Workshop 4.

1:
Modeling
16.0 Release

Introduction to ANSYS DesignModeler

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 Introduction
Background
• This workshop will focus on modeling operations. A
simple exhaust system will be created demonstrating
the usage of a number of common modeling tools.

Objectives
• Revolve
• Pattern
• Extrude
• Primitives
• Body Operations
• Using active & frozen body states
• Slice operations for decomposition

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 Project Startup

Create the Project

• Open Workbench
• Select the project “DMWS4-Startup.wbpj”
located in the DesignModeler Workshops Input
Files folder.

– Double click on the Geometry to start

DesignModeler.

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 Preparation
Planning
• This geometry has multiple modeling operations.

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 Preparation

Planning
• We’ll firstly create the corrugated flexible section.
• Two 3d operations will be required for this.
– A sketch will be revolved to produce one segment
– The segment will be patterned.

Revolve Sketch
Pattern Body

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 Revolve
Revolve a Sketch
• In the Tree Outline, select Sketch1.
3

• Select Revolve from the toolbar or Create menu.

2
4
• In the Details View click Apply in the box to the right
of Geometry as shown (upper right) – this will apply
the selected sketch.
• Activate the next selection box (Axis) by clicking as
shown (Apply & Cancel buttons appear)

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 Revolve

Revolve a Sketch
• Select the X-Axis as shown.
• If you can’t see it, you may need to switch it on using the
Display Plane button in the Toolbar.

• Click Apply in the Axis Selection Box in the Details View.

• Check Operation is set to Add Material then click

Generate.

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 Pattern

Pattern a Body
• From the Create Menu, select Pattern.

• Set Pattern Type to Linear if it is not already

set.
• Select the body as shown and apply the
selection in the Details view.

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 Pattern
Pattern a Body (Continued)
• In the Details View click in the selection
box to the right of Direction to activate it.
• Select the X Axis as shown (upper right).
• Click the right arrow in the bottom left
corner of the graphics window to reverse
the direction as shown and apply the
selection.
• Set Offset to 10mm and Copies to 15.

• Click Generate.
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 Pattern
Pattern a Body (Continued)
• The single segment has been
patterned linearly.
• Since the body was active and all
the patterned bodies were in
contact they have automatically
merged resulting in one body.

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 Preparation

Planning
• We’ll now create the pipe either side of the
flexible section.
• To do this we’ll extrude the highlighted face
on the existing body asymmetrically.

Extrude Face

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 Extrude
Extrude a Face
• Select the Face Selection Filter.
1
• Select the face as shown (upper right). 2
• Select Extrude.
3
• In the Details View Apply the Geometry
selection and click in the box to the right of
Direction Vector to activate it.
• Select the same face as shown (lower right -
you may need to reselect the Face Selection
Filter).
• Apply the selection.
4

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 Extrude
Extrude a Face (Continued)
• In the Details View set the
following;
– Direction to Both – Asymmetric.
– Depth to 140mm.
– Depth 2 to 910mm
– Check operation is set to Add
Material.
• Generate.

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 Extrude
Extrude a Face (Continued)
• The face has been extruded asymmetrically.
The side which has been extruded through the
flexible section has again merged
automatically to leave one body.

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 Preparation
Planning
• Next step, the catalyst. This is a simple cylinder
so we’ll create this directly using a primitive.

Primitive
Cylinder

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 Primitive

Create a Primitive Cylinder

• From the Create Menu, select Primitive > Cylinder

• In the Details View check that the Base Plane is set to the
XYPlane and Operation is set to Add Material.
• Set the Following;
– Origin X Coordinate = -300mm.
– Origin Y & Z Coordinates = 0mm.
– Axis X Component = -300mm.
– Axis Y & Z Components = 0mm.
– Radius = 60mm.
• Generate.

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 Primitive
Create a Primitive Cylinder (Cont..)
• The Primitive Cylinder is created and
merged with the existing body to form the
catalyst section.

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 Preparation
Planning
• Active bodies are useful for quickly
building up geometries. It is however
often desirable for simulation
purposes to create geometries
formed from multiple bodies.
• Bodies need to be in the Frozen state
to remain independent.
• Bodies can be created as frozen in
the first instance or we can use
slicing operations to decompose a
body.
• We’ll now decompose the body into
five sections using Slice operations.

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 Slicing
Slice by Edge Loops
• First, orientate the view. Click the +Z Axis of
the triad and zoom in using the box zoom
tool as shown (right).
• From the Create Menu, select Slice.
• In the Details View set Slice Type to Slice by
Edge Loop. Activate the Edges selection
box.
• Select the two edges either side of the
flexible section (CTRL click for multiple
selection).
• Apply the selection. Leave Slice Targets set
to All Bodies.
• Generate.

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 Slicing
Slice by Edge Loops (Continued)
• The body has been sliced at positions coincident with the
edge loops leaving three independent frozen bodies.
• Applying Slice operations to Active bodies automatically
converts them to the Frozen state.

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 Slicing
Slice by Surface
• From the Create Menu, select Slice.
• In the Details View set Slice Type to Slice by
Surface. Activate the Target Face selection
box.
• Select the face as shown.
• Apply the selection. Leave Slice Targets set
to All Bodies and Bounded Surface set to
No.
• Generate.

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 Slicing
Slice by Surface (Continued)
• The body has been sliced using the
surface as a tool.
• There are now four frozen bodies.

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 Slicing
Slice by Surface (Continued)
• Apply the same slice to the other side of
the catalyst.
• Select Slice.
• Select the face as shown on the other side
of the catalyst.
• Leave other parameters as default
• Generate.

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 Slicing

Slice by Surface (Continued)

• There are now five frozen
bodies.

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 Preparation

Planning
• The silencer assembly is a non primitive
elliptical shape so we’ll need to create a
new plane in the correct position, an
elliptical sketch and then a simple
extrusion.

Create Plane,
Sketch & Extrude

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 Plane & Sketch
Create a Plane and Sketch directly on a Face
1
• Select the face as shown (lower left).
• Switch to Sketching Mode using the tab.
2
• Click the Look At button in the Toolbar.
3

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 Plane & Sketch
Sketch
• First, change the View to Wireframe for 1
clarity.

• From the Draw Toolbox select the Ellipse 2

Tool.

1. Click on the Origin (make sure you see the

P symbol auto-constraint). 3
2. Click on the X-Axis in the approximate
location shown (make sure you see the C
symbol auto-constraint).
3. Click to define the vertical extent in the
approximate position shown.

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 Plane & Sketch

Sketch Dimensions
• From the Dimensions Toolbox, select the General Tool.
• As shown in the sequence below;
– Select the Y-Axis.
– Select the elliptical edge.
– Click to position the dimension in a convenient place.
• We’ll set the dimension value later.

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 Plane & Sketch
Sketch Dimensions (Continued)
• Using the General Tool again.
• As shown in the sequence below;
– Select the X-Axis.
– Select the elliptical edge.
– Click to position the dimension in a convenient place.
• We’ll set both dimension values in the next step.

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 Plane & Sketch

Sketch Dimensions (Continued)

• In the Details View set the Horizontal
dimension (H1) to 150mm and the Vertical
Dimension (V2) to 75mm as shown (below
left).
• Click the Zoom to Fit button.

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 Extrude
Extrude the New Sketch
• Switch to Modeling Mode using the tab.

• Set the view back to Shaded Exterior and Edges using

the View Menu.

• In the Tree Outline a new Plane & Sketch has been

created, Select the sketch.

• Select Extrude from the ‘create’ menu.

• In the Details View (right) Apply the Geometry
selection, set Operation to Add Frozen and Depth to
500mm then Generate.

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 Extrude
Extrude the New Sketch (Cont...)
• The elliptical sketch has been
extruded to form the silencer
assembly.
• The new body is in the frozen state
due to setting Operation in the
Extrude Details to Add Frozen.

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 Preparation

Planning
• We’ll now add the tail pipes. Since these
are cylinders we’ll use a primitive again.
To locate the primitive on the back face of
the silencer a plane will be created on the
face. Just one tail pipe will be created and
then copied.

Create Plane and Create mirror copy

Primitive relative to the using existing
new plane XYPlane

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 Plane

Create a Plane on a Face

• Select the back face of the silencer as
shown (right).
• Select the New Plane button.

• Check the Details View settings.

• Generate.

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 Primitive
Create a Primitive
• From the Create Menu, select Primitive > Cylinder.
• In the Details View, activate the Base Plane selection
box.
• The Plane created in the previous step is listed in the
Tree Outline, select it and apply the selection back in the
Details View.
• Set the Following;
– Operation = Add Frozen.
– Origin X Coordinate = 80mm.
– Origin Y & Z Coordinates = 0mm.
– Axis X & Y Component = 0mm.
– Axis Z Component = 250mm.
– Radius = 25mm.
• Generate.

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 Body Transformation
Mirror the Pipe
• From the Create Menu, In Body
Transformation select Mirror.
• Activate the Bodies selection box.
• Select the Tail Pipe as shown (right) and
apply the selection.
• Set Preserve Bodies to Yes.
• Activate the Mirror Plane selection box.
• Select the XYPlane in the Tree Outline and
apply the selection.

• Generate.

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 Body Operation

Mirror the Pipe (Continued)

• We now have two additional bodies
forming the twin tail pipes of the exhaust
system.

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 Preparation

Planning
• Lastly, as a finishing touch, we’ll create the
angle on the tailpipes by apply a slice
operation followed by a delete.

Create angled Plane,

use as a Slicing Tool
and delete bodies

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 Plane

Create a Plane on the Tail Pipe

• Select the back face of the tailpipe as
shown (right).
• Select the New Plane button.

• In the Details View set Transform 1

to Offset Z and Value 1 to -20mm.
• Set Transform 2 to Rotate about X
and Value 2 to 15.
• Generate.

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 Slice
Slice by Plane
• From the Create Menu select Slice.
• In the Details View set Slice Type to
Slice by Plane.
• Activate the Base Plane selection box.
• In the Tree Outline select the Plane
created in the previous step.

• Apply the selection.

• Generate.

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 Body Delete
Delete Bodies
1
• From the Create Menu select Delete.
– Create  Delete  Body Delete
• Activate the Bodies selection box.
• Select the two bodies as shown (CTRL click for 2
multiple selection).
• Apply the selection.

• Generate.
3

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 Multibody Part
Form a Multibody Part
• Right click in the Graphics Window and
select Select All from the context menu.

• Right click in the Graphics Window again

and select Form New Part from the Context
Menu.

• A new part containing all the bodies is

created and listed in the Tree Outline.
• This completes the workshop.

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 Saving the Project
• This completes the workshop.
• From the main menu select File  Close DesignModeler
– Workbench will save any application data.

• From the Workbench Project Page use the file menu and save the project as
“DMWS4.1.wbpj” to your working folder.

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 Optional Challenge 1: Prepare This Model 6mm

50mm
Chamfer of 3X3mm

12mm
Fillet of R1mm
50mm

160mm

R6
45mm

50mm
10mm

24mm
20mm
R5
20mm

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 Hints
1. There are 2 Bodies
I. Model “L” Shape body first
II. Then model Handle body

2. For any help refer project file “Modeling_challenge.wbpz”

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 Optional Micro Workshop (Micro-WS-02)
Perform Pattern operation on Fan hub model
• This is an optional workshop
• Workshop details can be found “DM-Intro_16_Micro-WS-01_Pattern.pdf”

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