assembly modeling
capability as an integral part of their geometric modeler.
• DFA is also considered in assembly design.
• If a product contains fewer parts it will take less time to
assemble, thereby reducing assembly costs.
• Parts are provided with features which make it easier to
grasp, move, orient and insert them → reduce assembly time
and assembly costs.
• The reduction of the number of parts in an assembly has the
added benefit of generally reducing the total cost of parts in
the assembly.
• This is usually where the major cost benefits of the
application of design for assembly occur.
Creating an assembly model
 6.2 Assembly Modeling

• An assembly is a collection of independent parts.

• A technology and methods used by Computer-aided design
and Product visualization computer software systems to
handle multiple files that represent components within a
product.
• Assembly modeling has 2 issues – hierarchy (sequence) and
mating (spatial relationship and orientations).
• The hierarchy (sequence) is shown in an assembly tree.
• Assembly planning is required to create a successful assembly
– especially for large assemblies that involve thousands of
part. (E.g. airplane, automobiles etc).
Assembly tree
Things to consider before creating an assembly:

1. Identify the dependencies between the components of an

assembly.

2. Identify the dependencies between the features of each

part.

3. Analyze the order of the assembly parts.

• A CAD designer is mainly concerned about the precise
geometric definition (i.e. graphical data) of a product, which
usually takes significant amount of design time.
• A CAD designer uses a product assembly modeling package to
design and develop an electronic definition of a product which
include activities:
– Defining assembly structure.
– Associating CAD models to various nodes on the assembly, if available.
– Creating or modifying component CAD models.
– Positioning component geometry to suit the mating condition on assembly.
– Performing collision checks on a component solid models to make sure that
there is no unnecessary interference with the proximity components.
– Visualizing and planning assembly and disassembly sequence.
 Bottom-up Assembly

• Types of Assembly Modeling Approach:

1. Bottom-up Assembly
– The bottom-up assembly is the traditional, logical and most preferred
approach for creating assembly models.
– Create individual parts independently → insert parts in an assembly
→ use mating condition to locate and orient.
– An assembly is created by adding parts and components to a base or
root (parent/host) part using assembly constraints.
– Parts inserted in an assembly are copies from the original parts
(instances) – it gives a parametric characteristic whereby updating
the original part, will also update the assembly.
– The base part is that part in the assembly to which most other
components are attached (e.g. in the assembly of an automobile, the
chassis would be considered the base part).
– A preferred technique for parts that have been constructed or
modeled.
Bottom-up Assembly
 Bottom-up Assembly

PROS CONS
Allows the designer to use part Errors are manually identified and
drawings that already exist (off the modifications to each component are
shelf). made to make the adjustment.

Provides the designer with more If any of the assembly components is

control over individual parts. moved from its original location, then
the assembly will not open.

Any changes in the original part is

reflected on all the instances in the
assembly

Assembly files created in this method

occupy less disc space as they contain
only the information related to the
assembling of the parts.
 Top-down Assembly

2. Top-down Assembly

– In the top-down assembly design approach, components are created

inside the Assembly Design workbench.
– These components are then assembled together whereby other
components to be assembled will be created referring to the
assembled modeled.
– It allows detail design to begin while the assembly layout is being
finalized.
– Design teams can work concurrently within a common framework.
– It allows designers to validate different design concepts before
implementing it and also practice ‘what-if’ design scenarios in their
design.

TOP DOWN ASSEMBLY VIDEO- https://www.youtube.com/watch?v=-RpWSvTveDI

Top-down Assembly
 Top-down Assembly

PROS CONS
The overall design information is Top-level change control
in one centralized location

Reduce errors within complicated Creating the top down assembly require
assemblies (relating to dimension issues) more analysis and work before start

Increased quality

Better project management visibility

Concurrent engineering

The approach is ideal for large

assemblies consisting of thousands of
parts.
 CATIA-Assembly Design

• The Assembly Design application allows you to

create a product model from a number of separate
parts.
• The parts in a product assembly are not joined
together, but assembled as they would be in a
physical assembly.
• The product assembly structure is hierarchical and
allows you to model complex product relationships.
• Constraints can be applied between the parts in
assembly to define relationships between them.
 Assembly Design

• Product Structure Tools • Move Toolbar

– Manipulate
– Snap
– Explode and Assembly
– Insert New Component
– Insert New Product • Constraints Toolbar
– Insert New Part
– Insert Existing Component
– Replace Component
– Reorder Tree – Coincidence
– Generate Numbers – Contact
– Offset
– Load Components
– Angular
– Unload Components – Anchor
– Manage Representations – Fix Together
– Multi-Instantiation
 Benefits of Assembly Modelling

• Support for reuse of standard parts

– Assembly design creates links to the master geometry definition,
so multiple instantiations of parts can be efficiently created
– Design changes are automatically reflected in the assembly
– Model sizes are minimised because geometry files are not copied

• Management of inter-part relationships

– Mating Conditions
– Contact Constraints

• Development of Kinematics models

– Simple mechanisms analysis available
 Using the Product Structure
Tree
• The specification tree shows product structure
information relating to the parts and sub-
assemblies contained in an assembly
– In the example shown on the right the product is
called Product1
– The product contains three components
CRIC_FRAME, CRIC_BRANCH_3 and CRIC_BRANCH_1.
• The Product and the Components do not
contain any geometry
– Geometry is stored in parts inside the Component
definitions
– The Constraints Branch shows the constraints that
have been created to define the relationships
between the components in the product structure
 Steps for Creating an Assembly

1. Create a new CATProduct using File -> New ->

Product.
2. Use the Product Structure tools to lay out the
main assembly structure
3. Use Insert Existing Component or Insert New
Part to create geometry in the Assembly
4. Use Constraints to capture the design
relationships between the various parts in the
assembly
 Saving Assembly Information

• Assembly information is stored in a file with the extension

.CATProduct.
• The CATProduct file contains only information relating to the product
assembly.
• The detailed geometric information about the parts in the assembly is
referenced to the original .CATPart files
Warning
– If you copy a.CATProduct file it will still point to the original part files
– To copy an entire assembly use File -> Save All As… , specify a new location for the
.CATProduct file, then click on the Propagate button.
 Considering Assembly Constraints

• Coincidence Constraints: aligns axes, planes

and points
• Contact Constraints: a tool for creating
contacts between 2 planes or surfaces
• Offset Constraint: defines a desired offset
distance between two elements
• Angle Constraints: A way to define an angular
relationship between two elements
 Considering Assembly Constraints

• Fix Component: A way to FIX a part “in space”

so that it will always remain there. Other
parts can be constrained relative to a Fixed
component
• Fix Together: Fixes two parts together
(forever)
• Flexible/Rigid Subassembly: in a flexible sub,
parts and components can be moved
regardless of the fact if it (or they) are the
active component
 Considering Assembly Constraints

• Use Save Management commands because of

the several links within the root tree
– Save or save-as individuals in the Save
Management window
– We can also just “Save All” for a full update
• When modeling because of constraining
issues, parts must have tolerenced dimensions
added
We Finish with an Assembly:
From Which we Make an Exploded Product Drawing

Note: The
Product is
highlighted –
We can
explode and
assemble!
 Building An Assembly

• Start Work in the Assembly Workbench

• We begin with a “Root” CATProduct
• We can create “Components” of the assembly that exist only
within the “Root Files”
• We can inport Existing Components to the Assembly (parts or
sub-assemblies created earlier) W/ or W/O positioning
• We can create Parts for the Assembly “on the Fly”
• We can create “Instances” or duplicates of parts
• We can create Numbers or Letters to Identify parts of an
Assembly – for BOM needs
• We can “Manage Representation” (names, associations, etc.) of
the components of an assembly
• We can Bring in Catalog – or standard – components to our
assemblies like bolts/nuts/pins, etc.
Because Assemblies are Multi-component products get in
the habit of ‘SaveManaging’ them and consider using
Folders to save all of the components and parts required
Lets Get Started:
 Using Ass’bly I & properties to name it then Add Part ICON to
create Part1.1 under it & then Properties/ set Instance Name to
ToolPostBody
This Part Is Finished – Save Manage!!
Standard Parts can be added We highlight the Assembly Then Click Tool
and Mech Std Parts – ASME, ANSI Inch Catalogs
 6.3 Interference of Position from Mating
Conditions

• Parts are assembled by locating & orienting its’ MCS properly

with respect to the global coordinate system of the assembly.
• To achieve this, mating conditions must be specified.
• Common mating conditions:
– Coincident
– Concentric
– Tangent
– Coplanar
– Parallel faces
– Perpendicular faces

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Global Coordinate
System
Local Coordinate
System
• Assembly constraints define how components or
subassemblies fit together.
• Constraints are used to align and orient parts in the assembly
model with respect to each other.
• Types of constraints available (e.g. CATIA):
– Coincide constraint
– Contact constraint
– Offset constraint
– Angle constraint
– Fix component constraint
– Fix together constraint
– Quick constraint
• A part should be fully constrained to allow the creation of the
correct assembly.
• When creating an assembly, bear in mind about the 6 degree
of freedom (DOF) a part has.
• Upon assembly, components may be under-mate (floating) or
over-mate (interference).
• To constraint all components are very important for
simulation reasons.
• Space analysis tool available in CATIA:

Clash : Analyzes interference between different products.

Sectioning : Manages sections and cuts of the products.
 6.4 Assembly analysis in
Industrial Application

• Assembly design and analysis are quite important in product

development, especially since it is estimated that the
manufacturing costs are tied up in the assembly process.

• The greatest potential for increased productivity and

significant reduction in production costs lies in the
consideration of assembly requirements during the design
stage of the product cycle.

• When evaluating alternate designs, ease of assembly (DFA) is

a key element in successful product development.

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• Common analytical procedures in assembly modelers:

Kinematic analysis - analysis of the motions of mechanisms.

Dynamic analysis - analysis of the motions of mechanisms and the

effects of mass.
Tolerance analysis - determines the effects of individual part tolerances
on the ease of assembly, the presence of tolerance stacks, and product
performance.

Finite element analysis (FEA) - analysis of stress or strain and heat

transfer.
Mass properties analysis - computation of properties such as weight,
center of gravity, and moments of inertia.

Interference checking - determines if an interference or clearance exists

between mating parts.
Generation of exploded views - automatic generation of an exploded
view of assembly.

Generation of Bill of Materials (BOM) - automatic generation of an

assembly parts list.