Shell vs Thicken

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Part Design in CATIA V5:A Comparison ofShell and Thicken

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Abstract In this workshop you will see how to model a thin-

walled part, such as a metal stamping or a plastic cover, using the Shell or Thicken command. This teleconference will show you the difference between developing thin-walled parts using Shell and Thicken, and the implications of these differences when modeling a metal stamping or a plastic cover.  We will cover several modeling strategies, and discuss the pros and cons of each method. This workshop is intended to be interactive and you will be invited to ask questions you may have.

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Presenter Terry Cussen

8 years of mechanical design experience automotive seating, robotics, and technology

research and development. designing metal stampings, machined parts,

and injection molded plastic components.

CATIA V5 Engineering Courseware Developer at Cadpo in Westminster, CO.

Masters and Bachelors degree in Mechanical Engineering from Stanford University.

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Intended Audience Engineers and Designers who make thin-

walled parts Injection molded Stamped Machined Cast

CAD department teams investigating best practice modeling methods

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Agenda What’s the difference? Shell vs. Thicken

Overview Issues to Think About When Modeling Modeling Methods Recommendations Questions & Answers

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Vocabulary Wall

The faces of the parts – usually the part’s sides.

Edge The end of a wall where thickness can

be measured – usually the part’s top or bottom.

Boundary Surface The surface will be made into the edges

of the walls, before the shell operation.

Thin-Walled Part

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What’s the difference?

Shell uses the existing boundaries of the solid as the limiting faces.

Thicken adds material to a surface in the direction normal to the face.

There is no difference between the two functions when the boundaries are perpendicular to the walls.

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What’s the difference? Drafted Wall – Positive Angle Drafted Wall – Negative Angle Transition Areas

Wall – Wall Fillet Wall – Floor Fillet

Hole Edges

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Drafted Wall – Positive AngleThicken has more material than Shell

Blue = ShellYellow = Thicken

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Drafted Wall – Negative AngleThicken has less material than Shell

Blue =

Shell

Yellow

= T

hicken

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Transition Areas: Wall - Wall

Smooth Transition

Shell Thicken

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Transition Areas: Wall - Floor

Smooth Transition

Shell Thicken

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Hole EdgesHole intersects the bead

•Red arrow: no difference because wall is perpendicular•White arrow: thicken area is very different because the thickness is applied normal to the surface.

If this is not what is intended, you should make the hole after the thicken operation.

Shell

Thicken

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Issues to Think About When Modeling How will the part be made?

Injection molded, stamped, machined, cast

Why model the edges correctly? How can the part be modeled to

accommodate design changes? What is the impact on linked files (drawings,

assemblies, other models) already in existence?

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How Will the Part be Made? Injection Molded

Parts are formed between two halves of a mold. The edges of the walls are the parting plane.

Stamped Parts begin as a flat sheet and are progressively formed to

the final shape. The edges are are perpendicular to the walls.

Machined Parts begin as a block and material is removed to leave

the final shape. The edges of the walls are determined by the cutting tool

Cast

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Why Model the Edges Correctly? Communicate design intent to manufacturing

For a stamping, it shows if secondary finishing or cam trimming is required.

Can this be handled by a note on the drawing? For an injection molded part, it shows where the parting line is. Will the edge be checked on the drawing?

Provide best information to design reviews Performing fit or clearance measurements in the assembly Evaluate part for safety, e.g. sharp edges

Even modeling “correctly” isn’t exact - the solid model doesn’t represent exactly what is made. Stamped edges already have die roll and tearout. Wrinkling at corners, thinning due to deep draws, etc. Plastic parts have flash at the parting line.

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Planning for Design Changes How can the part be modeled to

accommodate design changes? Solid modeling, shell is the most straightforward. Ordered geometrical sets make surface models easier to

modify. Maintain a strict hierarchy to feature creation, so children are

always listed below parents. Ordered set may use Scan to play the sequence of the surface.

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What is the Impact To Linked Files? If you change modeling strategy, linked files

will be impacted. Drawing

Loss of associativity of dimensions

Assembly Elements will need to be published again Constraints reconnected if not made with published

elements

Other part models Rebuild? Opposite hand parts e.g.

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Modeling Methods

1. Solid Model, Shell

2. Solid Model, Extract Surface, Thicken, Remove Lump

3. Surface Model (GSD), Thicken

4. Solid, Model Boundary Surface, Shell

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1. Solid Model, Shell

1a

1a. Solid Model

1b. Select Boundary Surface 1c. Shell Result

1c

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2. Solid Model, Extract, Thicken

2a

2a. Solid Model

2b. Extract Surface 2c. Thicken Surface 2b

2c2d

2d. Remove Lump from Solid

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Why Remove Lump? If Body is hidden

The body’s mass is included in Measure Inertia Dimensions in drawing are still maintained, but they are

still associated to the shelled body, not the thickened. Both solids are shown in sections

If Body has Remove Lump operation The body’s mass is not included in Measure Inertia. Dimensions in drawing are not maintained and need to be

reconnected.

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3. Surface Model, Thicken Model the surfaces directly using Generative

Shape Design Thicken

Model the surface Final Surface Thicken

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4. Solid Model the Boundary, Shell

Model the solid body

Model the resulting boundary surface using solid features (draft, rib,

loft, etc) using surface features (offset,

sweep, split, sew)

Shell

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Transition Areas: Wall - Wall

•Corrects difference due to drafted wall•Rough approximation of transition area

Solid Model

Thi

cken

She

ll

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Transition Areas: Wall - Floor

•Corrects difference due to drafted wall•Rough approximation of transition areaT

hick

enS

hell

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Recommendations

1. Solid Model, Shell

2. Solid Model, Extract Surface, Thicken, Remove Lump

3. Surface Model (GSD), Thicken

4. Solid, Model Boundary Surface, Shell

Try method 1 first. This is the most straightforward modeling process. It will work for injection molded parts and metal stampings where the boundary surface is normal to the walls.

Use method 2 for stamped sheetmetal parts where the walls are not normal to the boundary surface.

Use method 3 only for complex surfaces requiring the GSD functions.

Use method 4 as a last resort to correct a model which already has many files linked to it, such as drawings and assemblies with constraints.

When should I use a particular modeling method?

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Injection Molded Part Build the solid model, shell If you have a surface, close the surface with a

planar surface which represents the parting plane, then shell.

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Stamped Sheetmetal Part First try method 1 – solid model, and shell. If the edges are not being modeled correctly,

use method 2 – solid model, extract, thicken, remove lump.

Make this decision before creating drawings and assemblies. If you started with method 2 and the design changes such

that method 1 would work, don’t bother remodeling the part – you may need to change back in the future.

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Other Items to Consider Feature order: before / after shell?

Positive features Negative features Draft, fillets, holes, boss, ribs

Do holes have axis after thicken? Different wall thickness at different parts of

the model Shell has this function build in, Thicken does not Not relevant to stamped parts, since the stock size is

uniform.

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Tech Tips Reduce the number of surfaces you need to

select. Cut holes or pockets after the shell/thicken command. Fillet sharp edges prior to shelling.

Create a parameter for thickness Use to set shell/thicken command. Calculate inside / outside radii based on thickness Link to drawing using Attribute Text Link

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Attribute Text Link2. Select the parameter or feature to link to

3. Confirm the parameter to link to4. Text in the drawing is linked to the model

1. Right-click and select Attribute Link

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Summary What’s the difference between shell and thicken?

Shell uses the existing boundaries of the solid as the limiting faces. Thicken adds material in the direction normal to the face. This can lead to differences.

Issues to Think About When Modeling Manufacturing method Accuracy of the solid model - How important is it?

Modeling strategies 4 methods

Recommendations1. Solid Model, Shell

This is the most straightforward modeling process.

2. Solid Model, Extract Surface, Thicken, Remove Lump For use on stamped sheetmetal parts where the walls are not normal to

the boundary surface.

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Questions and Comments

Terry CussenCadpo – Westminster, CO

[email protected]