Ken Youssefi Mechanical Engineering Dept.

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I ntroduction to Solid Modeling
Parametric Modeling
Ken Youssefi Mechanical Engineering Dept.
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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.
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3D Modeling
Wireframe modeling
Surface modeling
Solid modeling
There are three basic types of three-dimensional computer
geometric modeling methods:
Ken Youssefi Mechanical Engineering Dept.
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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.
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Wireframe Modeling
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

Advantages:
Ken Youssefi Mechanical Engineering Dept.
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Wireframe Modeling
Do not represent an actual solids (no surface and
volume).
Cannot model complex curved surfaces.
Cannot be used to calculate dynamic properties.
Ambiguous views
Disadvantages:
Ken Youssefi Mechanical Engineering Dept.
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Wireframe Modeling
Uniqueness problem.
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Surface Modeling
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.
A surface model represents the skin of an object,
these skins have no thickness or material type.
Ken Youssefi Mechanical Engineering Dept.
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Surface Modeling
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.
Advantages:
Ken Youssefi Mechanical Engineering Dept.
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Surface Modeling
Surface models provide no information about the
inside of an object.
Complicated computation, depending on the
number of surfaces
Disadvantages:
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Solid Models
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.
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:
Ken Youssefi Mechanical Engineering Dept.
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Solid Models
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,
Advantages:
Ken Youssefi Mechanical Engineering Dept.
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Volumetric and Mass properties of an object can be easily obtained.
Corresponding mass properties are obtained if density is included.
Ken Youssefi Mechanical Engineering Dept.
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Solid Models
More intensive computation than wireframe and
surface modeling.
Requires more powerful computers (faster with
more memory and good graphics), not a problem
any more.
Disadvantages:
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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.
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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.
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B-Rep Data Structure
A B-rep model of an object starts with
storing all of faces, edges, vertices of an
object.
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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 Eulers operators
Ken Youssefi Mechanical Engineering Dept.
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Euler-Poincare Formula
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)
Applied to the geometric entities proves that the model
is a valid one
16 24 2 + 10 = 2(1 1)
Ken Youssefi Mechanical Engineering Dept.
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B-rep Polyhedral Objects
v = 8, e = 12, f = 6, h = 0, s = 1, p = 0
v e + f h =2 (s p)
2 = 2
(I)
(I)
(II) (III)
v = 5, e = 8, f = 5, h = 0, s = 1, p = 0
2 = 2
(II)
v = 16, e = 24, f = 10, h = 0, s = 1, p = 0
2 = 2
(III)
(IV)
v = 24, e = 36, f = 16, h = 2, s = 1, p = 0
2 = 2
(IV)
Ken Youssefi Mechanical Engineering Dept.
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B-rep Polyhedral Objects
2 = 2
4 = 4
v = 16, e = 24, f = 11, h = 1, s = 1, p = 0
v = 16, e = 24, f = 12, h = 0, s = 2, p = 0
v e + f h =2 (s p)
(V)
(VI)
0 = 0
v = 16, e = 24, f = 10, h = 2, s = 1, p = 1
0 = 0
v = 32, e = 48, f = 20,
h = 4, s = 1, p = 1
0 = 0
v = 24, e = 36, f = 14,
h = 2, s = 1, p = 1
(VII) (VIII) (IX)
(IX)
(VIII)
(VII)
(VI)
(V)
Ken Youssefi Mechanical Engineering Dept.
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Euler Operators
Ken Youssefi Mechanical Engineering Dept.
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Boolean Operations
Union
Subtract
Intersection
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I mplementing Boolean Operation
Consider solids A and B.
Ken Youssefi Mechanical Engineering Dept.
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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.
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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 A
1
are outside solid B, and those of group B
1
are
inside solid A.
Ken Youssefi Mechanical Engineering Dept.
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Boolean Operation
Groups of faces are collected according to the specific
Boolean operation and the unnecessary face groups are
eliminated.
For intersect operation,
A
1
and B
2
are removed
For subtract operation,
A
2
and B
2
are removed
For Union operation,
A
2
and B
1
are removed
Ken Youssefi Mechanical Engineering Dept.
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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.
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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
I ntersection - the operation keeps only the volume
common to both solids
Ken Youssefi Mechanical Engineering Dept.
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Primitive Solids and Boolean Operations
The basic (primitive) solids:
Ken Youssefi Mechanical Engineering Dept.
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Primitive Solids
The location of
the insertion base
or base point and
default axes
orientation.
Ken Youssefi Mechanical Engineering Dept.
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Union
Plan your modeling strategy
before you start creating the
solid model
Solid Modeling Example Using CSG
Cut
Cut
Ken Youssefi Mechanical Engineering Dept.
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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.
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Creating Solid Models
Parametric Modeling Concept
Parametric is a term used to describe a dimensions
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.
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Design I ntent
In parametric modeling, dimensions
control the model.
Design intent is how your model
will react when dimension values
are changed.
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Design I ntent
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.
The drawing shows the intent of the
designer that the inclined plane
(chamfer) should have a flat area
measuring 2.5 inches and that it
should start at a point 1.25 inches
from the base of the drawing. These
parameters are what the designer
deemed significant for this model.
2.50
4.00
1.25
2.50
Example:
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Design I ntent
In this drawing, what is important to
the designer is the vertical location and
horizontal dimension of the chamfer,
rather than the flat of the chamfer.
2.50
4.00
1.25
2.125
In the last drawing, the designer calls
for a specific angle for the chamfer.
In this case the angle of the chamfer
should be dimensioned.
2.50
4.00
1.75
30.0
O
Ken Youssefi Mechanical Engineering Dept.
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Design I ntent
The height is modified from 2.5 to 3.0
Ken Youssefi Mechanical Engineering Dept.
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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.
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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., SJSU
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CSG Versus Parametric Modeling
Example:

Lets 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
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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
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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.
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.
Subtract the pattern from the base part to
create the actual holes.
Ken Youssefi Mechanical Engineering Dept., SJSU
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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
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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
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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.
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.
60
10
15
30 Pattern: 8 Holes
Ken Youssefi Mechanical Engineering Dept.
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Thickness increased
Parametric Model
CSG Model (non-Parametric)
Original thickness
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Sketching and Features
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.
When discussing the mind-set needed for working with
parametric modelers, there are two topics that need to be
expanded: Sketching and Features
Sketching
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.
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Creating Features from Sketches
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Applied Features
Applied Feature
Applied feature does not require a sketch.

They are applied directly to the model.

Chamfer
Fillet
Groove
Boss
Pad
Hole
Threaded
hole
Slot
Pocket
Ribs