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It's a chapter on geometric modelling.

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Ch 4 Geometric Modelling

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.

CAD/CAM Principles and Applications by P N Rao, 2nd Ed

Fig. 4.1

manufacturing environment

Geometric Modelling

Ideas

Design Analysis

Production

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.

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.

CAD/CAM Principles and Applications by P N Rao, 2nd Ed 6

Manufacturing

Parts classification. Process planning. Numerical control data generation and verification. Robot program generation.

Production Engineering

Bill of materials. Material requirement. Manufacturing resource requirement. Scheduling.

Program generation for inspection machines. Comparison of produced part with design.

CAD/CAM Principles and Applications by P N Rao, 2nd Ed 8

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.

CAD/CAM Principles and Applications by P N Rao, 2nd Ed 9

4.2

Geometric Models

The line model, The surface model, and The solid or volume model

CAD/CAM Principles and Applications by P N Rao, 2nd Ed 10

P2 P1 P10 S6 P4 P9 P11 P12 P8 P5 S1 S7 S2 P3 S5 S4 S3 S8

P6 P7

V1 V2

11

12

13

Fig. 4.5 Impossible objects that can be modelled using a wire-frame model

14

S5

S3 S6 S6

S5 S4

S8

S8

S3 S1 S7 S2 S4

S1 S7

S2

15

The three-dimensional geometric construction methods which extend from the 2D that is normally used are:

Linear extrusion or translational sweep, and Rotational sweep.

16

Fig. 4.8

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Fig. 4.9

18

Fig. 4.10

19

Fig. 4.11

20

21

22

Fig. 4.14 The Boolean operators and their effect on model construction

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Fig. 4.15 The Boolean operators and their effect on model construction

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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)

25

appears with the permission of IBM World Trade Corporation/Dassault Systems - Model generated using CATIA)

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Classification of Surfaces Planar surfaces Plane Curved surfaces Single curved Double curved Free form surfaces Coons surface

Polygon Polyhedra

Cylinders Cones

Ruled surfaces

Lofted surfaces

27

Fig. 4.19

28

29

Fig. 4.21 The Bzier curve and the associated control polygon

Y

Control points

Control Polygon

Curve

O

CAD/CAM Principles and Applications by P N Rao, 2nd Ed

X

30

Fig. 4.22 The various examples of Bzier curves depending on the associated control polygons

p2 p1 p3 p0 p0 p1 p1 p3 p2

p3 p0 p2

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Fig. 4.23 The modification of Bezier curve by tweaking the control points

Y

Control points

Control Polygon

Control points

Control Polygon

Curve

Curve

32

Y

Control points

O

CAD/CAM Principles and Applications by P N Rao, 2nd Ed

X

33

34

35

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))

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37

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Fig. 4.29 The sketch shown above which is fully constrained and dimensioned

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Fig. 4.30 The sketch in Fig. 4.29 when swept along a linear path produces the solid

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41

Fig. 4.32 The solid after executing an extruded cut of the geometry in Fig. 4.31

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43

Fig. 4.34 The model tree of the part showing the modelling process

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Fig. 4.35 A geometric model created following the sequence of features as Box Hole Shell

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Fig. 4.36 A geometric model created following the sequence of features as Box Shell Hole

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Base feature Holes - 3 Slots - 2

Slots - 2

CAD/CAM Principles and Applications by P N Rao, 2nd Ed 47

48

T C R G N COMPOSED PART SYMBOL KEYS G

KEY SEQUENCE

49

Fig. 4.40 Examples of form elements used for model generation in the case of axi-symmetric components

Thread Arc Groove Taper Turn Fillet Knurl Chamfer Face

Blank

50

Fig. 4.41 Examples of form features for modelling axi-symmetric components with milled features

Turn

Taper

Face

Fillet

Chamfer

Groove

Thread

Knurl

Step

Axial hole

Keyway

Radial hole

Splines

Axial slot

Concentric slot

Radial slot

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Fig. 4.42 Example component modelled using the features shown in Fig. 4.41

3.2 Straight Knurl Pitch 1mm 1.6 M36x1

45

60

90 42

-0.015 -0.040

0.01 A

R1.5

32 75 187

+ 0.50 0.75

42 76

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Fig. 4.43 Example component modelled using the features shown in Fig. 4.41

Chamfer 2X2 @45 10 dia 4 holes M8X1 LHT

12.5

2X2 Groove

75

50

25

Sectional Elevation

CAD/CAM Principles and Applications by P N Rao, 2nd Ed

End view

53

Implicit form, and Parametric form. In parametric form, the curve is represented as X = x(t) Y = y(t) Z = z(t)

CAD/CAM Principles and Applications by P N Rao, 2nd Ed 54

Y

(X, Y)

55

Y

x y + 2 =1 2 a b

(X, Y) b

a X

56

p3 z y u x p0

CAD/CAM Principles and Applications by P N Rao, 2nd Ed 57

p2 p1

p2 p1 u p0 z y p6 x p5 p3 p4

58

59

Fig. 4.48 Typical surface display with the parametric variables u and v

v u y

x

CAD/CAM Principles and Applications by P N Rao, 2nd Ed 60

p(0,v), u=0 curve p12 p22 v p14=p(0,1) p(u,1), v=1 curve p13 p23 p24 p21 p33 p44=p(1,1) p21 p11=p(0,0) u p32 p31 p42 p43

z y

x

CAD/CAM Principles and Applications by P N Rao, 2nd Ed

p41=p(1,0)

61

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.

CAD/CAM Principles and Applications by P N Rao, 2nd Ed 62

63

Fig. 4.51

Model generated using CATIA))

64

appears with the permission of IBM World Trade Corporation/Dassault Systems Model generated using CATIA)

65

66

67

68

Scanning mirror Laser

Recoating bar

Platform

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Scanning mirror Laser

Platform

Build powder Sintered powder (to form parts)

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Binder solution Powder feed roller Printing head Nozzle

Platform

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Filament from a coil

Feeder

Melter

Platform

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Top view Splits in excess material (for ease of removal)

Laminating roller

Laminating roller

Laminate model

Take-up roll

Platform

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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.

CAD/CAM Principles and Applications by P N Rao, 2nd Ed 74

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.

75

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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