Chapter 4 Geometric Modelling PDF

CAD/CAM Principles and
Applications
Ch 4 Geometric Modelling
CAD/CAM Principles and 1

Applications by P N Rao, 2nd Ed
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.
4.1 Requirements of
Geometric Modelling

Fig. 4.1 Total product cycle in a
manufacturing environment
Geometric
Modelling
Ideas
Design Production
Analysis

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.

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.

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

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.

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.

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

Fig. 4.2 3D geometric representation
techniques
P2
P1 P3 S8
P10
S5
S6
P4 S4
P9 P12
P5 S3
P11
P8 S1
P6
S7 S2
P7
(a) LINE MODEL (b) SURFACE MODEL
V1
V2
(c) VOLUME MODEL

Fig. 4.3 A geometric model represented in
wire-frame model

Fig. 4.4 Ambiguities present in the wire-frame
model

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

Fig. 4.6 Generation of 3D geometry using
planar surfaces
S5
S3
S6
S5
S6 S8 S8
S4
S3
S1 S4
S7 S2
S1 S2
S7
(b) SURFACE MODEL

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.

Fig. 4.8 Component model produced using
translational (linear) sweep (extrusion)

translational (linear) sweep with taper in sweep direction

Fig. 4.10 Component model produced using linear
sweep with the sweep direction along a 3D curve

translational (linear) sweep with an overhanging edge

Fig. 4.12 Component produced by the
rotational sweep technique

Fig. 4.13 Various solid modelling primitives

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

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

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)

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)

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
Spheres B-spline
Polygon Cylinders Ellipsoids Bezier surface
Polyhedra Cones Paraboloid NURBS
Torus Fractals
Ruled surfaces Lofted surfaces

Fig. 4.19 Ruled surface on the left is shown the curves
from which the ruled surface on the right is formed.

Fig. 4.20 Coons surface generation

Fig. 4.21 The Bzier curve and the associated
control polygon
Y Control
Control points Polygon
Curve
X
O
Fig. 4.22 The various examples of Bzier curves
depending on the associated control polygons
p2 p2
p1
p3 p3
p0
p0
p1
p1
p3
p0
p2

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

Control points Polygon Polygon
Curve Curve
O X O X

Fig. 4.24 The spline curve
Y Control
Control points Polygon
Curve
O X
Fig. 4.25 The lofted surface

Fig. 4.26 Example of filleting or blend method
for model generation

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))

4.4 Constraint Based
Modelling

Fig. 4.28 Example of initial sketch without any
dimensions

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

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

Fig. 4.31 The sketch for the new feature (a
cut)

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

Fig. 4.33 The final solid

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

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

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

Fig. 4.37 Feature based model and its
modified form
Slots - 2
Base feature
Holes - 3
(A) Original model
Slots - 2
Base feature
Holes - 5
(B) Modified model

Fig. 4.38 Typical drawing for the variant
method of modelling

Fig. 4.39 Part model produced using the
symbolic programming
COMPOSED PART SYMBOL KEYS
C G C
KEY SEQUENCE

Fig. 4.40 Examples of form elements used for
model generation in the case of axi-symmetric
components
Turn
Thread Arc Groove Taper Fillet
Knurl
Chamfer
Face
Blank

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

Fig. 4.42 Example component modelled using
the features shown in Fig. 4.41
A All chamfers 1x45
0
3.2
Straight Knurl
Pitch 1mm
1.6 M36x1
45 60 90 -0.015
42 -0.040
0.01 A
R1.5
32 42
75 + 0.50
76
187 - 0.75

Fig. 4.43 Example component modelled using
the features shown in Fig. 4.41
Chamfer 2X2 @45
10 dia 4 holes
M8X1 LHT
2X2 Groove
12.5
75 50 25
Chamfer angle 45 2
12.5
25 80 4 holes on pcd 37.5
Sectional Elevation End view

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)
Fig. 4.44 Circle
(X, Y)

X
O

Fig. 4.45 Ellipse
Y 2 2
x y
2
+ 2
= 1
a b
(X, Y)
b

X
O a

Fig. 4.46 Parametric curve representation in
Cartesian space
p3
z
y p2
u
p1
x
p0
Fig. 4.47 Two cubic Bzier curves joined at p3
p2
p3
p1
u p4
p0
z
p5
y
p6

4.7 Surface Representation
Methods

Fig. 4.48 Typical surface display with the
parametric variables u and v
z v
u
y
x
Fig. 4.49 A bi-cubic Bzier surface patch
p(u,1), v=1 curve
p(0,v), u=0 curve p24
p13 p23
p21
p12
p22 p14=p(0,1) p33
p44=p(1,1)
v
p21 p32 p43
z
p11=p(0,0) u
p31
y p42 p(1,v), u=1 curve
p(u,0), v=0 curve
x p41=p(1,0)

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.
Fig. 4.50 Elimination of hidden lines in display

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))

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)

Fig. 4.53 Section view generation from a
geometric model

Fig. 4.54 Exploded view and bill of materials
of an assembly modelled

4.9 Rapid Prototyping (RP)

Figure 4.55 Schematic of Stereolithography
device
Scanning mirror
Laser
Cured resin
(to form model)
Liquid resin Recoating bar
Platform

Figure 4.56 Schematic of selective laser
sintering device
Scanning mirror
Laser
Powder feed roller
Platform
Build
powder
Sintered
powder
(to form parts)

Figure 4.57 Schematic of Three-dimensional
printing device
Binder solution
Powder feed roller

Printing head
Nozzle
Platform
Build
powder
Glued
powder
(to form parts)

Fig. 4.58 Schematic of Fused deposition
modelling device
Filament from a coil
Feeder
Melter
Extrusion nozzle
Solidified plaster
(to form model)
Platform

Fig. 4.59 Schematic of Laminated Object
Manufacturing device Top view
Splits in excess
material
(for ease of removal)
Laminating roller Contour of actual Band of

cross section of the model build material
Scanning mirror
Laser
Laminate model Band of

Laminating roller
build material
Excess
laminate
material
Take-up roll
Platform Material supply roll

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.

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.

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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CAD/CAM Principles and

CAD/CAM Principles and 1

CAD/CAM Principles and 3

CAD/CAM Principles and 4

CAD/CAM Principles and 5

CAD/CAM Principles and 6

CAD/CAM Principles and 7

Inspection and Quality Control:

CAD/CAM Principles and 8

CAD/CAM Principles and 9

CAD/CAM Principles and 10

(c) VOLUME MODEL

CAD/CAM Principles and 11

CAD/CAM Principles and 12

CAD/CAM Principles and 13

CAD/CAM Principles and 14

(b) SURFACE MODEL

CAD/CAM Principles and 15

CAD/CAM Principles and 16

CAD/CAM Principles and 17

translational (linear) sweep with taper in sweep direction

CAD/CAM Principles and 18

sweep with the sweep direction along a 3D curve

CAD/CAM Principles and 19

translational (linear) sweep with an overhanging edge

CAD/CAM Principles and 20

CAD/CAM Principles and 21

CAD/CAM Principles and 22

CAD/CAM Principles and 23

CAD/CAM Principles and 24

CAD/CAM Principles and 25

Systems - Model generated using CATIA)

CAD/CAM Principles and 26

Planar surfaces Curved surfaces Free form surfaces

Plane Single curved Double curved Coons surface

Ruled surfaces Lofted surfaces

CAD/CAM Principles and 27

from which the ruled surface on the right is formed.

CAD/CAM Principles and 28

CAD/CAM Principles and 29

CAD/CAM Principles and 31

Y Control Y Control points Control

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CAD/CAM Principles and 34

CAD/CAM Principles and 35

Corporation/Dassault Systems - Model generated using CATIA))

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(A) Original model

(B) Modified model

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COMPOSED PART SYMBOL KEYS

CAD/CAM Principles and 49