COMPUTER AIDED MANUFACTURING

Solid & Assembly Modeling-

Generative Design
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GEOMETRIC MODELING TECHNIQUES
• 2-D Projection (Drawings)

• Wireframe Modeling

• Surface Modeling

• Solid Modeling

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LIMITATION OF WIREFRAME MODELING
• Model consists entirely of points, lines, arcs and circles,
conics, and curves.
• Not possible to compute volume/mass properties of a design.
• Ambiguous representation.

wireframe model

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SURFACE MODEL
• Objects are defined by their bounding faces.
• Inside or outside of the objects can be determined.

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 SOLID MODELING
• Represent solid interiors of objects
- Surface may not be described explicitly.
• Possesses volume and boundary information

• Some applications require solids

- Example: CAD/CAM, robotic and assembly,
simulation

Tom Funkhouser
Princeton University
Intergraph Corporation 5
GEOMETRY VS TOPOLOGY
• Complete part representation including topological and
geometrical data.
- Geometry: shape and dimensions
- Topology: the connectivity and associativity of the
object entities
(relational information between object entities)

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ISSUES OF SOLID MODELING
• (information) • Able to resolve point inclusion test unambiguously
Completeness • Given a point and a solid; return In/Out/On

What does the object look like?

What is the weight, surface area
of the object?
Will the object hit the other
object on its path?

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SELF-INTERSECTING
Self-intersecting

Elements of the model

• should not self-intersect
• should not intersect each other
unless at their boundary.

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SOLID REPRESENTATIONS
• Constructive Solid Geometry (CSG)

• Boundary Representation (B-Rep)

• Sweeping

• Spatial Enumeration Schemes

• Parametric Feature-based Solid Modeling

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Constructive Solid Geometry (CSG)
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CONSTRUCTIVE SOLID GEOMETRY (CSG)
• A CSG model is based a set of primitives that can be combined in a certain order
following a set of rules (Boolean operations) to form the object.

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PRIMITIVE CREATION
• Intersection of half spaces.

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HALF SPACES

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 BOOLEAN OPERATIONS
• Boolean operations of a block A and Cylinder B

• Union ∪
• Intersection ∩
• Substraction −

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CSG TREE

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 CSG TABLE
• The creation of a model in CSG can be simplified by the use of a table summarizing
the operations to be performed.
The following example illustrates the process of model creation used in the CSG
representation.

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CSG TABLE

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CSG - OPERATIONS

• CSG operations are not commutative.

• CSG operations are not unique.

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CSG TREE PROBLEMS

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LIMITATIONS

• Inconvenient for the designer to determine simultaneously a

sequence of feature creation for all design iterations.

• Problem of non-unique trees. A feature can be constructed

in multiple ways.

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EXAMPLE
Union

Cut

Cut

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Boundary Representation (B-Rep)
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BOUNDARY REPRESENTATION (B-REP)
• Bounded by set of faces.
• These faces are regions or subsets of closed and orientable
surfaces.
- A closed surface is one that is continuous without breaks.
- An orientable surface is one in which it is possible to
distinguish two sides by using face normal.
• Each face is bounded by edges and each edge is bounded by
vertices.
surface
face
edge

vertice

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 Genus
B-REP ENTITIES
• Vertex → v
• Edge → e
• Face → F
• Loop (L): an ordered alternating sequence of vertices and
edges.
• Genus (G): passageway that passes through the object
completely (through-hole, torus, etc).
• Body (B): a set of faces that bound a single connected closed
volume.

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EXAMPLE
• Objects are represented by their bounded faces.

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CONT.

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EULER’S LAW
• Validity of B-rep: ensuring topological validation of the
boundary model.

F − E + V − L = 2(B −G)

F = number of faces
E = number of edges
V = number of vertices
L = Faces inner loops
B = number of bodies
G = number of genus (holes or handles)

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SIMPLE SOLIDS

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LOOPS, GENUS & BODIES

𝐺=0

𝐺=1

𝐺=2

𝐿=1

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EXAMPLES
𝐹−𝐸+𝑉 =5−9+6=2
2 𝐵−𝐺 =2

𝐹 − 𝐸 + 𝑉 − 𝐿 = 2(𝐵 − 𝐺)
15 − 36 + 24 − 5 = −2
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Sweeping
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SWEEPING
• Sweeping requires two elements – a surface to be moved and a
trajectory, analytically defined, along which the movement should occur.

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Spatial Resolution Schemes
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VOLUMETRIC REPRESENTATION

(Funkhouser, 2000)

1 solid
vijk =
0 otherwise

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QUADTREES & OCTREES

(Funkhouser, 2000)
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CONT.
• A solid object by dividing its volume into smaller volumes or cells.
• 2D: quadtree; 3D: octree.
• 2D: Pixel; 3D: voxel.

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Parametric Feature-based Solid
Modeling
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 PARAMETRIC AND FEATURE-BASED MODELING CONCEPT
➢Parametric is a term used to describe a dimension’s ability to
change the shape of model geometry if the dimension value is
modified.
➢Feature-based is a term used to describe the various
components of a model. For example, a part can consists of
various types of features such as holes, grooves, fillets, and
chamfers.
➢Parametric modeler are featured-based, parametric, solid
modeling design program: SolidWorks, PTC Creo (Pro-Engineer)
…
Unigraphics (CSG and parametric), ….. Chamfer
Fillet

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 PARAMETRIC FEATURE-BASED SOLID MODELING
• Define a profile with a set of parameters.
• Obtain 3D model by specific operations (i.e., extrusion).
• Modify parameter values to generate new design variations.
• Go back and change almost any parameter of the design.

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FEATURE RECOGNITION IN CAPP
• CAPP systems do not understand the 3D geometry of the
designed parts in terms of manufacturing.

• Feature recognition system should be able to:

1. Extract design information of a part from a CAD database
2. Identify all surfaces of the part
3. Recognize/interpret the surfaces in terms of features
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FEATURES AND THEIR GRAPHS
Step Four-side pocket

Slot
Pocket

Three-side pocket
Through hole

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EXAMPLE – RECOGNIZING FEATURES

Face/surface numbering

Pocket feature

Slot feature
AAG for the part 44
DESIGN BY FEATURES
• Designers create models directly from predefined features
or features from a standard library.
• Easy to produce process (manufacturing) plan.

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 Exploded assembly

ASSEMBLY MODELING
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 ASSEMBLY MODELLING
• An assembly consists of two or more parts located relative to each other in
space.
✓ Parts can be positioned by translating and rotating them into the right
locations.
• The relative motion is constrained.
✓ Most assemblies are fully constrained.
✓ Mechanisms are partially constrained.

Degree of freedom
• Translation – movement along X, Y,
and Z axis
(three degrees of freedom)
• Rotation – rotate about X, Y,
and Z axis (three degrees
of freedom)
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 HIERARCHICAL RELATIONSHIP
• Tree-like structure for the assembly → Assembly tree.
• The tree explodes the overall assembly into
subassemblies and parts.

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 ASSEMBLY MODELER

✓ Advanced geometric modelers.

✓ The geometric modeler acts as a front end to the

assembly modeler.

✓ The data structure is extended to allow representation

and manipulation of hierarchical relationships and
mating conditions that exist between components in an
assembly.

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EXAMPLE

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ASSEMBLY CONSTRAINTS
• In order to completely define the position of one part
relative to another, we must constrain all of the degrees
of freedom.

Mate
• Two selected surfaces become co-planar
and face in opposite directions. This
constrains three degrees of freedom (two
rotations and one translation)
Mate Offset
• Two surfaces are made parallel
with a specified offset distance.

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ASSEMBLY CONSTRAINTS
Align Coincident
• Two selected surfaces become co-
planar and face in the same
direction. Can also be applied to
revolved surfaces. This constrains
three degrees of freedom (two
rotations and one translation).

• When Align is used on

revolved surfaces, they
become coaxial (axes through
the centers align).

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ASSEMBLY CONSTRAINTS
Align Offset
This can be applied to planar
surfaces only, surfaces are made
parallel with a specified offset
distance.

Align Orient
Two planar surfaces are made
parallel, not necessarily co-planar,
and face the same direction (similar to
Align Offset except without the
specified distance).
- Constrains two degrees of freedom (two rotations)

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CREATING AN ASSEMBLY

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CREATING AN ASSEMBLY
• The example assembly requires three mates to fully define it.
First constrain: Mate between the hollow faces as shown.

Hollow faces

• This removes
three degrees
of freedom.

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CREATING AN ASSEMBLY
Second Constrain: Align the right faces of both
components.

Right side faces

One degree of
freedom left
Third Constrain: Align the top faces of both components.
top faces
✓ The
assembly
is fully
defined
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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

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Generative Design
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https://www.autodesk.com/solutions/generative-design/manufacturing

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BRACKET IMPROVEMENT
• Weight savings to help reduce fuel
consumption of airplanes.
• The main design objective is to
minimize weight while fitting in the
target envelope and meeting the
technical requirements.

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REQUIREMENTS
• Material: Additive Metals.
• Minimum geometric feature: 0.025 in.
• Minimum wall thickness: 0.045 in.
• Parts additively manufactured.
• Optimization objectives: Minimize weight with Factor of Safety of 1 or
greater.
• Parts should be optimized for minimum weight with the following
conditions:
• Boundary conditions
• Loading conditions

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BOUNDARY CONDITONS
1. Base support: The part is bolted against a mating plate of high-
stiffness.
2. Bolts interface: The part is fastened with four #10-32 high-
strength tension rated bolts.

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APPLY CONSTRAINTS

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LOADING CONDITIONS

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SPECIFY OBJECTIVES

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MANUFACTURING METHOD / MATERIAL

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FUSION 360

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GENERATE AND EXPLORE OUTCOMES

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FUSION 360: GENERATIVE DESIGN

https://www.youtube.com/watch?v=n5mh5RQZ4ts
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 REFERENCES
This presention is a compilation of following sources:

1. Assoc. Prof. Dr. Erkan Gunpinar, CAD/CAM Lecture Notes,

Istanbul Technical University.
2. Chang, T.C. Wysk, R. A. and Wang, H. P., Computer-Aided
Manufacturing. Prentice Hall, 2nd Ed., 1997
3. Funkhouser, T., F 2000, Solid Modeling, Lecture Notes, C0S 426,
Princeton University.

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