Introduction to Solid Modeling PDF

Introduction to Solid Modeling Parametric Modeling Ken Youssefi Mechanical Engineering Dept. 1  Why draw 3D Models? 3D models are easier to interpret. Alternative desi...

Introduction to Solid Modeling Parametric Modeling Ken Youssefi Mechanical Engineering Dept. 1  Why draw 3D Models? 3D models are easier to interpret. Alternative designs can be investigated. Analysis under real-life conditions.  3D models can be used to perform finite element analysis (stress, deflection, thermal, drop test….).  3D models can be used to perform motion analysis.  3D models can be used directly in manufacturing, Computer Numerical Control (CNC). Less expensive than building a physical model. Can be used for presentations and marketing: include animation, exploded and assembly views, section view, …. Ken Youssefi Mechanical Engineering Dept. 2  3D Modeling There are three basic types of three-dimensional computer geometric modeling methods: Wireframe modeling Surface modeling Solid modeling Ken Youssefi Mechanical Engineering Dept. 3  Wireframe Modeling Contains information about the locations of all the points (vertices) and edges in space coordinates. Each vertex is defined by x, y, z coordinate. Edges are defined by a pair of vertices. Faces are defined as three or more edges. Wireframe is a collection of edges, there is no skin defining the area between the edges. Ken Youssefi Mechanical Engineering Dept. 4  Wireframe Modeling Advantages: Can quickly and efficiently convey information than multiview drawings. The only lines seen are the intersections of surfaces. Can be used for finite element analysis. Can be used as input for CNC machines to generate simple parts. Contain most of the information needed to create surface, solid and higher order models Ken Youssefi Mechanical Engineering Dept. 5  Wireframe Modeling Disadvantages: Do not represent an actual solids (no surface and volume). Cannot model complex curved surfaces. Cannot be used to calculate dynamic properties. Ambiguous views Ken Youssefi Mechanical Engineering Dept. 6  Wireframe Modeling Uniqueness problem. Ken Youssefi Mechanical Engineering Dept. 7  Surface Modeling A surface model represents the skin of an object, these skins have no thickness or material type. Surface models define the surface features, as well as the edges, of objects. A mathematical or parametric equation describes the path of a curve (parametric techniques). Surfaces are edited as single entities. Ken Youssefi Mechanical Engineering Dept. 8  Surface Modeling Advantages: Eliminates ambiguity and non-uniqueness present in wireframe models by hiding lines not seen. Renders the model for better visualization and presentation, objects appear more realistic. Provides the surface geometry for CNC machining. Provides the geometry needed for mold and die design. Can be used to design and analyze complex free-formed surfaces (ship hulls, airplane fuselages, car bodies, …). Surface properties such as roughness, color and reflectivity can be assigned and demonstrated. Ken Youssefi Mechanical Engineering Dept. 9  Surface Modeling Disadvantages: Surface models provide no information about the inside of an object. Complicated computation, depending on the number of surfaces Ken Youssefi Mechanical Engineering Dept. 10  Solid Models In the solid modeling, the solid definitions include vertices (nodes), edges, surfaces, weight, and volume. The model is a complete and unambiguous representation of a precisely enclosed and filled volume Advantages: Has all the advantages of surface models (uniqueness, non-ambiguous, realistic, surface profile) plus volumetric information. Allows the designer to create multiple alternatives for a design. 2D standard drawings, assembly drawing and exploded views are generated form the 3D model. Ken Youssefi Mechanical Engineering Dept. 11  Solid Models Advantages: Can easily be exported to different Finite Element Methods programs for analysis. Can be used in newly manufacturing techniques; Computer Integrated Manufacturing (CIM), Computer Aided Manufacturing (CAM) and Design for Manufacturability and assembly (DFM, DFA), and Computer Aided Process Planning (CAPP). Mass and Volumetric properties of an object can be easily obtained; total mass, mass center, area and mass moment of inertia, volume, radius of gyration, … Ken Youssefi Mechanical Engineering Dept. 12   Volumetric and Mass properties of an object can be easily obtained. Corresponding mass properties are obtained if density is included. 13 Ken Youssefi Mechanical Engineering Dept.  Solid Models Disadvantages: More intensive computation than wireframe and surface modeling. Requires more powerful computers (faster with more memory and good graphics), not a problem any more. Ken Youssefi Mechanical Engineering Dept. 14  Methods of Creating Solid Models Boundary Representation (B-rep), mostly used in finite element programs. Constructive Solid Geometry (CSG), CAD packages; Unigraphics, AutoCAD – 3D modeler. Parametric Modeling, CAD packages; Inventor by AutoDesk, SolidWorks, Pro/Engineer, Unigraphics, CATIA, …. Ken Youssefi Mechanical Engineering Dept. 15  Solid Modeling Boundary Representation (B-rep) A solid model is formed by defining the surfaces that form its boundaries (points, edges, surfaces, holes, and loops). The face of a B-rep represents an oriented surface, there are two sides to the surface; solid side (inside) and void side (outside), unlike faces in a wireframe. Once all the information is stored, faces, edges and points are joined to form the 3D object. Many Finite Element Method (FEM) programs use this method. Allows the interior meshing of the volume to be more easily controlled. Ken Youssefi Mechanical Engineering Dept. 16  B-Rep Data Structure A B-rep model of an object starts with storing all of faces, edges, vertices of an object. Ken Youssefi Mechanical Engineering Dept. 17  Euler Operators Geometric entities stored in B-Rep data structures are the shell, face, loop, edge, and vertex. Operators are needed to manipulate these entities (e.g., an operator to make an edge, an operator to delete an edge,…). They are called Euler’s operators Ken Youssefi Mechanical Engineering Dept. 18  Euler-Poincare Formula Applied to the geometric entities proves that the model is a valid one v – e + f – h = 2 (s – p) v represents the number of vortices, e the number of edges, f the number of faces, h the number of hole loops, s the number of shells and p the number of passages (through holes of a solid) 16 – 24 + 10 – 2 = 2(1 – 1) Ken Youssefi Mechanical Engineering Dept. 19  B-rep Polyhedral Objects v – e + f – h =2 (s – p) (I) v = 8, e = 12, f = 6, h = 0, s = 1, p = 0 2=2 (II) v = 5, e = 8, f = 5, h = 0, s = 1, p = 0 (I) (II) (III) 2=2 (III) v = 16, e = 24, f = 10, h = 0, s = 1, p = 0 2=2 (IV) (IV) v = 24, e = 36, f = 16, h = 2, s = 1, p = 0 2=2 Ken Youssefi Mechanical Engineering Dept. 20  B-rep Polyhedral Objects v – e + f – h =2 (s – p) (V) v = 16, e = 24, f = 11, h = 1, s = 1, p = 0 2=2 (VI) v = 16, e = 24, f = 12, h = 0, s = 2, p = 0 (V) (VI) 4=4 (VII) v = 16, e = 24, f = 10, h = 2, s = 1, p = 1 0=0 (VIII) v = 32, e = 48, f = 20, h = 4, s = 1, p = 1 0=0 (IX) (VII) (VIII) (IX) v = 24, e = 36, f = 14, h = 2, s = 1, p = 1 Ken Youssefi Mechanical Engineering Dept. 0=0 21  Euler Operators Ken Youssefi Mechanical Engineering Dept. 22  Boolean Operations Subtract Union Intersection Ken Youssefi Mechanical Engineering Dept. 23  Implementing Boolean Operation Consider solids A and B. Ken Youssefi Mechanical Engineering Dept. 24  Boolean Operation The intersection curves of all the faces of solid A and B are calculated. These intersections are inscribed on the associated faces of the two solids. Ken Youssefi Mechanical Engineering Dept. 25  Boolean Operation The faces of solid A are classified according to their relative location with respect to solid B. Each face is tested to determine whether it is located inside, outside, or on the boundary surface of solid B. The faces in group A1 are outside solid B, and those of group B1 are inside solid A. Ken Youssefi Mechanical Engineering Dept. 26  Boolean Operation Groups of faces are collected according to the specific Boolean operation and the unnecessary face groups are eliminated. For Union operation, A2 and B1 are removed For intersect operation, A1 and B2 are removed For subtract operation, A2 and B2 are removed Ken Youssefi Mechanical Engineering Dept. 27  Boolean Operation The two solids are glued at their common boundary. 8 x MEL 8 x KZEV 8 x KEL Ken Youssefi Mechanical Engineering Dept. 28  Constructive Solid Geometry, CSG CSG defines a model in terms of combining basic (primitive) and generated (using extrusion and sweeping operation) solid shapes. CSG uses Boolean operations to construct a model (George Boole, 1815-1864, invented Boolean algebra). There are three basic Boolean operations: Union (Unite, join) - the operation combines two volumes included in the different solids into a single solid. Subtract (cut) - the operation subtracts the volume of one solid from the other solid object Intersection - the operation keeps only the volume common to both solids Ken Youssefi Mechanical Engineering Dept. 29  Primitive Solids and Boolean Operations The basic (primitive) solids: Ken Youssefi Mechanical Engineering Dept. 30  Primitive Solids The location of the insertion base or base point and default axes orientation. Ken Youssefi Mechanical Engineering Dept. 31 Solid Modeling Example Using CSG Union Plan your modeling strategy before you start creating the solid model Cut Cut Ken Youssefi Mechanical Engineering Dept. 32  Methods of Creating Solid Models Boundary Representation (B-rep), mostly used in finite element programs. Constructive Solid Geometry (CSG), CAD packages; Unigraphics, AutoCAD – 3D modeler. Parametric Modeling, CAD packages; Inventor by AutoDesk, SolidWorks, Pro/Engineer, Unigraphics, CATIA, I-Deas …. Ken Youssefi Mechanical Engineering Dept. 33  Creating Solid Models Parametric Modeling Concept Parametric is a term used to describe a dimension’s ability to change the shape of model geometry if the dimension value is modified. Feature-based is a term used to describe the various components of a model. For example, a part can consists of various types of features such as holes, grooves, fillets, and chamfers. Parametric modeler are featured-based, parametric, solid modeling design program: Inventor, SolidWorks, Pro-Engineer, Unigraphics (CSG and parametric), Catia, ….. Ken Youssefi Mechanical Engineering Dept. 34  Design Intent In parametric modeling, dimensions control the model. Design intent is how your model will react when dimension values are changed. Ken Youssefi Mechanical Engineering Dept. 35 Example: Design Intent The drawing shows the intent of the designer that the inclined plane 2.50 (chamfer) should have a flat area measuring 2.5 inches and that it 2.50 should start at a point 1.25 inches 1.25 from the base of the drawing. These 4.00 parameters are what the designer deemed significant for this model. Remember that the placement of dimensions is very important because they are being used to drive the shape of the geometry. If the 2.5 in. vertical dimension increases, the 2.5 in. flat across the chamfer will be maintained, but its angle will change. Ken Youssefi Mechanical Engineering Dept. 36  Design Intent In this drawing, what is important to 2.125 the designer is the vertical location and horizontal dimension of the chamfer, 2.50 rather than the flat of the chamfer. 1.25 4.00 1.75 In the last drawing, the designer calls for a specific angle for the chamfer. 30.0O 2.50 In this case the angle of the chamfer should be dimensioned. 4.00 Ken Youssefi Mechanical Engineering Dept. 37  Design Intent The height is modified from 2.5 to 3.0 Ken Youssefi Mechanical Engineering Dept. 38  Design Notes Keep in mind that dimensioning scheme can be changed at any time. You are not locked into a specific design. You can also design without dimensioning, rough out a sketch, and then later go back and fully define it. Do not be concerned with dimensioning to datum or stacked tolerances in the part. Those issues can be addressed in the drawing layout. Be more concerned with your design intent. Ken Youssefi Mechanical Engineering Dept. 39  Primitive using Boolean Operations Versus Parametric Modeling The ability to go back on some earlier stage in the design process and make changes by editing a sketch or changing some dimensions is extremely important to a designer. This is the main advantage of a parametric (SolidWorks, Unigraphics, Inventor, Pro-Engineer) over a non-parametric modeler (AutoCAD 3D modeler) Ken Youssefi Mechanical Engineering Dept. 40  CSG Versus Parametric Modeling Example: Let’s assume that it is desired to design a part consisting of a ring with a certain thickness and a series of counterbore holes along the perimeter. Ken Youssefi Mechanical Engineering Dept., SJSU 41  CSG Versus Parametric Modeling CSG (non-parametric) method Create the initial base part by extruding the profile in a particular direction. Or create two cylinders and subtract the small one from the large one Create the solid geometry that will become the counter bore holes. Ken Youssefi Mechanical Engineering Dept., SJSU 42  CSG Versus Parametric Modeling Position the pattern about the perimeter of the base part. Locating the holes is critical to creating an accurate solid model. Subtract the pattern from the base part to create the actual holes. What would happen if you had to come back to this part to change the thickness of the ring or size of the counterbore holes? Since CSG method was used to create the part, changing the thickness would not increase the height of the holes. There is no association between the thickness and the hole pattern location. Ken Youssefi Mechanical Engineering Dept., SJSU 43  CSG Versus Parametric Modeling Parametric modeling (SolidWorks, ProE, UG, …) Create the initial base, the ring, by extruding the profile (circles) in a particular direction (Pro/E or SolidWorks) or use primitive solids and Boolean operation (UG). Create the counterbore as a feature. Select the top surface of the ring and either sketch the two holes and extrude at different depth or use the hole feature option. Ken Youssefi Mechanical Engineering Dept., SJSU 44  CSG Versus Parametric Modeling The next step would be to pattern the hole. The pattern would actually be considered a feature in itself, and would have its set of parametric variables, such as the number of copies and the angle between copies. The model created would be identical to the one created using Boolean operation, but with intelligence built into the model. Ken Youssefi Mechanical Engineering Dept., SJSU 45  CSG Versus Parametric Modeling The true power of parametric modeling shines through when design changes need to be made. The design modification is made by simply changing a dimension. Pattern: 8 Holes  30 10 60  15 Since the counterbore is associated with the top surface of the ring, any changes in the thickness of the ring would automatically be reflected on the counterbore depth. Ken Youssefi Mechanical Engineering Dept., SJSU 46  Original thickness Thickness increased CSG Model (non-Parametric) Parametric Model Ken Youssefi Mechanical Engineering Dept. 47  Sketching and Features When discussing the mind-set needed for working with parametric modelers, there are two topics that need to be expanded: Sketching and Features Sketching Take the word sketch literally. A sketch should be just that, a sketch. When sketching, it is not necessary to create geometry with accuracy. Lines, arcs, and additional geometry need not be created with exact dimensions in mind. When the dimensions are added, the sketch will change size and shape. This is the essence of Parametric Modeling. In short, the sketch need only be the approximate size and shape of the part being designed. When dimensions and constraints are added, they will drive the size and the shape of the geometry. Ken Youssefi Mechanical Engineering Dept. 48  Creating Features from Sketches Ken Youssefi Mechanical Engineering Dept. 49  Applied Features Applied Feature  Applied feature does not require a sketch.  They are applied directly to the model. Boss Chamfer Fillet Pocket Hole Slot Groove Pad Threaded Ribs hole Ken Youssefi Mechanical Engineering Dept. 50