DM Chapter 4 3D Geometry

Chapter 4 3D Geometry
May 11, 2007 2007 ANSYS, Inc. All rights reserved.
ANSYS, Inc. Proprietary
Inventory #002496 4-1
Contents
Training Manual
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Bodies and Parts 3D Features Boolean Operations Feature Direction Feature Type Primitives Workshop 4.1
Bodies and Parts

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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 DesignModeler contains three different body types: Solid body: body has surface area and volume Surface body: body has surface area but no volume Line Li b body: d b body d consists i t entirely ti l of f edges, d no area, no volume l By default, DM places each body into one part by itself
Individual parts will always be meshed separately. If bodies in separate bodies share faces, the meshes on those shared faces will not be matched
Multiple bodies in a single part will have matched meshes on shared faces when meshed
Active and Frozen Bodies

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By default, DM will merge new geometry with existing geometry to maintain a single body. This can be controlled by working with either frozen or active bodies You can toggle between frozen and active states for using the Freeze and Unfreeze tools
Active and Frozen Bodies

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There are two body states in DM: Active: 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, solid surface 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. 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.
Active
Frozen
Bodies and Parts

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Body Suppression: Suppressed bodies are not plotted. 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). In I the th tree t view i an X is i shown h near suppressed db bodies di Unsuppressed
Suppressed
Bodies and Parts

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Parts: By default, the DesignModeler places each body into one part by itself. You can group bodies into parts Multibody parts contain multiple bodies (volumes), but have shared topology. The 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 The Form New Part option is available only when bodies are selected and you are not in a feature creation or feature edit state.
Bodies and Parts

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Why multi-body parts? Example: In DM: 3 parts, 3 bodies consisting of 3 solids During Meshing: 3 solids, 3 bodies Each solid meshed independently Nodes are not shared Nodes do not line-up In Simulation: 3 solids with 2 contact regions
Mesh
DM
Bodies and Parts

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Example (continued): In DM: 1 part, 1 body consisting of 1 solid During Meshing: 1 solid ,1body Entire solid meshed as one
DM
No Contact
Mesh
DM
Bodies and Parts

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Example (continued): In DM: 1 multi-body part, 3 bodies/solids During Meshing:1 multi-body part, 3 bodies/solids Each solid meshed independently but node d connectivity ti it among solids lid i is preserved
DM
Mesh
DM
May 11, 2007 2007 ANSYS, Inc. All rights reserved. ANSYS, Inc. Proprietary
3D Features
Training Manual
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You create 3D geometry from 2D sketches by creating a 3D feature. Common examples include: Extrude 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.)
3D Features
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Typically, the generation of a 3D feature (like Extrude or Sweep) consists of two steps: (a) Choose the desired feature and specify its details (b) Generate the feature bodies
Each 3D feature creation is controlled via the associated details The last step in creating 3D features is to click Generate
Extrude
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Extrusions:
Extrusions include solids, surfaces, and thin-walled features
To create surfaces, f select as thin/surface / f 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, p direction, and Boolean operation 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 Surface
Revolve
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Revolve: Active sketch is rotated to create 3D geometry 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 ect o Property ope ty for o Revolve: e o e Normal: Revolves in positive Z direction of base object Reversed: Revolves in negative Z direction of base object 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 creation
Sketch with Disjoint Line
Sweep
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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 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 p profile as it sweeps p along g the p path 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 Alignment: Ali t Path tangent: reorients the profile as it is swept along the path to keep the profile in the path's tangent direction Global: the p profile's orientation remains constant as it is swept p along g the path, regardless of the path's shape Examples . . .
Sweep
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Sweep example 1:
Path Tangent alignment: profile fil remains i tangent t t to t path Sketch1 = profile to sweep
Sketch2 = sweep path
Global Axes alignment: profile orientation p remains constant
Sweep
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Sweep example 2:
Sweep details: Scale = 0 0.5 5 Turns = - 4
Sketch1 = profile to sweep
Sketch2 = 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, 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
Skin/Loft
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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) 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 Ope Open a and dc closed osed p profiles o es ca cannot ot be mixed 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 tree After Af selecting l i an adequate d number b of f profiles, fil a preview i will ill 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 . . .
Skin/Loft
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Skin/Loft example 1: Three 5 sided sketch profiles have been created on three offset planes After selecting each profile (hold CTRL key) the guide line is displayed RMB for guide line options Continue through all profiles
Skin/Loft
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Skin/Loft example 1: Add operation generates 3D solid Guide Lines: Use RMB options to realign if necessary Can result in unexpected shapes when misaligned sa g ed
Skin/Loft
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Skin/Loft reordering: During creation or when editing selections the order of the profiles may be adjusted Highlight profile to reorder and RMB Choose from options menu
3D Feature Details (Extrude)

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3D Feature
Boolean Operations p
Frozen B di in Bodies i model?
Its all in the details!

Boolean Operations
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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 Cut Material: removes material from active bodies Slice Material: slices frozen bodies into pieces. Available only when ALL bodies in the model are frozen Imprint I i t Faces: F Similar Si il to t Slice, Sli except t that th t only l the th faces f of f the th bodies b di are split, lit and d edges d 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 Cut, Imprint Imprint, and Slice operations If frozen:
Boolean Operations
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Boolean Add:
Choose feature and Boolean operation to be performed on the active sketch
Extrude Add Material shown here
Note: If bodies already exist, add results in merged geometry after Generate
Boolean Operations
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Boolean Cut:
Existing solid (shown in wire frame for clarity)
Revolve with Cut operation
Axis of revolution
Active Sketch
Boolean Operations
Training Manual
Boolean Imprint Faces: Imprint Face operation allows continuous surface to be segmented (see below). below) Useful for applying FE boundary conditions at arbitrary locations.
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Active sketch to extrude
Extrude E tr de with ith Imprint Faces operation.
Boolean Operations
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Boolean Add Frozen: Similar to add operation but results in separate bodies (or single frozen body)
Active sketch to extrude
Extrude with Add Frozen operation
Boolean Operations
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Boolean Slice (all bodies must be frozen): Slices frozen bodies leaving new (frozen) body in the slice region
New frozen body
Active sketch to Extrude
Extrude with Slice operation
Feature Direction
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Direction:
Direction is with respect to the sketch plane Some operations (e.g. cut) result in automatic change in direction
Feature Type
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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 model
Feature Type
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To Next: Add will extend the profile up to the first surface it encounters. Cut, Cut Imprint Imprint, and Slice will extend the profile up to and through the first surface or volume it encounters
Feature Type
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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 p p profiles make sure that each p profile has at least one face intersecting g its extent. Otherwise, an extent error will result
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
Feature Type
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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) 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.
Unbounded surface selected as extent

Primitives
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Primitive Shapes: Create>Primitives Quickly create models by defining primitive shapes like spheres, cylinders etc.. Does not require sketches Requires a Base Plane and several point and / or direction inputs Inputs can be defined by typing in coordinates or by selecting existing geometry.
Primitives..
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Primitive Shapes Example: Cylinder Select Base Plane Define Origin Define Axis (also defines the height of the cylinder) Define radius Generate
Catalytic Converter
Workshop 4-1
Workshop 4-1, Catalytic Converter

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Goals:
Create the catalytic converter model shown below as 3 separate bodies. (Design Modeler) Create separate sketches and perform a skin/loft operation to make the converter body. (Design Modeler)

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1. Launch ANSYS Workbench and start new geometry Click Start > Programs > ANSYS 10.0 > ANSYS Workbench 2. Launch DesignModeler and start new geometry Left click Geometry After new window pops up, select l C Centimeter i f for length unit, then click OK

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3. Create the flange sketch #1 [Modeling] > Unnamed > XYPlane Toolbar: New Sketch Sketch1 will be created on XYPlane In the Details view, rename Sketch1 to BaseCircle. Toolbar: Look Look At At icon [Sketching] > Draw > Circle Move the cursor over the sketch origin, then when the P is displayed (auto-constraint) (auto constraint), click on the left mouse button. Click again to define the radius. [Sketching] > Dimensions > Radius , then Click on the circle to select it, 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 (contd) [Sketching] > Modify > Split at Select Right click anywhere on the Model view and select Split Edge into n Equal Segments from the pop-up menu. The Split tool will now change to Split Equal q Segments. g Enter 8 for the textbox 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 segments 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 p y this, we will first reorient the circle by using a Move command.

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Create the flange sketch #1 (contd) On the Selection Toolbar, select the New Selection Selection icon . New Click on the Select Mode icon and choose Box Select
Left click and drag to draw a box, selecting the entire circle. [Sketching] > Modify > Move In I the th text t t boxes b next t to t the th Move M tool, change r= to 22.5 and f= to 1. Right-click on the Model View and select Use Plane Origin as Paste Handle. Handle . This will make the moving reference point as the original, relative location of the sketch origin.

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Create the flange sketch #1 (contd) Right click anywhere on the Model View and select Rotate Rotate by r Degrees. This makes the moving operation include a rotation, as specified by the value of 22.5 degrees entered earlier. 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 was origin. the origin, this results in no translation but only a rotation, specified by r=22.5. Right click anywhere on the Model View and select and left-click End. This completes the Move operation.

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Create the flange sketch #1 (contd) You should see that the segments have been rotated by 22.5 degrees. Click on the Select Mode icon and choose Box Select
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 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 Select the New Plane icon from the Active Plane/Sketch Toolbar. This creates Plane4 based on XYPlane. , set Transform 1 to In the Details view, 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 sketch. k t h

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Create the flange sketch #2 (contd) Right-click on the Model View and select Paste Paste at Plane Origin. 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 circle i l onto t Sketch2 Sk t h2 with ith a scale l f factor t of f=1.05.
Right-click Ri ht li k on th the Model M d l Vi View and select and left-click on End. This terminates the Paste operation.

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Create the flange sketch #2 (contd) [Modeling] > Unnamed > XYPlane > BaseCircle Right-click on BaseCircle and select Always Show Sketch [Modeling] > Unnamed > Plane4 > Sketch2 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 the 1.05 scale factor.

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5. Create the flange sketch #3 Toolbar: XYPlane Toolbar: New Plane Select the New Plane icon from the Active Plane/Sketch Toolbar. This creates Plane5 based on XYPlane. In the Details view, 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, g and click a third time to define the fillet radius.

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Create the flange sketch #3 (contd) [Sketching] > Dimensions > General Dimension the sketch as shown at right. In the Details view, change Dimensions to be the values shown in the right plot On the toolbar click New Selection icon and set the mode to Box Select Left click and drag to select the entire sketch. [Sketching] > Modify > Copy Right-click anywhere on the Model View and select Use Use Plane Origin as Paste Handle.
10 6
10

Training Manual
6. Create the flange sketch #4 [Modeling] > Unnamed > Plane6 Highlight XY Plane 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 Offset Z, change FD1, Value to 6. Toolbar: Generate [Sketching] > Modify > Paste Enter 0 for r= and 1.05 for f=. Rightclick 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 Paste at Plane Origin 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. Rightclick on the Model View and select and left-click End.
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Create the flange sketch #4 (contd) [Modeling] > Unnamed > Plane5 > Sketch3 Right-click on Sketch3 and select Always Show Sketch [Modeling] > Unnamed > Plane6 > Sketch4 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 original i i l profile fil i is i indeed d d scaled l db by a factor of 1.05.

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7. Create the flange Toolbar: Skin/Loft 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 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 lofting is not t correct, t as it will ill t twist i t the geometry. If your grey line does not seem correct, this can be resolved by right-clicking anywhere on the Model View and selecting g Fix Guide Line.

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Create the flange (contd) Select the four vertices, which are circled on the top-right top right image. 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 the guiding profile, shown in grey, is now defined correctly.

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Create the flange section (contd) Set the Merge Topology option to Yes. Toolbar: Generate The resulting solid (shown here in wire frame display) appears on the right. Notes: Setting Merge Merge topology 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 Sketch5 will be created on XYPlane Choose the Look At icon In the Details view, rename Sketch5 to RevolveAxis 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 (contd) [Modeling] > Unnamed> XYPlane > BaseCircle Toolbar: Revolve In the Details view, change Base Object to BaseCircle. RevolveAxis as the Axis. Add RevolveAxis 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. Toolbar: Extrude In the Details view, change FD1, Depth (>0) to 10 Toolbar: Generate The straight end of the pipe should be generated 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. 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. 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 py the solid p part y you have created from Plane 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 y converter that y you j just created. Notes: 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 keep To k it separated t d it will ill b be generated t d as a F 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 sub-object object of Plane 6). 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.

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Chapter 4 3D Geometry

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

ANSYS, Inc. Proprietary

Inventory #002496 4-1

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

ANSYS, Inc. Proprietary

Inventory #002496 4-2

Bodies and Parts

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

ANSYS, Inc. Proprietary

Inventory #002496 4-3

Active and Frozen Bodies

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Active and Frozen Bodies

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ANSYS, Inc. Proprietary

Inventory #002496 4-5

Bodies and Parts

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

ANSYS, Inc. Proprietary

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Bodies and Parts

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ANSYS, Inc. Proprietary

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Bodies and Parts

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Bodies and Parts

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Bodies and Parts

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Sketch with Disjoint Line

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Sketch2 = sweep path

Global Axes alignment: profile orientation p remains constant

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Sweep details: Scale = 0 0.5 5 Turns = - 4

Sketch1 = profile to sweep

Sketch2 = sweep path

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