Graphics Display Area

When FloMCAD Bridge is launched from another FloVENT application, the display area is
empty. The geometry for import/export must be loaded using the FloMCAD Bridge External
Menu.

When FloMCAD Bridge is started automatically as part of a Project Manager command to

import MCAD geometry, the display contains the geometry on start-up.

After either importing MCAD files or geometry from the current FloVENT project, the display
area will show the objects to be converted.

MCAD Model
Geometry imported from MCAD files is initially displayed in the graphics display area as an
ACIS model. Any MCAD files not in *.sat file format will be converted into ACIS models
before appearing in the display area.

Figure 1-2. MCAD Model

FloVENT Geometry
FloVENT project geometry loaded into FloMCAD Bridge using External > Import Project
Geometry, or from the Project Manager Project > Export Assembly, appears in the window
ready to export to the file system using the FloMCAD Bridge External Menu.
 Figure 1-3. Geometry

Color Conventions
To help distinguish the geometry on display, FloMCAD Bridge uses the following color
convention:

Light blue MCAD Bodies

Dark blue FloVENT primitives

Light green bounding box around FloVENT objects and assemblies

Dark green FloVENT SmartParts

Magenta non-planar surfaces

Yellow non-manifold edges (face edges that could not be joined together,
that is, gaps in the surface)

Setting Display Options

The display of geometry can be configured for easy type recognition.

The geometry (for both MCAD Bodies or FloVENT objects) can be displayed in the same
color representation as the originating MCAD package, for example, as seen in
Pro/ENGINEER. Alternatively, you can choose a FloMCAD Bridge solid or wireframe
representation. The geometry can even be made invisible to unclutter the display.

Primitive assemblies can be displayed either showing their individual component parts or as
just a bounding box.Also, the orientation of the geometry can be indicated by the object
axes in the right-hand corner of the graphics display and non-planar faces can be
highlighted.

To configure the display, use the MCAD Picture Dialog Box.

 MCAD Picture Dialog Box
To access: MC Options > Picture or click the Modify Picture icon

Use this dialog box to set up the display representation to allow easy recognition of the
different types of MCAD objects.

Representation of MCAD Bodies

Set Display Bodies As to the representation required for MCAD Bodies that have not yet
been converted to FloVENT primitives. There are four options:

MCAD Color (as set in the originating MCAD package)

Solid,

Wireframe or

None (invisible)

Representation of FloVENT Primitives

Set Display Primitives As to the representation required for Primitives that have been
converted from MCAD Bodies. There are four options:

MCAD Color (as set in the originating MCAD package)

Solid,

Wireframe or

None (invisible).

Representation of Primitive Groups

Set Display Primitive Groups As to display the FloVENT primitives within an assembly as
either a green bounding box or individual primitives.

Highlight Non-Planar Faces

Activate Highlight Non-Planar faces to color non-planar faces mauve.

Display Axis
The axis in the right-hand bottom corner of the GUI is on by default. To remove the axis,
de-activate Display Axis.

MCAD Versus FloVENT Geometry

The MCAD application window distinguishes between the MCAD geometry and the geometry
already converted to FloVENT primitives.

Using the MCAD Picture dialog box, you can choose the type representation from the popup
lists.
Figure 1-4 shows a partially converted ACIS design. The top half is still an ACIS Body, but
the bottom half has been converted into FloVENT primitives.

The ACIS body is represented solid, but the primitive group is modeled in wireframe as
individual items.

Figure 1-4. Partially Converted Design

An example of a highlighted non-planar face of an ACIS body is shown in Figure 1-5.

Figure 1-5. Highlighted Non-Planar Face

Geometry Rendering Shortcut Keys

You can use shortcut keys to quickly change the geometry appearance as follows:

S to set displayed MCAD or FloVENT objects solid

W to cycle displayed objects through the settings listed in Table 1-2.

Table 1-2. Shortcut Key W Cycle

 V cycles through the settings listed in Table 1-3

Table 1-3. Shortcut Key V Cycle

MCAD Body FloVENT Object

Solid Void
Void Solid
Solid Solid

The ability to see either MCAD Bodies or FloVENT objects (or both) as wireframe, enables
the user to gauge the complexity of the MCAD geometry and also determine the amount of
MCAD geometry remaining to be simplified and dissected.

Geometry Rendering Shortcut Keys

You can use shortcut keys to quickly change the geometry appearance as follows:

S to set displayed MCAD or FloVENT objects solid

W to cycle displayed objects through the settings listed in Table 1-2.

Table 1-2. Shortcut Key W Cycle

MCAD Body FloVENT Object

Wireframe Solid
Wireframe Wireframe
Solid Wireframe

V cycles through the settings listed in Table 1-3

Table 1-3. Shortcut Key V Cycle

MCAD Body FloVENT Object

Solid Void
Void Solid
Solid Solid

The ability to see either MCAD Bodies or FloVENT objects (or both) as wireframe, enables
the user to gauge the complexity of the MCAD geometry and also determine the amount of
MCAD geometry remaining to be simplified and dissected.

Mouse Viewing and Selection Modes

The FloMCAD Bridge mouse mode works in the same way as that of the drawing board.
There are two options two different operating modes for picking geometry and manipulating
 the view. To swap between the two modes, toggle the mouse mode icon in the left tool bar
so it displays:

An arrow icon, for picking objects of the type selected for Current Selection
Mode.

A hand icon, for changing the view by dragging the mouse across the picture.
Alternatively, for more control use the view control dialog boxes, described in
the following sections.

Note that geometry cannot be selected when the mouse is in view manipulation mode.

Current Selection Mode

The Current Selection Mode button, near the bottom of the window, indicates the type of
geometry that can be selected in the display area when the mouse is in pick mode.

The mode can be changed using this button or the Selection Mode menu, which is displayed
by right-clicking a free area in the display area.

Both the Current Selection Mode button and the Selection Mode menu list the same
geometry options, namely, MCAD Part. MCAD Body, Feature (a hole or hump), Face (planar
face), Annotation, Edge and Vertex.

Selecting an Object Using a Dialog Box

If you want to choose an object for update using a selection dialog box, instead of clicking
on it, select Edit > Modify to launch the MCAD Assembly Dialog Box.

Clicking on an item in the dialog box list simultaneously selects it in the display area.
Clicking again on the item in the list de-selects it. Note however, this selection function
changes when quickly double-clicking. Double-clicking in the MCAD Assembly dialog box
launches the MCAD Part Dialog Box, so you can interrogate individual parts.

MCAD Part Popup Menu

If you have selected an MCAD Part, then right-clicking displays the MCAD Part popup menu.

Decompose launches the Decompose Dialog Box, to convert the MCAD Part into
FloVENT objects.

Global Simplify drops down a submenu to select the features to be removed

from the object according to the tolerances defined in the Global Simplification
Limits Dialog Box.
 You can select features individually from the menu or launch the Global Simplify
Dialog Box to simplify them collectively.

Dissect launches the Dissect Body Dialog Box to dissect the MCAD Part and
convert to FloVENT geometry according to defined tolerances.

Voxelize launches the Voxelize Dialog Box to convert an MCAD Part into
cuboids. This is a highly robust alternative method to Dissect Body but only
creates cuboids (not cuboids and prisms) to represent the MCAD Part.

Single Object drops down a submenu to select the FloVENT geometry type to
replace the MCAD Part.

You can select features individually from the menu or to launch the Single Object
Dialog Box.

The converted geometry, with the exception of prisms, will be collapsed if a side
of the replacement object is smaller than the collapse tolerance set in either the
Single Object Dialog Box or the Single Object Settings Dialog Box.

Heal Heals the selected MCAD Part by joining separate ACIS entities to create a
solid object. See Tools > Heal.
 Delete deletes the part.

Details launches the MCAD Part Dialog Box to identify the selected part and
indicate whether it has been fully converted to FloVENT objects.

MCAD Body Popup Menu

If you have selected an MCAD Body, right-clicking displays the MCAD Body popup menu.

The MCAD Body menu contains the MCAD Part menu entries plus three additional
commands:

Unite Bodies unites all selected bodies into one body

Intersect Bodies deletes all but the intersection of the bodies

Subtract Bodies subtracts all bodies from the first selected body

Feature(s) Popup Menu

If you have selected a feature, right-clicking drops down the Feature(s) popup menu.

Add Box removes the feature replacing it with a solid bounding box.

Subtract Box removes the feature replacing it with a bounding box.

Remove removes the feature.

Single Object displays a drop-down menu from which you can choose a FloVENT
object with which to replace the MCAD feature.
 Single Object launches the Single Object Dialog Box to define the object
collapse limits.

The other menu entries are the object selection types.

Face(s) Popup Menu

If you have selected a face, right-clicking drops down the Face(s) popup menu

Add Box removes the feature replacing it with a solid bounding box.

Subtract Box removes the feature replacing it with a bounding box.

Remove removes the feature.

Flatten flattens planar faces not aligned with an axis having slopes less than the
small draft angle.

Level levels faces with near-level tolerances.

Mark marks the selected non-planar faces so that they are ignored by the
simplifying operations of the Global Simplify Dialog Box.

Unmark reverses the Mark.

Rotate Align Part rotates the part, which contains the selected face, to align
with the nearest coordinate axis.
 Rotate Align Assembly rotates the assembly, which contains the selected face,
to align with the nearest coordinate axis.

Single Object displays a drop-down menu from which you can choose a FloVENT
object with which to replace the bounding box of the selected face(s).

FloMCAD Bridge External Menu

The FloMCAD Bridge External menu provides the interface between FloVENT
and MCAD packages. You can either load MCAD Assemblies into FloVENT or
export FloVENT geometry as MCAD files.
When an MCAD file is loaded into the application, it is translated into an ACIS
assembly. The FloMCAD Bridge Monitor Dialog Box automatically appears to
show the load progress.
To interrupt the loading of MCAD files, use the Interrupt MCAD button in the
MCAD Monitor dialog box. No data will be loaded in this case.
Any MCAD Bodies unrecognized during transfer are ignored and a warning
message is issued.
Table 1-10. FloMCAD Bridge External Menu Options

Menu Option Description

Default Reverts to the default window layout.

Layout

Import IGES Launches the Import IGES Data file selection dialog box to select and
load an IGES *.igs file.

Import STL Launches the Import STL Data file selection dialog box to select and load
an ASCII STL *.stl file. As *.stl files do not support unit definition, after
confirming the file selection, you are prompted to choose the units
FloVENT is to use to model the MCAD Assembly.

Import SAT Launches the Import ACIS Data file selection dialog box to select and
load an ACIS *.sat file. Note that for older *.sat files with no unit
definition, you are prompted to choose the units FloVENT is to use to
model the MCAD Assembly.

Import STEP Launches the Import STEP Data file selection dialog box to select and
load the STEP *.stp file.

Import Pro/E Launches the Import PROE Data file selection dialog box to select and
load a Pro/ENGINEER *.prt or *.asm files up to Pro/E release 20.0.

Import Catia Launches the Import CATIA Data file selection dialog box to select and
V4 load a CATIA V4 *.model or *.exp file.

Import DXF Launches the Import DXF Data file selection dialog box to select and load
an AutoCAD *.dxf file. DXF files from AutoCAD 2000 v.u15.0.02 to
AutoCAD 2007 v.u.21.1.01 are supported. See Usage Notes.

Import Launches the Import SolidWorks Data file selection dialog box to select
SolidWorks and load the SolidWorks *.sldprt or *.sldasm part or assembly files.

Export SAT Exports an MCAD Assembly as an ACIS *.sat file. It displays a sub-menu
 for ACIS version selection. After selecting the version required, the
Export ACIS Data file selection dialog box is launched so you can choose
how and where you want the file saved. Note that this *.sat file does not
include the assembly hierarchy, object names or units.

Export IGES Launches the Export IGES Dialog Box to save an MCAD Assembly as a
*.igs format file. See Usage Notes.

Export STEP Exports an MCAD Assembly as a STEP *.stp file. It displays a sub-menu
for ACIS version selection. After selecting the version required, the
Export STEP Data file selection dialog box is launched so that you can
choose how and where you want the file saved. See Usage Notes.

Export Catia Launches the Export CATIA Data file selection dialog box to save an
V4 MCAD Assembly as a CATIA V4 *.model format file. See Usage Notes.

Export STL Launches the Export STL Data file selection dialog box to save an MCAD
Assembly as a STL *.stl file.

Import Reads in the geometry from the current FloVENT project and converts it
Project to an ACIS assembly.
Geometry

Usage Notes
Importing DXF
DXF files created prior to AutoCAD 2000 do not support a unit definition. After
confirming the file selection, you will prompted to choose the units FloVENT is
to use to model the MCAD Assembly.
AutoCAD 2000 or later DXF files have the unit value embedded and this will be
read and used by FloMCAD Bridge.
Exporting IGES
The *.igs file does not include the assembly hierarchy, object or names.
Exporting STEP
The *.stp file does not include the assembly hierarchy, object names or units.
Exporting CATIA V4
The *.model file does not include the assembly hierarchy, object names or
units.
Related Topics

Importing MCAD Files Exporting FloVENT Geometry

FloMCAD Bridge Window Menu

The FloMCAD Bridge Window menu is used to open the supporting application
windows and packages and display FloVENT error/warning messages, or refresh
the current window.
Table 1-11. FloMCAD Bridge Window Menu Options
Menu Option Description

Application Launches the selected application window. If the application window is

Window open, but hidden behind other windows, it will be popped to the front.

Message Launches the Message Window dialog box to report error, warning and
Window information messages.

Note that the ACIS error messages can be output to the Message Window
dialog box by activating the Report ACIS Model Errors to Message Window
option in the MCAD Preferences Dialog Box.

Refresh Redraws the window.

FloMCAD Bridge Help Menu

The FloMCAD Bridge Help menu accesses the general product information and
the on-line help. Use the Project Manager Help Menu to link to FloVENT web
support.
Table 1-12. FloMCAD Bridge Help Menu Options

Menu
Description Shortcut
Option

On Opens the help for FloMCAD Bridge. There are links to F1

Window descriptions of dialog boxes and other application windows.

Version Displays the splash screen indicating the build number. To

remove the splash screen, just click on it.

About Displays information about the current software version you are
running and copyright issues.

FloMCAD Bridge Toolbar

The FloMCAD Bridge toolbar provides shortcut icons for common menu options. For
descriptions of these options, see "FloMCAD Bridge Tools Menu" and "FloMCAD Bridge
Options Menu".

Table 1-13. FloMCAD Bridge Toolbar Icons

Icon Name Menu Equivalent

Modify Picture Options > Picture

Decompose Tools > Decompose

Voxelize Tools > Voxelize

 Global Simplify Tools > Global Simplify

Dissect Body Tools > Dissect Body

Single Object Tools > Single Object

Local Simplify Tools > Local Simplify

Split Body Tools > Split Body

Heal Tools > Heal

Transfer Assembly Tools > Transfer Assembly

Mouse Selection No menu equivalent. A shortcut is the F9 key

Mode

Toggle Background No menu equivalent. Toggles the background color

Color through green, black, white and grey.

The remaining icons on the left side of the window launch the other FloVENT applications.

FloMCAD Mouse Pointer

The mouse pointer changes, depending on what you are pointing to or the task you are
performing, see Table 1-14.

Table 1-14. FloMCAD Mouse Pointer

Pointer Location Operation

Corner of an object Resizing an object in two directions.

Edge of an object Resizing an object in one direction.

Edge of an object, Moving an object to a new location.

between handles

Edge of an object Creating and moving a new copy of the object.

Graphics Display Zooming the view. Note that when using the mouse
Area scroll wheel to zoom, the pointer remains as an arrow.

Graphics Display Rotating the view.

Area

Introducing the Processes

 Overview of the Import Process
On import, the external MCAD Assemblies are translated by FloMCAD Bridge initially into
ACIS models. Before they can be used in FloVENT, they must be reformatted to represent
FloVENT objects. The three main stages of the MCAD import process are illustrated
schematically in Figure 2-1.

Figure 2-1. Overview of the Import Process

The basic procedure for importing MCAD assemblies is:

1. Start the import of the MCAD file using one of two methods: using the menu
options for FloMCAD Bridge External or the Project Manager Project > Import
Assembly.

2. Simplify the MCAD geometry and then decompose it into FloVENT geometry.
The simplest method is to let the program automatically simplify and convert
the geometry using Tools > Decompose.

Alternatively, you can selectively simplify the model. For example, by removing
holes and humps, levelling near-level features, straightening angled faces,
planing non-planar faces, removing parallel features, flattening draft angles as
well as splitting bodies before replacing the MCAD objects with selected FloVENT
geometry.

3. Transfer the converted assembly to the FloVENT project using Tools > Transfer
Assembly.

FloMCAD Bridge reports the progress of any operations in the FloMCAD Bridge Monitor
Dialog Box, which appears automatically.

For complicated models, it is more efficient to simplify the model by removing the geometry
not required for thermal calculation before exporting it from the MCAD package. See
Importing MCAD Files for a detailed description of using FloMCAD Bridge.

Overview of the Export Process

FloVENT project geometry is loaded into the FloMCAD Bridge window from the Project
Manager and then exported from FloMCAD Bridge in a selected file format. The basic
procedure is shown in Figure 2-2.

Figure 2-2. Overview of the Export Process

File Formats Supported

FloMCAD Bridge supports the file formats listed in Table 3-1 (Readers) and Table 3-2
(Writers).

Table 3-1. Reader File Formats

File Format File Extensions Versions Supported

CATIA V4 *.model 4.1.9 to 4.2.4

*.exp
*.session

CATIA V5 *.CATPart R2 to R23 (V5 to V6 R2013)

*.CATProduct
*.CGR

IGES *.igs Up to 5.3

*.iges

ACIS *.sat ACIS R1 to R23SP2

*.sab

Pro/E *.prt Pro/E 16 to Creo 2.0

*.prt.*
*.asm
*.asm.*

SolidWorks *.sldprt 98 to 2013

*.sldasm

STEP *.stp AP203, AP214 (Geometry only)

 *.step

Table 3-2. Writer File Formats

File Format File Extensions Versions Supported

CATIA V4 *.model 4.1.9 to 4.2.4

CATIA V5 *.CATPart R6 to R23 (V5 to V6 R2013)

*.CATProduct

IGES *.igs 5.3

*.iges

ACIS *.sat R18 to R23

*.sab

STEP *.stp AP203, AP214 (Geometry only)

*.step

Importing MCAD Designs into FloVENT

General Advice
To import MCAD models into a FloVENT assembly, perform the following basic procedure:

1. Within the MCAD package, simplify the assembly by removing as much as

possible of the geometry not required for the thermal calculation and create the
MCAD model file. For advice on creating the MCAD files, see Creating MCAD
Files Using External Software.

2. Import the MCAD file into FloMCAD Bridge using the FloMCAD Bridge External
Menu.

Note that a model may fail to heal if the accuracy of the imported file is too
coarse. In such cases, surfaces that are meant to join up have a gap between
them and so a solid manifold object cannot be derived. This may happen with
*.igs or *.stl data that contains just 1D and 2D geometric entities. It is because
of this that it is critical that the geometry is regenerated to the required accuracy
of 1e-6 in the MCAD tool prior to creating the *.igs or *.stl file.

Also, if geometry is less than 1e-6 times the size of the length unit set in the
Global Units dialog box, it will not be transferred successfully between FloMCAD
Bridge and the Project Manager. This might happen for example when
transferring micron scale geometry when the length units are set to meters. The
work around is to set the LENGTH unit in the Global Units dialog box to a small
unit, say mm.

3. If the model has failed to heal on import, either:

 Select Options > Preferences to launch the MCAD Preferences Dialog Box
and set a Healing Level then re-import the file, or

Select Tools > Heal for the translated geometry to create a solid model.

4. Realize the ACIS model into FloVENT objects using one or more of the following
commands from the Tools menu:

Global Simplify to simplify the entire MCAD Assembly prior to decomposition

into FloVENT objects. See "Global Simplify Dialog Box".

Local Simplify to simplify individual faces or features prior to decomposition

into FloVENT objects, see "Local Simplify Dialog Box".

Decompose to automatically simplify and dissect the selected MCAD Body or

parts into FloVENT objects, see "Decompose Dialog Box".

Single Object to replace with a single cuboid, prism, resistance, fan or

enclosure, see "Single Object Dialog Box".

Dissect Body to dissect into objects, see "Dissect Body Dialog Box".

Voxelize to convert an MCAD Part or Body into cuboids, see "Voxelize Dialog
Box".

Split Body to split body into more bodies, each of which can then be broken
down into FloVENT objects using Single Object or Dissect Body, see "Split
Body Dialog Box".

5. Add the converted assembly to the FloVENT project using Tools > Transfer
Assembly.

Retaining Color Attributes

By default, any MCAD geometry color data imported into FloMCAD Bridge will be lost when
you transfer the model to the Project Manager. If you need to retain the part colors, then
set the environment variable FLOMCAD_SET_COLOR_ON_TRANSFER to any value before
launching FloMCAD Bridge.

Note that the default emissivity for the surface attribute created to represent the MCAD part
color will have a value of 1.0. If this is not representative of the true emissivity, then the
default value should be edited using the Surface Attribute dialog box launched for the part.

Special Advice for DXF

DXF data supports 0D (vertices), 1D (edges) or 2D (faces). For FloMCAD Bridge to
successfully transfer DXF models to the Project Manager, it will need to be convert all the
data to at least 2D format.

There are two approaches to converting 1D and 2D DXF data to FloVENT objects:

Convert 1D edges to 2D faces, then convert the 2D faces directly into collapsed
cuboids.
 Convert 1D edges to 2D faces, then extrude the 2D faces into 3D bodies which
are processed in the normal way.

There follows a summary of the operations required.

Importing DXF files

After importing the DXF file (External > Import DXF), perform the following procedure:

1. Select Edit > Modify and in the MCAD Assembly dialog box, delete or hide
unwanted layers (that is, non-geometry layers). See "DXF Layer Suppression".

2. Render geometry in wire frame. By default, MCAD geometry is rendered as

solid. Any DXF 2D faces will be visible, but 1D edges will not. To display edges
in wireframe, press the w key.

Note that any 1D or 2D faces will be colored yellow as they form part of an
unhealed body. Subsequent extrusion or direct conversion to collapsed cuboids
will resolve this as follows.

3. Select the edges and Tools > Extrude and use the Extrude Dialog Box to convert
them to faces, if required, then:

Choose Tools > Voxelize and use the Voxelize Dialog Box to convert the 2D
face into collapsed cuboids. Voxelization will create a stepped representation
of curved faces.

Choose Tools > Dissect Body and use the Dissect Body Dialog Box, to
convert into collapsed cuboids or angled thin cuboids. Dissection will totally
square off a curved face.

Choose Tools > Extrude and use the Extrude Dialog Box to convert 2D faces
into 3D bodies and treat in the usual way. The main advantage of taking this
approach for DXF data is that prisms and cylinders will be created when
dissecting the body and an exact curvature representation will be obtained.

4. Add the converted assembly to the FloVENT project using Tools > Transfer
Assembly.

General Advice
To import MCAD models into a FloVENT assembly, perform the following basic procedure:

1. Within the MCAD package, simplify the assembly by removing as much as

possible of the geometry not required for the thermal calculation and create the
MCAD model file. For advice on creating the MCAD files, see Creating MCAD
Files Using External Software.

2. Import the MCAD file into FloMCAD Bridge using the FloMCAD Bridge External
Menu.

Note that a model may fail to heal if the accuracy of the imported file is too
coarse. In such cases, surfaces that are meant to join up have a gap between
them and so a solid manifold object cannot be derived. This may happen with
 *.igs or *.stl data that contains just 1D and 2D geometric entities. It is because
of this that it is critical that the geometry is regenerated to the required accuracy
of 1e-6 in the MCAD tool prior to creating the *.igs or *.stl file.

Also, if geometry is less than 1e-6 times the size of the length unit set in the
Global Units dialog box, it will not be transferred successfully between FloMCAD
Bridge and the Project Manager. This might happen for example when
transferring micron scale geometry when the length units are set to meters. The
work around is to set the LENGTH unit in the Global Units dialog box to a small
unit, say mm.

3. If the model has failed to heal on import, either:

Select Options > Preferences to launch the MCAD Preferences Dialog Box
and set a Healing Level then re-import the file, or

Select Tools > Heal for the translated geometry to create a solid model.

4. Realize the ACIS model into FloVENT objects using one or more of the following
commands from the Tools menu:

Global Simplify to simplify the entire MCAD Assembly prior to decomposition

into FloVENT objects. See "Global Simplify Dialog Box".

Local Simplify to simplify individual faces or features prior to decomposition

into FloVENT objects, see "Local Simplify Dialog Box".

Decompose to automatically simplify and dissect the selected MCAD Body or

parts into FloVENT objects, see "Decompose Dialog Box".

Single Object to replace with a single cuboid, prism, resistance, fan or

enclosure, see "Single Object Dialog Box".

Dissect Body to dissect into objects, see "Dissect Body Dialog Box".

Voxelize to convert an MCAD Part or Body into cuboids, see "Voxelize Dialog
Box".

Split Body to split body into more bodies, each of which can then be broken
down into FloVENT objects using Single Object or Dissect Body, see "Split
Body Dialog Box".

5. Add the converted assembly to the FloVENT project using Tools > Transfer
Assembly.

Retaining Color Attributes

By default, any MCAD geometry color data imported into FloMCAD Bridge will be lost when
you transfer the model to the Project Manager. If you need to retain the part colors, then
set the environment variable FLOMCAD_SET_COLOR_ON_TRANSFER to any value before
launching FloMCAD Bridge.
Note that the default emissivity for the surface attribute created to represent the MCAD part
color will have a value of 1.0. If this is not representative of the true emissivity, then the
default value should be edited using the Surface Attribute dialog box launched for the part.

Special Advice for DXF

DXF data supports 0D (vertices), 1D (edges) or 2D (faces). For FloMCAD Bridge to
successfully transfer DXF models to the Project Manager, it will need to be convert all the
data to at least 2D format.

There are two approaches to converting 1D and 2D DXF data to FloVENT objects:

Convert 1D edges to 2D faces, then convert the 2D faces directly into collapsed
cuboids.

Convert 1D edges to 2D faces, then extrude the 2D faces into 3D bodies which
are processed in the normal way.

There follows a summary of the operations required.

Importing DXF files

After importing the DXF file (External > Import DXF), perform the following procedure:

1. Select Edit > Modify and in the MCAD Assembly dialog box, delete or hide
unwanted layers (that is, non-geometry layers). See "DXF Layer Suppression".

2. Render geometry in wire frame. By default, MCAD geometry is rendered as

solid. Any DXF 2D faces will be visible, but 1D edges will not. To display edges
in wireframe, press the w key.

Note that any 1D or 2D faces will be colored yellow as they form part of an
unhealed body. Subsequent extrusion or direct conversion to collapsed cuboids
will resolve this as follows.

3. Select the edges and Tools > Extrude and use the Extrude Dialog Box to convert
them to faces, if required, then:

Choose Tools > Voxelize and use the Voxelize Dialog Box to convert the 2D
face into collapsed cuboids. Voxelization will create a stepped representation
of curved faces.

Choose Tools > Dissect Body and use the Dissect Body Dialog Box, to
convert into collapsed cuboids or angled thin cuboids. Dissection will totally
square off a curved face.

Choose Tools > Extrude and use the Extrude Dialog Box to convert 2D faces
into 3D bodies and treat in the usual way. The main advantage of taking this
approach for DXF data is that prisms and cylinders will be created when
dissecting the body and an exact curvature representation will be obtained.

4. Add the converted assembly to the FloVENT project using Tools > Transfer
Assembly.
 Note
When voxelizing or dissecting the 2D faces into collapsed cuboids, ensure the
resulting thickness in the collapse direction is set using 2D Face Collapse
Thickness and Collapse Below respectively (important for the preservation of
through and in-plane thermal resistance).

Connect IGES Reader

FloMCAD Bridge has two IGES readers: the robust ACIS Connect reader and an in-house
IGES reader. If FloMCAD Bridge fails to load the IGES file using the Connect reader, it
automatically tries again using the in-house IGES reader.

Increasing Performance
If you are importing complicated geometry with lots of non-planar faces, it may be
necessary to restrict the number of facets.

To restrict the number of facets, set Graphics Facetting Level to LOW in the MCAD
Preferences dialog box. The higher the facet level, the lower the performance.

FloMCAD Bridge Monitor Dialog Box

FloMCAD Bridge reports the progress of its importing and conversion operations in the
MCAD Monitor dialog box which automatically appears at the start of the operation. If
dismissed, the MCAD Monitor dialog box may be brought back by Shift+R. Figure 3-1 is an
example of its output while importing an MCAD Assembly.

Figure 3-1. Importing an MCAD Assembly

Each operation is named and the MCAD Body to which it applies is indicated inside the
angled brackets. Additionally, there are the following message conventions:

Dots operation in progress.

C, P, or Y cuboid, prism or cylinder creation respectively.

 F ACIS operation failed.

S small MCAD Body discarded from model.

U unclassified MCAD Body left after an interrupt now added to part as a new
Body.

For machines supporting multiple threads, the dialog box includes a progress bar which fills
proportionately as the operation approaches completion.

Note that you can cancel the file import by pressing the Interrupt button. Alternatively, you
can skip just the current operation by pressing Skip.

ACIS Error Messages

To investigate problems in a particular model, you can switch on the ACIS error messages
by choosing Options > Preferences and using the MCAD Preferences dialog box to direct the
output to the Message Window dialog box.

Additionally, log files can be created while reading or writing STEP, CATIA or IGES files.
When reading IGES files, you need to be using the Connect IGES reader (see "Connect IGES
Reader").

To create the read/write log, set the FLOMCADKEEPLOGFILES environment variable to TRUE
and restart FloVENT before attempting to import the MCAD file again. FloMCAD Bridge will
create the file in your systems TEMP directory, with the appropriate file type and date
stem-name, for example:

STEP_READ-05-04-16-30-39.log

STEP_WRITE-05-04-16-35-39.log

CAT_READ-05-04-16-35-31.log

CAT_WRITE-05-04-16-37-31.log

IGES_READ-05-04-16-35-35.log

IGES_WRITE-05-04-16-37-35.log

You can then view the log using a normal text editor.

Note that, on Windows systems, the Temp directory is normally found under:

Documents and Settings\Your username\Local Settings\Temp

Remember to reset FLOMCADKEEPLOGFILES afterwards, as a fresh log file will be created

each time you import a STEP, CATIA or IGES file, resulting in many unwanted temporary
files.

Identifying MCAD Assemblies and Parts

Realizing into FloVENT Geometry
Before the model imported into FloMCAD Bridge can be transferred to the FloVENT project,
it must be converted (realized) to FloVENT geometry. To do this, the assembly is split into a
hierarchical structure defined as follows:

MCAD Assembly the ACIS model.

MCAD Part an ACIS single solid part of the assembly.

MCAD Body a subset of the MCAD Part.

FloVENT Objects FloVENT primitives or SmartParts.

The MCAD Assembly is made up at least one MCAD Part. Each MCAD Part is made up of at
least one MCAD Body. Each MCAD Body is made up of zero (not yet realized) or more
FloVENT objects (realized).

Figure 3-2 shows the relationship between the MCAD Parts, bodies and the realized FloVENT
objects for an MCAD Assembly made up of two basic shapes.

Figure 3-2. MCAD Assembly

To check the realized states of the MCAD Assembly and its constituent elements, launch the
MCAD Assembly dialog box by selecting Edit > Modify.

MCAD Assembly Dialog Box

To access: MC Edit > Modify or click the Modify Items icon

Use this dialog box to change the name of the MCAD Assembly and check whether it has
been fully converted to FloVENT objects.

The dialog box is mainly for information only, but it can also act as a quick selection tool.
The individual parts that compose the assembly can be viewed by expanding the tree
displayed in the dialog box. Selecting an item in the tree also selects it in the display area.
Each MCAD Part comprises one or more MCAD Bodies which are shown as child nodes of the
MCAD Part icon. MCAD Bodies can be selected in the same way as MCAD Parts.

MCAD Assembly Dialog Box Settings

Name
Identifies the MCAD Assembly that is loaded in FloVENT.

Realized?
Indicates the conversion status of the assembly:

<Yes> indicates that all the components of the assembly have been fully
converted to FloVENT format.

<No> indicates that the assembly still comprises ACIS components.

Units
Indicates the units of the model.

MCAD Parts
Comprises a list of assembly parts. A FloMCAD icon before the part name indicates an ACIS
part that is not fully realized. Realized parts will be preceded by FloVENT geometry type
icons. For a fully realized assembly, there will be an assembly icon at the root node. See
Figure 3-3.

Figure 3-3. MCAD Parts Before and After Conversion

Selecting an item in the dialog box list causes it to become highlighted and selected in the
graphics display area.

Double clicking an item in the MCAD Parts list launches the MCAD Part dialog box, which
provides realization and volume information for the selected part.

Realized Part Names

The Realized parts are named according to the following conventions:

MCAD Parts
After importing the MCAD geometry into FloMCAD Bridge, if there is only one MCAD Part,
this will be named mcadpartname where mcadpartname is the name of the original MCAD
Part. If there are multiple parts, then each part will be named mcadpartname_# where # is
an import sequence number.

FloVENT Geometry
After realization, the FloVENT assemblies are named mcadpartname where mcadpartname
is the name of the original MCAD Part. If there are multiple assemblies created, then each
assembly will be names mcadpartname_# where # is a sequence number. When
transferred to the Project Manager, if an assembly of the same name exists, the names will
be appended by: #.

Objects contained in the realized assemblies will be named parentassemblyname_#.

Popup Menus
After selecting a part or body in the dialog box data tree, you can edit the object using
popup menus. Point at the part or body in the tree and right-click to display the respective
popup menu: MCAD Part or MCAD Body. The popup menus are the same as those for
selected MCAD Parts and Bodies in the display area. See Context Sensitive Popup Menus
for a full description of the menus.

DXF Layer Suppression

DXF data is often constructed from a number of layers (therefore sometimes called 2.5D
data). It is common that many of these layers do not represent geometry but other data
such as mark-up, annotation, drawing boarders, and so on.

Layers are represented as Parts in FloMCAD Bridge and can be selected, hidden or deleted.

To delete the non-geometry layers, select them in the tree and press the Delete key. Note
that the tree view supports click and Shift+click for range selection.

Global Simplify Dialog Box

To access: MC Tools > Global Simplify or click the Global Simplify icon

Use this dialog box to simplify the complete selected MCAD Body or part in preparation for
its conversion to FloVENT objects.

There are a number of different simplification techniques that can be applied. These
techniques are selected by check box and operate on features smaller than the tolerances
set in the Global Simplification Limits Dialog Box.

Global Simplify Dialog Box Settings

Remove Small Holes
Removes holes, that are smaller than the Small Hole Tolerance set in the Global
Simplification Limits dialog box, from the surface of the body.

Remove Small Humps

Removes humps, that are smaller than the Small Hump Tolerance set in the Global
Simplification Limits dialog box, from the surface of the body.

Remove Small Face Groups

Removes a face or pair of neighboring faces that are below the Small Faces Tolerance set in
the Global Simplification Limits dialog box.

Figure 3-4. Removal of Small Face Groups

Remove Non Planar Faces

Removes non-planar faces. This function first attempts to remove non-planar faces and
grow the remaining faces to remake the solid as shown in Figure 3-5.

Figure 3-5. Replacement of Non Planar Faces

If this method cannot be used, then a block is created from the bounding box and is either
united with or subtracted from the MCAD Body. The decision as to whether to unite or
subtract is based on the curvature of the surface. Figure 3-6 shows a non-planar face being
squared.

Figure 3-6. Replacement of Complex Non Planar Faces

Note
You can mark non-planar faces, using the Local Simplify Dialog Box, so that
 they will not be simplified when using Remove Non Planar Faces.

Flatten Small Drafts

Flattens planar faces not aligned with an axis having slopes less than the small draft angle.

This function first attempts to rotate the face and make it flat by growing and shrinking
the surrounding faces to remake the solid as shown in Figure 3-7.

Figure 3-7. Flattening Small Drafts

If the above method cannot be employed, then a draft face is flattened into a box half of the
height of its bounding box. The direction of the height is taken to be the average of the
surface normals for all vertices of the face, snapped to the nearest coordinate axis.
Figure 3-8 shows a small draft face being flattened.

Figure 3-8. Flattening of a Complex Small Draft

Level Near Level Faces

Levels faces that are within the near level tolerance.

Two faces are considered Near Level if they:

are within a small distance of each other in their normal directions,

overlap in another coordinate direction,

touch in the last coordinate direction.

The small distance is defined by the near level tolerance, which is a percentage of the
length of the diagonal of the bounding box of the MCAD Body. This percentage can be set by
the user.
The global simplification of the near level faces involves finding each of the pairs of near
level faces. The face with the smallest area is then moved up or down to the level of the
larger face, see Figure 3-9.

Figure 3-9. Levelling Near Level Faces

Limits
Displays the Global Simplification Limits Dialog Box to allow modification to the tolerance
limits.

Alternative Method
You can select the above simplification options from MCAD Part/MCAD Body > Global
Simplify, see Context Sensitive Popup Menus.

Failures
Sometimes, because of the complexity of the model, a global simplify fails. If this is the
case, then select Tools > Heal to create solid ACIS objects and/or manually simplify features
or faces using the Local Simplify dialog box before global simplifying again.

Local Simplify Dialog Box

To access: MC Tools > Local Simplify or click the Local Simplify icon

Use this dialog box to simplify individually selected faces or features.

The dialog box operates on features or faces selected using the mouse, so you must first
ensure you are in the correct selection mode. The object to be selected must match the
type chosen in the Current Selection Mode choice box located below the display area. See
Current Selection Mode.

Local Simplify Dialog Box Settings

Add Bound Box
Active when faces or features are selected. It adds a bounding box of either the selected
faces or each of the selected features to the owning MCAD Body. The shortcut key is +
 Figure 3-11. Addition of a Bounding Box

Subtract Bound Box

Active when faces or features are selected. It removes the bounding box of either the
selected faces or of each of the selected features from the owning MCAD Body. The shortcut
key is -

Figure 3-12. Subtraction of a Bounding Box

Remove
Active when faces or features are selected. It removes the selected face or feature. If a
non-planar face is selected and removed, the neighboring faces are grown to replace it.
This operation works most effectively with selected features. The shortcut is the Delete key.
 Figure 3-13.

Removal of Selected Feature

Flatten
Active when faces are selected. It flattens each of the selected faces. The shortcut key is F.

Figure 3-14. Flatted Selected Face

Level
Active when two or more faces are selected. It levels all selected faces to that of the first
selected. To create a manifold object, it may have to grow all the surrounding faces. To
select multiple faces, press Ctrl and click each face. The shortcut key is L.
 Figure 3-15. Levelled Selected Faces

Non-Planar Faces
Non-planar faces are highlighted in mauve if requested in the MCAD Picture Dialog Box. To
launch the MCAD Picture dialog box, choose Options > Picture.

The two buttons Mark and Un-Mark are active when faces are selected.

Mark marks the selected non-planar faces so they are ignored by the remove non-planar
faces global simplification process: the program does not attempt to remove them when
removing non-planar faces as described in the description of the "Global Simplify Dialog
Box". Marking non-planar faces changes the color of a highlighted non-planar face from a
deep to a light magenta as shown in Figure 3-16. The shortcut key is M.
 Figure 3-16. Un-Marked and Marked Non-Planar Face

Un Mark reverses the Mark command so that the selected face is included in the
simplification process. This action is best used to mark large holes that will have a dominant
effect on the air flow so that they are retained during simplification. The shortcut key is U.

Procedure
To simplify a feature of an MCAD Assembly:

1. Set the selection mode to the appropriate feature type

2. Select the feature or face

3. Activate the appropriate simplification method

Shortcut Keys for Simplification Method

Providing the feature or face is already selected, use the following shortcut keys (hotkeys)
to activate the simplification methods
 Table 3-5. Shortcut Keys for Simplification Method

+ Add bounding box

- Subtract bounding box

F Flatten face(s)

L Level faces

M Mark face(s)

U Un-mark face(s)

Delete Remove

Automatic Global Simplification

The same level of simplification can be applied to all sections of the selected MCAD
Part/Body by choosing Tools > Global Simplify and using the Global Simplify Dialog Box.
Global simplification is simply a batch run of a number of local simplification processes

Split Body Dialog Box

To access: MC Tools > Split Body or click the Split Body icon

Use this dialog box to specify the segmentation of the MCAD Body when you would like to
work on a small section of the body.

Indicate the location of the split, by either using the mouse pointer or setting the slice plane
direction and location.

Alternatively, you can use the Dissect Body Dialog Box to split the body according to defined
tolerances.

Split Body Dialog Box Settings

Select Face
Allows you to select a face of the body using the mouse. The cursor changes to cross-wires
as the mouse moves across the display area. Choose the face by clicking on it. The Planar
Orthogonal Slice settings indicate the slice location.

Select Vertex
Allows you to select a vertex of the body using the mouse. The cursor changes to cross-
wires as the mouse moves across the display area. Choose the vertex by clicking on it. The
Planar Orthogonal Slice settings indicate the slice location.

Planar Orthogonal Slice

Alternatively, define the location of the split by choosing the plane direction and typing in
the coordinates.
 Procedure
To split an MCAD Body:

1. Select the MCAD Body in the display area.

2. Choose Tools > Split Body to launch the Split Body dialog box.

3. Using the Split Body dialog box perform one of the following:

Press Select Face, then select the MCAD face

Press Select Vertex, then select the MCAD vertex and set the plane of the
cut

Type in the coordinate for a planar cut

4. Press Slice to mark (chalk-mark) where the split is to occur.

5. Press Split to split the MCAD Body into smaller bodies.

Figure 3-17 shows examples of splitting a body by slicing it through a vertex, face or
defined planar orthogonal slice.

Figure 3-17. Examples of Slicing

 Extrude Dialog Box
To access: MC Tools > Extrude

Use this dialog box to extend an MCAD Body either in a direction normal to a selected face,
or in a specified direction from a selected edge. Extruding a face changes the volume of the
geometry, see Figure 3-18.

Figure 3-18. Extruded Block

Extruding an edge creates a face.

Extrude Dialog Box Settings

Extrude Parameters
Sets the distance the selected face or edge is to move.

Extrude Direction
Only active when an edge is selected. It selects the axis direction, in which the edge will
move, from a drop-down menu list.

Procedure
To extrude MCAD geometry faces or edges:

1. First, ensure the mouse is in Pick mode and Current Selection Mode is set to
Face or Edge as appropriate.

2. Select the face or edge to be extruded.

3. Enter the distance the face or edge is to be moved into Extrude Distance.

4. If an edge is selected, also choose the direction of the extrude.

5. Click Extrude.

In Figure 3-19, the selected face is extruded to align with the top of the cabinet.
 Figure 3-19. Extruded Face

DXF Edge Extrusion

Edge extrusion is most common for representing walls or other building fabrics. Often DXF
data contains edge descriptions for both the inner and outer wall faces. Selection of only
those edges that represent the desired wall profile is required. This can be done by careful
selection of those edges, or deletion of the bodies containing the unwanted edges followed
by a rubber band select of the remaining desired edges. This latter method is often
preferable.

Figure 3-20. Edge Extrusion

Converting MCAD Geometry to FloVENT Geometry

 Methods
MCAD Parts and Bodies can be converted into FloVENT geometry using the following
methods:

Automatically simplifying and converting the selected MCAD Part or Body, see
"Decompose Dialog Box".

Replacing the selected MCAD Part or Body with a single object, see "Single
Object Dialog Box".

Dissecting the selected MCAD Part or Body according to defined tolerances, see
"Dissect Body Dialog Box".

Dissecting the selected MCAD Part or Body according to a defined grid, see
"Voxelize Dialog Box".

Decompose Dialog Box

To access: MC Tools > Decompose or click the Decompose icon

Use this dialog box to convert the selected MCAD Part or Body into FloVENT objects. If
nothing is selected, then the entire MCAD Assembly is converted (decomposed) into
FloVENT objects.

Decompose both simplifies AND dissects in a single operation. This dialog box decomposes
according to the simplification level and tolerance you set.

Decompose Dialog Box Settings

Complexity Level
Sets the tolerances for the decomposition. The position of the slider bar determines the
complexity of the conversion from the MCAD Assembly to FloVENT objects. Therefore, the
further the slider moves towards Complex, the greater the number of FloVENT objects
generated.

The program will automatically set up tolerances according to the slider bar setting, from 0
for simple basic conversion to 20 for complex modeling.

Collapse Below
Sets the thickness below which cuboids and sloping blocks are collapsed.

Prisms
Uses prism shapes to represent MCAD geometry. Prisms are best suited to represent
spherical and hemispherical geometries.

Cylinders
Converts cylindrical shapes into FloVENT cylinder SmartParts with a default number of
facets. Activate when cylindrical shapes are important.
 Note that you can change the facetting level of the cylinder SmartPart in FloVENT without
re-importing data from the MCAD package.

Sloping Blocks
Converts angled walls into FloVENT sloping block SmartParts.

Modeling Advice
This is a high-level one-step approach for decomposing the geometry into FloVENT objects.
If it does not give the desired result, then choose Tools > Split Body and use the Split Body
Dialog Box, or Tools > Local Simplify to use the Local Simplify Dialog Box.

Figure 3-21 illustrates the complexity level decomposition by showing the results for the
most simple complexity value.

Figure 3-22 illustrates the complexity level decomposition by showing the results for the
most complex and an intermediate complexity value.

Figure 3-21. Simplest Complexity

 Figure 3-22. Intermediate and Most Complexity

Single Object Dialog Box

To access: Tools > Single Object or click the Replace with Single Object icon

Use this dialog box to replace the selected MCAD Body, Part, Bounding box of any selected
Face(s) or Feature(s) with a single cuboid, prism, resistance, fan, enclosure, cylinder or
perforated plate.

Note that, for a selected Face or Feature, the bounding box volume of the Face or Feature
will be removed before inserting the selected single object.

Single Object Dialog Box Settings

Type
Allows you to chooses the replacement object type from a drop-down list.
 Bounding, Average, Flat or Long Cuboids
This method of realization involves replacing an MCAD Body with a single cuboidal primitive,
sized according to one of four selections shown in Figure 3-23.

Figure 3-23. Replacement Cuboids

Bounding or Average Prisms

This method of realization involves replacing an MCAD Body with a single prism primitive
sized according to either of the selections shown in Figure 3-24.

Figure 3-24. Replacement Prisms

Bounding Resistance
This method of realization involves replacing the selected MCAD object with a resistance
occupying the same space as the objects bounding box
 Example 3-1. Replacement Resistance.

Bounding Fan
A 3D 12 facets, simple 2D or rectangular fan depending on the two longest lengths of the
bounding box of the MCAD Body or part and the Collapse Below value.

This method of realization involves replacing the selected MCAD object with one of the
following types of fan:

3D 12 Facets Fan

Requires that the two longest lengths of the bounding box of the body/part differ
by less than 10% and the shortest length is greater than the Collapse Below
value.

The geometric center of the fan will be placed coincident with the geometric
center of the body/part it is replacing.

The fans Zo (depth direction) will be the same as the body/part shortest length
direction.

Simple 2D Fan

Requires that the two longest lengths of the bounding box of the body/part differ
by less than 10% and the shortest length is less than the Collapse Below value.

The geometric center of the fan will be placed coincident with the geometric
center of the body/part it is replacing.

The fans Zo (depth direction) will be the same as the body/part shortest length
direction.

Rectangular Fan

Requires that the two longest lengths of the bounding box of the body/part differ
by more than 10%.

The fans Zo location will be the middle of the shortest length of the body/part.

Bounding Enclosure
This method of realization involves replacing the selected MCAD object with a six sided
enclosure of the same bounding box size and location.

The enclosure will be Thick, with a thickness of 0.2m.

Bounding Cylinder
This method of realization involves replacing the selected MCAD object with a cylinder. The
cylinders local Z coordinate will be in the direction of the longest length of the bodys
bounding box. The cylinders radius will be half the length of the middle sized side of the
bounding box. The cylinder will be conducting, and have 12 facets.

Perforated Plate
This method of realization replaces the selected MCAD object with a perforated plate
SmartPart. The local Z-coordinate of the perforated plate will be in the direction of the
shortest length of the bounding box.

Collapse Below
Sets the limit below which the length of a side of the replacement object is collapsed to
create a planar surface.

Collapse is inhibited if either of the prism type options are chosen.

Using the Single Object Popup Menus

Alternatively, you can select the above simplification options and collapse limit from a popup
selection list displayed by right-clicking the selected MCAD Part, Body, Face or Feature and
selecting Single Object.

Using the popup menus you can set the collapse limits by clicking Settings to display the
Single Object Settings dialog box described below.

Dissect Body Dialog Box

To access: MC Tools > Dissect Body or click the Dissect icon

Use this dialog box to define how selected MCAD Bodies are dissected into FloVENT
primitives, cylinder SmartParts or sloping block SmartParts, working within given
tolerances.

The FLO_OVERCOMPLEX_CELL_LIMIT environment variable sets a limit to the dissection of

geometry. See Using Environment Variables in the FloVENT User Guide.

Dissect Body Dialog Box Settings

Min. Volume Tol.
Sets the minimum volume tolerance for MCAD dissection, specified as the percentage
volume of the MCAD Body being dissected. Figure 3-25 shows an MCAD Part being dissected
with a small MCAD Body falling below the Min. Volume Tol.
 Figure 3-25. Dissected Body

Empty Body Tol.

Represents the percentage of the volume of an MCAD Body to the volume of its bounding
box. MCAD Bodies less than Empty Body Tol. are replaced with a cuboid, see Figure 3-26.

Figure 3-26. Empty Body Replacement

Full Body Tol.

Represents the percentage of the volume of an MCAD Body to the volume of its bounding
box.

MCAD Bodies between Empty Body Tol. and Full Body Tol. are approximated with prism
MCAD primitives.

MCAD Bodies larger than Full Body Tol. are approximated with cuboidal MCAD primitives.

Figure 3-27. Full Body Replacement

Arc/Chord Ratio
Determines whether to slice non-planar faces at the mid point of the curve. This value
represents the ratio of the arc length of a curve on the face to the chord length of that
curve. For faces with values above this ratio, mid-point slices are performed as shown in
Figure 3-28.

Figure 3-28.

Sliced
Curve

Some common values for the arc/chord ratio and their effect when dissecting cylindrical
shapes into FloVENT primitives are shown below. The most accurate representations can be
achieved using an arc/cord ratio between 1.01 to 1.001.

Arc/Chord Ratio = 1.5

Dissects a cylinder into four prisms.

Figure 3-29. Arc/Chord Ratio of 1.5

Arc/Chord Ratio = 1.1

Dissects a cylinder into one cuboid and eight prisms.

Figure 3-30. Arc/Chord Ratio of 1.1

Arc/Chord Ratio = 1.025

Dissects a cylinder into five cuboids and sixteen prisms.

 Figure 3-31. Arc/Chord Ratio of 1.025

Collapse Below
Sets the tolerance thickness for cuboids and sloping blocks. Any cuboids found to be thinner
than this value are collapsed.

Conserve Volume
Volume is conserved for an MCAD Body approximated to a prism, as shown in Figure 3-32.

Figure 3-32. Conserved and Non-Conserved Volume Replacement

Prisms/Tets
Instructs the program to translate prisms and tets. When off, prisms or tets will not be
generated.

Representation of Prisms

When this option is off, any prisms are represented by one of two methods:

If a prism is smaller than the Empty Body Tol. of the original MCAD Body, it is
replaced with a cuboid of the same volume.
 Figure 3-33. Prism Smaller than Empty Body Tolerance

If a prism is larger than the Empty Body Tol. of the original MCAD Body, then it
is dissected into two prisms and a cuboid recursively, until the prisms are
smaller than the Empty Body Tol., then these are replaced by single cuboids as
above.

Figure 3-34. Prism Larger than Empty Body Tolerance

Cylinders
Instructs the program to replace cylindrical parts with FloVENT default cylinder SmartParts,
that is, cylinders with 16 facets.

When dissecting without cylinders, any cylinders that would have been created are
dissected into cuboids and prisms according to the Arc/Chord Ratio.

Sloping Block
Instructs the program to replace angled walls with FloVENT default sloping block
SmartParts.

Procedure
Dissect works by splitting the MCAD Body of an MCAD Part into several smaller MCAD
Bodies. A number of tolerances are used to decide whether to approximate these new MCAD
Bodies with MCAD primitives or to further split them into more MCAD Bodies as follows:

MCAD Bodies < Min. Volume Tol. are deleted.

MCAD Bodies < Empty Body Tol. are replaced with a cuboid.

Empty Body Tol. < MCAD Bodies < Full Body Tol. are approximated to prism
MCAD primitives.

MCAD Bodies > Full Body Tol. are approximated to MCAD primitives.
 Non-planar MCAD Bodies with an arc/chord ratio > Arc/Chord Ratio are sliced at
their mid-points.

Example
Figure 3-35 shows an MCAD Body dissected. One MCAD Body less than Empty Body
Tolerance is deleted, and one MCAD Body greater than Full Body Tolerance is replaced with
a cuboid.

Figure 3-35. Example of Dissected Body

Voxelize Dialog Box

To access: MC Tools > Voxelize or click the Voxelize icon

Use this dialog box to convert an MCAD Part or Body into cuboids. This is a highly robust
alternative method for conversion to FloVENT geometry, but it only creates cuboids (not
cuboids and prisms) to represent the MCAD Part or Body.

The Voxelization method requires the definition of a grid pattern that is used to break the
geometry down into a series of small cubes (voxels). Once broken down, neighboring cubes
that share a common face are merged together to minimize the total number of cuboids
needed to represent the geometry, see Figure 3-36.
 Figure 3-36. Voxelization

The grid used to Voxelize the geometry is defined in a similar manner to grid in FloVENT.
Either a minimum number of cells is defined over the geometry or a maximum cell size.

Voxelize Dialog Box Settings

Define Mesh
The method of defining the X, Y and Z grid over the geometry is chosen from one of two
options:

Minimum Number of cells over the geometry, or

Maximum Cell Size

The grid defined by these settings is in addition to the default grid based on every vertex in
the model.

Minimum Cell Size

A minimum cell size can be used to ensure no extremely small cuboids are created by the
Voxelization method. This in itself is a type of simplification in that no geometric feature
smaller than this minimum cell size will be represented. The default is 1 mm.

2D Face Collapse Thickness

Sets the collapsed thickness of any collapsed cuboids that are created during the voxelize
process. This is equally relevant when voxelizing geometry combining 2D faces. The default
is 2 mm.

Modeling Advice
Voxelization conversion is best suited to predominantly Cartesian type geometry that can be
effectively represented by cuboids alone. It is an extremely robust method of geometry
conversion compared to Dissect Body but will create a stepped representation of any non-
orthogonal surface.

For non-cartesian geometry that has a plane of symmetry, the voxelization method may not
create a symmetrical set of cuboids, depending on the complexity of the particular case. For
example, Figure 3-37 shows the solid representation of an angled fan body and its resultant
structure after voxelization. Notice the highlighted locations indicating a lack of symmetry
resulting from voxelization.

Figure 3-37. Lack of Symmetry Resulting from Voxelization

To voxelize geometry, you are advised to set the minimum cell size equal to the smallest
geometric feature that requires representation, then use either minimum number of cells or
maximum cell size to create a representation of the required resolution. Once transferred to
the Project Manager it might often be advisable to localize and inflate the assembly grid to
minimize the total number of grid cells in the model.

Recommended Neutral File Format

Recommendations for the most desirable neutral file format for robust and error free import
and manipulation within FloMCAD Bridge are based upon a combination of translation,
healing and subsequent simplification and dissection concerns. Figure 4-1 shows, on
balance, the preferred file types.
 Figure 4-1. Preferred File Types

If neither SAT or STEP formats are available, then the instructions for the generation of
IGES data must be followed for:

"Generating IGES files from Pro/ENGINEER Release 20.0"

"Generating IGES files from IDEAS 7"

"Exporting IGES Files from IDEAS 5"

If Pro/ENGINEER *.prt or *.asm files up to release 20.0 are available, then these should be
used in preference to the STEP, IGES or STL files. The same is true for CATIA V4 files. By
definition these files need no manual export from their MCAD tool.

Reduce the Geometric Complexity of the Model

FloMCAD Bridge has some methods for reducing the geometric complexity of models but it
is recommended that as much unnecessary detail as possible be removed from the model
before exporting it from the generating MCAD package.

Simplification involves removing small Features and Parts that are unimportant to the
FloVENT calculation. This will result in smaller files with faster translation and dissection in
the MCAD Interface.