CAD CAM - Chapter 4 Geometric Modelling

CAD/CAM Principles and
Applications by P N Rao, 2
nd
Ed
1
Applications
Ch 4 Geometric Modelling
nd
Ed
2
Objectives
Understand the various requirements for the information that is
generated during the geometric modeling stage.
Study various types of geometric models possible and their
applications
Develop various methodologies used for geometric construction
such as sweep, surface models, solid models, etc.
Recognize the various types of surfaces and their application as
used in geometric modelling
Appreciate the concept of parametric modeling which is the
current mainstay of most of the 3D modeling systems
Develop the various mathematical representations of the curves
used in the geometric construction
Discuss the various CAD system requirements that need to be
considered while selecting a system for a given application
Understand the concept of rapid prototyping and the various
methods available for the purpose.
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3
4.1 Requirements of
Geometric Modelling
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4
Fig. 4.1 Total product cycle in a
manufacturing environment
Ideas
Design
Analysis
Production
Geometric
Modelling
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5
Functions of Geometric
Modelling
Design analysis:
Evaluation of areas and volumes.
Evaluation of mass and inertia properties.
Interference checking in assemblies.
Analysis of tolerance build-up in assemblies.
Analysis of kinematics mechanics, robotics.
Automatic mesh generation for finite element
analysis.
nd
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6
Modelling
Drafting
Automatic planar cross sectioning.
Automatic hidden line and surface removal.
Automatic production of shaded images.
Automatic dimensioning.
Automatic creation of exploded views for
technical illustrations.
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7
Modelling
Manufacturing
Parts classification.
Process planning.
Numerical control data generation and
verification.
Robot program generation.
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8
Modelling
Production Engineering
Bill of materials.
Material requirement.
Manufacturing resource requirement.
Scheduling.
Inspection and Quality Control:
Program generation for inspection machines.
Comparison of produced part with design.
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9
Requicha and Voelker [1981] specified the following
properties to be desired of in any geometric modelling
(solids) system.
The configuration of solid (geometric model) must stay invariant
with regard to its location and orientation.
The solid must have an interior and must not have isolated
parts.
The solid must be finite and occupy only a finite shape.
The application of a transformation or other operation that adds
or removes parts must produce another solid.
The model of the solid in E3 (Euler space) may contain infinite
number of points. However, it must have a finite number of
surfaces, which can be described.
The boundary of the solid must uniquely identify which part of
the solid is exterior and which is interior.
nd
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10
4.2 Geometric Models
Two-dimensional, and
Three-dimensional.
The three principal classifications can
be
The line model,
The surface model, and
The solid or volume model
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11
Fig. 4.2 3D geometric representation
techniques
P1
P2
P3
P4
P5
P6
P7
P8
P9
P10
P11
P12
S6
S5
S1
S4
S3
S2 S7
S8
V1
V2
(a) LINE MODEL
(b) SURFACE MODEL
(c) VOLUME MODEL
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12
Fig. 4.3 A geometric model represented in
wire-frame model
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13
Fig. 4.4 Ambiguities present in the wire-frame
model
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14
Fig. 4.5 Impossible objects that can be
modelled using a wire-frame model
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15
Fig. 4.6 Generation of 3D geometry using
planar surfaces
S8
S6
S3
S6
S5
S1
S4
S3
S2 S7
S8
(b) SURFACE MODEL
S1
S5
S4
S2
S7
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16
4.3 Geometric Construction
Methods
The three-dimensional geometric
construction methods which extend
from the 2D that is normally used are:
Linear extrusion or translational sweep,
and
Rotational sweep.
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17
Fig. 4.8 Component model produced using
translational (linear) sweep (extrusion)
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18
translational (linear) sweep with taper in sweep direction
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19
Fig. 4.10 Component model produced using linear
sweep with the sweep direction along a 3D curve
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20
translational (linear) sweep with an overhanging edge
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21
Fig. 4.12 Component produced by the
rotational sweep technique
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22
Fig. 4.13 Various solid modelling primitives
nd
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23
Fig. 4.14 The Boolean operators and their
effect on model construction
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24
Fig. 4.15 The Boolean operators and their
effect on model construction
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25
Fig. 4.16 Creating a solid with the 3D primitives in solid modelling
and the model shown in the form of Constructive Solid Geometry
(CSG)
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26
Fig. 4.17 Model generated using the sculptured surfaces (Image
appears with the permission of IBM World Trade Corporation/Dassault
Systems - Model generated using CATIA)
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27
Fig. 4.18 The various types of surfaces used
in geometric modelling
Classification of Surfaces
Planar surfaces
Curved surfaces
Free form surfaces
Plane
Single curved
Double curved
Coons surface
Polygon
Polyhedra
Cylinders
Cones
Spheres
Ellipsoids
Paraboloid
Torus
Ruled surfaces Lofted surfaces
B-spline
Bezier surface
NURBS
Fractals
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28
Fig. 4.19 Ruled surface on the left is shown the curves
from which the ruled surface on the right is formed.
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29
Fig. 4.20 Coons surface generation
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30
Fig. 4.21 The Bzier curve and the associated
control polygon
X
Y
O
Control
Polygon
Curve
Control points
nd
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31
Fig. 4.22 The various examples of Bzier curves
depending on the associated control polygons
p0
p0
p0
p1
p1
p1
p2
p3
p2
p3
p3
p2
nd
Ed
32
Fig. 4.23 The modification of Bezier curve by
tweaking the control points
X
Y
O
Control
Polygon
Curve
Control points
Curve
O
Control points
Y
X
Polygon
Control
nd
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33
Fig. 4.24 The spline curve
X
Y
O
Control
Polygon
Curve
Control points
nd
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34
Fig. 4.25 The lofted surface
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35
Fig. 4.26 Example of filleting or blend method
for model generation
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36
Fig. 4.27 Example of tweaking method for surface
modification ((Image appears with the permission of IBM World Trade
Corporation/Dassault Systems - Model generated using CATIA))
nd
Ed
37
4.4 Constraint Based
Modelling
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38
Fig. 4.28 Example of initial sketch without any
dimensions
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39
Fig. 4.29 The sketch shown above which is
fully constrained and dimensioned
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40
Fig. 4.30 The sketch in Fig. 4.29 when swept
along a linear path produces the solid
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41
Fig. 4.31 The sketch for the new feature (a
cut)
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42
Fig. 4.32 The solid after executing an
extruded cut of the geometry in Fig. 4.31
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43
Fig. 4.33 The final solid
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44
Fig. 4.34 The model tree of the part showing
the modelling process
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45
Fig. 4.35 A geometric model created following
the sequence of features as
Box Hole Shell
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46
Fig. 4.36 A geometric model created following
the sequence of features as
Box Shell Hole
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47
Fig. 4.37 Feature based model and its
modified form
Base feature
Slots - 2
Base feature
Slots - 2
Holes - 5
(A) Original model
Holes - 3
(B) Modified model
nd
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48
Fig. 4.38 Typical drawing for the variant
method of modelling
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49
Fig. 4.39 Part model produced using the
symbolic programming
T
C
R
G
N
G C C
SYMBOL KEYS
COMPOSED PART
KEY SEQUENCE
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50
Fig. 4.40 Examples of form elements used for
model generation in the case of axi-symmetric
components
Knurl
Groove
Taper
Fillet
Arc
Chamfer
Turn
Thread
Face
Blank
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51
Fig. 4.41 Examples of form features for modelling axi-symmetric
components with milled features
Step
Keyway
Concentric slot
Axial hole
Radial hole
Axial slot
Radial slot
Splines
Turn Taper Face Fillet
Chamfer Groove Thread
Knurl
nd
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52
Fig. 4.42 Example component modelled using
the features shown in Fig. 4.41
R1.5
1.6
Straight Knurl
Pitch 1mm
All chamfers 1x45
0
-0.015
-0.040
32
75 76
42
187
90
42
M36x1
60
45
3.2
A
0.01 A
+
-
0.50
0.75
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Ed
53
Fig. 4.43 Example component modelled using
the features shown in Fig. 4.41
50
Chamfer 2X2 @45
10 dia 4 holes
12.5
25 80
Chamfer angle 45
25
4 holes on pcd 37.5
2
2X2 Groove
12.5
M8X1 LHT
75
Sectional Elevation
End view
nd
Ed
54
4.6 Curve representation
Implicit form, and
Parametric form.
In parametric form, the curve is
represented as
X = x(t)
Y = y(t)
Z = z(t)
nd
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55
Fig. 4.44 Circle
X
Y
O
(X, Y)
nd
Ed
56
Fig. 4.45 Ellipse
X
Y
O
(X, Y)
a
b
1
2
2
2
2
= +
b
y
a
x
nd
Ed
57
Fig. 4.46 Parametric curve representation in
Cartesian space
x
y
z
p0
p1
p2
p3
u
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58
Fig. 4.47 Two cubic Bzier curves joined at p3
x
y
z
p0
p1
p2
p3
u
p4
p5
p6
nd
Ed
59
4.7 Surface Representation
Methods
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60
Fig. 4.48 Typical surface display with the
parametric variables u and v
x
y
z
v
u
nd
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61
Fig. 4.49 A bi-cubic Bzier surface patch
x
y
z
p(u,0), v=0 curve
p11=p(0,0)
p21
p31
p42
p41=p(1,0)
p(0,v), u=0 curve
p12
p22
p32
p43
p33
p21
p24
p13
p23
p44=p(1,1)
p(1,v), u=1 curve
p(u,1), v=1 curve
p14=p(0,1)
u
v
nd
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62
4.8 Modelling Facilities
Desired
The geometric modelling features.
The editing or manipulation features.
The display control facilities.
The drafting features.
The programming facility.
The analysis features.
The connecting features.
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63
Fig. 4.50 Elimination of hidden lines in display
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64
Fig. 4.51 Shaded image of a CAD geometric model ((Image
appears with the permission of IBM World Trade Corporation/Dassault Systems -
Model generated using CATIA))
nd
Ed
65
Fig. 4.52 Orthographic views from a geometric model (Image
appears with the permission of IBM World Trade Corporation/Dassault Systems -
Model generated using CATIA)
nd
Ed
66
Fig. 4.53 Section view generation from a
geometric model
nd
Ed
67
Fig. 4.54 Exploded view and bill of materials
of an assembly modelled
nd
Ed
68
4.9 Rapid Prototyping (RP)
nd
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69
Figure 4.55 Schematic of Stereolithography
device
Scanning mirror
Laser
Recoating bar
Liquid resin
(to form model)
Cured resin
Platform
nd
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70
Figure 4.56 Schematic of selective laser
sintering device
Laser
Scanning mirror
Build
powder
Sintered
powder
(to form parts)
Powder feed roller
Platform
nd
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71
Figure 4.57 Schematic of Three-dimensional
printing device
Powder feed roller
(to form parts)
powder
Glued
powder
Build
Binder solution
Printing head
Nozzle
Platform
nd
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72
Fig. 4.58 Schematic of Fused deposition
modelling device
Filament from a coil
Feeder
Melter
Extrusion nozzle
Solidified plaster
(to form model)
Platform
nd
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73
Fig. 4.59 Schematic of Laminated Object
Manufacturing device
material
Take-up roll
Material supply roll
Top view
Laminating roller Contour of actual
cross section of the model
Band of
build material
Splits in excess
material
(for ease of removal)
Platform
Laser
Scanning mirror
Laminating roller
Laminate model
Band of
build material
Excess
laminate
nd
Ed
74
Summary
Information entered through geometric modeling is utilized in a
number of downstream applications such as drafting,
manufacturing, inspection and planning.
Geometric models are three types, viz line model, surface model
and solid model. Line model though simple is rarely used
because of the ambiguity present. Surface and solid models are
extensively used in industrial applications.
Among the geometric construction methods sweep or extrusion
is most widely used, because of its simplicity and elegance in
developing 3D models.
Solid modeling provides the most unambiguous representation
of the solid model, but is more computing intensive. However to
get the correct geometric model, it is essential to utilize solid
modeling approach.
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Ed
75
Summary
Surfaces are more widely used and it is necessary to use
different types of surfaces such as b-splines, Bezier, NURB,
lofted, to get the user requirements fulfilled.
Constraint or parametric based modeling is the main
methodology used by most of the 3D CAD systems. This system
helps in grasping the designers intent and would greatly
facilitate the modification and reuse of the existing designs.
Some variant modeling systems are used based on tabular data
for specific applications.
Form features is another form of modeling system that helps in
designing CAD systems with more intelligence built into the
geometric entities that is possible by purely geometric systems
discussed thus far.
nd
Ed
76
Summary
The mathematical representation of the geometric entities can
be in implicit or parametric form, the latter being the preferred
method used in CAD systems because of its easier adaptation
in software development.
The curve representation methods can be extended for surface
representations such as used in free form surfaces.
A number of modeling facilities need to be considered while
selecting a CAD/CAM system for any given application.
Rapid prototyping is used to generate the product directly from
the 3D CAD model data. A number of different processes such
as stereo lithography, selective laser sintering, 3D printing,
fused deposition modeling, laminated object manufacturing, are
used for this purpose.

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