15 September 2023

CAD/CAM/CIM– (MAT-613)

- THREE
UNIT
GEOMETRIC MODELING

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By：Yemane Z. (PhD)

Manufacturing Technology Department

Previous Session…

➢ NC Programming
➢ Concept of numerical control
➢ Advantages and major limitations of NC machine tools
➢ Cartesian coordinate system
➢ Programming fundamentals
➢ Programming Systems
➢ Programming Format

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3. Geometric Modeling
➢ Geometric modeling is the representation of physical
objects on computers, allowing both interactive and
automatic analysis of design, and the expression of
design in a form suitable for manufacturing.
➢ Geometric modeling is the starting point of the
product design and manufacturing process.
➢ Geometric modeling plays a crucial role in the overall
application of CAD-CAM system.
➢ Most Geometric modeling is
done with computer and
computer based applications.
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Fig. Typical Product Cycle (flowchart )

3.1 Need of geometric modeling

➢ For manufacturing automobile engine it require

around 10,000 drawings, models in various
departments with different styles.
➢ Once models are prepared using any CAD software,
these models can be used in almost all departments of
the organization which includes-
1. Designing the parts and assemblies and then
performing tolerance analysis of the assemblies
2. Preparation of production drawings of individual
parts, subassemblies, assemblies, tooling and jig-
fixtures
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 Cont...
3. Making structural, thermal and kinetic analysis
4. Considering volume of parts and after extracting
material properties from material library, cost
estimation can be easily done
5. Process plans are also prepared for all the components
6. Using CAM software’s, we can model as input for CNC
programming
7. Programming the movement of the components from
one station to another is possible using various
material devices such as robots, conveyors, automated
guided vehicles
8. Other supporting activities such as material
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requirement and procurement, preparation of bill of
materials, planning and scheduling, analysis.
➢ Once geometric models are available thus for all these
activities, geometric models becomes the central that
will be manipulate at all these storages.

➢ Why Geometric modeling is needed

❖ Geometric (3D) models are easier to interpret.
❖ Simulation under real-life conditions.
❖ Less expensive than building a physical model.
❖ 3D models can be used to perform finite element
analysis (stress, deflection, thermal)
❖ 3D models can be used directly in manufacturing,
Computer Numerical Control (CNC).
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❖ Can be used for presentations and marketing.
3.2 Requirements of geometric modeling
➢ The requirement of geometric modeling is manifold. The
conceptual design is the basis of the generation of
geometric model.
➢ The choice of the geometric model depends on the
mechanical functions to be performed by it.
➢ A valid geometric model is created by CAD system and
its model database is stored.
➢ The database of geometric modeling is used for
engineering analysis and for design optimization.
➢ Design testing and evaluation may necessitate changing
the geometric model before finalizing it.
➢ When the final design is achieved, it is documented and
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used for subsequent manufacturing applications, quality
and cost analysis.
➢ Information entered through geometric modeling is
utilized in number of downstream applications like:
➢ Design Analysis :-
✓ Evaluation of area, volume, mass and inertia
properties
✓ Interference checking in assemblies
✓ Analysis of tolerance build-up in assemblies
✓ Kinematic/ Dynamic analysis & simulation
✓ Evaluation of centroid, area (cross-sectional &
surface) & volume
✓ Finite element analysis for stress, vibration, thermal
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& optimization
➢ Drafting :-
✓ Automatic 2D view generation
✓ Automatic planar cross-sectioning
✓ Automatic hidden lines and surface removal
✓ Automatic production of shaded images
✓ Automatic dimensioning
✓ Automatic creation of exploded views of assemblies
➢ Manufacturing:-
✓ Part classification & Process planning
✓ NC data generation and verification
✓ Robot program generation 10

✓ NC tool path generation & verification

➢ Production & industrial Engineering :-
✓ Preparation of Bill of Material (BOM)
✓ Material requirement planning
✓ Manufacturing resource requirement
✓ Scheduling
✓ Marketing
➢ Computer Aided Inspection and quality control :-
✓ Program generation for inspection machines
✓ Comparison of produced parts with design
➢ Hence, it is important that the geometric model
generated should be as clear & comprehensive as
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possible so that the other downstream applications are
able to use this information in the most optimal way.
➢ Good geometric model is designed based on the
following important guidelines-
❖ Modeling method must be easy to use
❖ Representation should be able to represent a useful
set of geometric objects
❖ Model should not create any ambiguity (The ability
to express more than one interpretation) to users. A
given representation should correspond to one and
only one solid
❖ A geometric model must be very accurate. There
should not be any approximation
❖ Geometric modeling should not create any invalid or
impossible models 12
 Cont...

❖ The various transformations such as move, rotation,

scale etc… and manipulations such as union,
intersect, subtract etc… should able to be performed
on geometric model
❖ A good representation should be compact enough
for saving space and allow for efficient algorithms to
determine desired physical characteristics
❖ Geometric model should have shading and
rendering (Generation an image for a model by means
of a computer program) capability to give realistic
effect to the model
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3.3 Geometric models
➢ The geometric models are broadly classified on the
basis of geometric construction into the following
categories.

Two Dimensional
(2-D)

Geometric
Modeling Wireframe modeling

Three Dimensional Surface modeling

(3-D)

Solid modeling
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➢ Two Dimensional (2D)
The 2D modeling includes the construction of
geometrical faces, plane drawings, 2D views (Top,
Front, Right, and Light views) of objects.
Presently, the application of 2D model is limited to
drafting, sheet metal manufacturing, Spot welding,
Laser cutting etc.
➢ Three dimensional (3D)
The 3D modeling is widely used for engineering
applications.
It provides all the information required for animation,
design analysis and manufacturing.
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3D objects

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➢ The 3D models are further sub-divided into three
groups:
1. Wireframe modeling:-
➢ Wireframe modeling is the oldest and simplest methods
of geometric modeling which can be used to store model
mathematically in the computer memory.
➢ In this method the complete object is represented by
number of lines, points, arcs & curves and their
connectivity relationships.
➢ This is the lowest level of modeling and has serious
limitations.

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➢ Advantages: (Wireframe model)
✓ The construction of a wireframe model is simple
✓ It does not require much computer time & memory.
✓ It can be used for simple NC tool path generation
✓ Manipulations in the model can be done easily and
quickly
➢ Disadvantages:
✓ It cannot be used for calculation of mass, inertia
properties
✓ The interpretation of wireframe models having
many edges is very difficult
✓ Does not represent an actual solid (no surface and
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volume)
 2. Surface Modeling:-
➢ Surface modeling is the next stage of wireframe
modeling.
➢ In wireframe modeling models are unable to represent
complex surfaces of objects like car, ship, airplane,
wings, castings etc. only a surface profile of these
objects.
➢ A surface model represents the skin of an object. These
skins have no thickness or material type.
➢ Surface models define the surface properties, as well as
the edges of objects.
➢ These are often capable of clearly representing the solid
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from the manufacturing
➢ The surface model is constructed essentially from
surfaces such as planes, rotated curved surfaces & even
very complex synthetic surfaces.
➢ Surface creation on existing CAD system usually
requires wireframe entities as a start.
➢ Surface & wireframe form the core of all existing CAD
system

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➢ Advantages: (Surface model)
✓ Surface model of an object is a relatively more
complete & less ambiguous representation than its
wireframe model
✓ Renders the model for better visualization and
presentation, objects appear more realistic
✓ Provides the surface geometry for CAM, NC machine
✓ Provides the geometry needed by the manufacturing
engineer for mould and die design
➢ Disadvantages:
✓ Provides no information about the inside of an object
✓ Provides wrong results if mesh is too coarse
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✓ The calculation of mass & inertia properties would be
difficult
 3. Solid modeling :-
➢ Solid modeling is the most powerful of 3D modeling
technique.
➢ Solid model of an object is a more complete
representation than surface model, as all the
information required for engineering analysis &
manufacturing can be obtained with this technique.
➢ Defining an object with a solid model is the easiest of
the available three modeling techniques.
➢ The model is a complete and unambiguous
representation of a precisely enclosed and filled volume.
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➢ Advantages: (Solid model)
✓ Solid modeling produces accurate design,
✓ provides complete 3D definition
✓ Improves visualization
✓ Easily exported to different FEM programs for analysis
✓ It can be used in newly manufacturing techniques;
CIM, CAM, design for manufacturing (DFM)
✓ 2D standard drawings, assembly drawings and
exploded drawings are generated from the model
➢ Disadvantages:
✓ More intensive computation than wireframe and
surface modeling 23

✓ Requires more powerful computers (faster with the more memory)

3.4 Geometric Construction Methods
➢ The three-dimensional construction methods are:
✓ Wireframe modeling
✓ Surface modeling
✓ Solid modeling
✓ Extrusion
✓ Sweeping
✓ Feature modeling

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Extrusion
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3.5 MasterCAM

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➢ How it work?
• Developing NC code requires an understanding of:
1. Part geometry
2. Tooling
3. Process plans
4. Tolerances
5. Fixturing
• Most CAD/CAM systems provide access to:
1. Part geometry
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2. Tooling
➢ Instructions can be generated for a generic NC machine
✓ A set of tool paths and positions can be automatically
generated
✓ These paths can be edited and modified
✓ These paths and instructions can then be “posted” to
a specific machine

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➢ CAD/CAM Support
✓ AutoCAD
✓ Pro Engineer
✓ MasterCAM

➢ Essentials to begin MasterCAM?

❖ Part geometry (- Draw or import)
❖ Tooling (- Library or create)
❖ Process plans
❖ Fixtures (- Define orientation and location)
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MasterCAM

➢ MasterCAM is a three-dimensional geometry creation

engine along with features to aid in tool path generation
and verification.
➢ MasterCAM allows tool path planning and NC code
generation for a given part. This part can either be
drawn in MasterCAM or imported from other CAD
packages

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MasterCAM Drawing
➢ Geometrical part drawing
➢ In-built CAD package
o Two-dimensional parts
o Three-dimensional parts
➢ Translators (include)
o IGES (international Graphics Exchange Standard)
o DXF (AutoCAD)
o CADL (CADKey)

Tool Path Generation using MasterCAM

➢ Tool path generation
➢ Extensive Tool library
➢ Machining parameter selection 33
➢ NC program generator
➢ Animation to visualize machining operations
Getting Started with 2D Drawing
➢ Create simple 2D Geometries using basic shapes say a
Rectangle-

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Creating 2D Geometry
➢ Place and Dimension the Shape

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Creating Shape with Lines and Rectangles
➢ Complete the Basic profile. Then add arcs, fillets and
trim entities…

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Adding Arcs, Radius and Fillets
➢ Click on Main Menu [Create- Arc-pt. dia. Cir.] on to
dimension and place arcs/circles
➢ Click on Main Menu [Create-Fillets] to create Fillets.
Dimension them Suitably

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Completing our object Profile
➢ To Trim or Cut entities Main Menu [Edit-Trim/Break] to
get required profile.
Don’t forget to Save your file

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Getting started with Toolpaths
➢ After selecting the Machine Type from the Main Menu
(Mill-Default). Click on Main Menu [Toolpaths].
MasterCAM lists the different machining operations

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Pocketing Options (or Contouring Options)
➢ By Selecting Pocket the various pocketing Options are
listed. Select Chain and the geometry chains up and
shows tool travel direction

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Defining Tool Parameters
➢ Select the Pocket type and Tool Parameters Window pops
up. Feed the Right Parameters and Select Specific Tools.

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Selecting the Tools
➢ MasterCAM has a whole range of tools in a tool library
from which tool selections can be made. Now feed the
correct parameters.
➢ You can also specify your own tools.

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Displaying Toolpaths
➢ Once both the Tool parameters and Cut Parameters have
been Correctly defined. Click Ok to display the Tool
path.

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➢ Then:- Try out different toolpaths from the 46

toolpaths palette for the part in your lab exercises.

Thank you for your attention!

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