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Release 17 Version 1 Power Catalog

and Power Templates

User Manual.

For use with CATIA V5, Release 17.


Master Index:


Recommended File Structures
Starting a Progressive Die
Starting a Transfer Die
Stock Strip Template
Profile Templates
Dieset Template
Casting Templates
Nitrogen Manifold Template
Nitrogen Plumb Plate Template
Lifter Rack Template
Catalog Component Basics
Updating Drawings
Job Finishing Process
Simplify V5 Files for Export
Support and Updates
Frequently Asked Questions
Whats new in Release 17

p. 3
p. 4-5
p. 6
p. 7
p. 8-11
p. 12
p. 20
p. 21-24
p. 25-26
p. 27-29
p. 30-33
p. 34-35
p. 36-46
p. 47-48
p. 49
p. 50-51
p. 52-53
p. 54-58

I. INSTALLATION: How to install Power Catalog and Templates.

Simply drag the file from the CD to the directory on your network where you want
the catalog to be located.

Open Catia and select the catalog icon ( ).

At the upper right of the dialog box is the file open icon (
the path to the location where the catalog is located.

The CATDrawing files can now be opened and the title blocks and drafting sheet
sizes can be modified to suit the customers preferences. NOTE: There are
instructions on how to customize the title block on the first POD tab of the

Make all components in the catalog directory read only to prevent unwanted
alteration of components.

The 3D_Solutions_Catalog folder contains a folder named Macros. It contains

the macros for setting up the bill of materials, which needs to be run in the design

). Select it and redirect

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II. RECOMMENDED FILE STRUCTURES: Includes example file structures for

setting up new design projects on your system. Also includes example V5 file
structures for Design Assemblies (CATProducts).

File structure for design projects on your system: Every company has a different way of
managing and structuring their design folders and files. We have used a couple different
methods, but have had the best luck using the following example. You can vary from this
example but improper file structure can lead to linking issues in a design. So be careful!
Example Folder Name:
final out
temp review

master design folder
subfolder containing all design catia files
subfolder of final approved die design
subfolder to store press info, standards, etc.
translated drawings or designs for review

Examples of tree structures within CATIA V5: These examples show the method used for
managing the actual 3-D CATIA die design. The design templates provide some tree structure
when a new job is started. There is an assembly called PRODUCT NAMES that contains prenamed assemblies that can be cut/pasted into the lower and upper assembly. You can add to
these or remove from them as you see fit for your company naming preferences.
(assembly of lower die components)
(assembly of upper die components)
(stock strip assembly, SEE NOTE B)
5956_strip_positioner.CATPart (SEE NOTE C)
zero.CATPart (reference only file required for template functions)
5956_300T_Bliss_Press.CATPart (SEE NOTE E)

NOTE A: You will notice there are two dieset assemblies (CATProduct) in the tree structure.
The first one located near the top of the tree is NOT to be modified by the designer. The purpose
of it is to supply information to the dieset CATDrawing file only. Modifications to the dieset or
its components should be done in the dieset assembly that resides in the lower and upper
assemblies. We recommend hiding the first dieset assembly to avoid confusion by the designer.

NOTE B: The stock strip assembly is created using the Stock Strip Template in progressive dies.
The surfaces used to split steels (both shape and trimline) reside in these CATParts.

NOTE C: This part is linked to the Dieset Template to help designer attain correct feed height
and lower lift heights in the design. Do not modify or delete this CATPart.

NOTE D: Edit the sketches located here for correct cross-section location. Hide any that are not
required. Hint: set your display to wireframe and turn on the strip, upper and lower assemblies
while editing sketches.

NOTE E: Start with the GENERIC_PRESS.CATPart provided in the catalog. Modify to your
specific press specifications.

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III. STARTING A PROGRESSIVE DIE: Step by step directions to successfully set up a

new progressive die design project.

Use the Strip Template (see Stock Strip Template) to get the customer math into strip

Use the Die Set Template (see Die Set Template) and follow the instructions.

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IV. STARTING A TRANSFER DIE: Step by step directions to successfully set up a new
transfer die design project.

How to start a Transfer Die (common shoe):

If the transfer die will be on a single die shoe, you can use the same strip
template used for progressive dies. You can re-name the stations to Operations
if desired i.e. STATION 1 could be re-named OP10.

Follow the instruction in the Stock Strip Template and set the desired
progression to the transfer pitch, number of stations to the number of transfer
stations required and the flow direction as needed.

While surfacing part variation you will need to consider the amount of lift in
each station and surface the part variation moved down to the correct height.

If you choose to you can use individual parts for each station and manage the
pitch and height off bolster in the main assembly.

How to start a Transfer Die (individual shoes)

If the transfer will be split up with dies each having a separate shoe, it is
recommended that each die be treated as an individual design. (They may be
stored in sub-directories named OP10_design, OP20 _design, etc.) The part for
the Operation should reside in the directory that it corresponds to. By following
this method you will eliminate future linking issues. All file names should
contain the OP number in the name to avoid duplicate file names if the entire
transfer is brought together in a master assembly.

If at any time you need to bring together multiple parts or multiple operations
for flowcharts or assembly prints, you can create a master assembly file and
bring in the desired components. The only issue that may occur is if you do any
future send to operations one station may be linked to another as a result of
these master assemblies. This can be corrected by removing the master
assembly CATProduct from the folder on the network and putting it on a local
C: drive or if needed burn to a CD and delete the master file to eliminate the
links. This file can then be re-copied back to the directory where it originated
and opened up again if needed. The intent is to not allow the links created by the
master assembly to be found during the send to of individual parts or station.

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V. STOCK STRIP TEMPLATE: Using and modifying the stock strip template for your
progressive die design.

Create a part variation file by saving the customer supplied math data as
xxxx_part_variation.CATPart. (xxxx equals the job number)

In the part variation file, unfold and create a single closed out surface for each variation
of the part including one flat blank. Each part variation should include one progression of
the carrying web to create one full pitch of the strip. Save this part in the job folder.
NOTE: It is not necessary to move the part from car position, simply create an axis
system or plane that is oriented to the pressing direction desired in the design.

Next create the required die and punch split skins for each variation. NOTE: One split
skin may be used in several stations. Once a surface is created for each part variation and
corresponding split skins, you should create a new geometrical set called Feeder Joins
and do a join of each surface. (Both the part variation and the split skins) This will allow
engineering changes to be easily integrated should that be required. It is recommended
that you name these split skin joins in a way that it will be easy to recognize which
stations they go into. An example would be where a form and a re-strike follow each
other: Station 2-3 die split skin. This will assist during the rest of the strip creation. See
the example below.

To incorporate an engineering change, simply create a new geometrical set with the new
rev level added and update the new part and split skin variations in that geometrical set.
Then simply replace the old surfaces with the new ones as described below.

Open the strip template drawing file located in your catalog directory, and do a send to
into the job directory. Rename any files during the send to if desired, remembering
that you must also change the part name in CATIA when you open the strip if you want
it to appear in the tree.

From the job directory, open the Strip Template file and make it design mode active if
you are using cache mode. Set the flow direction, number of stations, desired
progression, stock width, material thickness, material type, lower lift, and upper pad
travel in the main assembly parameters. The number of stations should reflect the entire
blank as being (1) station regardless of the number of hits required for blanking. Remove
any additional stations only after strip has been approved. Hide the stations that are not
being used in the mean time.

Insert the part variation file into that assembly. Snap the part into position orienting it to
the developed_part.CATPart planes in the assembly.


Now in the Part and Skin Positioner Geometrical Set you can double click on each
station and select the multiple output icon ( ). Pick on the Generic Part Variation in
the box and select Replace. Select from the working customer part file the variation of the
part that will go in that station. Then repeat this process for the Generic Die and Punch
split skins. Be sure to keep a link when asked, to allow for future updating. This will
position each part and the corresponding split skins into the proper position in the strip
that is in the developed_part.CATPart. Repeat this process for each station.

Next activate the design_strip.CATProduct and update it. This should then match the
developed_part but each station will now be its own individual part. (This allows you to
activate one station at a time during designing and minimize the impact on your RAM.)
This is the CATProduct that will be inserted into the design.


To Create the Blank Station: In STATION 1 Trim Profiles Geometrical Set, create trim
profiles (either a curve or a sketch) by extracting or projecting curves from flat blank part
variation and translating them into position. Each opening should be its own sketch or
curve. This will allow the strip to update properly when the trim line is changed. This
same technique can be used for pilot and pierce holes that are in the blank station.

The next step in the blank station is to update the generic trim profiles with the new
profiles you created. To do this, simply double click on the Profile Join then right-click
on the Generic Trim Profile 1 and clear selection. Next select each of the new trim
profiles that were created in the previous step. Select OK after you have all the new
profiles selected. The profile split skins should now update to the new inputs.

When beginning die design insert only the design_strip.CATproduct from this template
into the STRIP_ASSEMBLY in the design instead of the entire strip template to avoid
excessive file size.

Locate the strip template to the work ht. part representation in the
STRIP_POSITIONER part to get the height set. Adjust the location front to back if
needed and locate the strip left to right over the dieset as required.

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VI. PROFILE TEMPLATE: Using the profile templates in your design strip or part files.

You must first have all the desired trim or form profiles created. Each profile must be its
own sketch or curve. If you are creating cam profiles there must also be a line indicating
the piercing direction.

Open the catalog and select either the Profile templates or the Advanced Profile
Templates. Pick the best-suited profile template for your application.

When the icon is double-clicked on in the catalog it will pop up a window asking for the
required inputs. (These will vary depending on the template selected and are self

Once all required inputs are selected the parameter icon in the middle of the pop-up
window will become active. This can be selected and the parameters can be adjusted at
this time. The template will bring the parameters in to the part so they can be edited at
any time.

The template will then create all needed split skins for the desired application.

In the Advanced Profile Templates you will only select the initial trim or form profile
while running it from the catalog and then double-click on the Profile Join that is created
in the tree and select each of the additional profiles to complete the split skins.

These created split skins are what will then be selected for splitting the trim or form

Profiles can be updated at any point when trim development is complete or if an

engineering change is required and all effected steels will update.

Important Tips:

Make sure the input profiles are good clean geometry. The most common problem is
poor quality geometry. All sketches should be on the xy plane of STATION_1.

While using the form profiles CATIA will occasionally create an error, while
splitting, if the form profile lies exactly on the edge line of a surface. This happens on
most commonly in wipe stations where a pad is required. If this occurs the simplest
fix is to offset your profile a minimal amount (.005in) and it should remedy the

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VII. DIESET TEMPLATE: How to use the dieset template for plate style diesets.

Open the appropriate Design_Prints.CATDrawing file in the library folder where the
template resides.

From the pull down menus select (File) (Send To) (Directory), In the middle of the
Send To Window there is a set of double arrows pointing down to the items to be sent.
Select these arrows and the entire contents of the upper window will be sent to the
directory that is designated at the bottom of the Send To Window.

Change the destination directory if needed to the job folder of your new design.


Before selecting OK, you have an opportunity to rename any of the files that are being
sent. If you wish to add the specific Job # as a prefix to the CATProducts or CATParts,
now would be the time to do so without impacting any of the linking to the
CATDrawings. NOTE: Renaming the file will only rename the actual file name that the
file is being stored as and not the PartNumber or Instance name within the actual
CATPart. We recommend that you only rename what is necessary to limit the possibility
of link problems.
NOTE: Do not re-name the SECTION SKETCHES CATPart. This could cause
linking issues to the drawing file.

Select OK and the files will send to the designated directory maintaining all links
between the template and the CATDrawing files for the design.

Open the CATProduct that is your entire design (The original name of the template or
whatever name was given to it during the Sent To operation) and rename any of the
PartNumber or Instance names that you want changed.


Under the top-level assembly go to the Properties. This will bring up a window where all
the customer, die, and press information can be input. This information will then drive
the template and linked drawings to update to the values entered.

Once the Properties window has been completed now you can adjust the STACK-UP
SKETCH and then pin and bushing parameters at the bottom of the tree. When you are
finished setting these parameters you should have all your die heights established and pin to
bushing entry set. NOTE: It is necessary for the entire Design Assembly to be in design
mode for changes to take effect properly.





NOTE: Any parameters may be changed after a project is in process as long as the
Dieset Assemblies are in Design mode.

At this point, you can make the STRIP_ASSEMBLY.CATProduct active, right-click on

it and select Insert an existing component. Path to the DesignStrip.CATProduct that
was created for your project. Select OK.

Once the strip comes in you can position it to the strip positioner that is in the template.
Make sure to position it to the working height strip (red).

Now Design of the tool begins. (Short sentence, slightly longer process!) Insert blocks
and purchased components using the catalog. It is recommended that all the screw and
dowel removes be done in the main assembly to insure proper linking and updating. Use
Cache Mode if file size becomes an issue. Only design mode the stations that you are
working on to keep the assembly light.

Once Design is complete, make sure all components that you want visible in the design
prints are shown in the 3-D assembly then save the assembly (* to see centerlines in the
drawing files you must have the open body visible in both the lower and upper diesets*).
Also, make sure that the strip positioner is visible in the strip assembly, there are
dimensions linked to that in section A-A. Generate Numbering can be run now replacing
existing numbers if needed. Make sure to have your tree in the sequence you want for
numbers to be in desired order. CATIA always numbers from the top down in the
specification tree giving priority to parts then products. These numbers will be used if
you choose to generate balloons automatically. If you elect to not show an item in the bill
of materials CATIA will put it to the end of the numbering sequence regardless of its
position in the tree. If you wish to manually number an assembly, simply use the Part
Number field and also put the number in the Instance name field of the first instance of
each component. Set your drafting options to use Instance name for the balloons instead
of Numbering. The only draw back to this method is that it will create a balloon for every
instance of a component, whereas, Numbering can be changed to show only one balloon
for a given part by setting it in the options. NOTE: If you are doing the design for an
outside customer using different software and providing a STEP file, different fields will
need to be filled in with the part number. Unigraphics requires that the Part Number field
be filled. Solidworks requires that the Definition field be filled.

Adjust the section lines in the SECTION SKETCHES part to cut through the tool where
desired. Any section sketches not used may be hidden. You will also need to edit the
sketch with the arrowheads in it. We recommend that you window the arrowheads and
letters that are not being used, change them into construction geometry, and then exit the
sketch (this way if an additional section is added later you can get them back). This will
insure that they dont show up on the 2-D prints.


With the top-level assembly active, select (Tools) (Macros) (Run), and select the BOM
macro. After it has run you can select Analyze Bill of Materials and check the BOM
for accuracy. If BOM is satisfactory it can be saved to HTML or Excel at this time. If you
manually numbered the assembly you can select on the define format icon and remove
Number and add Part Number then re-order it to the top of the list.

Save and exit out of CATIA.

To update the drawing for a completed job, refer to the update drawings section of

See the Job finishing process section to learn how to complete your job for delivery to
your customer.

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VIII. CASTING TEMPLATES: How to use the Casting Power Templates.

Casting Templates are created on a case-by-case basis with our customers. Therefore the
documentation for such templates is specific to the template itself and will be supplied to
the customer at the time of customization. Should you need to create a casting on your
own you can simply use a center zero starter block from the catalog and modify from
Please feel free to contact us regarding what we can create and supply to you in regards
to casting templates and components. We have many generic templates and can easily
customize them to suit your needs.

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Open the template drawing file from the library and do a "send to" to the job directory.
(Re-name all components / drawings at this time)

Open the xxxxx_Manifold_Assembly.CATProduct from the job directory, make design

mode active. Adjust the current nitro cylinder to the needed size and stroke. You can set
the travel at this time or wait until you are in the entire design assembly

Multi-instantiate or Copy/Paste to achieve the quantity of cylinders needed. (Location of

cylinders will be done in the entire design assembly.)

Save all and exit the assembly.


In the entire design assembly, insert an existing component (the manifold assembly in the
job directory) and position it in the tool.

Adjust the location of the nitro cylinders and manifold plate to suit tool. There is a sketch
of points in the Manifold Plate that can be used to position cylinders. Points can be added
or removed as needed. Once you locate the points where cylinders are to be placed, you
can either snap them into position or use assembly constraint (coincident) to locate them
to the points.


Tools/Options/Parameters and Measures/Units/
Volume = Cubic inch (in3)
Area = Square inch (in2)
Force = Pound Force (lbf)
Pressure = Lb. Force per square inch (psi)


Tools/Options/Parameters and Measures/Measure Tools

Check Automatic update in part
Check Automatic update in product

Set the travel on the cylinder if it is not already set. This must be set prior to the assembly
parameters being adjusted to insure accurate pressure calculations. Be aware that the
template may fire a warning that there is inadequate volume, this will occur until the
check is green and the manifold has enough volume for the desired pressure rise.

Edit the parameters in the xxxxx_Manifold_Assembly.CATProduct as follows:

o Put in the number of cylinders used in the application
o Select the desired amount of pressure rise
o Input the desired volume hole diameter
o Adjust the actual plate thickness to suit
o Adjust the desired manifold charge pressure


By inputting these parameters the Template will calculate the total volume required,
linear inches of drilling required at the set volume hole diameter, maximum drilling depth
for volume holes, suggested plate thickness (minimum based on volume hole diameter),
plug style to be used, A&B distance for locating core holes, and Total force achieved at
contact. In the Manifold Plate there is a parameter called CORE HOLE VOLUME that
will calculate the volume achieved by the Volume holes in the plate. Compare this to the
TOTAL VOLUME REQD parameter in the Template parameters. NOTE: plate
thickness may need to be increased beyond suggested plate thickness to
accommodate longer stroke cylinders.

If additional volume holes are required to achieve proper pressure rise, simply edit the
sketches used to create the original holes. Additional plugs can be instantiated as needed
and positioned to proper location. NOTE: Volume hole sketches are constrained to the
middle of the manifold plate. If the thickness of the plate is such that these need to move
up or down, simply edit the sketch, edit the formula of the dimension that you wish to
change and remove the formula from the field then OK it. This will allow you to input
any dimension you desire to properly locate the volume holes. If additional volume holes
of different depths are required you can ad pockets just be sure to do so in the volume
holes Partbody under the VOLUME HOLES feature in the manifold plate. Failure to
do this in the proper place could result in in-accurate volume measurements.

When 3-D is complete and numbered, open the corresponding manifold CATDrawing
from the job directory and unlock the views to update drawing. Insert a BOM onto print
to stock list manifold assembly. Add additional dimensions and balloons as required. Relock views before exiting drawing. NOTE: The BOM will look exactly like the last
BOM analyzed in the job. If it does not appear how you want it to then open the assembly
and re-run the bill of material how you want it to appear. We recommend applying the
detail number to the manifold plate and have the other components with a letter suffix
added (#105 manifold plate, #105a control panel, #105b manifold plug) This way
your bill of materials shows detail #105 as Manifold See Print and there is no risk of
double ordering the components.

It is recommended that the Design Prints be updated prior to the secondary drawing files
such as Manifold Drawings. This will allow you to insert an updated title block into the
background of the secondary drawing files. To do so select (File) (Page Setup), Insert
Background View, Browse. Locate the Design Prints of the job that the file resides in.
Select a page from the design prints that has been updated and OK it. You will need to
Edit Background and modify the text description in the side-bars to suit. The other
option is to cut and paste the manifold views into the design prints on a newly added
sheet. If you choose to do this, the manifold CATDrawing file would no longer be
needed. Insert the Bill of Materials onto the new sheet rather then the original

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Open the template drawing file from the library and do a "send to" to the job directory.
(Re-name all components / drawings at this time)

Open the xxxxx_plumb_Plate_Assembly.CATProduct from the job directory, make

design mode active.

Insert from the Catalog the desired nitrogen cylinder and adjust parameters to suit.

Multi-instantiate or Copy/Paste to achieve the quantity of cylinders needed.

(Location of cylinders will be done in the entire design assembly.)

Save all and exit the assembly.

In the entire design assembly, insert an existing component (the plumb plate assembly in
the job directory) and position it in the tool. Re-size the plate to suit the application and
locate the control panel. *NOTE: the Plumb Plate has a fixed constraint on it. Locate the
entire assembly first positioning the plate in its desired location.


Adjust the location of the nitro cylinders and plumb plate to suit tool. There is a sketch of
points in the Plumb Plate that can be used to position cylinders. Points can be added or
removed as needed. Once you locate the points where cylinders are to be placed, you can
either snap them into position or use assembly constraints (coincident) to locate them to
the points.

When 3-D is complete and numbered, open the corresponding CATDrawing from the job
directory and unlock the views to update drawing. Insert a BOM onto the print to stock
list Plumb Plate Assembly then add additional dimensions and balloons as required. Relock views before exiting drawing. NOTE: The BOM will look exactly like the last
BOM analyzed in the job. If it does not appear how you want it to then open the assembly
and re-run the bill of material how you want it to appear.

It is recommended that the Design Prints be updated prior to the secondary drawing files
such as Plumb Plate Drawings. This will allow you to insert an updated title block into
the background of the secondary drawing files. To do so select (File) (Page Setup), Insert
Background View, Browse. Locate the Design Prints of the job that the file resides in.
Select a page from the design prints that has been updated and OK it. You will need to
Edit Background and modify the text description in the side-bars to suit. The other
option is to cut and paste the manifold views into the design prints on a newly added
sheet. If you choose to do this, the plumb plate CATDrawing file would no longer be
needed. Insert the Bill of Materials onto the new sheet rather then the original
CATDrawing. You will need to Edit Background and modify the text description in the
sidebars to suit.

FYI: DADCO plumb plates can be sent directly to DADCO saved out of CATIA in .dwg
format and they will layout the optimum fittings and hose locations and send a file back
to you with all components stock-listed. You can also use the reference drawing number
on that file to order the plumb plate. They will retain it in their files and recall it when
you order it. Use this information to make updates to your 3-D assembly.

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Open the LifterRackTemplate.CATDrawing file in the library folder where the

template resides.

Do a Send to of the drawing to the job folder where you are designing your project.

Open the CATProduct file in the new location and re-name any PartNumber or
Instance name. Save & close the file

In your main assembly you can now select (Insert) (Existing Component) into the proper
product of your design. The rack system will come in at the zero of the dieset. Before
adjusting the height of the rack in the assembly, you may want to set the parameter
Amount of material to be machined off top surface after welding because this will
impact the final height location of the rack system.

Now you can set the rack to the height desired in the assembly. Once this is done you can
adjust the size of the lifter rack and its sub-components by filling out the parameters.
NOTE: Some components do not have the external parameters and can be modified in the
same way a standard made component is modified. Make sure to fill out all parameters to
insure your desired result.


The stock guides are linked to the sketch lines found in the lifter_zero part. As long as the
parameters that impact these lines have been filled out they will locate automatically and
can then be adjusted in the (X) axis to the location desired. Take note that there is one
adjustable guide set to the coil width, one fixed guide set to the coil width, and one fixed
guide set to each of the notched widths both front and back. If you do not use some of
these, simply delete them. If you need additional unique stock guides we recommend you
simply use the copy/paste special/break link method to retain the external parameters
and insure proper updating when the values are changed. If you need more instances of
an existing stock guide copy/paste works well. Any additional stock guides added will
need a coincidence constraint added to them if you want them to update with the

The center supports are constrained front to back, but they can be moved in the (X)
direction to suit. All of the center supports are individually modifiable to suit your
application, they can vary in thickness and the shape cut in them to clear for the part. If
you do not use some of these, simply delete them. If you should need additional supports
that are unique we again recommend that you utilize the copy/paste special/break link
method. If you need more instances of an existing support copy/paste works well.

The blank station plate can be changed in size by double-clicking on it. It can be moved
from one side to another by using the Stock Feed Direction parameter. NOTE: If the
flow is changed to Right to Left and you edit the sketch it will size the plate up in the
opposite direction of what you would like. This will self correct once you come out of
sketcher and update the assembly.

The pin block, pin and spool locations can be adjusted by the sketches found in the
lifter_zero part. The nitro striker block and bottoming blocks will adjust with the pin
block. You can utilize the pin and spool sketches and constrain those items to the points
or snap them into position. NOTE: There are dimensions in the drawing files that are
linked to the points so they will need to be visible for the dimensions to update properly.
If you do not want them visible you can re-link the dimensions to the actual pin and spool
holes after the drawing is updated.

As with all the templates, if you need to free up a block you simply need to find the
constraints that control it and de-activate them or delete them.

Once the 3-D model is updated you can open the corresponding drawing file and update
it by unlocking the views and updating them, then re-locking them. Make sure that you
only have shown in the 3-D what you want to see in the 2-D. This will require that you
hide/show the lifter components that you do not want to appear in the weld assembly
drawing. There are some dress-up details available for weld location and finish machine


It is recommended that the Design Prints be updated prior to the secondary drawing files.
This will allow you to insert an updated title block into the background of the secondary
drawing files. To do so select (File) (Page Setup) (Insert Background View) (Browse).
Locate the Design Prints of the job that the file resides in. Select a page from the design
prints that has been updated and OK it. You will need to (Edit) (Background) and modify
the text description in the side-bars to suit. The other option is to cut and paste the lifter
rack views into the design prints on a newly added sheet. If you choose to do this, the
LifterRackTemplate.CATDrawing file would no longer be needed. Insert the Bill of
Materials, if required, onto the new sheet rather then the original CATDrawing.

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CATALOG COMPONENT BASICS: General functionality of items in the Power


In the assembly CATProduct select on the catalog icon ( ). (If the catalog does not
show up you may need to re-path to the directory where it resides)

Select from the available folders for made components or purchased components.
(When searching through some purchased components you can use the filter icon to
narrow the search down to only components that fit your application)

Double-click on the component you wish to instantiate into your assembly. The
component can be placed roughly by selecting a corner or point on another
component already in the assembly. Otherwise it will default to come in at the zero of
the assembly. The catalog will always re-appear after a component is instantiated
simply close it if you are finished bringing in catalog components or select the next
component to bring into your assembly.

Position the steel in your using the compass, the translate or rotate icon ( ), or the
manipulation ( ) and snap ( ) icons. Constraints may be used but be careful! We
do not recommend as a best practice using constraints except in templates.

To change the size of the made components you can simply double-click on the block
and edit the sketch. Select on a corner point and drag the block to the desired size. (It
is recommended that you have the snap grid active and set to or 5mm increments
so round steel sizes are maintained.


Next go through the parameters in the component and modify the material, notes,
fastener pattern and size, etc. until all the information is complete. In purchased
components you will need to adjust the parameters to customize the component for
your specific application. (We recommend that you check all parameters in any given
part to insure proper ordering and function.)

To adjust screw and dowel locations simply show the geometrical set named
Fastener Locations.

Double-click on the point you wish to modify. The dimensions are reference dims so
you can have your sketcher snap grid on set to even increments to adjust location.
Red points are the primary location and green points are the pattern. NOTE: to
have more then (2) screws click on the green screw point and you will notice several
other points with dims on them. Adjust the location of additional screws required and
pick on the point and change it from construction geometry to non-construction. This
will activate the screw and it will appear when you exit the sketch. In any pattern
(screws, dowels, or jack-screws) you can add additional points for more instances.


To transfer screws and dowels from one block to another: activate the part that you
will be machining into by double-clicking on it. (Make sure you are in the Part
workbench); right-click on the steel which has the screws, dowels, or machine bodies
and center on graph; pick on the DrillHole and/or TapHole, and/or MachineHole
and right-click (copy) then pick on the part you want to paste into and right-click
(paste special) as result with link into the steel. Repeat this process for all the steel
that will be mounting to a given block. Once this is done you can right pick on the
body or bodies that were copied in and select the boolean remove from the menu and
remove it after the steel. This should subtract the taps etc. from the steel. Repeat this
process as needed until job is complete. Do all screw removes in the main assembly
to insure proper linking and updating.

If you are using the drill components feature (MTD or TG1) you can simply select
the Drill Components icon ( ), select the block you wish to drill then select the
blocks you want to drill it with and choose weather you want DrillHoles, TapHoles,
or both to be removed. NOTE: There are components that have more then the (2)
machine bodies currently available in the drill components feature. For these machine
bodies use the method described in the previous step.

NOTE: All tap depths are controlled by the FASTENING INTO STEEL OR CAST
parameter. The tap representation shown is the same depth as the screw. We recommend
that taps always be tapped deeper than the representation to prevent bottoming out the


To split a block with either a Trim profile or form profile, activate the part by double
clicking on it. Select the Split icon ( ), click in the Splitting Element box then
on the profile you want the part to be split with. Click on the arrows so they point in
the direction of the steel you want to keep. Select OK. NOTE: It is important to
have the Create Datum icon active ( ) to ensure proper linking during the splitting
process. If the Icon looks like this ( ), simply select it to activate it.

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UPDATING DRAWINGS: Step by step procedure to update linked 2-D design


Complete 3-D die design and save all changes.

Open the xxxxx_Design_Prints.CATDrawing from the job directory.

Select the POD tab on the top of the page.

Right click on the view that needs updating in the tree, or on the frame of the view itself.

Select properties under the pop up menu.

Un-check the Lock View box.

Select OK

The Update (

Select the icon to update the view. This will update any views on that current sheet that
are unlocked and in need of updating.

Always update the section lines drawing before updating any section views.

Add any dimensions, notes or dress-up features to the drawing. You can add dress up
features by clicking on the instantiate 2-D Component icon ( ) and selecting from the
tree which dress up feature you would like to insert. Remember that if you do not explode
the 2-D Component it will change anytime that the original is changed on the dress-up
features sheet. NOTE: Double click the view in the tree or on the frame to make it active.

To add balloons make sure that the view you want them added to is active and either
for single balloons or
to automatically generate the balloons based on the
parameters you have set under (Tools) (Options) (Mechanical Design) (Drafting)
(Annotation and Dress-up) (Balloon Generation). The value can be set to Numbering,
Instance Name or Part Number. NOTE: If Generate Numbering is not used, we
recommend that the Instance name be used to ease the removal of the extra balloons that
will be generated. For example if you have a design that uses three buttons that are the
same detail number, Catia will put a balloon on the drawing for each one. If the Instance
name is filled out as described in the Dieset Template section, the first instance of each
detail will have just the detail number. Each instance after that will have an obviously
different balloon that can be deleted.

Right click again on the view in the tree or the frame, select properties, check the Lock
View box and select OK.

) icon should be highlighted.


Save the CATDrawing after each view is updated! Then repeat steps as needed until
drawings are completely updated. It is not unusual to have to exit and re-enter the
Drawing file a couple of times to complete updates in LARGE assemblies (500MB or
larger). An X in the view frame with no other geometry visible is a good indication that
there could be a memory shortage.

Repeat these steps for each view on each sheet.

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XIV. Job Finishing Process

Complete entire design and all accompanying drawings.

Close the CATDrawing, and open the design CATProduct. Make sure the main product
is active. Click on Analyze, Bill of Material

In the Bill of Material : job #_DESIGN dialog box select Define formats



In the Bill of Material : Define formats dialog box there are two distinct areas.
Properties for the Bill of Material, and Properties for the Recapitulation with two
separate windows in each area. Under the Properties for the Bill of Material, click the
double arrow pointing to the right,

, to remove all the items from the left window.

Under Properties for the Recapitulation, click the double arrow pointing to the right,
, to remove all the items from the left window.


The next step will depend on what method was used in numbering the components.

o If Generate Numbering,
, was used, under Properties for the
Recapitulation select Default Representation Source from the right side, then
the single arrow pointing to the left,
Select OK.

. Then select Number and do the same.

o If the components were manually numbered, under Properties for the

Recapitulation select Default Representation Source from the right side, then
the single arrow pointing to the left. Then select Part Number and do the same.
Select OK.

In the Bill of Material : job #_DESIGN dialog box click Save As In the Save Bill of
Material As dialog box click in the Save as type: box select Microsoft Excel worksheet
(*.xls). Click in the File name: box, type send_to_bom. Browse to the location of the
die design. Select Save. Click OK.

Exit out of the design.

Open Excel. Click File, Open. Browse to the location you saved the Bill of Material and
select the file. Select Open.


The file will have extra information that is not needed. Simply delete the rows that are
un-needed. The rows are numbered to the far left of the worksheet. Click on the number
1, scroll down until Default Representation Source is showing. Hold down the Shift
key and select the number of the row above Default Representation Source. Right click
on the number and select Delete. Click anywhere in the worksheet to un-highlight the


Scroll down to the bottom of the list. There are some other items that also can be deleted.
Anything without a part number can be deleted.


Scroll back to the top of the page. Click on the A2 cell (column A, row 2). In the
formula box at the top of the page, highlight all of the text except the file name itself.
Right click on that portion and select Copy.

Click Edit, Find. In the dialog box, click the Replace button. Click in the Find what:
box. Hit Ctrl+V to paste the portion copied from the previous step in the box. Right
click paste will not work in this dialog box. Leave the Replace with: box empty. Select
Replace All. Now all that is left in the cells in the A column is the file name for each
of the details.


Click on the A1 cell. The text in the field should be Default Representation Source.
Click on the Sort Ascending icon,
. This will arrange the files in alphabetical order
with file names beginning with numbers at the top of the list. This is the order CATIA
uses when doing the Send To.

Print the list.

Exit out of Excel.

Create a final_out_catia folder in Windows.

Open the existing design CATDrawing.

Click File, Send to, Directory.


In the dialog box that comes up select the double arrow pointing down,
. All the
files that are linked with the drawing file will be moved from the top box to the lower
box. Some files may still be in the top box with a message that they are Not found.
These files may be of blocks that have been deleted. Review these files and make sure
that they are un-needed.

Rename all of the CATParts to match the send to bill of material. Click on the
component to be changed. Select Rename Target.


Enter the new names for all the components in the format required by the customer.
Ensure that each name is correct. The new names will become the file names in the final
out directory.

Click Browse and locate the final_out_catia folder that was created earlier. Select it
and OK.

In the Send To Directory dialog box the OK box may not be able to be selected. There
may be duplicate files in the list that need to be cleaned up. Scroll down in the lower
window until any problem files are showing. Select it and hit the single arrow pointing
up. Do this with any other files that have identical names. The file that is linked to the
catalog is the one that needs to remain in the lower box.

After all the duplicate files have been cleaned up, the OK button will be able to be
selected. We recommend that the file linked to the catalog is the one that goes with all the
job files. This will insure that the final job has no links back to the catalog in case you
change any information in the screw tables at a later date or for a different customer.

Double-check all the file names and the location before selecting OK.


Depending on the size of the design it may take a few minutes. After which a window
will pop-up showing how many files were copied. Select OK.

Close the CATDrawing.

Rename the old folder where the design was located to include _obs at the end of the
name. This will ensure that all the files in the final out folder are linking properly to the
correct files. (This will also effectively break the link to any duplicate txt files ie material
/ notes / etc)

Open the CATProduct of the design located in the final out folder.

Run a final Bill of Material to customer specifications. Save as an Excel file in the final
out folder and modify it in Excel as needed.

Go through the design and make sure that all the items you want shown are visible.

If a STEP file is required, Design Mode the entire assembly, and save the design as a
Step file. If necessary create a step_design folder and save the STEP file there.

If the design is going to a customer that requires native V5 files, but has not purchased
the catalog the design MUST be simplified (per the End User License Agreement) before
sending the design to them. See the SIMPLIFY V5 FILES FOR EXPORT section
for instructions to do this. Close the design.

If needed the drawings can be saved as DWG files, and opened and modified in

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XV. SIMPLIFY V5 FILES FOR EXPORT: Required when supplying native V5 data to
anyone who has not purchased the Power Catalog or Power Templates.
If customer will accept STEP format it is the easiest way to simplify a design.
If customer requires a CATIA V5 design then follow the steps described below.
(Will take approx. 15-20min. to complete depending on number of components)
Larger jobs may require that you do one half of the die (i.e. upper assembly) then open the
entire design and repeat the process.
*Please note that it is required in our licensing agreement that all files distributed to
non-catalog customers be simplified prior to release.

Send To desired files to a folder where the simplified job will reside. DO NOT

Make main CATProduct active and put into design mode.

Select EDIT ~ SEARCH from the pull down menus

Select KNOWLEDGEWARE under Workbench

Select Set of Relations under Type

Select the Search and Select icon ( ) to search for objects listed above.


Then use the delete key on your keyboard to remove these relations. (Note: this will
cause blocks to turn red and want to be updated. Do not update at this time.) You must
answer yes when prompted by the warning message.

Repeat steps #2 thru #7 for the type: Set of parameters as well

If you are doing a single CATPart then your simplifying is complete.

If you are doing an entire job go thru the tree and delete Assembly Constraints you
may leave the fix constraint on the Lower Assembly.

After the previous steps are complete Update and do Save Management to make sure
all files are pointed to the CORRECT simplified directory not the main folder where the
intelligent version resides. If everything appears to be pointed to the proper directory then
simply OK the save. If needed you can re-direct the save by using the Save As and
path out the desired directory. Do this on the main CATProduct and then select
Propagate directory to get all the other files to follow the new path.

After saving go into the simplified job directory and delete any .txt or .xls files. also
delete the following.developed_part.CatPart, job#_developed_part.CatPart, and
right_to_left.CatProduct if they are present

Re-open job to check for anything that needs to be updated and make sure everything is
in place.

With these steps completed the simplified job or part is ready to send out to your
customer or outside source. (Be sure to send the entire simplified folder not just the
Design.CATProduct. All part files will be needed for a customer to view the assembly)
Return to index

XVI. SUPPORT AND UPDATES: Description of services; how updates are received.
Users who have maintained their Power Catalog/Templates Annual License are entitled to
product support through the Technigraphics support service.
All questions regarding CATIA V5 and the Power Catalog and Power Templates should be
directed to TGI support first. Their support technicians will answer any questions related
with the functionality of CATIA V5. The will also be able to answer the majority of
questions related to the Power Catalog and Templates.
Attempt to resolve all problems through the TGI support service first before contacting
your 3-D Solutions Representative. If your question requires contact with 3-D Solutions,
the TGI support technician will also be involved in all remedies so their support service can
better serve customers in the future.
Please use email to contact your 3-D Solutions representative. We will answer your
question as soon as possible. General questions may have an answer the same day.

Return to index

XVII. COLOR-CODING: Color-coding has been added to the components to simplify the
machining process on the blocks. The following chart shows the color and function
they represent:

C-bore holes = Magenta

Taps = Green
Dowel reamed and clearance drilled for relief = Dark Blue
Dowel drilled and reamed = Red
Jack Screws = Cyan
Burnout Edges = Orange
Clearance machine = Yellow
Finish Machine = Rust
Wire to Cad = Dark Green
Wire (To Be Developed) = Purple
Base steel color = light gray
Zero corners (3) sides = white


Changing the color-coding to match your standards:

Search for the color representing the feature you want to change. For example if
you want change the color of the zero corner follow the steps listed below:
1. Click Edit, Search and the Search dialog box will pop up.
2. Click on the Advanced tab.
3. Click on the Workbench pull down menu and select Topology.
4. Click on the Type pull down menu and select Topology.
5. Click on the Attribute pull down menu and select Color. This will pop
up a new window where you can select the color you are searching for.
6. Select the color White. The Search window should look like this:

7. Click on the Search and Select button.

8. The zero corner faces will be highlighted, and a new color can be seleted
from the color pull down menu.

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XVIII. FREQUENTLY ASKED QUESTIONS: Trouble shooting operator problems with

the Power Catalog and Power Templates.
Q. My section views update but, they do not show the entire length or width of my die.
Why is this?

The section lines drawing must be updated prior to updating the

individual section views.

Q. I am splitting a block and I get an error that it cannot split. What should I do?
A. There are two possibilities: First make sure that the surface you are using to
split is larger than the steel and that it has no holes in it. You can check for
holes using the boundary command in the surfacing workbench. The second
possibility is the there is a combination of a profile split and a surface split
that create a corrupt surface. This can sometimes happen when a profile lies
directly on a surface edge. To correct this simply offset the profile a few
thousands one way or the other.

Q. When I turn on my screws I get an error about fillets, why?

A. On occasion a screw will cut through a fillet and create a corrupt surface.
You can simply re-order the screws and dowels to the bottom of the tree in
the part and this should remedy the problem.

Q. I have a block that I only want one screw or ejector in a block. Is there a way to do
A. In this release of the Power Catalog each block has the option of having
single screws and ejectors. See the Whats new section for a more complete

Q. I have a block where I want to have two different screw heights but I dont see how
to do that in the blocks. Is there a way?
A. Set the screw length to achieve the lower screw counter-bore height. On the
counterbores where you want a longer screw, simply thicken the surface of
the counter-bore face to achieve the desired result.


Q. There is a parameter that I want to alter but it is grey and will not allow me to
change it. What can I do?
A. The parameter is either controlled by a table, formula, or a knowledgeware
rule. For a table you can right-click on the value and disassociate it from the
design table. (be careful, this could allow you to change a component beyond
manufacturer specifications) For a formula you can right-click on the value
and select formula, deactivate. For a KWA rule you must de-activate or
delete the rule to have access to the value.

Q. I want to create my own custom blocks. Is there any procedure I should follow?
A. We always recommend that you begin by using one of the standard blocks
from the catalog. This will insure that it performs similar to the rest of the
catalog and properly links with the bill of materials function. Make the
alterations you desire and store the block in your own company catalog. You
can create a link to another catalog from the main 3-D Solutions catalog and
link it up to you specific company catalog. You will need to maintain those
blocks on your own and re-link the catalog to any new catalogs we distribute
with updates.

Q. I would like to add new material types or notes to be available in our blocks. How
do I do this?
A. You can select on the appropriate design table in any block in the catalog
under the relations and edit table. Add any new materials or notes to the
bottom of the table. (Note: If you add them higher up you will need to open
all of the made blocks in the catalog directory and re-set the material and
notes as desired because they are tied to a particular row in the table and will
show whatever is in that row on the table. This would need to be repeated
each time you receive an update.)

Q. I changed the dieset template to de-mountable pins and bushings and they dont
show up in the dieset print in the drawings?
A. The dieset drawing is made from the DIESET ASSEMBLY in the main
design. If you want something to show up in the drawing then it must be in
that assembly. You can get items in there by simply copy/paste them and set
them to not be visualized in the bill of materials to prevent double ordering.

Return to index

XIX. Whats new in Release 17:

1. New catalog format for made components locating components simpler
2. All components are morphable.
3. Many made components combined to provide flexibility.
a. All stock guides combined into one with parameters to change between various
types: adjustable, fixed, etc
b. All parallels (mounting and non-mounting) combined with parameters to change
between them.
c. Stock load plate combined with parameters to change between.
And many more
4. All made steels are color-coded, including any machining bodies to be removed from
adjacent steels. Also the machine bodies in the purchased components are color-coded.
5. Screw lengths if an English screw size is chosen only English lengths are available
same for Metric sizes.
6. All fastener holes are native CATIA holes for ease in machining.
7. Title blocks for the design prints have been made into a detail on the detail page.
Instructions for use are on the first page (POD) of the design prints.
8. In made components the screws can be flipped so that either counterbores or taps will be
in the component.
9. Editing a sketch in the template controls the heights of the blocks in the dieset template.
10. In the Dieset template, all the die information is under the design properties. There is no
longer a separate Die Info Sheet.
11. The pins and bushings on the dieset template are now individual components instead of
bodies in the shoes.
12. Many purchased items added.
13. Hyson TNK Series cylinder has been discontinued by Hyson and replaced by the TNKB
14. Added Die spring with correct lengths available depending on the diameter chosen.
15. Casting dress-up features added.


Previous Whats New (R16V1)

1. Re-built all components to function in R16sp5 and above.
2. Added Forward MP 10000 flange.
3. Corrected call-outs for Hyson T2B cylinders.
4. Added additional configurations of Hyson T2-90 and T2-180 cylinders.
5. Added additional configurations of Hyson T3-350, T3-500, T3-1000, T3-2400 and T34200.
6. Added additional configurations of Hyson T2L-300.
7. Added additional configurations of Hyson T2-90 threaded micro cylinders.
8. Added additional configurations of Hyson TNK 1 cylinders.
9. Added additional configurations of IEM Medium duty keepers.
10. Added additional configurations of Lamina Guide Bushings (English).
11. Added additional configurations of Lamina Guide Bushings (NAAMS).
12. Added additional configurations of Lamina Guide Pin (NAAMS)
13. Added additional configurations of Lamina Guide Pin (TPB)
14. Added a part description parameter to made blocks for selecting (automatic steel size /
manual / burnout / casting) this will adjust the part description accordingly.
15. Added machine pockets to made components that previously did not have them and
added the option of NONE to the available machine pockets
16. Added a parameter in the Machining Parameters of the made steels for pocket machine
clearance to be adjustable. (this can be set to zero if a 1:1 fit is desired)
17. Added a parameter for screw quantity (multiple / single) in the fastener parameters of
made steels. This will allow single screws in blocks.
18. Added a parameter for fastener style in block to allow flipping the fastener direction from
counter-bored to tapped.
19. Added a parameter for selecting if steel is fastened into steel or casting. If steel is
selected, the tap depth will be 1.5 times the tap diameter. If cast is selected it will be
changed to 2 times tap diameter. The screw table no longer controls tap depth.

20. A tolerance parameter has been added to the following components: Risers / Stripper
Pads / Binder Pads / Parallel / Mounting Parallel. This will automatically add a tolerance
to the thickness of the component in the part description.
21. Added (2) blocks that will allow you to select varying sizes for screws / dowel /
jackscrews. (example: SHCS / 3/8 dowels / jack screws could reside in the same
block) These have been added to the raw stock section in the made components portion
of the catalog.
22. Keys have been adjusted to have the zero in the center on one end of the key instead of a
corner. This will eliminate keys needing to be moved back to center if a size change is
made after placement.
23. Added AUAC / APAC / KUAC / KPAC (short pilots) to the Dayton catalog. These are
primarily used for pilots mounted in the pad.
24. Added Dayton Easy Fit Retainer inserts to the Dayton catalog.
25. Transferred zero to stock surface on all made lifting components. This will allow
thickness adjustment without having to readjust the location of the lifter in relation to the
26. Added Travel and Safety parameters to shoulder screw remove.

Previous Whats New (version 4 - R15sp5)

1. We have consolidated the Danly and the IEM catalog and now all components reside in
the IEM folder in the main catalog.
2. Jergens spring plungers (1 dia) KWA rule has been updated for thread size.
3. Positive returns for cams have been enhanced. There is now an added machine pocket in
the DrillHole body that will establish travel and can be removed from the cam slide or
driver. This eliminates the need to manually create the clearances needed for proper
operation. Select from configuration A or B to alter the angle direction, set the cam angle,
input the desired clearances and the DrillHole remove will update. Be sure to check that
the cam angle is set properly, it can be confusing when initially becoming familiar with a
new component.
4. Dadco control panel (model #90.406.03) has been updated to have (2) counter-bores
instead of (3) and other cosmetic updates have also been made.
5. We have added the pocket option under the machining parameters to the following
components that previously did not have it: Trim Steel, Filler Block, Button Retainer,
Form Post, and Form Steel.


6. A Nitro Clip has been added to the made components misc. section of the catalog. There
are parameters in the part for cylinder diameter, cylinder height above mounting surface,
and sheet metal thickness of the clip. The Part Description is set to STOCK and it is
assumed that the toolmaker can find a suitable piece of sheet metal to manufacture these
7. Groove location and size updated on Standfast cylinders and added two new models
(SD125 Series and HP2400 Series).
8. Added ejectors to pocketed insert B made blocks for better use in a cut-off punch
9. Added Nitro Extension to the made components miscellaneous section of the catalog.
10. Added ISO flange mounts for Standfast, Dadco, Forward, and Hyson nitrogen cylinders.
11. Changed the Round lifters, round keyed lifters, and lifter bars to have zero on the stock
mating face instead of the bottom.
12. IEM ball cages (both English and Metric) have been added. There is an attachment point
that can be located to the end of the pin, then adjust the PIN ENTRY parameter to stroke
ball cage up the pin to reflect the die closed position.
13. Corrected Lamina metric cam gib. (counterbore did not show properly in 45mm tall gibs)
14. Corrected IEM metric L-Gibs. Catalog call-out was out-dated.
15. Added Standard Guided Keepers to the STANDARD LIFTER catalog folder. (GK 125,
GK 175, GK200 series)
16. Corrected tap size on Hyson T3 2400 series nitros, was 6mm now 8mm.
17. Corrected cam slide component so height dimension will appear correctly on BOM.
18. Added Jolico Inch lift bollards.
19. Added Hyson Control Panel CP-N2-EZ .
20. Added parameters in the dieset template to turn off the press-in pins in the upper shoe and
the press-in bushings in the lower shoe. The parameters are located in each die shoe
respectively. Then the designer can insert in demountables from the catalog as needed.
21. The strip template has been enhanced to provide better functionality (see updated
documentation for instructions on use)
22. The form and trim profiles have been enhanced and cam trim profiles are now available.
(see updated documentation for instructions on use)

23. Square tube raw stock has been added to the catalog.
24. Frequently asked questions section is now available in the documentation to assist in
trouble-shooting problems in design.

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