Chapter 6

Applying the CAD model

in design
6.1 Applications to drafting
Drawing comprises:

Geometry
+
a range of annotating entities(such as annotations and cross-hatching)
*Drawing organization:
The partitioning of a drawing or model may be assisted by use of:
layers or levels.
A layer : is a number usually in a limited range, with which entities are
associated.
The user may partition a drawing to improve performance and to make
viewing and manipulation more straightforward.
In some systems the layer facility is enhanced by allowing layers to have
different status:
• Active layer ( being displayed and selectable)
• Reference layer ( displayed but not selectable)
• Inactive layer ( will not be displayed)
Fig 6.1 subdivision of a drawing
according to the scheme above
 *Annotating the drawing:
In addition to lines and curves, drawings also contain :
Dimensions, surface condition, materials and tolerance of the design.
CAD systems provide functions to generate annotation as drafting
entities.

Fig 6.2 annotating of drawings

Another aspect of drawing annotation that CAD may offer is the
cross-hatching of sectional views.

Fig 6.3 example of hatching

*Example of system application:
The development of most mechanical assemblies is from initial layout
drawing, through detail drawings of individual components for
manufacture, to assembly drawings that show arrangement of
components. ( the repetitive aspect of CAD in this processes from the
reuse of part geometry).
This sequence for elements of mechanical handling machine, is shown
below :
Fig 6.4 layout drawing of
A motor drive
Fig 6.5 detail drawing
of a torque arm
Fig 6.6 Assembly drawing of
a motor drive
*Guidelines for drafting:
1- to achieve a productivity advantage, there must either be some
repetitive element in the drawing task, or there must be use of the
drawing geometry as a basis for analysis and production of
manufacturing data.
2- the CAD geometry should be drawn accurately, at full size to exploit
automatic dimensioning facilities
6.2 three-dimensional modeling applications
The aim of computer-integrated manufacture CIM was to integrate the
design, analysis and manufacturing activities of companies around a
central computing database, one of the core elements being three-
dimensional geometric models of the product.
*The use of 3D modeling for 2D representation
One application of a 3Dmodel is in generating of an engineering
drawing by arranging multiple views of the model on a drawing sheet,
and then annotating these views with dimensions, labels and notes.

6.7 wire frame model and

The arrangement of views
Of this model on a drawing
sheet
*Three dimensional modeling for geometric
problem solving
• Useful modeling features:
1- the generation of curves that represents the intersection between
two surfaces.
2- the generation of section through models, for example showing
spline curves where surfaces are intersected.
3- the facility to develop certain surfaces.

Fig 6.8 drawing in which the curve of

Intersection between the two tubes
Is taken from a 3D model, as is the developed shape
Of one tube
*Approaches to 3D modeling
• The choice of a 3D modeling scheme should be made on the basis of
what is required of the model.
• In summery, applications for the different modeling techniques are:
1- Wire-frame models: the generation of view data for 2D drafting, the
dynamic manipulation of images (e.g. for animation of robot models),
modeling of geometrically simple shapes ( sheet metal components).
2- Surface models : used where machining data, volume analysis and
picture generation are required, or for the packages of complex shapes.
3- Solid models : used where mass property analysis and interference
checking are required.
• Once it has been decided that a 3D model is appropriate, the user
should answer the questions:
• 1- Is it necessary to model all the component or assembly?
• 2- Are the modeling tools and the system performance adequate for
the task? If not is it possible to simplify the model?
6.3 the integration of design analysis and CAD
• Successive models form the basis for the evaluation of the design, and the
generation of further information, especially for manufacturing.
Design evaluation means the generation of information about the design
that allows a judgment to be made about its fitness for purpose.
A design has to be judged in many respects. It has, for example to have
acceptable stress, thermal and dynamic performance, weight and weight
distribution and resistance to wear and to damage by corrosion.
• In some, data may be extracted directly from the design geometry.
• In some cases, it is necessary to use supplementary model of the design.
*Direct assessment from the geometric model
• The scope of direct assessment is mainly to extract geometric
property data from the model.
This includes:
1- the slope and curvature of curves.
2- normal vectors and curvature of surfaces.
3- perimeter, area, center of area and moments of area of closed planar
profiles.
4- volume, surface area, mass and internal properties of closed
volumes.
• Geometric analysis essentially involve subdivision of region of interest
into a number of elemental shapes and the numerical integration of
the properties of those shapes, generally by simple summation.
Although arbitrary profile may be used as the basis for geometric
analysis- the shape may comprise multiple boundaries with internal
islands, and those may include various curve types- they are reduced
for the purposes of analysis to a series of lines that approximate the
shape to a certain tolerance.
This may be achieved by summing either the property of the trapezia
formed by each line and the coordinate system axes OR the triangles
formed by each vector and an arbitrary point.
*The mathematical basis of 2D section analysis
• Let us consider the analysis of the area, center of area and second
moment of area of a planner shape, as shown below:

Fig6.9 example of 2D analysis

• The shape lies within the +x, +y quadrant, described as series of lines.
• The properties are obtained by considering trapezia formed by the
profile lines and coordinate system axes.
For the trapezium Pi-1 , Pi , B , A : (with respect to x-axes)
**Center of area = ( y²i + yiyi-1 + y² i-1 )/3(yi + yi-1 )
**the second moment of area about 0x,I0x, is given by:
I0x = (xi - xi-1) x (yh³ - 3yh²xyL + 9yhxyL² - 3yl³ )/I2
yh = MAX (yiyi-1 )
yL = MIN (yiyi-1 )
• Similar for the trapezium Pi-1, Pi, C, D (with respect to 0y).

• The properties for the whole shape are achieved by summing these
values for each trapezium:

AREA = σ𝑛𝑖=1 (xi − xi−1)𝑥 (yi + yi-1 )/2

*3D section analysis:
• The 3D analysis functions most commonly provided in CAD systems
are for planar shapes projected in the z-direction and for profiles
revolved around one of the principle axes of the coordinate system,
as shown :

Fig6.10 example for 3D analysis

*Analysis of 3D surface-bounded shapes or
solids
• This techniques may be extended into three dimensions for analysis
of the volumes bounded by surfaces. In this case the summation
involves numerical integration over the surfaces themselves.
• It is necessary for the user to ensure that the boundary is closed and
does not include any overlapping surfaces.

Fig6.11 a surface-bounded shape for

Volumetric analysis
*Generating of new models from the
geometric model
• The analysis of mechanism is based on a knowledge of its structure
and topology ( the links and how they are joined to other links and to
loads)
• In a mechanism, the link dimensions and connections may easily be
identified by inspection of the geometric model.( also the mass
properties)
• The CAD model provides a good basis for generation of input for such
analysis.
*finite element analysis
• This method solves complex problems by numerical solution of a
large number of simpler problems.
• The problem domain is subdivided into a number of simple shapes
(finite elements ) which are defined and located by the position of
points in the domain called nodes.
• The collection of nodes and elements describing the whole model is
known as mesh.
*Finite element modeling FEM
• There are three stages involved in applying the FEM to an engineering
problem:
• 1-proposing some idealization of the problem (using this idealization
as a basis for the generation of an input into analysis).
• 2- Executing, or processing of the analysis.
• 3- Interpretation of the results
Data preparation → pre-processing
Interpretation → post-processing
 Fig6.12 meshing of a sheet metal spring seat
a- shows the geometric subdivision of a sheet metal spring seat
b- shows elements fitted to this division
*Interface to CAD
• Transcription errors can be minimized if the CAD model can be used
directly for the development of the mesh
• This can be achieved in one of two ways:
1- the CAD system may interface to a dedicated FE pre-processor.
2- the CAD system may itself incorporate a mesh generator.
6.4 System customizing and design automation
• In many cases a company which uses CAD wish to develop the system
to meet its specific needs, this is called System customization.
• The most important aspect of System customization is the drawing or
modeling parts, which are variation on a theme.
• In many cases these designs or design elements are based on rules
that may be expressed by an equation or are dimensions that may be
tabulated.
*for example, standard metric bolt may be identified in terms of
dimensions shown in the figure below:
Fig6.13 example of system customization
• The typical facilities for system customization:

• 1- Customizable user interface.

• 2- Key-Log files ( commands recorded and play back )
• 3- Macro languages ( allow commands to be recorded but with
control ).
• 4- Graphics programming languages.
• 5- Interfaces to high-level languages in which the system was written.
*Parametric and variational geometry
• To integrate parametric features into modeling approach of the
system
• For example, instead of describing the dimension of modeled
geometry by numbers, they are described by expressions that relate
the dimensions to the values of variables ( which can be entered by
user or may be tabulated).

Fig 6.17 illustrates the

Parametric and variational
geometry