Slovak University of Technology

Faculty of Material Science and Technology in Trnava

CAD/CAM Systems
Course Slides
Note:
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Contents

Historic Milestones, Concepts & Terminology

Computer-Integrated Manufacturing (CIM)
Computer-Aided Design (CAD)
Computer-Aided Manufacturing (CAM)
Computer-Aided Design & Manufacturing
(CAD/CAM)
PLM/PDM
Rapid Prototyping, Concurrent Engineering &
Reverse Engineering
CATIA

Introduction

It has long been the dream of the industrial system

engineers to integrate the operating units in order to be
able to produce products at minimum cost and at maximum
overall profit.
CAD/CAM can improve productivity, product quality, and
profitability.
CAD/CAM is a common method of manufacturing used by
many corporations.
The term CAD/CAM is a shortening of Computer-Aided
Design (CAD) and Computer-Aided Manufacturing (CAM).
CAD/CAM software uses CAD drawing tools to describe
geometries used by the CAM module of the program to
define a toolpath that will direct the motion of a machine
tool to produce the exact shape that was drawn.
A CAD system is a combination of hardware and software
that enables engineers and architects to design products.
Until the mid 1980s, all CAD systems were specially
constructed computers.

Three Requirements for Production

1.

Build and deliver products in response to the

demands of the customer at a scheduled
delivery time

2.

Provide an acceptable quality level

3.

Provide everything at the lowest possible cost

Product Improvements With Computer

Technology

Computer-Aided Design - CAD

Computer-Aided Manufacturing - CAM

Computer-Integrated Manufacturing - CIM

Production Techniques

Flexible Manufacturing

Lean Manufacturing

Mass Customization

Historic Milestones,
Concepts & Terminology

Scientific Management
Frederick Winslow Taylor (1856-1915)
The Principles of Scientific Management (1911)

U.S. engineer and management consultant, originator of the concept of "scientific management" to
increase worker output. Taylor grabbed public attention in the 1880s when he reduced the number
of workers shoveling coal at the Bethlehem Steel Works from 500 to 140 without loss of
production.

According to Taylor, industrial productivity was lower than it ought to be due to two factors:
deliberate malingering by workers and unscientific design of work practices by management. He
held that workers could be forced to put the maximum effort into work by a combination of
motivating them with higher wages, financed on the basis of higher productivity, and most
significantly, by closely monitoring the workers every movement so that it was impossible to go
slow without detection. In order to achieve the maximum productivity, Taylor proposed that instead
of reducing the number of "unproductive" workers to a minimum, about 25% of all employees
should be dedicated to supervising, monitoring, measuring and accounting. This was the beginning
of the stratification of the working class into more and more layers of supervisory, administrative
and technical workers, enjoying privileges over and above the "blue-collar" trades they supervised.

The symbol of Taylors management methods was the stop-watch, ever-present as supervisors
conducted "Time and Motion Studies", timing every hand-movement, every step, every breath a
worker made. Hatred against the stop watch built up to such a pitch that by 1912 laws were
passed in the U.S. banning the use of stop-watches in the civil service.

Lenin studied "Taylorism" with a view to applying the progressive and genuinely scientific aspects
of his theory to Soviet industry.

History of CAD/CAM
4 major phases of development
1950s: Start of interactive computer graphics,

CRT

(Cathode Ray Tube),

NC (Numerical Control),
APT (Automatically Programmed Tools)

1960s: Critical research period for interactive

computer graphics
Sketchpad

by Ivan Sutherland, CAD,

Lockheed initiated CADAM,
Storage tube-based turnkey system

History of CAD/CAM contd.

1970s: Potential of interactive computer

graphics was realized by industry:
SIGGRAPH,

NCGA, IGES,
Golden era for computer drafting,
Wireframe modeling

1980s: CAD/CAM heady years of

research,
Integration,

Solid modeling

1990s: CIM, EDB, PDM, CALS, VR

Background

In todays global competition, industries cannot survive unless they

introduce new products or existing ones with:
Better quality
Lower cost
Shorter lead time

Computers have come to play an important role in helping

industries achieve these goals:
Enables automation
Helps integration of cumbersome and separate life cycle
tasks
The CE Paradigm:
CAD/CAM facilitates CE based Product and process design.

Key Technologies
CAD,

CAM, CAE
To understand the role of CAD and
CAM, we need to examine the various
activities and functions that must be
accomplished in general in life-cycle

Traditional View of Product Life Cycle

Taken from Principles of CAD/CAM/CAE

By Kunwoo Lee

Main Areas of the Product Life Cycle

Two focus areas

Product design
Process design
Product design:
Starts from the customers demands that are identified by marketing
personnel
Ends with a complete description of the product, usually in the form of a CAD
model
Process design:
Starts from manufacturing planning, mfg., assembly, testing and shipping
There has to be concurrency of product and process design (CE)
Product design activities:
Initially, synthesis sub process
Identification of design need, formulation of design specs., design
conceptualization

Simplified Flow Chart of the Route from the Order to the

Finished Product

CAD/CAM Systems An Overview

Unclassified Overview of CAD & CAD/CAM systems:

http://www.freebyte.com/cad/cad.htm

There are a variety of systems and programs available in the CAD/CAM industry and new
programs are frequently introduced.

Pro/Desktop
AutoCAD

Architectural Desktop

Mechanical Desktop
OtherCAD

CADDS

Medusa Euclid
Unigraphics
Autodesk Inventor
Solid Edge

MicroStation

CATIA

Allplan

VariCAD

ArchiCAD
SolidWorks

Pro/ENGINEER
TurboCAD

I-DEAS

PowerCAD

ME 10
CADKEY

Concepts Terminology

CIM - Computer - Integrated Manufacturing

CHIM Computer - Human - Integrated Manufacturing
IMS - Integrated Manufacturing Systems
CAD - Computer - Aided Design
CAM - Computer - Aided Manufacturing
CAPP - Computer - Aided Process Planing
CAD/CAM - Computer - Aided Design and Manufacturing
CADMAT - Computed - Dided Design, Manufacturing and Testing
PLM/PDM - Process Lifecycle Management / Process Data Management
FMS - Flexible Manufacturing Systems
RE Reverse Engineering
CE - Concurrent Engineering
RP Rapid Prototyping

Computer - Integrated
Manufacturing

What is CIM?

The integration of business, engineering, manufacturing and management

information that spans company functions from marketing to product
distribution.

CIM is a unified network of computer systems controlling and/or providing

information to the function of a manufacturing business in an integrated way.
(Thomas, 1986)

Computer integrated manufacture (CIM) refers to the integrated information

processing requirements for the technical and operational tasks of an
industrial enterprise.
(Scheer, 1986)

CIM relates to the use of computers for integrating the flow of

information to aid the overall control of a manufacturing unit. .
(Parnaby et al., 1986)
...

The Evolution of CIM

CAM

CAPP

EDI
CAD

ROBOTICS
NC
FMS
CAPM
GT

DNC
CNC
FMC
MRP
OPT
JIT
TPM

CIM
CAE
AMT

VM
PDM
CE/SE
AM

MRPII
WCM
LM

QC
1960

1970

QA
1980

TQM
1990

Change in Manufacturing Emphasis,

after Scott (1994)

Philosophy
Techniques
Product range
Tooling
Fixed costs
Labour costs
Product life cycle
Competition
Customers
Inventory
Pricing

1960s

1990s

production led
simple
narrow
dedicated
low
high
long
national
stable
order point
cost plus

market led
complex
wide
flexible
high
low
short
global
demanding
just-in-time
market driven

The Need for Integration & Standardisation

Dedicated and Open Systems

Manufacturing Automation Protocol (MAP)

General Motors (circa 1980s) recognized

New CAD/CAM system or robot or data collection system
Required new cabling and networking facilities
Different vendors DIFFERENT implementation requirements
only 15% (approx) of 40 000 shop floor devices communicated beyond their
own processes
40% of total investment used in communication related activities.

Ford (1995/96)
Moved to single (reliable) supplier of CAD systems rather than pursue mix &
match strategy.

Stages of CIM Development

Note:

Computerization of function
Islands of automation
Interfacing
Integration

advances in computing, information technology,

database technology, communications, etc. have supported
the development of CIM.

Islands of Automation
Designer creates geometry

CAD

Drawing
of part
Manual geometry
specification

CAD
geometry

APT commands

NC Package
Includes
tooling
and
cutting
technology
database

Part program
(punched on to
cards and verified)
APT processor
CL file

Data link

Post-processor
for machine

Plot

NC tape is
Manually loaded
Machine
1960s

Machine
Developments in NC tape generation

1980s

CIM

Computer-integrated manufacturing (CIM) in engineering is a method of

manufacturing in which the entire production process is controlled by computer.
The fact that CAD, CAE, and CAM work best together has led to the breakdown
of many of the traditional barriers between functional and manufacturing units.
The goal of CIM is a database, created and maintained on a factory-wide
computer network, that will be used for design, analysis, optimization, process
planning, production scheduling, robot programming, materials handling,
inventory control, maintenance, and marketing.
Functional areas such as design, analysis, planning, purchasing, cost
accounting, inventory control, and distribution are linked through the computer
with factory floor functions such as materials handling and management,
providing direct control and monitoring of all process operations.
CIM may be viewed as the successor technology which links Computer-Aided
Design (CAD), Computer-Aided Manufacturing (CAM), robotics, numerically
controlled machine tools, automatic storage and retrieval systems, flexible
manufacturing systems (FMS), and other computer-based manufacturing
technology.
CIM is also known as Integrated Computer-Aided Manufacturing (ICAM).
The CIM factory concept includes both soft and hard technology. Soft
technology can be thought of as the intellect or brains of the factory, and hard
technology as the muscles of the factory.
Whatever the products, the CIM factory is made up of a part fabrication center,
a component assembly center, and a product assembly center. Centers are
subdivided into work cells, cells into stations, and stations into processes.

Characteristics of CIM
Complete automation of a manufacturing
plant
Processes functioning under computer
control
Digital information tied them together

Typical Elements of a CIM System

CIM system
manufacturing planning & control
- MRPII, MRP, CRP, shop floor control, inventory control,
manufacturing engineering
- CAD/CAM, CAPP, coding & classification,
manufacturing processes
- NC/CNC/DNC, FMS, robots, material handling systems,
indirect elements:
- sales order processing (& marketing)
- finance & accounting

Key Challenges
Integration of components from different
suppliers
Data integrity
Process control

Y CIM Model after A.-W. Scheer

All operational information
systems of an industrial
company are to be linked by
CIM with one another.
Is the center of attention in
particular the connection
between commercial and
technical systems.
The Y-CIM-model of August
William Scheer shows the
components of both ranges
taken part in the integration in
descriptive form.

Characteristics:
The Y-model tries to represent
functions at their expiration, to
detailing up to level data and
working model.
Restriction on production, no
holistic model of the industrial
company
Differentiation between technical
and economical tasks.

CIM Model after Helberg

CIM Wheel

Cyber Manufacturing What Does It Mean?

See:

http://www.mazak.jp/english/

What is Required?
Standard for the product data
Easy to use
Internationalization

Data and Process Integration (Scheer, 1988)

Integrated Product Model

Integrated Digital Product Line

MFG Engineering
NC Programming

2D Drawing
Authority

Manufacturing

2D Drawing
Interpretation

Quality Assurance

Tooling

3D Design
3d Model Oriented
Detail Assembly

3D Model Release
And Authority

2D
Assembly
3Ddrawing
Model Assembly
Inspection

3D Measurement
Equipment

Product
Product

Development of Standards for Data Exchange

STEP (ISO 10 303)

STandard for the Exchange of Product data

Protocol for neutral form of data definition
Covering the full range of product data
Over the complete life cycle
Independent from any particular system
PDES (Product Data Exchange Using Step)

Why needed?
Collaborative e-engineering
Assure the quality of the communicated product model
data
Relationship of contractor, subcontractor, customer or
supplier

Criticism
Automation, robots = less jobs
Ignoration of human and organizational
factors
Result = CHIM (Computer and HumanIntegrated Manufacturing) appeared

Computer-Aided Design

CAD Intro

The application of digital computers in engineering

design and production.
Computer-aided design (CAD) refers to the use of
computers in converting the initial idea for a
product into a detailed engineering design.
The evolution of a design typically involves the
creation of geometric models of the product, which
can be manipulated, analyzed, and refined.
In CAD, computer graphics replace the sketches
and engineering drawings traditionally used to
visualize products and communicate design
information.

CAD - History
Four decades of CAD evolution:
1970s Academic development and large institutional pilots (little or no CAD standards,
data exchange or project collaboration).
1980s Vendor developed systems, Mini, Unix and PC based, AutoCAD & MicroStation
launched (CAD standards and data exchange start to emerge, project collaboration still a
pipe dream).
1990s Large, Medium, Small client server CAD networks become the norm (mainly
windows based), CAD standards and data exchange are commonplace (sometimes
supported by contractual Terms & Conditions) project collaboration and drawing
management systems start to emerge.
2000 onwards Critical mass of data starts to impact medium to large systems, extensive
use of drawing management and project collaboration systems. CAD standards
supported by contractual Terms & Conditions. CAD QA (sometimes automated) starts to
emerge.

CAD History contd.

CAD - An acronym for Computer Aided Design. It is synonymously used for Computer Aided Drafting too.

CAD is a computer graphics

software that is commonly used
to design products and make
engineering drawings.

1950: Light pen & vector display

SAGE (Semi-Automatic Ground Environment) developed in M.I.T. Lincoln Labs.

CAD History contd.

Vector refreshable display

CAD History contd.

Minicomputer PDP-11/40 with TU56 dual DECtape

drive.

CAD History contd.

Workstation IBM 6090 with display resolution 1024x1280px and

24 bit color depth (1978)

A typical
CAD Process

Logical Model of Design Process

(Archer,1968)
Real world
Op e ra tio n al mo d el
A n alo gu e s

Syst e mat ic mo de l

O m1

Om 2

O m3

O m4

A1

A2

A3

Sm 1

Sm 2

Sm 3

P1

P2

P3

Phase 1

Phase 2

Phase 3

De sig n pro gra m

P rob le ms

De sig n pro ce ss

A Model of the Design Process

Depicted as DFD

Definition of CAD Tools Based on Constituents

Definition of CAD Tools Based on Implementation

Design Documentation
CAD

models, reports and design bill of

materials
In traditional environment, the product
designers focus on product design
activities
Once design is documented it is passed
on to manufacturing

Use of CAD Technology

Design conceptualization and feasibility can be aided

by CAD systems
Design conceptualization involves the intellectual
creative process
While computer systems havent advanced to
completely support this task, they can contribute by
physically generating various conceptual designs
efficiently (CAD based geometric modeling system)
Analysis activities can be facilitated by use of CAE
technology

Coordinate Systems

Object coordinates
World coordinates
Camera coordinates
Normalized device coordinates
Window coordinates

3D Coordinates

The 3D coordinates can be entered using the

following formats:
Cartesian

coordinates
Spherical coordinates
Cylindrical coordinates

World Coordinates
Common coordinates
for the scene
O

M wo = TSR

Normalized Device Coordinates

Device independent coordinates
Visible coordinate usually range from:

1 x 1
1 y 1
1 z 1

Window Coordinates
Adjusting the NDC to fit the window

( x 0, y 0 )

is the lower left of the window

Window Coordinates
Adjusting the NDC to fit the window

( x 0, y 0 )

is the lower left of the window

height

width
xw = ( xnd + 1)
+ x0
2
height
yw = ( ynd + 1)
+ y0
2

width

Window Coordinates Transformation Matrix

width
2

M w_ p 0

0
0

0
height
2
0
0

0
0
1
0

width
x0 +
2
height
y0 +
2
0
1

Object Coordinate to Device Coordinate

Take your representation (points) and transform

it from Object Space to World Space (Mwo)
Take your World Space point and transform it to
Camera Space (Mcw)
Perform the remapping and projection onto the
image plane in Normalized Device Coordinates
(Mw_p Mpc)
Perform this set of transformations on each point
of the polygonal object (M= Mw_pMpcMcwMwo)

Modeling

The mathematics behind the creation and

manipulation of the 3D representation of the
object.

Model

Computer

Image

Modeling vs. Drafting

A primary and essential difference between modern CAD/CAM (Pro/ENGINEER, Catia,) and
traditional computer aided drafting systems is that CAD models are three dimensional
In CAD, drawings are produced as view of the model.
Models are NOT drawn so much as sculpted from solid volumes of materials.

Drawing

Model

Traditional CAD

Model

Drawing

Modern CAD/CAM

3D Geometric Modeling

3D modeling capabilities allow to create 3D images that are as realistic as

the actual objects. These images are called 3D models because, just like a
physical model, they can be rotated on the screen. We can display views
from a 3D model, such as isometrics or perspectives, from any angle with a
few simple steps. 3D modeling is usually a separate CAD module that has
its own set of functions.

The 3D models fall into the following categories:

Wire-frame models
Surface models
Solid models

Objects Representation in CAD

(3D Models)

Solid model

Wireframe model

Surface model

Wireframe Model and Viewing Ambiguity

A wire frame model is a visual presentation of a three dimensional physical object used in 3D
computer graphics. It is created by specifying each edge of the physical object where two
mathematically continuous smooth surfaces meet, or by connecting an object's constituent
vertices using straight lines or curves. The object is projected onto the computer screen by
drawing lines at the location of each edge.

Wireframe model

Possible interpretations

Criteria for Object Representation in CAD

Modeling
Representation

power
Interactivity support
Transformation and combination
Multiple use

Rendering
Representation

precision
Memory requirements

Data Representation of Wire-frame Model

Explicit list of Edges
y
Redundancy

Edge Matrix (12x6)

v4

e3

v3

e9
v6 e10

e5

v5

e4

e2
e6

e8
v1

e1

v2

e12
e11
v8

e7

v7

Edge Vertex

e1

0.0

0.0

0.0

1.0

0.0

0.0

e2

1.0

0.0

0.0

1.0

1.0

0.0

e3

1.0

1.0

0.0

0.0

1.0

0.0

e4

0.0

1.0

0.0

0.0

0.0

0.0

e5

0.0

1.0

1.0

1.0

1.0

1.0

e6

1.0

1.0

1.0

1.0

0.0

1.0

e7

1.0

0.0

1.0

0.0

0.0

1.0

e8

0.0

0.0

1.0

0.0

1.0

1.0

e9

0.0

1.0

1.0

0.0

1.0

0.0

e10

1.0

1.0

1.0

1.0

1.0

0.0

e11

1.0

0.0

1.0

1.0

0.0

0.0

e12

0.0

1.0

0.0

0.0

0.0

0.0

Implementation in C as 2D array (static data structure)

double hObjekt[POCETH][6]

Data Representation of Wire-frame Model

List of Edges & Vertices
Edge Matrix (12x2)

Vertices Matrix (8x3)

v4

e3

v3

e9
v6 e10

e5

v5

e4

e2
e6

e8
v1

e1

v2

e12
e11
v8

e7

e1

0.0

0.0

0.0

e2

1.0

0.0

0.0

e3

1.0

1.0

0.0

e4

0.0

1.0

0.0

e5

0.0

1.0

1.0

e6

1.0

1.0

1.0

e7

1.0

0.0

1.0

e8

0.0

0.0

1.0

e9

e10

e11

e12

v7
Indexes of Vertices

Implementation in structure
typedef struct hObjekt {
zoznamV zv;
zoznamH kh;
};

Implementation in C as two 2D arrays

typedef double zoznamV[POCETV][3];
typedef int zoznamH[POCETH][2];

Data Representation of Wire-frame Model

Separating Topology & Geometry
y
Connectivity Matrix (12x2)
v4

e3

v3

e9
v6 e10

e5

v5

e4

e2
e6

e8
v1

e1

v2

e12
e11
v8

e7

v7

Vertices Matrix (8x3)

0.0

0.0

0.0

1.0

0.0

0.0

1.0

1.0

0.0

0.0

1.0

0.0

0.0

1.0

1.0

1.0

1.0

1.0

1.0

0.0

1.0

0.0

0.0

1.0

Implementation of Wire-frame Model in C

(Example)
POCETV maxi. no. of Vertices
POCETH max. no. of Edges

typedef struct bod {

float x,y,z;
};
typedef struct hrana {
bod v1,v2;
};

or

typedef struct hrana {

bod *pv1,*pv2;
};

typedef struct hObjekt {

int pocetH,pocetVrch;
bod zoznamV[POCETV];
hrana zoznamH[POCETH];
}

Static data structures

Data Representation of Wire-frame Model - List

typedef struct zoznamV {

Dynamic Data Structures

double x,y,z;
zoznamV *nextV;

v4

e3

};
typedef struct zoznamH {

v3

zoznamV *zVrchol;

e9
v6 e10

e5

v5

e4

zoznamV *kVrchol;
zoznamH *nextH;

e2

};

e6

e8
v1

e1

v2

typedef struct hObjekt {

e12

zoznamH *zho;

e11
v8

e7

zoznamV *zvo;

v7
e1

e2

e3

e12
NIL

List of Edges

List of Vertices

};

0.0 0.0 0.0

0.0 1.0 0.0

1.0 1.0 0.0

v1

v2

v3

NIL
1.0 0.0 1.0

v8

Data Representation of Wire-frame Model

List with Return Pointer
Start

Data

NIL

Data

Fragment of code in C:
typedef struct vrchol{
int x,y;
vrchol *next;
};
vrchol *temp,*nlink;
temp=(struct vrchol *) malloc(sizeof(vrchol));
temp->x=40;
temp->y=50;
temp->next=NLINK;
nlink=temp;

Data

Data Representation of Wire-frame Model

Relational Database
(0,1)

Relations for object description:

1. Vertex is defined by coordinates x, y.
2. Edge is defined by vertices.

(1,1)

e4

e2

(0,0)

Tab. of vertices

e3

e1

(1,0)

Tab. of edges

No_vertex

No_edge

Z-bod

K-bod

Using of Dynamic Data Structure

Change of configuration
V4

V3

tart

x1

y1

x2

y2

x3

y3

NIL

tart

x1

y1

x2

y2

x3

y3

NIL

V1
x4

y4

V2

Surface Model

CAD software packages use two basic methods for the creation of
surfaces:

The first begins with construction curves (splines) from which the 3D surface
is then swept (section along guide rail) or meshed (lofted) through.
The second method is direct creation of the surface with manipulation of the
surface poles/control points.

From these initially created surfaces, other surfaces are constructed

using either derived methods such as offset or angled extensions from
surfaces; or via bridging and blending between groups of surfaces.

Surface edited by poles (animation)

Surface defined by curves (animation)

Surface Model of the Rotational Part

3D Faces

Surface Model
Data Representation
v4
e9
v5

v3

e3
f5
e5

v6 e10
f3

e8

e2

e6

f2

Edge Matrix (12x2)

Face Matrix (6x4)

1

11

10

12

10

11

12

v2

Static structures

e11
v8

e7

v7

Dynamic data structure

f2

f1

Vertex Matrix (8x3)

0.0

0.0

0.0

1.0

0.0

0.0

1.0

1.0

0.0

0.0

1.0

0.0

0.0

1.0

1.0

1.0

1.0

1.0

1.0

0.0

1.0

0.0

0.0

1.0

10

11

12

List of faces

e1

e2

e3

e12
NIL

List of edges

List of vertices
0.0 0.0 0.0

0.0 1.0 0.0

1.0 1.0 0.0

v1

v2

v3

1.0 0.0 1.0

v8

Classification of Regions for Geometric Modeling

Continuous

region:

K-times

continuous region:

Convex

region:

3-times continuous region

Continuous region
Non-convex region

Convex region

Representation of a Face with Hole

e3

v4

v3
v7

v6
e6
e7

e5

e4

e2

e8
v8

v5
e1

v1

Non-convex 2-times continuous region.

v2

Start & direction of describing

e2

e3

e4

e5

e6

e7

e8

List of half edges

e1

Global cycle
Local cycle

v1

v2

v8

NURBS-Nonuniform Rational B-Splines

NURBS are industry standard tools for the representation and design of geometry.
Some reasons for the use of NURBS are, that they:
offer one common mathematical form for both, standard analytical shapes (e.g. conics) and free
form shapes;
provide the flexibility to design a large variety of shapes;
can be evaluated reasonably fast by numerically stable and accurate algorithms;
are invariant under affine as well as perspective transformations;
are generalizations of non-rational B-splines and non-rational and rational Bezier curves and
surfaces.

See:
http://en.wikipedia.org/wiki/NURBS

Solid Modeling Methods

Easy (2,5D) Modeling Methods (sweeping)

Solid (3D) Modeling Methods
BREP - Boundary Representation
CSG
- Constructive Solid Geometry
Feature Based Modeling
Parametric Modeling
SE - Spatial Enumeration
Spatial Occupancy Enumeration (SOE, voxels)
Binary Space Partitioning (BSP) Tries
Octrees
FREP - Function Representation
Facet Modeling

Solid Model
Interpretation of the Object Volume (Material)

Interconnected open boundaries

Closed boundary

Interior

Exterior

Edges

Notes on Valid Solids

The valid solid surface is locally topological

equivalent with the Euclidean plane.
Which solids are not valid?
Sphere

is equivalent with the plane.

Zero thickness is invalid.

Dangling Edge & Face

Not a solid model!
Dangling face
Dangling edge

Nonsense #1

Not a solid model

Nonsense #2

Not a solid model

Opened Object
Here is not a face

Not a solid model

Manifolds - Topological Consistency Objects

Manifold
The surface of a solid must satisfy some conditions so that the resulting solid is well-behaved. This is the so
called manifold condition.
A surface is a 2-manifold if and only if for each point x on the surface there exists an open ball with center x
and sufficiently small radius so that the intersection of this ball and the surface can be continuously deformed
to an open disk.

Topological inconsistency

Easy (2,5D) Solid Modeling

Sweeping
Idea:

Move a 2D-Object (Contour) in the space.

All enclosed points generate the object swept.
Forms:

Translational sweep
Rotational sweep
Conical sweep
Sphere sweep
General cylinder,

Sweeping

Translational

Rotational

Translational Sweeping

Define the object with the contour (2D) and

the path.

Rotational Sweeping

Define the object by rotating of the contour

(2D) with the arbitrary axis.

Conical Sweeping

Define the object by the contour (2D) and a

3D-point (top of the pyramid).

Sphere Sweeping

Define the object by the sphere with the

varying radius and a path.

General Cylinder

Define the object by the set of controlcontours and by the path.

Quadrics

Quadrics are all objects, which is possible to describe using

quadratic functions (polynomials).

Quadrics - Examples

Half Spaces Representation

BREP

Point list
Elements: 3D coordinates
Linked lists

Face list
Elements: Index lists to the 3D
points
Linked lists

STEP defines data models for boundary representations.

The common generic topological and geometric models are defined in ISO
10303-42: Geometric and topological representation.

BREP Data Structure

Topology and geometry

Teleso
Object

Face

Edge

Vertex

v2

BREP Winged Edges Data Structure

f1

f2
e

weObjekt
pVrch
pHran

weStena

pStien

next

v1

zacVrchol
zacPolhr

vrcholy
steny

wePolhr
T

vid
next
lokalhr
susedp
zacVrchol

weVrchol
x
y
z
next

Winged Edges Data Structure

Alternative to hierarchical BRep
Central element is the edge:

BREP Advantages and Disadvantages

+
Simple

transformations
General representation
Supported by many graphics libraries

Higher

memory requirements
Combinations necessary and non-robust
Approximation of curved objects

The Euler-Poincar Formula Topological Integrity

of BREP Model
Euler-Poincar formula describes the relationship of the number of vertices, the number of edges and the number
of faces of a manifold. It has been generalized to include potholes and holes that penetrate the solid.

fe+v=2
6 12 + 8 = 2

fe+v=2
10 24 + 16 = 2

f e + v - h = 2 (m g)
14 36 + 24 - 2 = 2 (1 1)

CSG

CSG Main Characteristics

Composition of primitives
Primitives: sphere, cone, cube, cylinder, ...
Operations: +, -, , U, ...
Primitives in the leafs and operations build
the rest nodes of the CSG-tree

CSG Boolean Operations

Using 3 operators enables for all possible

combinations - not uniquely

CSG tree

CSG Rendering

Rendering Algorithms
Ray

casting (tracing)
Extended depth buffer algorithm

Evaluation/Conversion Algorithms
Boundary

representation

Octree
Constructive

cubes

CSG Advantages and Disadvantages

+
Low

memory consumption
Simple combining
Exact representation of complex surfaces
12 Mantylas operators and his proof

Slow

and difficult processing

Not unique representation

CSG Regular Boolean Operations

Basic-Operations:
Union

U*
Intersection
Subtraction -*

*U

CSG - Regular Boolean Operations

S
R
Union

Intersection

RS

RS

R *S

R *S

Subtraction

R-S

R - *S

SE - SOE (Voxels Representation)

Dividing the volume into the regular grid

Elements: equally sized cubes (voxels)
Each element has density (Hounsfield)
Main applications:

Scientific

visualization
Medical data visualization (CT, MR, US, ...)

SOE - Voxels
Solid

Octants definition

BSP Trees
A Binary Space Partitioning (BSP) tree is a standard binary tree used to sort and
search for polytopes in n-dimensional space. The tree taken as a whole
represents the entire space, and each node in the tree represents a convex
subspace.

Subdivisions in half spaces

Generating the binary tree sequentially - from the start
polygon until all polygons processed
Nodes represent polygons
Node attributes:
Plane equation
Normal vector
See:
ftp://ftp.sgi.com/other/bspfaq/faq/bspfaq.html#6.txt

Generating BSP Trees

1.
2.

For convex objects trivial - lists

BREP traversal:

Polygon search, with least points of intersection

Subdivide the face list: 2 parts (in/out)
Insert polygon into tree, recursive subtrees
processing

BSP Tree - example

An easy way to think about BSP trees is to limit the discussion to two dimensions. To
simplify the situation, let's say that we will use only lines parallel to the X or Y axis,
and that we will divide the space equally at each node.

BSP Trees Advantages and Disadvantages

Easy transformable
Fast rendering with correct visibility
Universal like Brep

Higher memory consumption

Curved objects to be approximated

Octrees

Iterative space subdivision

Nodes signed as empty, full, or partial: E, F or P
Subdivide until the approximation satisfies required quality for
example 512*512*512
Dividing planes not object dependent (differs from BSP tree)
Analogy in 2D: Quad Tree

Octrees Advantages & Disadvantages

Simple combination-operators
Fast rendering
Spatial queries/search very fast

Higher memory consumption for well approximated

objects
Limited transformability
Approximation (criterion)

SOE - Advantages and Disadvantages

+
Simple

combinations in the same grid

Direct utilization of medical data

Extreme

memory consumption
Representation of voxels necessary
Curved objects has to be approximated

FREP

The Function Representation (or FREP) defines a geometric object by a

single real continuous function of point coordinates.
HyperFun is a simple language for FREP geometric modeling. It is
intended for modeling geometric objects described in the form:
F(x1, x2, x3, ..., xn) >= 0
This language is applicable to modeling algebraic and skeleton-based
"implicit" surfaces, convolution surfaces, distance-based models, voxel
objects, constructive solids, and more general FREP objects.
The model in HyperFun is interpreted by the modeling and visualization
software tools.
See:
http://hyperfun.org/wiki/doku.php?id=hyperfun:main
http://cis.k.hosei.ac.jp/~F-rep/HF_descr.html
http://www.cgg.cvut.cz/members/zara/HyperFun/

HyperFun - Example

Fragment of Notation

-- Aizu chair model of 1993

-- bounding box [-12,12]
-- Translated from Fortran 6.1.2002, A. Pasko
aizu_chair(x[3],a[1])
{ Xt = x[1];
Y = x[2];
Z = x[3];
-- Seat
SUP1 = 1-((Xt-0.)/6.)^4-((Y+3.)/2.)^4-((Z-0.)/6.)^4;

See complete HyperFun Notation here:

here

See notation of the object in VRML here:

here

FREP Summary

FREP is the functional representation

Implicit surfaces using the functional form of set
operations (union, intersection, difference)
Discovery by Raschev thus enables for unified
language for both CSG tree (or scene graph) and
subsequent primitives
Problems: costly, interpolation

Facet Modeling - Solid Model with Faceted

Primitives

Using VRML for Object Description - Example

IndexedFaceSet

Basic Deformations (Local Operations)

Transformations that do not preserve shape

Tapering
Twisting
Bending

Tapering

Position dependent functions work like the scaling

factors.
x ' 1
y ' 0
=
z ' 0

1 0

0
f ( x)
0
0

0 x
0 y
f ( x ) 0 z

0
1 1
0
0

Bending

Transformation that
does not preserve
shape

x ' 1
y ' 0
=
z ' 0

1 0

0 x
f ( y ) g ( y ) 0 y
h( y ) k ( y ) 0 z

0
0
1 1
0

Twisting

Position dependent functions work for twisting of

the object, too.
x' cos( ( y ))
y '
0
=
z ' sin( ( y ))

0
1

0 sin( ( y ))

0 x
1
0
0 y
0 cos( ( y )) 0 z

0
0
1 1

Solid Modeling - Summary

Elementary objects
Sweeps,

Quadrics, ...

Transformations
Combining Objects (CSG, FRep)
Volume representation
Rendering (Polygonal case)
Future works: transparent objects, bumpy surfaces,
textures, global illumination, animation, ...

CAD Data Formats

Normalized CAD data formats

IGES
AutoCAD
VRML

DXF

IGES

Initial Graphics Exchange Specification

Neutral format translators needed
Developed by National Aeronautical and Space Administration and National
Bureau of Standards in 1979
Reasonably comprehensive tool
Neutral data format
For transmission of CAD data
Between dissimilar CAD/CAM systems IGES file:
What should go into a data file?
Translate from their system to the IGES format or vice versa

Computer-Aided Manufacturing

CAM Intro

Computer-aided manufacturing (CAM) refers to the use of computers in

converting engineering designs into finished products.
Production requires the creation of process plans and production schedules,
which explain how the product will be made, what resources will be required,
and when and where these resources will be deployed.
Production also requires the control and coordination of the necessary physical
processes, equipment, materials, and labor.
In CAM, computers assist managers, manufacturing engineers, and production
workers by automating many production tasks. Computers help to develop
process plans, order and track materials, and monitor production schedules.
They also help to control the machines, industrial robots, test equipment, and
systems which move and store materials in the factory.
The first commercial applications of CAM were in large companies in the
automotive and aerospace industries for example UNISURF in 1971 at Renault
(Bezier) for car body design and tooling.
Traditionally, CAM has been considered as a numerical control (NC)
programming tool wherein three-dimensional (3D) models of components
generated in CAD software are used to generate CNC code to drive
numerically controlled machine tools.
Although this remains the most common CAM function, CAM functions have
expanded to integrate CAM more fully with CAD/CAM/CAE PLM solutions.

History of CAM

CAM

software was seen to have several shortcomings that necessitated an overly

high level of involvement by skilled CNC machinists. CAM software would output
code for the least capable machine, as each machine tool interpreter added on to the
standard g-code set for increased flexibility. In some cases, such as improperly set
up CAM software or specific tools, the CNC machine required manual editing before
the program will run properly.
Integration of CAD with other components of CAD/CAM/CAE PLM environment
requires an effective CAD data exchange. Usually it had been necessary to force the
CAD operator to export the data in one of the common data formats, such as IGES
or STL, that are supported by a wide variety of software. The output from the CAM
software is usually a simple text file of G-code, sometimes many thousands of
commands long, that is then transferred to a machine tool using a direct numerical
control (DNC) program.
The largest CAM software companies (by revenue 2005) are UGS Corp (now
Siemens PLM Software, Inc) and Dassault Systmes, both with over 10% of the
market; CAMWorks (From Geometric Ltd) is the first CAM package with Automatic
Feature Recognition Technology,PTC, Hitachi Zosen and Delcam have over 5%
each; while Planit-Edgecam, Tebis, TopSolid, CATIA, CNC (Mastercam), SolidCAM,
DP Technology's ESPRIT, OneCNC, and Sescoi between 2.5% and 5% each. The
remaining 35% is accounted for by other niche suppliers like T-FLEX, MecSoft
Corporation, SurfCAM, BobCAD, Metamation, GibbsCAM,and SUM3D

Process Design

Traditionally, begins with process planning ends with

product
Process planning
Is a function which establishes which processes,
parameters and tools are to be used to convert a
raw material into the final part

Jigs and fixtures are also part of this function.

Process planning involves human expertise.
Production planning, materials management and machines programming are the
next activities to be accomplished.

Process Planning Life Cycle

A typical
CAM process

CAM Tools Required to Support Manufacturing

Process

Definition of CAM Tools Based on Constituents

Definition of CAM Tools Based on Implementation

Software for Concurrent Product & Process Design

5 Axis CNC Machine

MotionMaster
X,Y,Z,B,C

Disadvantages of CAM
Results in loss of jobs
Requires skilled computer operators
Expensive to set up initial system

Computer - Aided Design

& Manufacturing

What is CAD/CAM

CAD - a computer aided system for creating,

modifying and communicating a plan for a
product or components of a product

CAM - broad term used when several

manufacturing processes are carried out at one
time aided by a computer. These may include
process control, planning, monitoring and
controlling production.

CAD/CAM Contents and Tools

2 main process: Design + Manufacturing

2 sub-process of design: Synthesis + Analysis

The end goal of the synthesis is a conceptual design of

the prospective product

The analysis evaluate the performance of the expected

product

Computer prototypes: Less expensive and faster to

generate

The core of the CAD tools are geometric modeling and

graphics applications

CAM Tools . . .

2 main factors that determine the

success of CAM implementation
the

link between CAD and CAM must be a

two-way route
the hardware and software networking of
the various CAM elements

Timely synchronization among robots,

vision systems, manufacturing cells,
material handling systems, and other
shop-floor tasks is most important

Main Activities

CAD + CAPP + NC
Manufacturing activities:
Programming robot motion, conveyors, etc.
Testing: Co-ordinate Measuring Machine (CMM)
Manufacturing process begins with the process
planning.
The outcome of the process planning is a production
plan, tools procurement, material order, and
machine programming.

Definition of CAD/CAM Tools Based on Constituents

Definition of CAD/CAM Tools Based on

Implementation

Typical utilization
of CAD/CAM system

Composition of CNC System & Equipment

Pro\ENGINEER - The Manufacturing Process

Design
Design Model
Model

WorkPiece
WorkPiece
Manufacturing
Manufacturing
Model
Model

Fixture
Fixture Setups
Setups

Set
Set Up
Up Process
Process
Environment
Environment
Define
Define
NC
NC Sequences
Sequences

Pro-MANUFACTURING

Create
Create CL
CL Data
Data
Files
Files (APT)
(APT)
Post-Process
Post-Process
Drive
Drive NC
NC
Machine
Machine Tool
Tool

Machine
Machine Tools
Tools
(Workcells)
(Workcells)
Tools
Tools

Different CA Systems Integration

Central to overall Supply
Chain integration is
CAD/CAM/CAE Systems
Integration
Data interoperability for the
many and varied end user
systems and applications
Different systems have
different requirements
Different applications have
different requirements

Upstream
Upstream
CAD
CAD

Application
Interoperability

Data
Data
Exchange
Exchange

Downstream
Downstream
CAx
CAx

Require effective exchange and sharing of CA model

data between different systems and applications

Integration Challenges

Getting the right electronic data to collaborators

2D drawings or 3D solid, surface, or wire frame models?

Detailed modifiable models or simple external representations?

Are exchange requirements up to date?

Providing data in an immediately usable form

Seamless flow of data between applications?

Correct CAD system and format?

Do quality or structure issues require manual rework?

Transmitting data quickly, inexpensively, and reliably

Are iterations necessary to get it right?

Costly overnight shipments?

Securing sensitive information

Can competitors get my proprietary data?

Common Data Integration Obstacles

Quality of the Native CAD Data

Effective Data Exchange and Model Re-use

The Data Exchange Process

Understanding Customer / Supplier Requirements

Delivery of Data from the Producer to the Consumer

Data Management

Source: TranscenData client assessments

The Number of Interfaces Required by direct Translation and by Using

a Standard

Costs: Independent USA Survey Results

The National Institute of

Standards and Technology in
the United States reveals that
CAD model quality and poor
data interoperability costs the
U.S. Automotive Industry in
excess of $1Billion annually

Similar independent studies

have found that the problem
crosses all applications,
industries and geographical
boundaries

CAD/CAM Market Trends

Microcomputers and engineering workstations
(EWS).
Traditional turnkey systems.
The key factor to the future success of
CAD/CAM is the development of versatile
tools for design and manufacturing
applications

CAD/CAM Market Dynamic

CAD/CAM Market Dynamic contd.

CAM in Product Life Cycle

FMS

PDM/PLM
Process data Management
Process Life Cycle Management

Product Life Cycle (PLC)

The PLC goes through many phases, involves many professional

disciplines, and requires many skills, tools and processes.
A product's life cycle can be divided into several phases characterized by
the revenue generated by the product.
Product development is the incubation stage of the product life cycle.
After a period of development the product is introduced into the market; it
gains more and more customers as it grows; eventually the market
stabilizes and the product becomes mature; then after a period of time the
product is overtaken by development and the introduction of superior
competitors, it goes into decline and is eventually withdrawn.
Product life cycle phases

Product Life Model

Process Management Systems

Process management systems normally have three broad functions:
1. They manage what happens to the data when someone works on it (Work Management).
2. They manage the flow of data between people (Workflow Management).
3. They keep track of all the events and movements that happen in functions 1 and 2 during the history of a
project (Work History Management).
Examples of PDM/PLM systems:
Windchill

PTC

OneSpace
Autodesk DM Server (Vault)
Teamcenter

CoCreate
AutoDesk
Siemens PLM Software (UGS)

Stages of PLM

Browser of the Product Structure

Web Browser of the Product Structure

PDM / PLM Internet References

http://en.wikipedia.org/wiki/Product_Data_Management
http://www.johnstark.com/epwld.html
http://www.plmic.com/
http://www.pdm-if.org/pdm_schema/
http://www.systemonline.cz/clanky/pdm-systemy-nastupuju.htm
http://newsletters.hagerman.com/newsletters/ebul22-Mech.htm
http://usa.autodesk.com/adsk/servlet/index?id=4502718&siteID=123112
http://manufacturing.cadalyst.com/manufacturing/Column:+Avatech+Tricks/Inv
entor-Excel-and-Vault----An-UnbeatableCombinat/ArticleStandard/Article/detail/470091

Rapid Prototyping,
Concurrent Engineering
& Reverse Engineering

Rapid Prototyping (RP)

RP is the most common name given to a host of related

technologies that are used to fabricate physical objects
directly from CAD data sources. These methods are unique in
that they add and bond materials in layers to form objects.
Such systems are also known by the general names freeform
fabrication (FFF), solid freeform fabrication (SFF) and layered
manufacturing. Today's additive technologies offer
advantages in many applications compared to classical
subtractive fabrication methods such as milling or turning.
Objects can be formed with any geometric complexity or
intricacy without the need for elaborate machine setup or final
assembly.
Rapid prototyping systems reduce the construction of
complex objects to a manageable, straightforward, and
relatively fast process.

RP Technologies

Stereolitography (SLA)
Selective Laser Sintering (SLS)
Laser Sintering Plastic
Laser Sintering Metal
Laser Sintering - Foundry Sand
Laser Sintering - Ceramic (Direct Shelt Production Casting)

3D Printing (PolyJet, Multi-Jet)

Laminated Object Manufacturing (LOM)
Fused Deposition Modeling (FDM)
Solid Ground Curing

RP & CAD

For rapid prototyping, CAD software generates the program for driving the
rapid prototyping machine (*.stl files)

Today, a new technology called virtual prototyping is becoming widely

used to evaluate design especially to detect problems in downstream
activities:
In Virtual Prototyping, A DIGITAL MOCKUP OR VIRTUAL
PROTOTYPE IS USED
Analysis tools can be used to evaluate this digital mockup
Virtual manufacturing, Virtual testing, Virtual assembly
Digital mockups reduce need to build physical prototypes
Software: Envision, Virtual NC, dVise

Stereolitography - Principle
Stereolithography is a common rapid manufacturing and rapid prototyping technology for
producing parts with high accuracy and good surface finish. A device that performs
stereolithography is called an SLA or Stereolithography Apparatus.
Laser a optick systm
Stiera prebytonej tekutiny

Pohybliv stl - os Z

Ndrka s tekutm polymrom

SLS - Principle
Laser a optick systm
Podva prku

Zsobnk prku

Pohybliv stl - os Z

LOM -Principle

Laser a optick systm

Polohovacie zariadenie

Laminovac valec

Navjac valec

Flia

Fyzick model

Pohybliv stl - os Z

Podvac valec

3D Printing - Principle
Hlava

Vstup materilu

Pohybliv stl os YZ

Advanced Laser Processing

RP Device STR 200 (Stratasys)

RP Device Helisys LOM 2030 and Physical Model

Manufacturing Process of Z402 3D Printer

Transform from 3D
CAD Data To Model

3D scanner to scan 3D
data

Use 3D CAD software to establish

3D model

Generate 3D Solid
*.STL

Read 3D solid *.STL file

prepare print work
proceed printing

finished part
post process

The Printing Process of Z402 3D Printer

Rapid Prototyping Technology is a unconventional processing means. Z402 System is based on the
Massachusetts Institute of Technology's patented 3DPTM(Three-Dimensional Printing) Technology. The Z402
System Software first converts a three-dimensional design built using 3D CAD (and saved in STL format) into
thousands of cross-sections or slices. The Z402 three-dimensional printer then prints these cross-sections one
after another from the bottom of the design to the top. This radical new process provides a means for designers
to detect mistakes, improve their designs, and communicate more effectively with each other as well as with
marketing and manufacturing decision-makers.

1.Collect powder from supply piston

2. Distribute powder on the build piston

3.Collect additional powder in recycle

tank

4.Spread the binder

6.Repeat previous 5 steps, until

finish the 3D parts

5.Supply piston ascent, and build piston descent.

7.Finish the part inside the build

piston.

High

speed of model printing

Low

material cost

The

dimension of parts can be as large as 203*254*203 mm

Nonpoisonous
Suitable
Not

for size examine and some function test

deform due to the change of the weather temperature

Several
The

material

parts can be built at the same time

part can have different tolerance in different sections

8.Remove unbounded powder from parts

Applications of RP

Functional Prototyping

Engine Block

Ear gun

Screw pump

Mask

Carry out conceptual design

Bottom of shoes

Juicer

Applications of Bio-Engineering

Head bone

Buildings

3D toy model

Head bone model

Head bone model and

skin

Others

Piping& tubing

Flexible tube

Curved ball

Conceptual design

Exhaust pipe

Parts design

Head bone assembly

Conjugate

Mobile parts

RP Internet Sources
http://www.zcorp.com/

Firm Z Corporation

http://en.wikipedia.org/wiki/Selective_laser_sintering

Wikipedia SLS

www.3dsystems.com

Firm 3D Systems

www.stratasys.com

Firm Stratasys Inc.

www.3dtech.cz

Firm 3D Tech

www.mcae.cz

Firm MCAE Systems (CZ)

home.att.net/~castleisland/

CASTLE ISLAND Co.

http://www.charlyrobot.com/

Firm Charlyrobot SA, France

http://www.cc.utah.edu/~asn8200/rapid.html

RAPID PROTOTYPING HOME PAGE

Concurrent Engineering (CE)

Concurrent Engineering:
a systematic approach to the integrated, concurrent design
of products and their related processes, including
manufacture and support. This approach is intended to
cause the developer, from the outset, to consider all
elements of the product lifecycle from concept through
disposal, including quality control, cost, scheduling and user
requirements. (Institute for Defense Analyses).

The Phase and Concurrent (Simultaneous)

Model of Product Development

Influence of Relative Cost of Changes in Dependency of

the Product Life Cycle Phase

Concurrent Product & Process Modeling

CE Internet Sources

http://www.ceraj.com/

Concurrent Engineering: Research and

Applications

http://cic.vtt.fi/cib_tg33/

Concurrent Engineering in Construction

http://www.virginiadot.org/projects/concurengdefault.asp

CE: Virginia Department of

Transportation

RE What Does It Mean?

Reverse engineering (RE) in general is the process of discovering the

technological principles of a device, object or system through analysis of its
structure, function and operation. It often involves taking something (e.g., a
mechanical device, electronic component, or software program) apart and
analyzing its workings in detail, used in maintenance or to try to make a new
device or program that does the same thing without copying anything from the
original.
Many companies begin their design cycle by creating models sculpted by hand in
order to communicate thoughts and ideas more effectively.
As ergonomics and product differentiation become increasingly important in the
design of a product, shapes become more complex and irregular.
The challenge is then to capture these hard models and import them into CAD
systems.

RE - Motivation
Reasons for reverse engineering:

Interoperability.
Lost documentation: Reverse engineering often is done because the
documentation of a particular device has been lost (or was never written),
and the person who built it is no longer available.
Product analysis. To examine how a product works, what components it
consists of, estimate costs, and identify potential patent infringement.
Academic/learning purposes.

RE Information Flow

Reverse engineering has become a viable method to create a 3D virtual model of

an existing physical part for use in 3D CAD, CAM, CAE and other software.
The reverse-engineering process involves measuring an object and then
reconstructing it as a 3D model.
The physical object can be measured using 3D scanning technologies.

Product
Vrobok
Drawing
Vkres

CAD

CAM

Classical Process versus RE

Classical Process
CAD Model

NC Manufacture

Real Product

CAD Model

3D Digitalization

Real Product

Measurement System TriTop

Application of the TriTop

System ATOS II

RE Internet Sources

http://www.3dscanners.com/

3D Scanners

http://www.cad-based.com/

CAD-Based Solutions

CATIA

CATIA

Start Part Design

Another way is to choose:
START>
MECHANICAL DESIGN>
PART DESIGN

There are a few different ways to

begin a Catia session.
From the start-up screen, choose:
FILE > NEW > PART

THREE DIMENSIONAL PART GENERATION IS VERY EASY AND

FOLLOWS A LOGICAL PROGRESSION WHEN YOU KNOW HOW TO USE A
FEW ICONS

to THIS

going from THIS

to THIS

Is as easy as 123!

This is the first screen you will encounter on the way to making
your part. There are a few primary choices you will make here that
determine the outcome of your part

Part tree

Then, pick SKETCHER

from the toolbar on the
right.
Firstly, choose which plane that
you wish to sketch in.

To keep it simple, pick the

xy plane when beginning a
part. This will help you to
draw in a familiar plane.

The PART TREE always tells you where

you are. Notice at the top it says PART1
and at the bottom it is waiting for you to
do something with PartBody.
6

SKETCHER
From here you pick an icon from the PROFILE toolbar and Click-andDrag that shape in the sketcher environment.

Notice the Part Tree reflects

the fact that you are working on
Sketch1.

This square was drawn using

the square icon in the
sketcher environment.

At this point you are just

roughing in the shape. The exact
dimensions will be added next if
needed.

This is the
PROFILE toolbar.
These shapes are
easy to use and
the icons are self
explanatory.

To CONSTRAIN, or dimension a part, first

click on the line to be done as shown here

This is the CONSTRAINTS

toolbar

Constraints are used

throughout Catia and
can be demanding.

picked

Defined in dialog box

Normal constraint
Auto Constraint
Animate constraint
Exit Sketcher

Click the line and click on Normal

Constraint for the dimension to
appeardouble click to change the
dimension that appears

Once you have all of the required parts

dimensioned, you are ready to go into
3D mode

Click EXIT
for Catia to
leave the
sketcher
mode and
enter 3D
modeller

Once you enter the 3D environment, the

part profile you were working on takes
on an isometric orientation as seen
here.

This is the SKETCHER

toolbar from which you can
choose a process of building
your 3D model

Pad icon

3D Model Definition
Notice that not all of the icons
shown on the shortened
SKETCHER toolbar are active.
This is because some other
variable must be satisfied for
Catia to allow its use.

Once PAD is chosen, the

PAD DEFINITION pop-up
will appear. From here you
define the TYPE and
LENGTH of the pad. You
can also choose to mirror
the pad or reverse its
direction from here.

The pad definition box will cause the limits that have been selected to be
applied in a wire frame representation first. Now if you click on APPLY and
then OK, your wire frame will finally become a solid 3D model.

Notice that on your PARTS TREE, pad1 has been added

BEFORE sketch1 that was already there. This is all part of
Catias hierarchy system.

DRESS-UP FEATURES

Although technically not a Dress-Up Feature, POCKET is

a tool that is used often.
Unlike HOLE, the feature to PUNCH must be defined in
SKETCHER mode since it is user defined, not just a
hole.

pocket

The first thing to do is pick the face that you want to pocket
the void through, then pick Sketcher

Line is picked

In Sketcher, pick the proper shape icon from the Primary toolbar, and
sketch the shape ON THE 3D PART represented in sketcher. Once
this is done, EXIT sketcher to return to 3D mode

Notice that the shape that

will eventually become a
hole in your part is
represented in the part tree
as Sketch2

Sketched circle

This is how your

part will look once
you have returned
to 3D. The sketch
you made will
appear flat on the
face you chose. If
it is not orange,
choose it to make
it active and ready
for pocketing
sketch

Notice that in our 3D part the sketch we

made was not orange immediately
when we returned to 3D mode.
NO PROBLEM.we just need to either
pick it manually from the object we are
creating, or directly from the parts tree.

Now click on
POCKET from the
Sketcher Based
Features
toolbar pocket

With POCKET picked, the POCKET DEFINITION input

box will appear. Input the desired information and Catia
will show you a dashed line sketch of your pocket. If all
the information is correct, push APPLY and hole will
appear in 3D, then push OK to make it permanent.

Notice POCKET1 is active

on the action tree.

From TYPE, you can enter a dimension or constrain

the depth of the punch by choosing up to next,up to
last,up to plane, etcusing the arrow.

Depth is where you enter the dimension for the depth of

your pocket.

Click on Mirrored extent to mirror or send your

pocket in both directions.

Since Catia automatically sends your pocket in the

most logical direction, if you want it to go the other
way click on Reverse Direction.

Here is the part with the pocket in it.

Now lets begin to DRESS IT UP

Dress Up Features toolbar

A close look up at DRESS UP

TOOLBAR shows that it is
ready to do five basic
functions

Fillet
Chamfer
Draft
Shell

DRAFT is what you use to

angle the sides of your part
in preparation for possible
casting processes.

Mirror

Orange means it is picked

Noted on the tree

The first thing we will do is FILLET. Pick the face that you
wish to fillet, then pick fillet from the toolbar. The Edge Fillet
Definition box will appear, which you will fill in with the
appropriate info. RADIUS is the size of the fillet and
OBJECTS lists the number of faces that you are going to
fillet. The box also allows you to pick the propagation of the
fillet (Tangency is the best for now).

You dont have to pick an entire facea single edge may be

picked instead. To pick MORE than one edge, but NOT and
entire face simply hold down CONTROL.

Here we have chosen two different

edges using the CONTROL
buttonnotice the edges you
choose turn red. MULTIPLE faces
can be picked the same way.

MOUSE MANIPULATION
The 3 button mouse is your tool for manipulation of the parts and assemblies that you
have created. With it you can ZOOM, ROTATE and PAN your parts or manipulate the
specification tree. First, place your cursor ANYWHERE on the screen
CLICK AND HOLD
CLICK AND RERLEASE

To ZOOM, click and hold the MIDDLE mouse button, click and release the LEFT mouse
button, then PUSH the mouse away from you to make your part smaller and PULL it
towards you to enlarge your part.

ZOOM in from a small part

To a LARGE part with

this simple technique.

The next thing you can do is ROTATE your part

CLICK AND HOLD FIRST
CLICK AND HOLD SECOND

This is accomplished by HOLDING the MIDDLE mouse button and then the
LEFT mouse button while keeping the middle one depressed.

Another useful mouse aided motion is PANNING

CLICK AND HOLD

To PAN a part across the screen, click and hold the MIDDLE mouse button only.
This allows you to move your part around the screen in a single orientation.

The SPECIFICATION TREE can also

be manipulated. You can EXPAND
and SHRINK, MOVE and ZOOM it.

HAND

Note the HAND cursor on the

tree. To manipulate the tree, you
must first click on it. This will turn
your part DARK, signaling you
are ready to perform various tree
functions.

The tree responds the same as a

part does for manipulation. To
move the tree, simply place the
cursor near it and click and hold the
middle mouse button. Now drag the
tree wherever you wanted it.

TO HERE

FROM HERE

Here we have moved the tree by

dragging it from one corner of the
screen to the other.

By using the same mouse clicks to ZOOM as

you did with a part, you can make your tree
larger or smaller as you need to.

TO THIS

FROM THIS

Click and hold the middle mouse

button, while single clicking the left
mouse button. While holding the
middle button, move the mouse
toward and away from you to make
the tree bigger or smaller

To SHRINK or EXPAND your specification tree, you simply click on the + or signs.

CLICK HERE TO OPEN TO THIS

Clicking a + opens up the tree into its

individual branches. Clicking a does
the reverse.

Different RENDERING STYLES give you different views of your part. The most
common one is SHADING. It is chosen by clicking on it in the VISUALIZATION
toolbar.

VISUALIZATION TOOLBAR

SHADING

This is the same part, but with the WIREFRAME picked

WIREFRAME

This is HIDDEN LINES REMOVED mode

HLR

This is SHADING WITH EDGES

SHD+E

This is CUSTOMIZED. When this is picked, you can apply materials to your
part. This is useful visually, and needed when you are going to do a stress
analysis. Once applied, a single mouse click can get you a lot of useful
information, ie: Centre of Gravity, density, weight etc

CUSTOMIZED

If CUSTOMIZED is not available, go to VIEW>RENDER

STYLE>CUSTOMIZE VIEW, and then click on materials. To have your
material apply to the part, you must click PART BODY on the spec tree
BEFORE clicking a type of material.

ADVANCED DRESS-UP FEATURES

Once OK has been selected, your part will appear with the filleted
area highlighted by orange lines at the boundaries. Click anywhere
OFF the part to get rid of the lines and see your part
40

chamfer

A CHAMFER is used the same way as the fillet

command. Important changes that you can make in the
Chamfer definition box include changing the length
and angle of the chamfer.

Just like FILLET, the CHAMFER is shown with an orange border until you
click off of the part in the blue area.

Another thing that becomes important, especially

during the manufacturing process, is DRAFT ANGLE.
This is the angle that you build into your part so that it
can easily be extracted from a mold during the casting
process

draft

The faces that you pick to draft are the ones that turn red,
and the Neutral Element face picked becomes blue. The
arrow determines which way the angle will occur. Dont
forget to click on the neutral element selection box before
clicking on the chosen face.
CLICK HERE
Direction arrow and angle relation

There is a direct relation between

the direction arrow and the angle
shown. Closer inspection shows
that as you switch the direction of
the arrow, you also switch the
direction of the draft.

Now your part has a five degree draft angle that you have
designed into it. This draft angle in no way changes the way
that your part will act in relation to other parts in an
assembly.

Another handy Dress-Up Feature is SHELL.

This is used for hollowing out your part when a
solid part is not needed. Shell is defaulted to
.079in (if you are using inch units) but you may
change the inside and outside dimensions,
along with the faces to remove, in the Shell
Definition Box.

.079in default shown on chosen face

shell

Now your part is shelled and awaiting

any other dress up features that you may
wish to do.

The last major dress up feature that you can

utilize is the THICKNESS utility. This allows
you to increase the thickness of just the area
of the part that you have chosen. Here we
have chosen to make the one side of the box
.039in thick.

thickness

The part is now thicker on the

edge that you chose, and will
remain highlighted until you click
off of it.

Here is your final part, with its draft

angle, shell and thicknessall you need
to do now is save it as a part and get
ready to put together your assembly. This
will be covered in a later chapter.

Now your part has a five degree draft angle that you have
designed into it. This draft angle in no way changes the way
that your part will act in relation to other parts in an
assembly.

Constraints

You do CONSTRAINING in Sketcher mode to create your part to

exacting dimensions. This is the opposite of free-form creating we
have done up to this point.

constrain

Pick the edge that you want to constrain, or

give a definite dimension to, and then click
CONSTRAIN from the toolbar.

Another way to constrain a line on the part is to pick it and then click on
CONSTRAIN IN A DIALOGUE BOX. You will have many different ways of
constraining the area that will appear in the dialogue box. The ones that you can
use will allow you to pick them.

Constrain in

Picked point

Picked line

The Constraint Definition box allows you to chose one or more

constraints and apply it or them to the line that you have chosen to
constrain.

Now that we have clicked on DISTANCE, the distance between the two
areas we have chosen will be defined.

distance

If your REFERENCE
ELEMENTS toolbar is not in
view and not hidden, you can
retrieve it from the toolbars
menu seen here.

Reference Elements

REFERENCE ELEMENTS play an important part in any solid modeling.

Without them, you can only do work to the outermost surfaces of the part,
which may not always be practical or involve a lot of pre-draw planning.
66

To carve a step into your part without setting a reference plane, you
are very limited as to where you can put it. You must first pick a part
face that you are going to work on. This will unfortunately be where
your step will begin, like it or not, without setting a plane.
67

Once you have entered sketcher, you will draw the shape of the
step that will be in your part. Notice in this example that part of
the step shape extends beyond the part. The bit of shape that
is not part of the step is of no consequence at this point.

overhang

This method is the quickest and most

convenient way of carving out a stepbut
keep in mind that if ACCURACY is
important, you must consider how much of
the step is overhanging the part in you
overall calculations.

Once back in 3D mode, you can see Sketch2 in relation

to the part. You can now POCKET out this shape from
one end to the other, and anywhere in between.

At this point we have highlighted Sketch 2 and picked Pocket

from the Dress Up toolbar. The Pocket Definition dialog box
pops up for you to enter the initial depth of pocket.

Depth of pocket

Mirror (pick)

Lets take the same shape and carve a step into the middle of the front
edge, leaving material on both sides. For this we are going to have to
do the same things as before, only first we must add a REFERENCE
ELEMENT.

plane

A Reference Element is another plane you can use as a

reference for other drawing bits on your part. To do this we first
pick the face we wish to reference from, pick PLANE from the
Reference toolbar, and in the Plane Definition dialog box we will
enter how far the plane should be from the face we initially
picked.
Enter offset

To use the reference element, first pick it ( it will

highlight orange) and then pick sketcher.

75

Here in sketcher it is difficult to know which plane you are

drawing on. If you forget, check the tree. Here we see that
the sketch we are doing at the moment is being done in
plane2, as we wished. Other than that, you proceed exactly
as we did the other step.

Back in 3D we see that our shape is exactly in the

middle of the part, as we expected.

77

From here we do exactly as we did with the other step.

We highlight the shape and choose the pocket icon.
Give it depth in the dialog box and maybe even mirror it
as we did here) for extra size.

Click here
Click here

Click here

There is a number of ways to enter

ASSEMBLY DESIGN mode.

Basic Assembly Design

Assembling your individual parts into one assembly

is very simple and user friendly in Catia. The first
thing to do is gather up your parts. Here we have a
simple plate with a hole in the middle.

We are going to take this one inch diameter rod

and insert it through the hole in our plate using the
ASSEMBLY DESIGN features. Ensure that you
have saved your parts to a convenient location for
quick access later.

82

Both parts are now in the Assembly environment, and

both are reflected in the tree. They enter the environment
in approximately the same orientation that they were
saved. You can now move and orient them the way you
wish. Catia will help you here.

The first skill you will want to learn here is how

to manually move parts around relative to one
another. Pick the face of the Plate and prepare
to move it.

Grab the COMPASS from the top right corner of your screen.
Put your cursor on the red square of the compass and click
and drag it to the highlighted part.

89

Once you have moved the parts relative to one

another, since we are locating round parts we will use
COINCIDENCE RESTRAINT. Choose this and then
pick the centerlines of the two parts involved.

Centerline chosen

As you pick the second centerline, Catia will

automatically constrain them. If Catia does
not immediately line them up, click the
UPDATE icon.

92

Here are the two parts with a coincidence

constraint applied , ready to be put together. We
can do this manually.

93

Finally, here is your part ready to

be DRAFTED and put into
production. Notice all the
constraints are reflected in the
specification tree.

A properly dimensioned drawing of a part is very important to the

manufacturing outcome.

Drafting and Dimensioning

Part Design icon

Choose DRAFTING

There are a few simple ways to go from Part

Design to DRAFTING. If you double click
the Part Design icon (top right hand corner)
you will access a navigation window as
shown. From here, you can pick
DRAFTING.

100

The NEW DRAWING CREATION dialog box will appear.

The first thing to do is pick your automatic layout.
Orange shows it has been chosen

Next, you can choose MODIFY and change ISO and ANSI standards,
number of sheets and orientation, scale and others.

Quickly the drawing is generated. All of the views we asked

for in proper orientation to each other.

This drawing is now ready for dimensions. Since the

front view is highlighted, we can start there.

Click on DIMENSIONING from the

toolbar

Chosen surface

DIMENSIONING

And then choose a

curved surface to
dimension.
104

If default is DIAMETER, this is what you will see. If you wish to dimension a
RADIUS, highlight the line and right click on it.

105

Your dimension is now a Radius. Lengthen and shorten the dimension line by dragging it.

Click
and
Drag

107

All lines can be done in the same way. Simply pick them and click on Dimension. If you are
working on a large drawing, this single line picking would be rather tedious. There is another
way

111

Click on GENERATING DIMENSIONS Step By Step. This will allow CATIA to do the dimensioning
one at a time, every few seconds, whatever timeout you choose.

Click here to
start the
dimensioning
.

Generating Dimensions icon

112

Once all of the automatic dimensioning is finished, you will get an ANALYSIS of what
was done.

113

After the Auto Dimension, you

may want to go back and
make changes. This is as
simple as highlighting the
dimension and making the
appropriate change.

114

Sources
Books:
Computer-Based Design and Manufacturing by Emad Abouel Nasr,
Ph.D. and Ali K. Kamrani, Ph.D.
Collaborative Product Design and Manufacturing, Methodologies and
Applications by W.D. Li, S.K. Ong, Andrew Y.C. Nee and Chris
McMahon
Internet:
http://en.wikipedia.org/wiki/Computer_Integrated_Manufacturing
http://www.steptools.com/library/standard/step_1.html
http://design.osu.edu/carlson/history/PDFs/iges.pdf