Degree In Mechanical Engineering

ECD6323
CAD / CAM
Chapter 1: Geometric Modelling
(Various CAD modeling system, its components and Finite element analysis)
(7 Hours)

By Dr. Umar Nirmal

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 PART 3: 3D
MODELING

geometric
modeling

PART 1: PART 2:
INTRODUCTION COMPUTER
TO CAD GRAPHICS

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PART 1: INTRODUCTION TO CAD

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 CAD/CAM Tools
Computer
graphics Networking

CAD Manufacturing CAM

Design tools tools tools
tools (manufacturing
(analysis, codes, Geometric
processes,
heuristics, etc.) modeling CAD
heuristics, etc.)

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 CAD/CAM Tools

Manufacturing Design
tools tools

CAD/CAM
tools Geometric
Networking,
integration and modeling
automation

Computer
graphics

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 The Product cycle
The product cycle is composed of two main processes:

a) The design process: can be classified into two types of sub processes:
- i) synthesis and ii) analysis.
- Identification of the design need, design specifications, feasibility study with collecting relevant design information, and design conceptualization
are part of the synthesis sub process.
- The outcome of the synthesis sub process is a conceptual design of the prospective product in the form of a sketch or layout drawing that shows the
relationships among the various product components. This is done in the CAD systems.

b) The manufacturing process begins with process planning.

- In this stage, you will have CAM such as computer-aided process planning (CAPP), computer-aided numerical control (NC), computer-aided tool
design (CATD) to design and fabricate jigs and fixtures and lastly material requirement planning (MRP) to manage the materials needed for
fabrication and assembly.
(i.e. CAM + CAPP + NC + CATD + MRP)

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The Product cycle (cont’d) Q1.1: What is the
importance of
product life cycle
in Engineering?

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PART 2: COMPUTER GRAPHICS

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A typical database structure of a product may consist of a number of component parts as shown in figure below:

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Translation
Translating a model means that all of its points move
an equal distance in a given direction.

Figure shows a translation of a curve by a vector d.

To relate the final position vector P* of point P on the

curve to its initial position vector P,

P* = P + d

This equation is applicable to both two and 3D points

and can be written in a scalar form for the 3D cases

X* = x + xd
Y* = y + yd
Z* = z + zd

Q1.2: By means of a neat sketch and detail labelling, give

an example of using ‘translation’ in CAD modeling.
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PART 3: 3D MODELING

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 Modeling Systems

• Wireframe
• Surface
• Solid

Q 1.3: Illustrate with a sketch the three basic steps in ‘Modeling Systems? 12
Wireframe Modeling
Q 1.3: Why wireframe modeling suffers from
uniqueness and ambiguity issues?

Wireframe Model 13
Surface Modeling (skin generation)
• The development of aircraft, ships, and complex consumer
products led to 3D surface modeling

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 Surface Modelling Systems
There are two types of dimensional surfaces:

i. Analytical Surfaces - defined in x, y, z by a single equation, eg quadratic surfaces -

cylinders, spheres, cones, paraboloids, etc. Ex: Volume of sphere:

ii. Sculptured Surfaces - also known as free-form or non-analytical surfaces. Unlike

analytical surfaces, sculptured surfaces cannot be described by a single mathematical
relationship. Sculptured surfaces are used in the design of ship’s hull, aircraft, car bodies,
turbine blades, telephone handsets, etc. Ex: Multiple equations are used through solid
modelling software. Ex:
Q 1.4: Why are sculptured surfaces hard to produced using
‘hand drawing’ or ‘free hand’?
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Classification of surfaces

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 Q 1.5: Give four examples each for planar, curved and ruled surfaces.

Planar Surface:

Curved Surface:

Ruled Surface:

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Coons Surface
A Coons surface or patch is obtained by blending four boundary curves. The single patch
can be extended in both directions by adding further patches.

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Bezier Curves & Surface
Bezier curve uses the vertices as control points for approximating the generated curve.

Bezier surface:

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B-Splines
B-spline generates a single piecewise parametric polynomial curve through any number of control points.

Ex: The curve is broken down into more segments with better control exercised with individual segments,
while maintaining a simple continuity between the segments.

Local control in B-Spline surface

The B-Spline curve and

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NURBS

Bezier + B-Spline curves.

Control Points

Control Surface

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Q 1.6: Explain why engineers and
scientist had designed the following in
a: (a) sports car; (b) cargo ship; (c)
turbine engine of an aero plane?

Why such designs?

bulbous bow 22
Application based question: When an aircraft jet turbine is in operation, it will generate an enormous amount of vortex which
is either from the ‘a’, ‘b’ or ‘a + b’. This is dangerous especially when it comes to ‘b’ as small abrasive particles can be
directly sucked into the turbine causing damages to the turbine. How can you eliminate this? Submit your proposal to the
link given.

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 Solid Modeling
Common geometric primitives:

*Solid modelling systems are used to model an object having a closed volume, called solid.
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Solid Modelling: The three Boolean operations: union, difference, and intersection

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Solid Modelling: Exact versus faceted surfaces

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 Solid Modelling: A part defined by features

Q 1.7: Why is it important to

define a ‘part drawing’ with
features?

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Solid Modelling: Types of Extrusion operations

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Solid Modelling: Types of revolved operations (Shaft)

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Solid Modelling: Creating a solid model using Revolving (R) and Boolean (B) operations

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Solid Modelling: Feature ordering affects final geometry (Multiple Operations)

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Solid Modeling: Linear and Radial Arrays (Patterns)

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 Solid Modeling: Constraint-based Modeling

Allows designers to capture intended geometric relationships between elements of the model
Q1.8: Why do we perform a ‘Constraint-based Modeling’ on a part design?

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PART 4: ASSEMBLY MODELING

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The main Objective in Assembly Modeling:

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 The importance of Assembly Modeling

• Solve the problem of proto-type actual component assembly

• Automotive and aerospace industries among the first to make extensive use of
assembly modeling.

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Set Flexible property to a subassembly to allow movement independent from other occurrences of the subassembly

Example of ‘Set Flexible property’ means apply material which is elastic such as High-density polyethylene (HDPE) or
polyethylene high-density (PEHD)

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 Assembly Constraints
• Example assembly constraints are: mate, align, angle, parallel,
perpendicular, center, distance, tangent.

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 Assembly Modeling: Type of Mating Conditions
Type of Mating conditions:

Align coplanar mating condition

Co-axial mating condition Coincident mating condition 39

Assembly Data Structure Q1.9: What is the importance of the ‘Tree Diagram’ in solid modeling?

Bottom
Up

Tree Diagram

Top
Down

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PART 5: GEOMETRIC TOLERANCING

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 Geometric Tolerancing
Geometric tolerancing is a system that specifies the form, profile, orientation, and location of part’s features using the ANSI
(American National Standards Institute) standards.

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 Geometric Tolerancing: Examples
a) Form tolerancing

Flatness Straightness

Profile tolerancing line

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 Geometric Tolerancing: Examples (cont’d)
b) Orientation tolerancing
Perpendicularity

Parallelism Angularity
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 Geometric Tolerancing: Examples (cont’d)

c) Location tolerancing

Concentricity

Symmetry

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 Geometric Tolerancing: Datum Feature

The actual plane on the part (imperfect)

corresponding to a (perfect) datum plane

datum feature A datum feature B

datum plane A datum plane B

datum B datum C

datum A

Sequence of establishing datums:

PRIMARY (3 points) → SECONDARY (2 points) → TERTIARY (1 point) 46
 Q1.10: Based on the figure given, illustrate why is it important to define a ‘datum’ in CAD modelling.

A datum is a plane, a straight

line, or a point that is used as a
reference when processing a
material or measuring the
dimensions of a target – as per
ISO

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Geometric Tolerancing: Some common ANSI symbols for geometric tolerancing
Type of Tolerance Characteristic Symbol ANSI modification symbols

Straightness
MMC
M
Flatness
Regardless of feature size S
Form
Circularity
LMC
L
Cylindricity
Projected Tol Zone P
Line profile
Diameter
Profile
Surface profile
Spherical Diameter
S
Angle
Radius R
Orientation Perpendicular
Spherical Radius
SR
Parallel
Reference size
( )
True Position
Location Arc length
Concentricity

Circular runout
Runout
Total runout
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 Geometric Tolerancing: Different allowed notations (ANSI)

3.00 basic size

-A- datum

0.001 M A M

symbol tolerance modifier datum modifier

0.001 A B C

symbol tolerance primary- secondary- tertiary datum

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 Geometric Tolerancing: Location tolerances

Conventional system:
rectangular tolerance zones

True Position Tolerancing:

circular (cylindrical) tolerance zone

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Geometric Tolerancing: The Positional Tolerance Feature Control Frame

Geometric Control Symbol

Diametric or Linear Tolerance
Material Condition Symbol
Primary Datum Reference Plane
Secondary Datum Reference Plane
Tertiary Datum Reference Plane

Material Condition Symbols Maximum Material Condition

Least Material Condition
Regardless of Feature size
Projected Tolerance
Free State Condition
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PART 6: FINITE ELEMENT METHOD (FEM)

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 What is FEM?

A procedure that transforms insolvable calculus problems into

approximately equivalent but solvable algebra problems

DOMAIN

SYSTEM
GOVERNING EQUATION
(Containing interior loads)

Differential Integral BOUNDARY

equation equation CONDITIONS

Recall:
PDE – BC, IC
ODE?
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FEM: cont’d
DOMAIN DISCRETIZED

BOUNDARY
BOUNDARY CONDITION
CONDITIONS
INTERELEMENT
BOUNDARY
CONDITION

GOVERNING ALGEBRAIC [K] {a} = F

EQUATION EQUATIONS
Stiffness Load
Matrix Vector

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 FEM: Application of FEM a)

I. Stress analysis
II. Dynamic analysis
III. Deformation analysis b)
IV. Fluid flow analysis
V. Heat flow analysis Q1.11: Based on the figures (a) to (e),
VI. Seepage analysis identify the correct FEM analysis.
VII. Magnetic flux analysis
VIII. Acoustic analysis

d)
e)
c)

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PART 7: PRODUCT LIFE CYCLE MANAGEMENT (PLM)

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 What is PLM?

• PLM is a total production system that tracks a product from

inception to disposal

• It includes, marketing, sales, design, planning, production,

quality requirements, packaging, shipping, and disposing of the
product when it’s useful life is over

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 Plus the engineering
Product business
PLM:
systemsThe Scope
to Lifecycle
make of PLM
the process
work with the rest of the company

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 PLM: Product Realization Challenges

• Decreasing time to market

– Shorter window of opportunity for new products
• Geographically distributed operations
– Desire for lean operation, and economics of scale
• Rapidly changing manufacturing technology
– Need to train employees quickly
• Global competition
Example 1: Biodegradable cup
– Need to be cost-effective and timely
• Need to consider life-cycle impact from the outset
– Cost, performance, serviceability, environmental impact

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Q1.12: Explain how giant automotive industries save their operational cost when launching of new version of
existing vehicles; example is Mazda CX5?

Vs.

Year 2013 Year 2025

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 ~ end ~

More Info on CAD/CAM at - [Link]

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