Solid Modeling

Techniques
(Lecture #7)

Solid Modeling Techniques

Feature construction and techniques
Feature based modeling
Hard--coded features
Hard
Combining objects
Basic concepts of creating parts
Constraint--based systems
Constraint
Variational geometry
Types of contraints
Sketcher, constant engine, feature manager, solid
modeling system
Parametric & variational modeling
Assembly modeling
Mechanisms

1
 Feature Construction

Traditional CAD modeler creates

geometry a specified size (A)
(A)..
In a constraint
constraint--based modeler,
the geometric relationships are
coded directly into the model
with parameters.
parameters. (B & C)

Feature Construction

Like dimensions, parameters can be associated with

geometric features such as lines, curves, and planes.

Unlike dimensions, parameters do not have to

represent a single static value.

It is important to remember that parameters are

always related back to geometric features.

Likewise, geometric relationships such as parallelism

are made between features such as lines or planes.

2
 Feature Construction
Modeling Process

1. 2-
2-D skecth profile (A)
2. Assign enough parameters to fully
define size & shape (B)

Feature Construction
Modeling Process

3. Alter one or more of th parametric

values (C)
4. Extrued or sweep the 22--D profile into
3-D part (D)

3
 The Effect of Design Intent on
Model Changes
The part on the left intends to have the bole fixed
at an offset of 10 from the left edge whereas the
part on the right intends to have the hole centered.
The differences in the design intent can be seen
when the overall width of the part is altered.

Feature ConstructionTechniques

Computer-generated objects are typically made up of

Computer-
features. Most modern CAD software employs a
methodology know as feature
feature--based modeling
modeling..

The features available in the software are usually

designed to relate to how engineers think in their
design and manufacturing work.

Most software packages such as Mechanical Desktop

and Pro/E have predefined features that you use to
build your objects
objects..

4
 Feature-
Feature-based Modeling
An important advancement in 3-D solids modeling
is the introduction of feature
feature--based modeling.
modeling.

Like constraint
constraint--based modeling, feature
feature--based
modeling is an attempt to make modeling a
more efficient process more in tune with how
designers and engineers actually work
work..

Feature-
Feature-based Modeling
Feature modeling interface
higher level interface would permit
specification of entities in terms of geometric
and dimensional constraints
permit definition of features directly by user,
with appropriate geometric shape created
within solid modeling engine
– solid modeling engine: a toolkit of modeling
subroutines called by software

5
 Feature--based modeling
Feature
Dimension
Dimension--driven design refers to a collection
of solid
solid--modeling capabilities that include
variational, parametric, and feature based.

Feature
Feature--based modeling has, among engineers,
rapidly become the preferred method of
constructing solid models.

Feature--based modeling
Feature
Solid models are constructed from geometric
features such as slots, shells, bends, drafts,
rounds, and so forth.

One advantage of features is that they

provide dimensions that correctly define how
the feature behaves when dimensions change.

6
 Feature--based modeling
Feature
The geometry has
enough embedded
intelligence to know
that the hole should go
all the way through
the plate, regardless
of how thick the plate
is.
If the designer
decides to increase
the plate thickness
tenfold, the hole will
still go through to the
other side.

Feature--based modeling
Feature
The most important aspect
is that they capture design intent.

In the drilled hole example, the designer

intended to put a hole through the plate.
This intent was maintained regardless of
what changes were made in the plate
dimension.

7
 Feature--based modeling
Feature
Another important property of feature
feature--
based modelers is the ability to let a
feature reference the geometry of
various models in an assembly.

This referencing allows changes made in

one model to propagate to other
affected models.

Variational Sketching

The variational approach couches the design

in a mathematical model such that whenever
the designer makes a change, the package
recalculates the entire model.
This capability makes for a flexible system
and is most useful in early design stages
where relationships between geometric
constructions can change drastically.

8
 Variational Sketching

Variational sketching is a capability used to

let designers turn 2D profiles into 3D models.
Profiles typically represent cross sections of
extruded objects or sections used for
complicated skinning and lofting operations.
The designer typically creates only the part
shape with no regard for final dimensions.

Parametric modeling

Parametric methods depend on the sequence of

operations used to construct the design.
The software maintains a history of changes in
specific parameters.
Parametric modeling is most efficient in
working with designs where changes are likely
to consist of dimensional changes rather than
grossly different geometries.

9
 Relationship of Feature-
Feature-Based
Interface to Geometric Modeler

Feature- Solid Modelling

User Based Engine :
Input Interface (B-rep or CSG)

Modeling Systems

CAD Package Manufacturer Primary Modeling

Format Enginee
AutoCAD AME AutoDesk CSG PADL
AutoCAD 2000 AutoDesk B-Rep ACIS
Designer AutoDesk B-Rep ACIS
MicroStation Bently B-Rep ACIS
Modeler
Pro/E Parametric Tech B-Rep proprietary
I-DEAS SDRC B-Rep Geomod
SolidDesigner Hewlett Packard B-Rep ACIS
Unigraphics EDS B-Rep Parasolid

10
 Feature-
Feature-based Modeling
One of the newest developments in solid
modeling.
Addresses the design concerns previously
noted.
Represents an attempt to tighten the
relationship between the model and the
manufacturing processes required to produce
the component.

Feature-
Feature-based Modeling
Geometry is defined in terms of real world
“features” as opposed to abstract geometric
entities.
For example:
– work with holes as opposed to cylinders
– cuts and extrusions rather than blocks and
wedges.

11
 Feature-
Feature-based Modeling
Parts are represented in terms of higher level
entities (features) that have engineering
meaning.
Models contain not just basic geometric and
topological data (as all solid models will),
will), but
also higher level information.

Feature-
Feature-based Modeling
Features capture “design intent”
Included information defines how the features
behaves in editing
– for example, a “through” hole
Features store non
non--graphic information for
use in:
– 2D drawing creation, FEA, CNC and kinematic
analysis

12
 Shape Features
Created through:
– sweeping and blending (lofting) of 2D profiles

• features used to add material (protrusions) or remove

(depressions, cuts, etc.)
•Profiles may defined as constrained sketch geometry
(constraint-based systems)

Classifying Shape Features

Type Description
Passages subtracted volumes that intersect
the pre-existing shape at both ends
Depressions subtracted volumes that intersect
the pre-existing shape at one end
Voids subtracted volumes completely
enclosed by material
Protrusions added volumes that intersect the
pre-esixting shape at one end
Connector added volumes that intersect the
pre-existing shape at both ends

13
 Hard-coded features

have a characteristic topology

have a generic geometry
user input for specific properties such as
- diameter, depth, entity reference (mounting
face)
examples
– holes, slots, fillets, rounds

Hard-coded features

Examples of manufactured features

created through special
feature-based dialog boxes
include the following:
Blind holes
Counterbores and countersinks
Slots
Bosses

14
 Hard-coded features

The variables entered through the dialog box

largely define the shape and size. Once these
variables of the feature are defined, the
location is defined. By convention, features
usually don’t constitute an entire part.

Reference features

▪Not geometric features

▪Used for orientation and location of features

within model

▪Examples are:
– datum planes
– datum axes

▪Also include defined 2D “sketch planes”

15
 Base feature

First feature created is the “base feature”

The base feature:
– provides the initial reference for all
subsequent features, regardless of type
– may be reference feature(s)
– may be a stand-alone shape feature

Relation to traditional design

During the design process of a component, more

attention is given to form and topology than
dimensional precision in the conceptual phase.

In a feature-based which supports constraints,

profiles are sketched to capture this “design
intent”.

16
The Features of Feature-based Modeling

Feature-based modeling refers to the

construction of geometries as a combination of
form features. The designer specifies
features in engineering terms such as holes,
slots, or bosses rather than geometric terms
such as circles or boxes.

The Features of Feature-based Modeling

Features can also store nongraphic information

as well. This information can be used in
activities such as drafting, NC, finite-element
analysis, and kinematic analysis. Furthermore,
feature-based packages frequently record the
geometric construction and modification
sequences used in building the model.

17
The Features of Feature-based Modeling

Old method: Define slot as Boolean difference

between the part and space.
The problem: Lengthening the part geometry
turns the slot into a blind hole.
Feature method: Through-hole feature
understands that it must pass through the
part, no matter how the part changes.

Feature-Based Modelling
• Parts modelled by adding features to a base part
• Features represent manufacturing “operations”
– holes, ribs, fillets, chamfers, slots, pockets,
etc.
• Material can be added or subtracted, similar to
CSG
• Features are not limited to simple primitives, and
can be created by extrusion, sweeping, revolving,
etc.
• A history tree is created, similar to a CSG boolean
tree

18
 Feature-Based Modelling

The designer would simply define a part in

terms of fundamental manufacturing
features, such as chamfers, through slots,
blind slots, etc.

Very high level, but can complicate additions of

unanticipated features, like a ridge in a car
hood.

Feature-Based Modelling

Advantages,
• very intuitive and easy to use
• can simplify other aspects of CIM (eg. If a
standard feature is used there will be a
standard process plan to make that feature).
• emphasizes the use of standard components.

19
 Feature-Based Modelling
Disadvantages,
• restrictive when dealing with nonstandard
features
• interaction of features can be hard to
estimate
• a complete set of all possible features would
be very large

There are two levels of features commonly

used in these systems,
• micro
• macro

Feature-Based Modelling

A set of prismatic features might be,

Macro Features Internal Features

box rectangular pocket
External Features linear fillet
linear chamfer
linear round
linear v slot
linear slot
linear round slot
linear t-slot

20
Feature-Based Modelling
A set of standard features for rotational parts might be,
Macro Features Internal Features
cylinder internal taper
taper internal slot
External Features internal tapered radial slot
rotational fillet internal round slot
thread countersink
square neck internal spline
chamfer woodruff keyseat
shoulder
external radius
key seat
spline
flat
thread

Feature Catalogs

21
Feature Catalogs

Using Feature Catalog

22
Part Families

Features overview
Extrude Boss/Cut solid

23
 Combining Objects

To learn how features are used to create objects, it is

important for you to first understand how two objects
combine to form a third object.
Basically, a cutting, a joining, or an intersecting
operation combines objects.
Notice that these two objects
overlap each other.
In other words, they share
a common volume.

Combining Objects
Basic Concepts of Combining Parts

To combine two parts, you first identify which

one you want to use as the base part and
make it active.

Then you position the toolbody part on the base

part using MOVE, ROTATE, or assembly
constraints.

24
 Combining Objects
Basic Concepts of Combining Parts

You can combine as many toolbodies with a base

part as you like, but the base part and
toolbody must be instances of different pars.

External parts cannot be used to create a

complex part.

Combining Objects
Combining Objects with Relations

When you are combining objects by cutting,

joining, or intersecting them, you need to
establish relationships between the two
parts being combined in order to simplify
the modification of the part at a later date
or to create parts to exact size or shape
specifications.

25
 Combining Objects
Modifying the Features of an Object
The major advantages of feature-based
modeling is your ability to change the size of
individual features on an object at any time.
You can define the basic shape that your final
object will have and then modify the
individual sizes of the features that make up
the object.

Combining Objects
Modifying the Features of an Object

These modifications usually consist of

modifying the order of construction for the
features included in your object or deleting
the features themselves from the object

26
 Basic Concepts of Creating Parts
In general you may follow this process to developed a
part design:

• Look at the whole part & decide how it can be

broken down into simple shapes.
• Identify the most simple element to use as your
base feature.
• Decide the order for creating additional features.
• Determine the methods for creating the features.
• As you build individual features, review & adjust
your ideas about how the features work together.
• As you adjust your design strategy, you can revise
the features you created earlier.

Cut the solid

Features
overview

Sheet metal

27
Features overview

Corner Fillets

Features overview

Sweep

Loft

28
Features overview

Face
Blend
Fillet

Extrude
with
center
line

Features
Slot Hole

Counterbore

Countersink

29
History Tree

Final Part
Increasing
part Part3 Shell
complexity

Part2 Hole

Part1 Fillets
Features
added
Base Slot

Modifying Parts

• The part is created from the history tree

• Features can be added, deleted and re-
ordered
• Feature dimensions can be changed
• Feature parameters can be changed
– eg. From protrusion to cutout

30
Modifying Parts

Draft

Chamfer

Modifying Parts

Pattern

Shell

31
 Constraint-based
systems

What are Constraints ?

The solid model stores more than just the final

geometry— it stores the “design intent” rules
that govern what will happen when geometry
changes. This makes it easy to make flexible
design changes to part models.

32
 What are Constraints ?

These rules are described as “constraints” on

wireframe geometry used to extrude and
revolve pans, and as “relations” when parts are
cut, joined, or intersected.
There are two major types of constraint-based
modeling systems available on the market
today: variational geometry and parametric
modeling.

What is a variational geometry?

A variational geometry is a set of plane curves

and lines to which you can assign geometrical
and dimensional constraints and which you can
use to create solids or to add features to
existing solids.

Variational geometries are the basic

components of parametric structure.

33
What is a variational geometry?

You can use profiles to create solids and

features by applying a linear sweep or
revolving the profile.

In the case of a feature, the profile is used

either to add material to or remove material
from a solid.

Rules for building a profile

You can create a profile from any set
of curves that meet the following
conditions:

• The curves must be co-planar and be

drawn on the Work Plane.

• The curves can form an open or closed

profile and may contain islands, but not
islands within islands.

34
 Variational Geometry

With variational geometry, constraints are

applied to the 2-D shape in terms of degrees
of freedom. A degree of freedom exists if
there is currently no constraint applied to
control a specific feature of the geometry of
your sketch.

Variational Geometry

This concept is best described by a simple example.

Start with a simple 4-sided polygon, defined by 4
points, 1 through 4, as shown below. What do we want
to happen if point 3 is translated to the right?
1 4

1 4
2 3
1 4

2 3

2 3

35
 Uses of Variational Geometry
How Many Constraints do You Need?
Some mathematically-inclined readers may have a
question at this point about how many constraints can
be applied to a section. Normally, to solve a set of
simultaneous equations, the number of equations
must equal the number of unknowns.

Uses of Variational Geometry

What happens if fewer than this number are applied,
and a change is made to a value?
There could be more than one possible solution. If you
were using a general-purpose symbolic math package,
it might not let you try to solve a set of equations
where there were more unknowns than there were
equations.
The solver used to solve variational geometry is not just
a simple simultaneous-equation solver. It looks at the
geometry, and attempts to make the minimum change
if more than one solution is possible.

36
 Constraint-based systems
Constraint-based modeling is a technique that
can help the CAD operator manage the model
modification process.

In a constraint-based modeler, describing the

relationship of geometric elements with
equations and logical relationships creates a
part.

Constraint-based systems

• User constrains geometry based on Design

Intent
• Design variations can be generated by
changing a few key dimensions
• Geometry is automatically regenerated based
on constraints

37
 Constraint-based systems
Concept first developed in 1970’s
First commercial system in 1988
Most current professional level feature-based
modelers use constraint-based techniques to
help define features.
(through the creation of profiles)

Constraint-based systems
2D profile geometry not explicitly defined, but
rather driven by the constraints.

Constraints stored internally as equations.

Equations are solved to resolve the sketch

geometry.

38
 Solving constraint equations
Set of constraint equations solved to define a
unique solution profile.
Equations may be solved sequentially
– referred to as “parametric system”
– results of each previous solution used in next
Equations may be solved simultaneously
– referred to as “variational system”

Constraint-based systems
Constraint-based systems may be
– parametric (sequential evaluation of
constraints)
Variational (simultaneous evaluation of
constraints)
Many systems use a combination of
both techniques

39
 Constraint-based systems
Constraints also used to control:
the relationships between features on the
same component
the relationships between features on the
different components (in separate files)
the relationships between components in
an assembly

Types of Constraint
Constraints enable you to preserve the original
design intent even as changes are made to the
model you have created.

Constraints allow for a great deal of flexibility

in the design, but it is important that you
apply the constraints properly so that the
integrity of the design is maintained.

40
 Types of Constraint
Constraint Types
• Ground constraints
• Dimensional constraints
• Geometric constraints

Types of Constraint
Ground constraints
When you constrain your sketch, you establish
relationships that must be maintained as
modifications are made to its geometry.
Ground constraints are added to your sketch to
define which of the pair of lines involved is
the movable line.

41
 Types of Constraint
Ground constraints
• Vertical
• Horizontal
• Angular Vertical Horizontal

• X,Y

(X,Y) Location
Angular

Types of Constraint
Dimensional constraints
Dimensional constraints specify the length, radius, or
rotation angle of the geometric ele-ments in your
sketch. Geometric constraints force the profile to
conform to a specific shape.

Dimensional constraints, on the other hand, add the

parametric characteristic to the profile. You can
change a dimension at any time and its new value will
be immediately reflected in the design.

42
 Types of Constraint
Dimensional constraints
Specified as dimensions
– e.g. linear, radial, angular, diametric
Dimensional constraints also stored as
equations in database

Types of Constraint
Dimensional constraints
• Horizontal dimension
• Vertical dimension
• Linear dimension
• Angular dimension
• Radial dimension

43
 Types of Constraint
Dimensional constraints
Linear
This constraint is used to define – the linear
distance between two lines between a line and
a point, or between two points.

Types of Constraint
Dimensional constraints
Angular
Angular dimensions are used to define the angle
between two lines on your sketch.

44
 Types of Constraint
Dimensional constraints
Diametral & Radial
Diametral constraints are used to control the
diameter of any circles on your sketch.
Radial dimensions control the radius of any
arcs on your sketch.

Types of Constraint
Method of Entry & Display of Dimension Values

Dimensions can be shown and entered as either

numeric constants or as equations.
d1=2
d0=1
Use numeric values when the
size of an object is not related
to another object and use an
equation when the size of an
object is directly related to d4=4 d3=d4/2
another object.

d2=(d4-d3)/2

45
 Types of Constraint
Geometric constraints
Size and position of specified 2D geometry
controlled by geometric relationships with
other entities.
May be implied (system created) or applied
(user created), depending upon software.

Types of Constraint
Geometric constraints
Geometric constraints control the shape of the
profile. When you profile your sketch, the
sketch is analyzed and geometric constraints
are added to suit the sketch.

Geometric constraints are used to define the

shape of your 2-D geometry.

46
 Types of Constraint
Geometric constraints
Examples of geometric constraints:
– parallelism, equal length/angle, co-linearity,
perpendicularity...
– concentric arcs/circles, horizontal, vertical,
parallel, tangent

Types of Constraint
Gemetric constraints
• Parallel
• Perpendicular
• Collinear
• Coincident Parallel
Perpendicular
• Tangent
• Horizontal
• Vertical
• Project Coincident
• Join
• Xvalue Colinear
• Yvalue
• Radius Tangent

47
 Types of Constraint
X X
X
X

Original sketch of 2-D geometry Parallel constraints applied between

lines labeled with a “X”.
Y
Y 4
3
Y

2
1
Y
Parallel constraints applied between lines
Colinear constraints applied between
labeled with a “Y”. Perpendicular
lines 3 and 4.
constraints applied between lines 1 and 2.

Constraint-based systems
Applying Constraints to 3D Geometry
It is possible sketch directly on a surface of a 3-
D object. When constraining 2-D geometry on
3-D objects, remember to add the
dimensions before
extruding to cut-out or to
protrude because
constraints cannot be
added as a portion of the
definition of the 3-D part.

48
 Constraint-based systems
A typical constraint-based system includes:
• Sketcher
• Constraint engine
• Feature manager
• Solid modeling system

Sketcher
2D input system
– creation of 2D entities (lines, arcs, splines)
Sketch geometry used for feature construction
– through sweeping and lofting techniques
and in some hard-coded features
Includes link to constraint engine

49
 Sketcher
Sketch geometry constrained geometrically and
dimensionally
Sketcher...
– allows creation of dimensional constraints
– controls implied geometric constraints
– may allow user control of geometric
constraints (add or remove)

Constraint Engine
Provides for creation and modification of:
– dimensional relationships in sketches
– dimensional relationships between features
– all geometric constraints
Provides for resolution of constraint equations

50
 Constraint Engine

(Factors related to its usefulness)

• dimension types recognized (angular, linear,
etc.)
• types and level of geometric constraints
(concentric, collinear, etc.)
• freedom to postpone dimensioning
– work with under constrained geometry

Constraint Engine

(Factors related to its usefulness)

• dealing with “parent/child” relationships
• external compatibility
(importation/exportation)
• configuration of variables
– symbolic name associated. with value,
parameter associated. with unrelated
geometry, etc.

51
 Constraint Engine

(Factors related to its usefulness)

• User may choose whether implied constraint
apply to all or part of the geometry
• Incorrect constraints automatically flagged
(in fully constrained approach)

Constraint Engine

(Factors related to its usefulness)

• Ability to undo or abort constraint operation
• Over or under constrained situation allowed
temporarily
• Implied constraints may be overridden

52
 Constraint Engine

(Factors related to its usefulness)

• Large number of hard-coded features
• Feature editing which permits complete re-
definition at later time
• Feature re-ordering capability
• Patterning and instancing of features

Feature Manager

Allows insertion of “hard-coded” , shape and

reference features.
Also special “user-defined” features
– user-defined features may be created,
stored, and inserted

53
 Feature Manager
Supports feature editing processes
Typically supports:
– feature suppression (from display and editing)
– control of feature construction order
– control of feature references (parent/child)

Flags violation of feature intent

– e.g. A blind hole becomes a through hole because of a
transaction subsequent to its insertion

Model creation order

• order dependent process

• parent/child relations based upon order of
creation
• only able to reference previously defined
features
• may be able to “re-order” model in feature
manager

54
 Parent/Child relationship
• dependency exists between created feature
(child) and parent: e.g.
– other features used to locate it
– insertion features
• mounting feature: surface or sketch plane
– source features

• patterns and part families

• dependency means process of editing parent
feature requires considering child features of
that parent

Desired Characteristics of
Modeler
• examine what is:
– desirable
– useful
• in feature-based, constraint-based system

55
 Constraint-based systems
Example
D5

D1
D2

D4

D3

Constraint-based systems

Design Intent
• The part should be twice as long as it is wide
• The hole should be centred in both directions
• The hole diameter should be 50mm

56
 Parametric &
Variational Modelling

Parametric Modelling
a subset of variational geometry.
allows for a flexible design in much the same
way that variational modeling does.
able to add constraints to sketch to control how
the geometry will behave as modifications are
made.
need to have a fully constrained shape before
using parametric modeling to create a 3-D
solid.

57
Parametric & Variational Modelling
Parametric modelling
– constraints defined sequentially
– each constraint calculated based on
previously defined constraints
– order of constraint specification is
important
• Variational modelling
– constraints solved simultaneously
– order of constraint specification doesn’t
matter

What is a profile?
A variational profile is a set of plane curves and
lines to which assigning geometrical and
dimensional constraints and which using to create
solids or to add features to existing solids.

Variational profiles are the basic components of

parametric structure.

One can use profiles to create solids and features

by applying a linear sweep or revolving the profile.

In the case of a feature, the profile is used

either to add material to or remove material from
a solid.

58
Rules for building a profile
You can create a profile from any set of
curves that meet the following conditions:

• The curves must be co-planar and be

drawn on the Work Plane.

• The curves can form an open or closed

profile and may contain islands, but not
islands within islands.

A closed profile containing one A sweep solid cannot be created

island can be created from this set from this set of curves
of curves

Parametric & Variational

Modelling
Parametric definition
User specifies dimension D1, other dimensions
calculated sequentially

D1 = x
D2 = D1/2
D3 = 2 D1
D4 = D3 / 2
D5 = 50

59
 Parametric & Variational
Modelling
Variation definition

Solve system of simultaneous equations:

D1 – 2D2 = 0
2D1 – D3 = 0
D3 – 2 D4 = 0
D1 – x = 0
D5 – 50 = 0

Modelling Approach
• Sketch approximate geometry
• Generate solids and features
• Add constraints and dimensions
afterwards

60
 Smart Skectching
• Most CAD systems use “smart”
sketching tools
• Design intent is inferred, and
constraints added automatically
• For example, two lines that are nearly
perpendicular “snap” perpendicular,
with a constraint

Introduction to Parametric Feature

Based Solid Modeling
Questions :
1. List and describe five types of geometric contraints used
during the sketch constructive process of a parametric
design package.
2. Explain what is meant by the parent-child relationship that
exists between parametric features.
3. Describe feature-based modelling and contstraint-based
modelling.
4. Why should design features be used for modeling in CAD
rather than geometric primitives? Under what
circumstances do you think that feature-based design may
be particularly appropriate ?
5. What are the limitations in the features approach?

61
 Assembly Modelling

Assembly Modelling

• Many modelers have been used to create

models of single components.
• Design procedure was to assembly the actual
components or prototype later in the design
cycle.
• Physical distance between design teams in
global corporations and the need for
electronic transfer fueled the need for
computer-based assemblies.

62
Assembly Modelling

Assembly modellers which form part of an

integrated product design system.

Additional benefits include the ability to check

for interference between parts.

Assembly modeling allows the integration of

design and manufacturing to production
planning and control.

Assembly Modelling

• An assembly consists of two or more parts

located relative to each other in space
• Normally the relative motion is constrained
• Most assemblies are fully constrained
• Mechanisms are partially constrained

63
Assembly Modelling

Bill-of-materials (BOM) can be generated for each

subassembly and assembly.
BOM is a full definition of how a product is
structed
Context of
materials requirements planning (MRP)
manufacturing resource planning (MRP II).

Assembly Modelling

Automotive and aerospace industries

among the first to make extensive used
of assembly modeling.

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Assembly Modelling

Provides a logical structure for grouping and

organizing components into assemblies.
Structure permits:
– identification of components
– control of associated data (e.g. BOM)
– control of relationships between components
and sub-assemblies

Assembly Modelling

Most assembly modelers work by creating a file

which includes only:
– pointers to the individual components used
– the constraints used to position the
components with respect to one another
– multiply occurrences of the same component
are handled by instancing

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Assembly Modelling

Relationship data includes

– Constraint information
• orientation and location of components with
respect to one another
• variational relationship between features of
different parts

Assembly Modelling

Relationship data includes ...

– Instancing information
• multiple occurrences of the same component
– Tolerance and fit information
• part interference and clearance

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Assembly Modelling

Inter-part dimensions provide control when an

assembly depends upon key dimensions
(e.g. hole patterns)

Provides a mechanism for propagating a design

change though out all components of an
assembly without modifying each component
individually.

Assembly Model Used for ...

ØCreation of orthographic assembly

drawings.
ØCreation of exploded assemblies.
ØFacilitate packaging
ØPerform interference and clearance
checks.

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Assembly Modelling

Most modern feature-based, constraint-based

systems have assembly capabilities.

In addition to
the Sketcher,
Constraint Engine
Feature Manager,
Assembly Manager

Assembly Manager

• Permits creation of:

– sub-assemblies from parts
– assemblies from sub-assemblies and parts
• Controls relative placement of parts/sub-
assemblies (constraints)
• Controls regeneration of
assemblies/subassemblies after modification

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Part/Sub-assembly Placement

Examples of constraints applied to assemble

components
– alignment
• surfaces, axes
• with offset distances

– mating
• surfaces, edges

– coincidence
• points, edges

Simplified Representation

Large assembly models can serious stain the

processor capabilities of the hardware
system being used.
In these cases, many assembly modelers provide
means for simplifying the assembly.
The use of instancing helps reduce complexity.

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Simplified Representation

Another technique used is aggromeration.

– Grouping components and sub-assemblies into
a single static definition.
Many systems also support the use of simplified
representations.
– complexities such as fillets/rounds removed
– representation may simply be the “envelope”
of the part with mating features.

Applications of Assembly Models

• Interference checking
• Visualization
– rendered
– exploded
• Animation
• Mechanism analysis

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 Assembly Hierarchy
• The assembly hierarchy defines
relationships of parts to each other
• There can be multiple levels of sub-
assemblies

Assembly Hierarchy Example

• Pump Assembly
– Link assembly
• offset link Multiple
instances
• offset link
– Piping assembly
• well casing
• well seal
subassembly
•…
– Handle assembly
– ...

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Another View

Assembly

Subassemblies

Parts

Positioning Parts in an Assembly

• Parts can be positioned by translating and
rotating them into the right locations
• This requires careful measurement of relative
locations, knowledge of coordinate systems,
and entry of numerical values
• If position or dimensions of one part change,
this has to be redone

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Example

Assembly

Position
& orientation
Subassemblies

Parts

Using Assembly Constraints

• Constraints can be used to create permanent
relationships between parts
• THEY use the same commands as 2D constraints
• Typical constraints:
– two faces meet
– axes coincident
– two faces parallel at fixed distance
– etc.

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 Example

Assembly

Constraints
Subassemblies

Parts

Assembly Constraints Mating

Concentric
Coincidence

Parallel

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Animations and Motion
Submit the mechanism to
the embedded simulation
engine, so it can determine
how the mechanism will
perform and behave.
The results of the
simulation as an animation
showing the motion of your
mechanism or as numeric
output.

Motion Type

• Constant
Displacement
• Constant Velocity
• Constant
Acceleration
• Motion Expression

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 Mechanism Design
• A mechanism is an assembly that allows relative
motion between parts
• The mechanism consists of links connected by
joints
• Types of joints:
– rotational
– sliding
– spherical
– cylindrical
– screw

Mechanism
Joints

Joint Translational Rotational Total DOF

DOF DOF Constrained
Revolute 3 2 5
Translational 2 3 5
Cylindrical 2 2 4
Spherical 3 0 3
Universal 3 1 4
Screw .5 .5 1
Planar 1 2 3
Fixed 3 3 6
Point-curve 2 0 2
Contact
Curve-curve 2 0 2
Constraints:

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Mechanism Revolute Joint Translational Joint
Joints

Spherical Joint Cylindrical Joint

Curve/Curve
Mechanism Constraint
Constraints and Joints

Screw Joint

Universal Joint

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Mechanism
Constraints and Joints
Point/Curve Constraint

Planar Joint Fixed Joint

Mechanism Analysis
• The mechanism to be “driven”
by defining an input motion for
one of the links
• The other links move based on
the kinematics
• Reaction forces based on
gravity and applied forces
calculated

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Dynamic Analysis
• More advanced software can model and
analyse complete dynamics
• Applications:
– vehicle dynamics
– suspension analysis
– biomechanics
– robotics

A Simple Example:
Pendulum

Dynamic analysis
software
will generate the
motion
by solving the
equations
of motion

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Other Examples:
Dynamic analysis software will generate the
motion by solving the equations of motion

Radial Piston Air Motor Motorcycle

Other Examples:
Dynamic analysis software will generate the
motion by solving the equations of motion

Radial Piston Air Motor Piston rod

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Intelligent Assembly Modeling and Simulation

• The goal of IAMS is to avoid this expensive and

time-consuming process by facilitating
assemblability checking in a virtual, simulated
environment.
•In addition to part-
part interference
checking, the IAMS
tool will check for tool
accessibility, stability,
and ergonomics.

Intelligent Assembly Modeling and Simulation

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Intelligent Assembly Modeling and Simulation

• The simulation of the assembly process can

also be used for instructional purposes. It
allows for 3-dimensional interactive assembly
and service instructions.
• The operators can interactively change their
viewpoint and look at any assembly operation
in a random access manner.

Intelligent Assembly Modeling and Simulation

• Approach
– Comprehensive assembly models
– Composition of individual simulation tools
• Impact
– Reduce physical prototyping
– Reduce design cycle time
– Improve agility of work force

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Intelligent Assembly Modeling and Simulation

The approach is based on the following two

concepts:
• comprehensive assembly models: besides
relative positioning information of the
individual parts constituting the assembly,
our comprehensive models contain
information about the nature and the goal
of the contacts between parts (e.g.
rotational joints, fixed contact).

Intelligent Assembly Modeling and Simulation

comprehensive assembly models: (cont’d)

This allows us to model articulated assemblies.
In addition, assembly models of tools are
augmented with models describing the tools
behavior.
By combining these behavioral models with
feature models on both tools and parts, we
can automatically generate detailed
simulations from high-level assembly plans
entered by the user.

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Intelligent Assembly Modeling and Simulation

• Composition of individual simulation tools:

depending on the analysis the designer or
process engineer needs, he or she can
compose the corresponding simulation
components into a custom simulation that
provides the needed feedback in minimal time.
This composition is based on an agent-based
distributed implementation.

Novel Features

• Articulated tools and products

By capturing not just the relative position of
parts with respect to each other, but also the
kinematic structure of the assembly,
articulated tools and products can be
modeled.
• This is especially important for tools, because
many of them are articulated (e.g. pliers,
robotic tools, etc.)

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Novel Features

• Automatic plan completion (micro-planning)

Micro planning allows the users to do what they
are good at (high level planning: sequencing of
operations) without having to worry about
filling in all the tedious details (micro-planning).
– path planning
– tool motions

Novel Features

• Assembly process modeling

When analyzing an given assembly plan, it is
important to consider the complete
environment in which the plan will be
executed, including the workspace and the
tools.
In most currently existing assembly planning
systems, these components are not
considered at all.
– workspace
– tools

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Novel Features

• These are the different componenets and capabilities

of our current implementation. Each of these will be
further discussed after a highlevel overview.
• Create Assembly Models
– Import models of individual parts
– Group a set of parts into assembly
– Add information related to material, color and
features to each part
– Add information about joints between parts
• Add High Level Plans
• Perform Simulations
• Generate Assembly Instructions

Novel Features

Example Scenario
This example scenario illustrates how the iams
system will be used in a typical concurrent
design context. (the image should be
interpreted starting from the top left and
circling counter clock-wise to the right top).

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Novel Features: Example Scenario

Detailed design: a design created detailed

models of the parts of a complex electro-
mechanical system (e.g. copier) and uses the
IAMS assembly editor to create an
assembly model that includes a kinematic
model of the assembly.

Novel Features: Example Scenario

• The designer can then use the assembly

toolkit to verify whether there are any
part-part interferences for the assembly
sequence that he had in mind when designing
the assembly.
• This sequence does not have to be complete
in order to perform the analysis. One can
analyze only the motions of the critical
parts that may cause problems.

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Novel Features: Example Scenario

• In collaboration with a process engineer, a

more detailed assembly plan can then be
generated using the toolkit.
• The level of detail can be increased
gradually: start with detailed part motions,
then include tools, finally include the
workspace layout.
• These analyses will provide feedback to the
design engineers on how to improve the
assembly (without having to build physical
mock-ups).

Novel Features: Example Scenario

• After several re-designs and corresponding

modifications of the assembly plan, the
product development team is satisfied with
the results.
• The design and process information can be
sent directly (electronically) to the shop
floor.
• The results of the simulations can there be
used as instructions for the assembly
operators.

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 Assembly Editor

• The assembly editor allows the user to generate an

augmented assembly representation that include
(besides initial part positions) a model of the
kinematic structure of the assembly.
• From the geometric data, the editor automatically
generates a contact graph indicating the contact
relationships between the individual parts of an
assembly.

Editing A Part

• The part editor allows one to modify

attributes of individual parts of the assembly:
material properties, color, reference frame
etc.
• A very important
attribute is the list
of assembly features.
• These features are
later used for the
automatic generation
of assembly
operations and tool
motions.

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 Editing A Joint Definition

• The joint editor allows the user to define the

kinematic relationship between different parts in
the assembly.
• For instance, one can
define a "Rotational"
joint, by selecting
the cylindrical
surfaces on the two
parts that are in
contact with each
other.

Plan Editor

• In the plan editor, the

user can specify a high
level assembly plan by
selecting generic
assembly operations
(screw, position, solder,
etc.) and providing the
corresponding
attributes.
• In the background,
these high-level
specifications are
translated into low-level
simulation commands by
the micro planner.

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Smart Tools

• Tools are modeled as

assemblies with
additional
attributes.
• In addition to the
geometric and
kinematic models
contained in the
assembly model, the
tools contain a
behavior model.

Random Access Playbacks

• As a by-product of the
analyses performed with
the assembly toolkit, a
complete detailed
graphical simulation of
the assembly process is
generated.
• This graphical simulation
can be used for
instructing the assembly
operators.

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Solid Modeling
Questions :
1.What is the main advantages of modelig an
object using manufacturing features in a
feature based modeling system?
2. Describe feature-based modelling and contstraint-
based modelling.
3. What is variational geometry ? Explain in plane
English.
4. What is defference between geometric
representations and topological representations?

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