DMD 90 CH04 3dgeom

Chapter 4
3D Geometry
3D Geometry
Contents Training Manual
ANSYS Workbench - DesignModeler

• Bodies and Parts
• 3D Features
• Boolean Operations
• Feature Direction
• Feature Type
• Feature Creation
• Workshop 4-1, Catalytic Converter
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3D Geometry
Bodies and Parts Training Manual

• 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 body: body consists entirely of edges, no area, no
volume
• By default, DM places each body into one

part by itself
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3D Geometry
Bodies and Parts… Training Manual

• There are two body states in DM:
– Active:
• Body can be modified by normal modeling operations Active
(cannot be sliced)
• Active bodies are displayed in blue in the Feature
Tree View
• The body's icon in the Feature Tree View is
dependent on its type - solid, surface, or line
– Frozen: (>Tools>Freeze)
• Two Purposes:
– Provides alternate method for Sim Assembly Frozen
Modeling
– Provides ability to “Slice” parts.
• A Frozen body is immune to all modeling operations
except slicing
• 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
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– Frozen bodies are displayed “lighter” in the Tree View Inventory #002176
4-4
3D Geometry

• Body Suppression:
– Suppressed bodies are not plotted.
– Suppressed bodies are not sent to Design Simulation for analysis, nor
are they included in the model when exporting to a Parasolid (.x_t) or
ANSYS Neutral File (.anf) format.
– In the tree view an “X” is shown near suppressed bodies
Unsuppressed
Suppressed
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3D Geometry

• Parts:
– By default, the DesignModeler
places each body into one part
by itself.
– You can group bodies into
parts
• These parts will be
transferred to Design
Simulation as parts
consisting of multiple
bodies (volumes), but with
shared topology.
– 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. December 17, 2004
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3D Geometry

• Why multi-body parts? DM
• Example:
– In DM: 3 parts, 3 bodies consisting
of 3 solids
– In Sim: 3 solids with 2 contact
regions
– Each solid meshed independently
• Nodes are not shared
• Nodes do not line-up
Si
m
DM
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3D Geometry

• Example (continued):
DM
– In DM: 1 part, 1 body
consisting of 1 solid
– In Sim: 1 solid (no contact)
– Entire solid meshed as one
• One material
• No internal surfaces
Sim
DM
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3D Geometry

• Example: DM
– In DM: 1 multi-body part, 3 solids
– In Sim: 3 solids (no contact)
– Each solid meshed independently but
node connectivity among solids is
preserved
Sim
DM
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3D Geometry
3D Features Training Manual

• 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”
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3D Geometry
3D Features… Training Manual

3D Feature
Frozen
Bodies in
model?
It’s all in the details!

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3D Geometry
Boolean Operations Training Manual

• 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 Faces: Similar to Slice, except that only the faces of the bodies
are split, and edges are imprinted if necessary (no new bodies created)
– Add Frozen: Similar to Add Material, except that the feature bodies are
not merged with the existing model but rather added as frozen bodies
• Line bodies are immune to Cut, Imprint, and Slice operations
If frozen:
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3D Geometry
Boolean Operations… Training Manual

• Boolean Add:
Choose feature and

Boolean operation to be
performed on the active
sketch
Extrude – “Add Material”

shown here
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Note: If bodies already exist, “add” results in merged geometry after “Generate” Inventory #002176
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3D Geometry

• Boolean Cut:
Existing solid (shown in

wire frame for clarity)
Revolve with Cut operation
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Axis of revolution Active Sketch Inventory #002176
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3D Geometry

• Boolean Imprint Faces:
– Imprint Face operation allows continuous surface to be segmented
(see below). Useful for applying FE boundary conditions at arbitrary
locations.
Active sketch to extrude
Extrude with Imprint Faces

operation.
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3D Geometry

• 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
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3D Geometry

• 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
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3D Geometry
Feature Direction Training Manual

• Direction:
Direction is with respect to

the sketch plane
Some operations (e.g. cut)
result in automatic change
in direction
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3D Geometry
Feature Type Training Manual

• Fixed:
– Fixed extents will extrude the profiles the exact distance specified by
the Depth property. The feature preview shows an exact
representation of how the feature will be created:
Fixed
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3D Geometry
Feature Type… Training Manual

• Through All Type: will extend the profile through the entire model
– When adding material the extended profile must fully intersect the
model
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3D Geometry

• To Next:
– Add will extend the profile up to the first surface it encounters.
– Cut, Imprint, and Slice will extend the profile up to and through the
first surface or volume it encounters
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3D Geometry

• To Faces: allows you to extend the Extrude feature up to a
boundary formed by one or more faces
– For multiple profiles make sure that each profile has at least one face
intersecting its 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
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3D Geometry

• 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).
– 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.
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Unbounded surface selected as extent Inventory #002176
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3D Geometry
Feature Creation Training Manual

• Extrusions:
– Extrusions include solids, surfaces, and thin-walled features
• To create surfaces, select “as thin/surface” and set the inner and
outer thickness to zero
– The active sketch is the default input but can be changed by selecting
the desired sketch in the Tree View
– The Detail View is used to set the Extrude depth, direction, and
Boolean operation (Add, Cut, Slice, Imprint, or Add Frozen)
– The Generate button completes the feature creation
– Note: the previous section (Feature Type) shows various extrusion
examples
To Create
Surface December 17, 2004
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3D Geometry
Feature Creation… Training Manual

• 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 Property for Revolve:
• 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
Sketch with Disjoint Line
• Both - Asymmetric: Applies feature in both
directions. Each direction has its own angle
property
– The Generate button completes the feature
creation December 17, 2004
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3D Geometry

• 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 profile as sweeps along the 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:
• Path tangent: reorients the profile as it is swept along the path to
keep the profile in the path's tangent direction
• Global: the profile's orientation remains constant as it is swept
along the path, regardless of the path's shape
– Examples . . .
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3D Geometry

• Sweep example 1:
Path Tangent alignment:
profile remains tangent to
path
Sketch1 = profile to sweep
Sketch2 = sweep path
Global Axes alignment:

profile orientation
remains constant
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3D Geometry

• Sweep example 2:
Sweep details:
Scale = 0.5
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, then Turns must be an integer
• If the sweep path is an open chain, then any value for Turns is acceptable
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– The default values for Scale and Turns are 1.0 and 0.0 respectively Inventory #002176
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3D Geometry

• 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
• Open and closed profiles cannot be mixed
• 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 selecting an adequate number of profiles, a preview will appear
showing the selected profiles and the guide polygon
– The guide polygon is a gray poly-line which shows how the vertices
between the profiles will line up with each other
– Skin/Loft operation relies heavily on RMB menu choices
• Examples . . . December 17, 2004

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3D Geometry

• 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 polygon is displayed
– RMB for guide polygon options
– Continue through all profiles
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3D Geometry

• Skin/Loft example 1:
– Add operation generates 3D solid
• Guide Polygons:
– Use RMB options to realign if
necessary
• Can result in unexpected shapes
when misaligned
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3D Geometry

• 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
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3D Geometry

• Point Features:
– The Point feature allows for controlled and fully
dimensioned placement of points relative to
selected model faces and edges
– Select a set of base faces and guide edges
– Select the Point (Analysis) Type:
• Spot Weld: Used for “welding” together
otherwise disjointed parts in an assembly
(only those points that successfully
generate mates are passed as spot welds to
Sim)
• Point Load: Used for “hard points” (nodal
ponts) in the analysis (all points
successfully generated are passed to Sim as
vertices
• Construction Point: No points of this type
are passed to Sim
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3D Geometry

• Select from three possible Point Definition options each with certain
placement definitions:
• Single: Sigma and Offset
• Sequence By Delta: Sigma, Offset, Delta
• Sequence By N: Sigma, Offset, N, Omega
• From Coordinates File: Formatted text file, similar to 3D curve (later)
– Sigma: the distance between the beginning of the chain of guide edges
and the placement of the first point
– Edge Offset: the distance between the guide edges and the placement of
the spots on the set of base faces
– Delta: the distance, measured on the guide edges, between two
consecutive points, for the Sequence By Delta option
– N: the number of points to be placed, relative to the chain of guide edges,
in case of the Sequence By N option
– Omega: the distance between the end of the chain of guide edges and the
placement of the last spot, for the Sequence By N option
• Some examples follow . . .
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3D Geometry

“Sequence by N” placement options:
Sigma
Base
Face
Guide
Edge
Edge
Omega Offset
Face
Offset
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3D Geometry

“Sequence by Delta” placement options:
Guide Edge
Delta Base Face
Above:
Guide edge = 50 mm
Points = 6 (Guide edge/Delta + beginning point)
Delta = 10 mm
Note: all other placement options, Sigma, Omega, etc. are the same as
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in the previous example Inventory #002176
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Workshop 4-1, Catalytic Converter Training Manual

• Goals:
– Create the catalytic converter model shown below.
– Create separate sketches and perform a skin/loft operation to make
the converter body.
– Use a Thin/Sheet operation to shell out the solid for future simulation.
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1. Use >File>New, or Launch ANSYS Workbench and choose to
start New Geometry
2. When prompted specify “centimeters” for length unit
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3. Create the flange sketch #1 on XY Plane.
– Click on >XYPlane in Tree
• Toolbar: >New Sketch
– Sketch1 will be created on
XYPlane
• In the Details view, rename Sketch1 to
“BaseCircle”.
• Toolbar: >Look At
– [Sketching] >Draw>Circle
• Move the cursor over the sketch origin,
then when the “P” is displayed (auto-
constraint), click on the left mouse
button. Click again to define the radius.
– [Sketching] >Dimensions>Radius
• Click on the circle to select it, then click
again on the screen to define where to
place the dimension.
• In the Details view, modify >R1 to be
“2.5”.
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Create the flange sketch #1 (cont’d)
– [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 Segments. Enter “8”
for the textbox n=.
• In the Model View, select the circle.
It will now be split into eight
segments.
Notes:
In this step, we split and reoriented the

circle.
We will create the surfaces of the flange

by lofting four sketches using this one as
our basis.
In order to do so, we must have the same

number of divisions on each sketch, all
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oriented appropriately. Inventory #002176
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– [Sketching] >Draw
• Using the Box Select option, select
the points and edges of the circle.
– [Sketching] >Modify >Move
• In the text boxes next to the Move
tool, change r= to “22.5” and f= to
“1”.
• Right-click on the Model View and
select “Use Plane Origin as Paste
Handle”. This will make the
moving reference point as the
original, relative location of the
sketch origin.
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View and select “Rotate by r
Degrees”. This makes the moving
operation include a rotation, as
specified by the value of “22.5”
degrees entered earlier.
View and select “Paste at Plane
Origin”.
• Right click, >End
• This completes the move operation

by moving the model to the origin.
Since the reference point was the
origin, this results in no translation
but only a rotation, specified by
r=22.5.
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• On the Selection Toolbar, select the
“New Selection” icon. Looking at
the segments, one can see that
they are now rotated 22.5 degrees.
the points and edges of the circle.
We will copy this sketch profile to
be used for the next one.
– [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, relative
location of the sketch origin as the
pasting point.
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4. Create the flange sketch #2
– Toolbar: XYPlane
– Toolbar: >New Plane
• Select the New Plane icon from the
Active Plane/Sketch Toolbar. This
creates Plane4 based on XYPlane.
• In the Details view, create an Offset
Z and set FD1 to “1”.
– Toolbar: “Generate”
– [Sketching] >Modify>Paste
• Enter “0” for r= and “1.05” for f=.
View and select “Scale by factor f”.
This will scale the original sketch
profile by a factor of 1.05 for our
new sketch.
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select “Paste at Plane Origin”. Our
reference point was the sketch
origin from BaseCircle, and the
pasting location is the origin on
Sketch2, so this essentially copies
the original circle onto Sketch2
with a scale factor of f=1.05.
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– In Tree, Click on >BaseCircle
• Right-click on BaseCircle and
select “Keep visible”
– In Tree, Click on >Plane4 >Sketch2
• Right-click on Sketch2 and select
“Keep Visible”.
– 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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– Toolbar: XYPlane
– Toolbar: >New Plane
creates Plane5 based on XYPlane.
Z, and set FD1 to “5”.
– Toolbar: “Generate”
– [Sketching] >Draw >Rectangle
• Check Auto-Fillet checkmark next
to the Rectangle tool.
• Click once to define one corner of
the rectangle, click again to define
its diagonal, and click a third time
to define the fillet radius.
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– [Sketching] >Dimensions >General
• Dimension the sketch as shown at
right.
• In the Details view, change
Dimensions > H1 to “10”, L4 to
“10”, L5 to “6”, R3 to “5”, V2 to “2”.
the points and edges of the flange
on Sketch3.
– We will copy this sketch
profile to be used for the
next one.
– [Sketching] >Modify >Copy
View and select “Use Plane Origin
as Paste Handle”.
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– [Modeling] >Converter >Plane5
– Toolbar: New Plane
creates Plane6 based on Plane5.
Z, and set FD1 to “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”.
(scales the original sketch profile by
a factor of 1.05).
select “Paste at Plane Origin”. Our
reference point was the sketch
origin from Plane5, and the pasting
location is the origin on Plane6, so
this copies the rectangle onto
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Plane6 and scales it by 1.05. Inventory #002176
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>Sketch3
“Keep Visible”
>Sketch4
“Keep Visible”. This makes both
sketches visible at the same time,
so we can easily see that the
original profile is indeed scaled by
a factor of 1.05.
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7. Create the flange
– Toolbar: Skin/Loft
• Select the Skin/Loft icon
• and the Details view, Profiles
should be active.
• Hold the CTRL key and, from the
graphics window select the four
edges 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
lofting is not correct, as it will
‘twist’ the geometry. If your grey
line does not seem correct, this can
be resolved by right-clicking
anywhere on the Model View and
selecting “Fix Guide Line”.
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Create the flange (cont’d)
• Select the two top edges that the
arrows point to on the top-right
image. This redefines the lofting
guide such that the model will not
‘twist’.
• After selecting the two edges, the
guiding profile, shown in grey, is
now defined correctly as shown in
the bottom-right image.
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Create the flange section (cont’d)
• The resulting solid is plotted.
– Toolbar: View >Wireframe Display
• The wire frame display is shown
below.
– Toolbar: View >Shaded Display
• [Modeling]
>Converter>XYPlane>BaseCircle
• Right-click on BaseCircle and select
“Don’t keep visible”
• Repeat the above command to turn
off Sketch2, Sketch3, and Sketch4
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8. Create the pipe bend
– [Modeling] >Converter >XYPlane
– Toolbar: New Sketch
• Sketch5 will be created on XYPlane
• Choose the “Look At” icon
• In the Details view, rename Sketch5
to “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 as “15”.
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Create the pipe bend (cont’d)
– [Modeling] >Converter >XYPlane
>BaseCircle
– Toolbar: Revolve
• In the Details view, the Base Object
should be set to “BaseCircle”.
• Add “RevolveAxis” as the Axis by
selecting the line and then pick
Apply.
• 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.
• This will generate the pipe bend.
• Select the end circular surface for
our next step. December 17, 2004
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9. Create the pipe end
• Make sure the end circular surface
is highlighted (from step 8).
– [Sketching] >Draw >Circle
• A new sketch is automatically
created. Create a circle the same
size as the end circle of the pipe
bend. Use of auto-constraints, as
shown on the top-right image, will
ensure that the circle sketch will
match the end surface.
– Toolbar: Extrude
• In the Details view, change FD1,
Depth (>0) to “10”
• The straight end of the pipe should
be generated.
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Create the pipe end (cont’d) Surface 1
• Select the 2 end surfaces (see right)
Create a Surface model

– Toolbar: Thin/Surface
• In the Details view, change “Selection
Type” to “Faces to Remove” and FD1,
Thickness (>0) to “0”
• The result is a surface model that can
be meshed using shell elements during
FE simulation.
Surface 2
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DMD 90 CH04 3dgeom

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Chapter 4

ANSYS Workbench - DesignModeler

• Workshop 4-1, Catalytic Converter

December 17, 2004

ANSYS Workbench - DesignModeler

• DesignModeler contains three different body types:

• By default, DM places each body into one

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ANSYS Workbench - DesignModeler

ANSYS Workbench - DesignModeler

December 17, 2004

ANSYS Workbench - DesignModeler

ANSYS Workbench - DesignModeler

ANSYS Workbench - DesignModeler

December 17, 2004

ANSYS Workbench - DesignModeler

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ANSYS Workbench - DesignModeler

• Each 3D feature creation is controlled via the associated details

• The last step in creating 3D features is to click “Generate”

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ANSYS Workbench - DesignModeler

It’s all in the details!

ANSYS Workbench - DesignModeler

December 17, 2004

ANSYS Workbench - DesignModeler

Choose feature and

Extrude – “Add Material”

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ANSYS Workbench - DesignModeler

Existing solid (shown in

Revolve with Cut operation

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ANSYS Workbench - DesignModeler

Active sketch to extrude

Extrude with Imprint Faces

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ANSYS Workbench - DesignModeler

Active sketch to extrude

Extrude with Add Frozen

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ANSYS Workbench - DesignModeler

New frozen body

Active sketch to Extrude

Extrude with Slice operation

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ANSYS Workbench - DesignModeler

Direction is with respect to

ANSYS Workbench - DesignModeler

December 17, 2004

ANSYS Workbench - DesignModeler

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ANSYS Workbench - DesignModeler

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ANSYS Workbench - DesignModeler

ANSYS Workbench - DesignModeler

December 17, 2004

ANSYS Workbench - DesignModeler

ANSYS Workbench - DesignModeler

ANSYS Workbench - DesignModeler

December 17, 2004

ANSYS Workbench - DesignModeler

Sketch2 = sweep path