DMD 90 CH04 3dgeom

Chapter 4
3D Geometry
3D Geometry
Contents
Bodies and Parts
3D Features
Boolean Operations
Feature Direction
Feature Type
Feature Creation
Workshop 4-1, Catalytic Converter
ANSYS Workbench - DesignModeler
Training Manual
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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
Decem
3D Geometry
Bodies and Parts

There are two body states in DM:
Active:
Body can be modified by normal modeling operations
(cannot be sliced)
Active bodies are displayed in blue in the Feature
Tree View
The body's icon in the Feature Tree View is
dependent on its type - solid, 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
Frozen bodies are displayed lighter in the Tree View
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Active
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3D Geometry
Bodies and Parts

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
Bodies and Parts

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.
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3D Geometry
Bodies and Parts

Why multi-body parts?
Example:
DM
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
Training Manual
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3D Geometry
Bodies and Parts

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
Bodies and Parts

Example:
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
DM
Sim
DM
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3D Geometry
3D Features
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
Frozen
Bodies in
model?
Its all in the details!
3D Feature
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3D Geometry
Boolean Operations
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
Boolean Add:
Choose feature and

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

shown here
Note: If bodies already exist, add results in merged geometry after Generate
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3D Geometry
Boolean Operations
Training Manual
Boolean Cut:
Existing solid (shown in

wire frame for clarity)
Revolve with Cut operation
Axis of revolution
Active Sketch
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3D Geometry
Boolean Operations
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 Operations
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 Operations
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
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
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
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
Feature Type
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
Feature Type
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
Feature Type
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.
Unbounded surface selected as extent
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3D Geometry
Feature Creation
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
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3D Geometry
Feature Creation
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
Both - Asymmetric: Applies feature in both
directions. Each direction has its own angle
property
The Generate button completes the feature
creation
Sketch with Disjoint

Line
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3D Geometry
Feature Creation
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
Feature Creation
Sweep example 1:
Sketch1 = profile to sweep
Training Manual
Path Tangent alignment:

profile remains tangent to
path
Sketch2 = sweep path
Global Axes alignment:

profile orientation
remains constant
Decem
3D Geometry
Feature Creation
Sweep example 2:
Sweep details:
Scale = 0.5
Turns = - 4
Sketch1 = profile to sweep
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
The default values for Scale and Turns are 1.0 and 0.0 respectively
Sketch2 = sweep path
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3D Geometry
Feature Creation
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 . . .
Training Manual
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3D Geometry
Feature Creation
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
Feature Creation
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
Result
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3D Geometry
Feature Creation
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
Feature Creation
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
Point Type
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3D Geometry
Feature Creation
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 . . .
Training Manual
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3D Geometry
Feature Creation
Training Manual
Sigma
Base
Face
Guide
Edge
Edge
Omega
Offset
Face
Offset
Sequence by N placement options:
Decem
3D Geometry
Feature Creation
Training Manual
Delta
Guide Edge
Base Face
Above:
Guide edge = 50 mm
Delta = 10 mm
Points = 6 (Guide edge/Delta + beginning point)
Note: all other placement options, Sigma, Omega, etc. are the same as
in the previous example
Sequence by Delta placement options:
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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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Use >File>New, or Launch ANSYS Workbench and choose to
start New Geometry
2.
When prompted specify centimeters for length unit
1.
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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 (autoconstraint), 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.
3. Create the flange sketch #1 on XY Plane.
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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
oriented appropriately.
Create the flange sketch #1 (contd)

[Sketching] >Modify>Split at Select
Right click anywhere on the Model
view and select Split Edge into n
Equal Segments from the pop-up
menu.
The Split tool will now change to
Split Equal Segments. Enter 8
for the textbox n=.
In the Model View, select the circle.
It will now be split into eight
segments.
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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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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.
4. Create the flange sketch #2
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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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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.

[Sketching] >Dimensions >General
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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=.
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
Plane6 and scales it by 1.05.
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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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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.
7. Create the flange
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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.
Create the flange (contd)
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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
Dont keep visible
Repeat the above command to turn
off Sketch2, Sketch3, and Sketch4
Create the flange section (contd)

Toolbar: Generate
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[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.
8. Create the pipe bend
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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.
Toolbar: Generate
This will generate the pipe bend.
Select the end circular surface for
our next step.
Create the pipe bend (contd)

[Modeling] >Converter >XYPlane
>BaseCircle
Toolbar: Revolve
In the Details view, the Base Object
should be set to BaseCircle.
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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
Toolbar: Generate
The straight end of the pipe should
be generated.
9. Create the pipe end
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Surface 1
Create a Surface model

Toolbar: Thin/Surface
In the Details view, change Selection

Type to Faces to Remove and FD1,
Thickness (>0) to 0
Toolbar: Generate
The result is a surface model that can
be meshed using shell elements during
FE simulation.
Surface 2
Create the pipe end (contd)

Select the 2 end surfaces (see right)
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Chapter 4

Workshop 4-1, Catalytic Converter

ANSYS Workbench - DesignModeler

Bodies and Parts

DesignModeler is primarily intended to provide geometry to an

DesignModeler contains three different body types:

By default, DM places each body into one

ANSYS Workbench - DesignModeler

Bodies and Parts

ANSYS Workbench - DesignModeler

Bodies and Parts

Suppressed bodies are not plotted.

ANSYS Workbench - DesignModeler

Bodies and Parts

ANSYS Workbench - DesignModeler

Bodies and Parts

In DM: 3 parts, 3 bodies consisting

ANSYS Workbench - DesignModeler

Bodies and Parts

In DM: 1 part, 1 body

ANSYS Workbench - DesignModeler

Bodies and Parts

ANSYS Workbench - DesignModeler

Typically, the generation of a 3D feature (like Extrude or Sweep)

Each 3D feature creation is controlled via the associated details

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

ANSYS Workbench - DesignModeler

Its all in the details!

ANSYS Workbench - DesignModeler

You can apply five different Boolean operations to 3D features:

ANSYS Workbench - DesignModeler

Choose feature and

Extrude Add Material

ANSYS Workbench - DesignModeler

ANSYS Workbench - DesignModeler

Existing solid (shown in

Revolve with Cut operation

Active sketch to extrude

Extrude with Imprint Faces

ANSYS Workbench - DesignModeler

Active sketch to extrude

Extrude with Add Frozen

ANSYS Workbench - DesignModeler

New frozen body

Active sketch to Extrude

Extrude with Slice operation

ANSYS Workbench - DesignModeler

Direction is with respect to

ANSYS Workbench - DesignModeler

ANSYS Workbench - DesignModeler

ANSYS Workbench - DesignModeler

Add will extend the profile up to the first surface it encounters.

ANSYS Workbench - DesignModeler

The To Faces option is different from To Next. To Next does not

ANSYS Workbench - DesignModeler

To Surface: option is similar to To Faces, except only one face can

Unbounded surface selected as extent

ANSYS Workbench - DesignModeler

Extrusions include solids, surfaces, and thin-walled features

ANSYS Workbench - DesignModeler

Sketch with Disjoint

ANSYS Workbench - DesignModeler