Surfacing Best Practices

AITHcrew Automotive Interior & Exterior Trim Design
Shivkumar Gummadi Page 1

Unit: 13

Surfacing Best Practices

82: Surfacing Best Practices Unit Introduction
83: Surfacing Considerations
84: Avoiding Problems in Surfacing
85: How to Fix Imperfect Faces and Bodies
86: Finding the Balance



82: Surfacing Best Practices Unit Introduction

Introduction

In this unit ...
Learn to choose and create appropriate features.
Comprehend how to avoid common surfacing problems and how to improve the quality of
imperfect surfaces and bodies.
Find the balance between speed and quality.




Overview: Because there are hundreds of features, each containing multiple options, deciding on
which one to use for your application can be daunting. Within surface features alone, there are
dozens to choose from. Then, to take the issue a bit further, within a single surface feature there
are multiple options available. Demystifying some of these functions can help you complete your
work without the software hindering your progress. The following sections explain surface features
and options we recommend.
Surfacing using Sections and Guides:
Probably the two most useful features in surfacing are Multi-Sections Surface and Sweep. Even
if you don't create many surface objects, it's a good idea to learn these features because most
surface models contain them.

Multi-Sections Surface
The Multi-Sections Surface feature, one of the most versatile commands in CATIA, enables you
to create some of the most complex surfaces, and is a standard method when producing a surface
with smooth transitions between section strings. Unlike other CAD systems, the Multi-Sections
Surface feature produces surfaces through sections, or uses a combination of sections and
guides.
Here are some advantages to using the Multi-Sections Surface feature:
- You can define various cross-sections that do not need to be evenly spaced.
- You can use the operation on a blend surface.
- You can create a surface that is tangent to an existing surface.


02: Section String for Multi-Sections Surface

03: Multi-Sections Surface with Tangency Constraint


- You can use the operation when you do not have a smooth transition between your section
strings. Like the sections, you can also add tangent constraints to the start and end guide string.

04: Multi-Sections Surface with Guide Strings
- In conjunction with the re-limitation options, you can extend the surface to the ends of the guides
or spine without defining a section at either end.
When using Multi-Sections Surface, you cannot create a curvature constraint between a section
and an existing surface. Nor can you can add tangent constraints to intermediate sections.
Sweep: The Sweep feature is extremely useful when creating a surface that is controlled using
one section and a guide. Options available to you vary, depending on which workbenches you
have available. With the Wireframe and Surface Design workbench, the standard Explicit sweep is
available. This feature allows you to sweep one section along one or two guides. In addition, you
have extra control over the orientation of the section as you sweep it along.

05: Sweep
One disadvantage is that you can only define one section. If more than one section is required,
then use the Multi-Sections Surface or Adaptive Sweep feature (which is only available in the
Generative Shape Design workbench).

If you have the Generative Shape Design workbench, the Sweep command really comes into its
own. The extra features allow you to create linear, conical, and circular sweeps along guides,


without defining the section strings. After you define the guides, you can modify the values
explicitly or control them by using a law. The guides themselves don't need to be linear, but can
vary in shape.

06: Conic Sweep with Three Guide Curves
Adaptive Sweep: Adaptive Sweep is only available with the Generative Shape Design
workbench. This function allows you to sweep a profile along a guide and gives you control over
the profile dimensions as you sweep it. The aim of the feature is to stop you from having to create
multiple sections with different dimensions. While the intention is good, it proves difficult to predict
the position of the computed generated sketches. To make this command work, you need to be
extremely careful in how you constrain the original section sketch. The extra sections created
along the guide keep the original constraints and often become out of place. If you have difficulty
getting the sections to perform correctly, it may be best to create the various sections and use
Multi-Sections Surface to create the surface.
Spine Curves: A commonality to most surfaces created through sections and guides is the use of
a spine curve. A spine controls the orientation of the surface as you create it. Using a spine
creates the surface normal to the spine.

08: Sweep with Spine
Using Surfaces with Solid Bodies: One common question asked after you create a surface is,
"How do you turn it into a solid or use it to modify the shape of an existing solid?" The following
sections describe the surface-based features, which control the shape of a solid or create a solid
itself. You use the following features regularly after you create your required surface and you must
be in the Part Design workbench to access them.
Split and Sew: Split and Sew are similar features in that they both style an existing solid to take
the form of a surface. The difference is that Split always removes material while Sew can add
material between an existing solid and the surface.


09: Splitting a Surface

ThickSurface: The ThickSurface feature allows you to give a surface a constant thickness, thus
creating a solid that follows the form of the surface.

10: Thickening a Surface

Close:
The Close surface allows you to create a solid body from a surface that has only a planar opening
or is totally closed by surfaces. You can create an entire product representation in surfaces, join
them together, and then close them to produce a solid.

11: Close Surface
Tips
Multi-Sections Surface was formerly named Loft.


84: Avoiding Problems in Surfacing

Overview:
When working with surfaces, you can prevent many problems by carefully planning your model.
Start with a good foundation using the correct curves and modeling techniques. Try to avoid
creating a complex model when a simpler design will do. Surface features are essential for
creating complex models, but they also invite trouble.

Closing Points and Coupling

It is extremely important that the Closing Point in each section is in the equivalent area to
prevent the solid from twisting.

01: Incorrect Closing Point 02: Correct Closing Point



On open sections, the arrows in each section should point in the same direction to avoid the
same twisting problem.

Another important feature in Multi-Section Surfaces is coupling. Coupling defines how points in
one section connect to points in the next section. The options include Ratio, Tangency,
Tangency then curvature and Vertices. If there are an uneven number of points in each
section, the surface becomes disjoined. Try to use the same number of points in each section, or
use the Curve Smooth feature as described below. Always remember that you can manually
specify the coupling, if required.

Using the Right Section Curves

If you start with the right set of section curves, you reduce the possibility of bad surfaces. How do
you create the right set of section curves? Reduce the complexity of the curves that form the
basis of the surface.

Free form features take on the characteristics of the underlying curves. Use a single curve for a
section where possible. Multiple curves in a section string can create unwanted faces in the
resultant body. In the figure, a Multi-Section Surface feature was created using multiple curve
section strings and guide strings.

03: Multiple Face Surface 04: Single Face

The resultant surface has three faces with undesirable tangent edges between the faces.
Although the section and guide strings are associative sketches, the result is not acceptable.
Smooth the curves to produce one continuous section. This action results in a single face sheet
body.

Trim Solid Versus Final Look

Deciding whether to create a solid's final shape with one feature or multiple features is a
dilemma. If you try to add too much curvature into one operation, the resulting surface can have
many irregularities. Instead, create a base shape and use Split or Boolean operations to finish
the shape.
In the figure, a solid was created using different trim and Boolean operations.


05: Solid Model From Boolean Operations

If you try to model the cutout area into the main solid, there are problems. In the locations
labeled Problem area, you get irregularities in the face. Multi-Section Surface or Sweep cannot
transition quickly enough to make an acceptable face. Instead, a base model with the general
shape is created.

06: Base Model 07: Cutout 08: Blends Added

The section curve did not include the fillet on one side. A sketch was created to remove the
material in the cutout area. Edge fillets were then added to round out the corners.

Keep It Simple

Just because you know how to create a surface feature does not mean you want to use it for
every feature. If a cylindrical surface is acceptable, create the face as one; it is easier to model
and machine. As stated before, do not try to do too much with each surface feature. When it
comes to editing your model, if it is too complicated, an update can take a long time (1-2 hours).





Overview:

There are methods you can use to repair parametrically created surface features, and techniques
you can use so you do not create imperfect faces. In this course, we do not cover how to fix
unparametric sheet or solid bodies. Imperfect faces / bodies are faces that contain unwanted dips
and blemishes, as well as faces that do not pass Connect Checker tests.

Checking for Negative Gaussian Radius

In order to check the Gaussian radius, you need to know what it is. Selecting Insert | Analysis |
Surfacic Curvature Analysis is one way you can check a face. Gaussian radius checks the
radius at any given point that is determined by a group of section curves passing through the
point. Each point on the surface has a normal (N). The section curves are created from the
intersection of sectioning planes, which revolve around the point through the normal (N) and the
face being analyzed. CATIA uses these section curves to analyze the curvature of the face at
each point. A negative Gaussian radius causes an opposite curvature in at least two sections
(imagine a saddle). A positive Gaussian radius creates all curvature in the same direction.

01: Positive Gaussian Radius 02: Flat Spot and Negative Gaussian 03: Smooth Looking Surface 04: Analysis Showing Defects

If you have a flat spot, the Gaussian radius tends towards infinity. It also checks for dips or
bumps in the face. Many times, a face appears to be smooth with no apparent defects. However,
once you perform a face analysis, the Gaussian radius check shows the defects.


It is easier to edit the curves if you create your sections by creating sketches and then joining the
curves. When you get a bump or dip in the face, check the curvature of the curves first, which
should not be an issue if you used Join curves. Usually the curves will only cause localized
deformities. Sometimes, the locations of your section strings cause the deformities. You may
have a section string that is not aligned with other sections.

Connect Checker

If you discover problems in the surface, they are usually caused by problems in the construction
curves. If you have a number of curves joined together to produce a section, Connect Checker
allows you to check

05: Connect Checker

the distance between the endpoints, as well as the tangencies and curvatures between the
curves.

After you identify the problem areas, you can modify the original sketch or wireframe geometry.

If you have the Generative Shape Design module, you can use the Curve Smooth feature to
modify the curves automatically to make them tangent and curvature continuous.

With the surface analysis and Connect Checker, you should be able to pinpoint the problem
areas and fix the underlying cause.





Overview:

Whenever you are creating complex surfaces, you are inevitably facing a project deadline. If you
have no schedule to meet, you are one of the lucky few. Finding the balance between speed,
complexity, size, and best features, while taking into account schedule time, file size, and the
function of the part, can sometimes be a difficult task. Asking questions, such as "Do I need to
create a surface with 50 sections when I can create a surface using four sections and still satisfy
the design parameters?" is important.

Speed Versus Caution:

Each time you add a section to your surface, you need to create the curves and planes, and
determine the curve parameters. Next, you must locate the section in the correct position, hoping
you sized it correctly. You may need to adjust each section string's location or size to get the
surface required. As you adjust the geometry, you need to check the validity of the faces. Not
surprisingly, these steps take time. Do not spend hours trying to make the face perfect if it does
not need to be. If the function of the part does not depend on a perfect face, do not belabor it.

File Size Versus Multiple Features

With every feature you add to your model, you increase the file size of the model. Some
operations can increase the size of a file dramatically. For example, if you create a trimmed
surface and then use that to trim the main solid, it quickly increases the file size. Most often,
these types of trim surfaces contain many wireframe features. You may need many features to
build one trim surface. You must decide if you need all the surfaces in one trim surface or in
multiple trim surfaces.



Surface Complexity

Surface complexity affects model size, update time, and manufacturing. If you truly need to keep
surfaces highly complex, you will have these obstacles. Most machined surfaces cannot even be
manufactured to the modeled solid. It is best if you can decrease model complexity without
compromising design intent.

Quite often, someone new to surface modeling creates the most complex surface possible, just
because they can. You want to create the simplest model possible while maintaining design
intent. You must remember that someone needs to machine the electronic model you are
designing. The fact that you can create it on a screen does not mean that someone can actually
create it in reality. Even if it can be manufactured, how much time and money will it take? Simple
surfaces are the most desirable for model size and manufacturing.

When you try to put many different curvatures into a surface, you increase the complexity. A
better method is to use multiple features to achieve the same topology. Your file size may
increase, but the surface complexity remains small.

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AITHcrew Automotive Interior & Exterior Trim Design

Shivkumar Gummadi Page 1

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