UNIT-3 Geometric Modeling

Modeling is the art of representation of an object, system or

phenomenon.
The Modeling can be:
1. Geometric Modeling: “It is defined as complete representation
of an object with the graphical and non-graphical information”.
2. Non-Geometric Modeling: It is usually applied to physical
process.
Geometric Modeling:

1. Preliminary idea should be developed from market research

and product feedback or some innovative idea.
2. Preliminary idea can be expanded into some preliminary
designs and finally into production.
Functions Expected from Geometric Modeling:
Requirements of Geometric Modeling:
 Salient Features of Geometric Models:
1. As the model is stored in mathematical form, any type of data related with
the object can be stored in the model. This makes a true replica of an actual
object.
2. As the model is stored in mathematical form, the model modification can
be carried out easily using transformations.
3. Used to evaluate various properties such as mass, volume, moment of
inertia, etc.
4. Provides a sophisticated tool for 3- D visualization of the object by using
different colour combinations and light effects.
5. It can be automatically converted into 2D views.
6. It can be used by the FEA software to perform different types of analysis
such as: stress-strain, kinematic analysis, dynamic analysis, thermal
analysis, etc.
7. It can be used by the CAM software to generate a complete tool path
required for the automatic manufacturing.
Geometric Model Classification:
1. Two Dimensional: Limited utility because of their inherent
difficulty in representing complex object.
2. Three Dimensional: Ability to provide all the information
required for the manufacturing applications.
Three Dimensional representation can be done in Three
ways:
 Line Model
 Surface Model
 Volume or Solid Model
Solid Modeling:
Geometry and Topology:
3-D Primitives:
Approaches of Solid Modeling:
1.Constructive Solid Geometry (CSG):
CSG Tree of Solid Model:
Example of CSG Tree:
2. Boundary Representation ( B-Rep):
B-Rep Approach:
Validity using Euler’s Equation:
Comparison between CSG and B-Rep:
3. Sweeping:
i. Linear Sweep: Translational sweep and Rotational sweep
ii. Non-Linear Sweep
iii. Hybrid Sweep
ii. Non-Linear Sweep
iii. Hybrid Sweep:
4. Parametric (Analytical ) Solid Modeling:
5. Primitive Instancing:
6.Feature based Modeling:
Steps in Feature Based Modeling:
Features Operations:
Revolve:
Sweep:
7. Constraint Based modeling:
Applications of Solid Modeling:
For e.g. Cubic splines, Bezier curve, B- splines, Beta splines, Nu-
splines.
Approaches of Generation of Synthetic Curves:

1. Interpolation
2. Approximation
Types of Synthetic Curves:
1. Hermits Cubic Splines
2. Bezier Curves
3. B-Splines Curves
Controlled of Cubic Splines Curve:
2. Bezier Curves:
 Provide more flexibility for changing the shape of curve. Flexibility increases
with increase in number of control points.
 It allow global control over the shape of curve
 Bezier curve developed by P. Bezier at Renault Automobile Company, France,
is used for car surface.
Where
Characteristics of Bezier Curves:
3. B-Spline Curves:
 B- Spline separates the order of polynomial representing the curve from the
number of given control points.
 B-spline curves allow local control over the shape of curve as against the
global control in case of Bezier curves.
 Characteristics of B- Spline Curves:
1. The degree of polynomial representing the curve is independent of the number
of control points.
2. The maximum order of the curve is equal to the number of vertices of
defining polygon.
3. B-spline curves allow local control over the shape of curve as against the global
control in case of Bezier curves. Wherever a single control point is moved, only
those vertices around the moved vertex will be affected and the local portion of
the curve is affected, while the rest remain unaffected. For e.g. change in control
point from P3 to P3’ to P3” as shown in Fig.
4. B-spline curves gives better control.
5. B-spline curves permit to add or delete any number of control points without
changing the degree of polynomial.
 Automation
Definition:
“Technique used for the application of integrated mechanical, electronics and
computer based system in the operation and control of production system”.

Technology by which a process or procedure is accomplished without human

assistance.
Automation of production system means:
i. Automaton of manufacturing facilities. or
ii. Automaton of manufacturing support systems. or
iii. Automaton of both the facilities and the manufacturing support systems.
Comparison of production Systems:
 Automation: Features
Automation of manufacturing facilities or support system or both
Solution for improving the productivity, quality and economy
Feasible only for bigger production volume
e.g.: NC and CNC m/c
Automatic assembly m/c
Automatic transfer line
Automatic assembly line
Industrial robots
Automated material handling system
Automated storage system
Automated inspection and quality control system
 Automation: Need
1. To increase productivity
2. To reduce cost of production
3. To improve production quality
4. To reduce production time
5. To minimize the effect of labour shortage
6. For better control over manufacturing activities
7. To improve worker safety
8. To reduce/eliminate manual /clerical tasks
9. To avoid high cost of not automating
 Automation: Types

1. Fixed (Hard) Automation

2. Programmable Automation

3. Flexible (Soft) Automation

1. Fixed (Hard) Automation
Sequence of operations is fixed
Can not be changed once it is established
Economical for high volume of production
Suitable for continuous flow type and mass production
e.g. bottling plant, packaging plant etc.

Features:
High initial cost
High production rate
Inflexible for production variety
No tool set-up time as tooling is fixed.
2. Programmable Automation
Sequence of operations can be changed
Controlled by a program
New program for new product
Suitable for batch production
e.g. NC m/c tool, industrial robots, PLC etc.
Features:
High initial cost
Low production rate
More flexible for production variety
Tool set-up time required from batch to batch
3. Flexible (Soft) Automation
Capable for production of design variation
Extension of programmable automation
Continuous production of various combination of product
Variety less than programmable automation
Suitable for continuous production
Features:
High investment cost
Medium production rate
Less flexible for production variety
Minimal tool set-up time required
Production Quantity and Production Variety For different
Automation Systems:
 Comparison Between Types of Automation:
Sr. Comparison Fixed (hard ) Automation Programmable Flexible (soft))
No. parameters Automation Automation

1 Initial Investment High for custom –engineered High for general High for custom –
equipment purpose equipment engineered
equipment

2 Production rates High Low to Medium Medium

3 Flexibility Highly Flexible Flexible in Flexible in
accommodating accommodating
changes in product changes in product
variety. design variation.

4 Production system Suitable for continuous flow or Suitable for batch Suitable for
mass production system production system continuous
production of
variable products.

5 Tool setup time No tool setup time as tooling is Varies form batch Minimal tool setup
fixed to batch time
Automation: Advantages
1. Increase in productivity
2. Reduction in labour cost
3. Improvement in production quality
4. Minimized the effect of labor shortage
5. Reduction in inventory
6. Reduction in scrap/rework
7. Increase in shop efficiency
8. Better control over manufacturing activities
9. Increase in sales and profit
10.Relief to worker fatigue
11.Flexibility and variety in production
12.Reduction in lead time
Automation: Limitation
1. High initial cost
2. High maintenance cost
3. Expensive break-down time
4. Worker unemployment
5. No reward for human skills
6. Lesser job opening and social imbalance
Automation: Levels
 Automation: Levels

1. Device level – actuators, sensors, and other hardware

components to form individual control loops for the next level

2. Machine level – CNC machine tools and similar production

equipment, industrial robots, material handling equipment

3. Cell or system level – manufacturing cell or system

4. Plant level – factory or production systems level

5. Enterprise level – corporate information system

Automation: Advanced Automation Functions

1. Safety monitoring

2. Maintenance and repair diagnostics

3. Error detection and recovery

1. Safety monitoring
Sensors are used to track the system's operation and identify
conditions that are unsafe or potentially unsafe
Reason: To protect workers and equipment
Possible responses to hazards:
Complete stoppage of the system
Sounding an alarm
Reducing operating speed of process
Taking corrective action to recover from the safety violation
2. Maintenance and repair diagnostics
Status monitoring:
Monitors and records status of key sensors and parameters during
system operation
Failure diagnostics:
Invoked when a malfunction occurs
Purpose: analyze recorded values so the cause of the malfunction can
be identified
Recommendation of repair procedure:
Provides recommended procedure for the repair crew to effect repairs
3. Error Detection and Recovery
Error detection – functions:
Use the system sensors to determine when a deviation or
malfunction has occurred
Correctly interpret the sensor signal
Classify the error
Error recovery – possible strategies:
Make adjustments during or at end of work cycle
Stop the process to invoke corrective action
Stop the process and call for help