dm chapter 4 3d geometry

Chapter 4Chapter 4

3D Geometry3D Geometry

May 11, 2007© 2007 ANSYS, Inc. All rights reserved.

ANSYS, Inc. Proprietary Inventory #0024964-1

Training Manual

ContentsTraining Manual

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• Bodies and Parts• 3D Features gnM

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• Boolean Operations• Feature Direction• Feature Type er• Feature Type• Primitives• Workshop 4.1


Inventory #0024964-2

ANSYS, Inc. Proprietary

Training Manual

Bodies and PartsTraining Manual

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• DesignModeler is primarily intended to provide geometry to an analysis environment. For this reason we need to see how DM treats various geometries gnM

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• DesignModeler contains three different body types:– Solid body: body has surface area and volume– Surface body: body has surface area but no volume

Li b d b d i t ti l f d l

er– Line body: body consists entirely of edges, no area, no volume

• By default, DM places each body into one part by itselfIndividual parts will always be meshed separately.If bodies in separate bodies share faces, the mesheson those shared faces will not be matched

– Multiple bodies in a single part will have matchedmeshes on shared faces when meshed




Training Manual

Active and Frozen BodiesTraining Manual

Desig• By default, DM will merge new geometry with existing

geometry to maintain a single body. gnModele

• This can be controlled by working with either frozenor active bodies

er• You can toggle between frozen and active states for using the Freeze and Unfreeze tools




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Active and Frozen Bodies…Training Manual

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• There are two body states in DM:– Active:

• Body can be modified by normal modeling operations

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• Body can be modified by normal modeling operations (cannot be sliced)

• Active bodies are displayed in blue in the Feature Tree View• The body's icon in the Feature Tree View is dependent on

its type solid surface or line

Active

erits type - solid, surface, or line– Frozen: (>Tools>Freeze)

• Main Purpose: – Provides alternate method for Assembly Modeling.

• A Frozen body is immune to all modeling operations except slice, blend, chamfer, face delete and split edges.

• To move all active bodies to the Frozen state, use the Freeze feature.

Frozen

• To move individual bodies from the frozen to active, select the body and use the Unfreeze feature.

– Frozen bodies are displayed as transparent in the Tree View.




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Bodies and Parts…Training Manual

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• Body Suppression:– Suppressed bodies are not plotted. gnM

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– Suppressed bodies are not sent to other Workbench modules for meshing or analysis, nor are they included in the model when exporting to a Parasolid (.x_t).I th t i “X” i h d b di

er– In the tree view an “X” is shown near suppressed bodies

Unsuppressed

Suppressed




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• Parts:– By default, the DesignModeler places

each body into one part by itself. gnModele

– You can group bodies into parts• Multibody parts contain multiple

bodies (volumes), but have shared topology.The meshes on shared faces will be erThe meshes on shared faces will be matched

– To form a new part, select two or more (or RMB “Select All”) bodies from the graphics screen and use

>Tools>Form New Part>Tools>Form New Part– The Form New Part option is available

only when bodies are selected and you are not in a feature creation or feature edit state.




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• Why multi-body parts?• Example: gnM

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– In DM: 3 parts, 3 bodies consisting of 3 solids– During Meshing: 3 solids, 3 bodies– Each solid meshed independently

• Nodes are not shared er• Nodes are not shared • Nodes do not line-up

– In Simulation: 3 solids with 2 contact regions Mesh

DM




DM

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• Example (continued):– In DM: 1 part, 1 body consisting of 1 DM gnM

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solid– During Meshing: 1 solid ,1body– Entire solid meshed as one er– No Contact

MeshMesh

DM




DM

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• Example (continued):– In DM: 1 multi-body part, 3 bodies/solids

DM

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– During Meshing:1 multi-body part, 3 bodies/solids

– Each solid meshed independently but d ti it lid i

ernode connectivity among solids is preserved

Mesh




DM

Training Manual

3D FeaturesTraining Manual

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• You create 3D geometry from 2D sketches by creating a 3D feature. Common examples include:

– Extrude er

– Sweep– Revolve– Skin/Loft– Thin/Surface

• The effect of the feature creation is determined by the type of the feature, the Boolean operations performed as it is created, and the extent of the feature (fixed, to next, through all, etc.)




Training Manual

3D FeaturesTraining Manual

Desig• Typically, the generation of a 3D feature (like Extrude or Sweep)

consists of two steps:

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consists of two steps: – (a) Choose the desired feature and specify its details– (b) “Generate” the feature bodies

er

Each 3D feature creation is controlled via the associated details• Each 3D feature creation is controlled via the associated details• The last step in creating 3D features is to click “Generate”




Training Manual

ExtrudeTraining Manual

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• Extrusions:– Extrusions include solids, surfaces, and thin-walled features

f “ / f ”

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• To create surfaces, select “as thin/surface” and set the inner and outer thickness to zero– The active sketch is the default input but can be changed by selecting the desired

sketch in the Tree View– The Detail View is used to set the Extrude depth, direction, and Boolean operation erp p

(Add, Cut, Slice, Imprint, or Add Frozen)– The Generate button completes the feature creation– Note: the section on Feature Type shows various extrusion examples

To Create




To Create Surface

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RevolveTraining Manual

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• Revolve: – Active sketch is rotated to create 3D geometry gnM

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– Select axis of rotation from details• If there is a disjoint (free) line in the sketch, it is

chosen as the default axis of revolution– Direction Property for Revolve: erect o ope ty o e o e

• Normal: Revolves in positive Z direction of base object

• Reversed: Revolves in negative Z direction of base objectobject

• Both - Symmetric: Applies feature in both directions. One set of angles will apply to both directions

• Both - Asymmetric: Applies feature in both directions. Each direction has its own angle property

– The Generate button completes the feature creationSketch with Disjoint Line




Training Manual

SweepTraining Manual

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• Sweep:– Solids, surfaces, and thin-walled features can be created by using this feature

to sweep a profile along a path

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to sweep a profile along a path– Scale and Turns properties can be used to create helical sweeps

• Scale: tapers or expands the profile along the path of the sweep• Turns: twists the profile as it sweeps along the path erp p g p• A negative value for Turns will make the profile rotate about the path in the

opposite direction. +Turns: Rotates counterclockwise• See documentation for other restrictions

Ali t– Alignment:• Path tangent: reorients the profile as it is swept along the path to keep the

profile in the path's tangent direction• Global: the profile's orientation remains constant as it is swept along the p p g

path, regardless of the path's shape

– Examples . . .




Training Manual

Sweep…Training Manual

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• Sweep example 1:

Path Tangent alignment: fil i t t t

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Sketch1 = profile to sweep

profile remains tangent to path

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Sketch2 = sweep path

Global Axes alignment: profile orientation premains constant




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Sweep…Training Manual

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• Sweep example 2:

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Sweep details:

Scale = 0 5

erScale = 0.5

Turns = - 4

Sketch1 = profile to sweepSketch2 = sweep path

• Scale and Turns restrictions:– Scale: The sweep path must be an open chain AND smooth– Turns: The sweep path must be smooth

• if the sweep path is a closed loop then Turns must be an integer

Sketch2 = sweep path




• if the sweep path is a closed loop, then Turns must be an integer• If the sweep path is an open chain, then any value for Turns is acceptable

– The default values for Scale and Turns are 1.0 and 0.0, respectively

Training Manual

Skin/LoftTraining Manual

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• Skin/Loft:– Takes a series of profiles from different planes to create 3D geometry fitting

through them (must select two or more profiles)

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through them (must select two or more profiles)• A profile is a sketch with one closed or open loop or a plane from a face• All profiles must have the same number of edges• Open and closed profiles cannot be mixed erOpe a d c osed p o es ca ot be ed• All profiles must be of the same type

– Sketches and planes can be selected by clicking on their edges or points in the graphics area, or by clicking on the sketch or plane in the feature treeAf l i d b f fil i ill– After selecting an adequate number of profiles, a preview will appear showing the selected profiles and the guide polygon

– The guide polygon is a gray poly-line which shows how the vertices between the profiles will line up with each other

– Skin/Loft operation relies heavily on RMB menu choices• Examples . . .




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Skin/Loft…Training Manual

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• Skin/Loft example 1:– Three 5 sided sketch profiles have been created on three offset planes gnM

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– After selecting each profile (hold CTRL key) the guide line is displayed– RMB for guide line options– Continue through all profiles

er




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• Skin/Loft example 1:– Add operation generates 3D solid gnM

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• Guide Lines:– Use RMB options to realign if necessary

• Can result in unexpected shapes when misaligned ersa g ed




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• Skin/Loft reordering:– During creation or when editing selections the order of the profiles may be

adjusted

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adjusted– Highlight profile to reorder and RMB– Choose from options menu

er




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3D Feature Details (Extrude)Training Manual

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Boolean Operations gnM

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p

erBodies in model?

It’s all in the details!




It’s all in the details!

Training Manual

Boolean OperationsTraining Manual

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• You can apply five different Boolean operations to 3D features:– Add Material : creates material and merges it with the active bodies.

• It is always available

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• It is always available– Cut Material: removes material from active bodies– Slice Material: slices frozen bodies into pieces.

• Available only when ALL bodies in the model are frozenI i t F Si il t Sli t th t l th f f th b di lit d d

er– Imprint Faces: Similar to Slice, except that only the faces of the bodies are split, and edges are imprinted if necessary (no new bodies created)

– Add Frozen: Similar to Add Material, except that the feature bodies are not merged with the existing model but rather added as frozen bodies

• Line bodies are immune to Cut Imprint and Slice operations• Line bodies are immune to Cut, Imprint, and Slice operations

If frozen:




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Boolean Operations…Training Manual

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• Boolean Add:

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Choose feature and Boolean operation to be erperformed on the active sketch

Extrude – “Add Material” shown here




Note: If bodies already exist, “add” results in merged geometry after “Generate”

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• Boolean Cut:

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Existing solid (shown in wire frame for clarity)

Revolve with Cut operation




Active SketchAxis of revolution

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• Boolean Imprint Faces:–Imprint Face operation allows continuous surface to be segmented (see below) Useful for applying FE boundary conditions at arbitrary

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(see below). Useful for applying FE boundary conditions at arbitrary locations.

er

Active sketch to extrude

E tr de ith Imprint FacesExtrude with Imprint Faces operation.




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• Boolean Add Frozen:–Similar to add operation but results in separate bodies (or single gnM

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frozen body)

er

Active sketch to extrude

Extrude with Add FrozenExtrude with Add Frozen operation




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• Boolean Slice (all bodies must be frozen):– Slices frozen bodies leaving new (frozen) body in the slice region gnM

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New frozen body

Active sketch to Extrude

Extrude with Slice operation




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Feature DirectionTraining Manual

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• Direction:

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Direction is with respect to the sketch plane

Some operations (e.g. cut) result in automatic change




result in automatic change in direction

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Feature Type…Training Manual

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• Through All Type: will extend the profile through the entire model– When adding material the extended profile must fully intersect the gnM

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model

er




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• To Next: – Add will extend the profile up to the first surface it encounters.

Cut Imprint and Slice will extend the profile up to and through the first surface

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– Cut, Imprint, and Slice will extend the profile up to and through the first surface or volume it encounters

er




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• To Faces: allows you to extend the Extrude feature up to a boundary formed by one or more faces

– For multiple profiles make sure that each profile has at least one face intersecting its gnModele

p p p gextent. Otherwise, an extent error will result

er

– The “To Faces” option is different from “To Next”. To Next does not mean “to the next face”, but rather “through the next chunk of the body (solid or sheet)”

– The “To Faces” option can be used with respect to faces of frozen bodies




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• To Surface: option is similar to To Faces, except only one face can be selected. The extent is defined by the underlying and possibly unbounded surface of the selected face (see below)

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unbounded surface of the selected face (see below).– In this case a single face is selected and its underlying surface is used as the

extent. The underlying surface must fully intersect the extruded profile or an error will result. er




Unbounded surface selected as extent

Training Manual

PrimitivesTraining Manual

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• Primitive Shapes: Create>Primitives– Quickly create models by defining primitive shapes like spheres, gnM

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cylinders etc.. – Does not require sketches– Requires a Base Plane and several point and / or direction inputs er– Inputs can be defined by typing in coordinates or by selecting

existing geometry.




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Primitives…..Training Manual

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• Primitive Shapes Example: Cylinder– Select Base Plane gnM

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– Define Origin– Define Axis (also defines the

height of the cylinder) er– Define radius– Generate




Catalytic ConverterCatalytic ConverterCatalytic ConverterCatalytic Converter

Workshop 4-1


ANSYS, Inc. Proprietary Inventory #0024964-36

Training Manual

Workshop 4-1, Catalytic ConverterTraining Manual

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• Goals:– Create the catalytic converter model shown

below as 3 separate bodies. (Design Modeler)

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below as 3 separate bodies. (Design Modeler)– Create separate sketches and perform a

skin/loft operation to make the converter body. (Design Modeler)

er




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1. Launch ANSYS Workbench and start new geometry• Click Start > Programs > ANSYS 10.0 > ANSYS Workbench gnM

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2. Launch DesignModeler and start new geometry

• Left click Geometry• After new window pops

l C i f

erup, select Centimeter for length unit, then click OK




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3. Create the flange sketch #1– [Modeling] > Unnamed > XYPlane

• Toolbar: New Sketch

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• Toolbar: New Sketch • Sketch1 will be created on XYPlane• In the Details view, rename Sketch1

to “BaseCircle”.• Toolbar: “Look At” icon

er• Toolbar: Look At icon– [Sketching] > Draw > Circle

• Move the cursor over the sketch origin, then when the “P” is displayed (auto-constraint) click on the left(auto constraint), click on the left mouse button. Click again to define the radius.

– [Sketching] > Dimensions > Radius• Click on the circle to select it, then ,

click again on the screen to define where to place the dimension.

• In the Details view, define Dimensions > R1 as “2.5”.




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Create the flange sketch #1 (cont’d)– [Sketching] > Modify > Split at Select

• Right click anywhere on the Model

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Right click anywhere on the Modelview and select “Split Edge into n Equal Segments” from the pop-up menu.

• The Split tool will now change to Split Equal Segments. Enter “8” for the erq gtextbox n=.

• In the Model View, select the circle. It will now be split into eight segments.

Notes:We have now split the circle into 8 segmentsWe have now split the circle into 8 segments. We will create the profile of the flange by lofting four sketches using this one as our base. We will need to have the same number of divisions on each sketch, all with similar orientations. To simplify this, we will first p yreorient the circle by using a Move command.




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Create the flange sketch #1 (cont’d)• On the Selection Toolbar, select the

“New Selection” icon .

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New Selection icon . • Click on the “Select Mode” icon and

choose “Box Select”

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• Left click and drag to draw a box, selecting the entire circle.

– [Sketching] > Modify > MoveI th t t b t t th M• In the text boxes next to the Movetool, change r= to “22.5” and f= to “1”.

• Right-click on the Model View and select “Use Plane Origin as Paste Handle”. This will make the moving




Handle . This will make the movingreference point as the original, relative location of the sketch origin.

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Create the flange sketch #1 (cont’d)• Right click anywhere on the Model

View and select “Rotate by r

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View and select Rotate by r Degrees”. This makes the moving operation include a rotation, as specified by the value of “22.5” degrees entered earlier. er• Right click anywhere on the Model View and select “Paste at Plane Origin”. This completes the move operation by moving the model to the origin Since the reference point wasorigin. Since the reference point was the origin, this results in no translation but only a rotation, specified by r=22.5.

• Right click anywhere on the ModelView and select and left-clickEnd. This completes the Moveoperation.




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Create the flange sketch #1 (cont’d)• You should see that the segments have

been rotated by 22.5 degrees. gnModele

• Click on the “Select Mode” icon and choose “Box Select”

er

• Left click and drag to draw a box, selecting the entire circle.

– [Sketching] > Modify > Copy• Click on the Copy tool to copy this profile.• Right-click anywhere on the Model View and

select “Use Plane Origin as Paste Handle” to make the paste operation use the original




make the paste operation use the original, relative location of the sketch origin as the pasting point.

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4. Create the flange sketch #2– [Modeling] > Toolbar: XYPlane– Toolbar: New Plane

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Toolbar: New Plane• Select the New Plane icon from the

Active Plane/Sketch Toolbar. This creates Plane4 based on XYPlane.

• In the Details view, set Transform 1 to er,Offset Z, change FD1, Value to be “1”.

– Toolbar: Generate– [Sketching] > Modify > Paste

• Enter “0” for r= and “1.05” for f=.• Right-click anywhere on the Model

View and select “Scale by factor f”. This will scale the original sketch profile by a factor of 1.05 for our new k t hsketch.




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Create the flange sketch #2 (cont’d)• Right-click on the Model View and

select “Paste at Plane Origin”. Our

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select Paste at Plane Origin . Our reference point was the sketch origin from BaseCircle, and the pasting location is the origin on Sketch2, so this essentially copies the original i l t Sk t h2 ith l f t

ercircle onto Sketch2 with a scale factor of f=1.05.

Ri ht li k th M d l Vi• Right-click on the Model Viewand select and left-click on End. This terminates the Paste operation.




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Create the flange sketch #2 (cont’d)– [Modeling] > Unnamed > XYPlane >

BaseCircle gnModele

• Right-click on BaseCircle and select “Always Show Sketch”

– [Modeling] > Unnamed > Plane4 > Sketch2 er• Right-click on Sketch2 and select

“Always Show Sketch”. This keeps both sketches visible so we can easily see that one circle is the same as the other except for the Z offset and theother except for the Z offset and the 1.05 scale factor.




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5. Create the flange sketch #3– Toolbar: XYPlane– Toolbar: New Plane gnM

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• Select the New Plane icon from the Active Plane/Sketch Toolbar. This creates Plane5 based on XYPlane.

• In the Details view set Transform erIn the Details view, set Transform 1 to Offset Z, change FD1, Value to “5”.

– Toolbar: Generate– [Sketching] > Draw > Rectangle

• Check Auto-Fillet checkmark next to the Rectangle tool.

• Click once to define one corner of the rectangle, click again to define its diagonal, and click a third time gto define the fillet radius.




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Create the flange sketch #3 (cont’d)– [Sketching] > Dimensions > General gnM

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• Dimension the sketch as shown at right.

• In the Details view, change Dimensions to be the values shown in the right plot

105

6 erthe right plot• On the toolbar click “New Selection”

icon and set the mode to “Box Select”

• Left click and drag to select the entire 10

2

• Left click and drag to select the entire sketch.

– [Sketching] > Modify > Copy• Right-click anywhere on the Model

View and select “Use Plane Origin asView and select Use Plane Origin as Paste Handle”.




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6. Create the flange sketch #4– [Modeling] > Unnamed > Plane6– Highlight XY Plane

Toolbar: New Plane

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– Toolbar: New Plane• Select the New Plane icon from the

Active Plane/Sketch Toolbar. This creates Plane6 based on XYPlane.

• In the Details view, set Transform 1 to erOffset Z, change FD1, Value to “6”.– Toolbar: Generate– [Sketching] > Modify > Paste

• Enter “0” for r= and “1.05” for f=. Right-click anywhere on the Model View andclick anywhere on the Model View and select “Scale by factor f”. (scales the original sketch profile by a factor of 1.05).

• Right-click on the Model View and select “Paste at Plane Origin” Ourselect Paste at Plane Origin . Our reference point was the sketch origin from Plane5, and the pasting location is the origin on Plane6, so this copies the rectangle onto Plane6 and scales it by 1 05 Right




1.05. Right-click on the Model View and select and left-click End.

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Create the flange sketch #4 (cont’d)– [Modeling] > Unnamed > Plane5 >

Sketch3

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Sketch3• Right-click on Sketch3 and select

“Always Show Sketch”– [Modeling] > Unnamed > Plane6 >

Sketch4 er

• Right-click on Sketch4 and select “Always Show Sketch”. This makes both sketches visible at the same time, so we can easily see that the

i i l fil i i d d l d boriginal profile is indeed scaled by a factor of 1.05.




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7. Create the flange – Toolbar: Skin/Loft

• Select the Skin/Loft icon

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• Select the Skin/Loft icon• and the Details view, Profiles should

be active. • Hold the CTRL key and, from the

graphics window select the four ergraphics window select the four sketches shown at the right in the direction noted by the solid arrow. They will highlight in yellow.

• Note: it is only necessary to select one line from each sketch.

• Apply• A grey line appears showing the

lofting behavior. In this case, the l fti i t t it ill ‘t i t’lofting is not correct, as it will ‘twist’ the geometry. If your grey line does not seem correct, this can be resolved by right-clicking anywhere on the Model View and selecting “Fix Guide




gLine”.

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Create the flange (cont’d)• Select the four vertices, which are

circled on the top-right image This

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circled on the top right image. This redefines the lofting guide such that the model will not ‘twist’.

• After this is done correctly, you can note on the bottom-right image that erthe guiding profile, shown in grey, is now defined correctly.




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Create the flange section (cont’d)– Set the ‘Merge Topology’ option to ‘Yes’.

Toolbar: Generate

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– Toolbar: Generate• The resulting solid (shown here in

wire frame display) appears on the right.

Notes: Setting ‘Merge topology’ to yes erNotes: Setting Merge topology to yes optimizes the number faces for the skin/loft operation. This results in a smoother surface mesh.




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8. Create the pipe bend– [Modeling] > Unnamed > XYPlane– Toolbar: New Sketch

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Toolbar: New Sketch• Sketch5 will be created on XYPlane• Choose the “Look At” icon• In the Details view, rename Sketch5

to “RevolveAxis” erto RevolveAxis .– [Sketching] > Draw > Line

• Create a single line as shown on the bottom-right. Make sure it has an auto-constraint of “V” (vertical).( )

– [Sketching] > Dimensions > General• Dimension the distance of the line

from the vertical axis Y as “15”.




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Create the pipe bend (cont’d)– [Modeling] > Unnamed> XYPlane >

BaseCircle

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BaseCircle– Toolbar: Revolve

• In the Details view, change Base Object to “BaseCircle”.

• Add “RevolveAxis” as the Axis. erAdd RevolveAxis as the Axis.• Look at the Model View. The

revolution operation is in the wrong direction, so change Direction to “Reversed” with the pull-down menu.

• Change FD1, Angle (>0) to “45”. The revolve preview should look similar to the top-right image.

– Toolbar: Generate• This will generate the pipe bend.




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9. Create New Plane at the pipe end• Left click the pipe end to highlight it, click New Plane icon, leave everything as default in

detailed window, click Generate.

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detailed window, click Generate.– Toolbar: Extrude

• In the Details view, change FD1, Depth (>0) to “10”– Toolbar: Generate

• The straight end of the pipe should be generated er• The straight end of the pipe should be generated.




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• You have created one end of the catalytic converter. To create the other end, you can copy the solid part you have created to a new plane. gnM

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• The first step is to create the destination plane. Select Plane 6 from the tree view. You can see that it is located at the base of the solid part. Make sure that Plane 6 is selected as the Active Plane and click on the New Plane icon Plane 8 will be located 20 cm

erthe New Plane icon. Plane 8 will be located 20 cm from Plane 6 in the +z direction. You should also reverse the normal direction. Once you have entered the data, click on Generate to create Plane 8.

• You will now copy the solid part you have created from py p yPlane 6 to Plane 8. Click on Create/Body Operation and change the type to Copy. Select the Body and click Apply. Set the Source Plane to Plane 6 and the Destination Plane to Plane 8 and click Generate.




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You will now complete the model by extruding the sketch on Plane 6 to the base face of the new end of the catalytic converter that you just created. gnM

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y y jNotes: This new solid will represent the porous region of

the converter. To be able to identify this internal mesh region and set flow resistances, this solid should NOT be merged with the rest of the geometry. T k it t d it ill b t d ‘F

erTo keep it separated it will be generated as a ‘Frozen Material’.

Set the 3D operation to be Extrude.Click in the Base Object List, highlight Sketch 4 in the tree

view (located as a sub object of Plane 6) You shouldview (located as a sub-object of Plane 6). You should see the base profile of the first end section become highlighted. Click Apply.

Set the the Operation to ‘Add Frozen’ and the Type to ‘To Next’.




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Click on Generate to add the material. Note that the number of bodies and parts has now increased to three. gnM

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dm chapter 4 3d geometry

Documents

frozen body

solid body

body states

single body

volume surface body

different body types

individual bodies

separate bodies