Handbook of Solid Modeling

Donald E. LaCourse, Editor in Chief President The Solid Modeling ExChange

McGraw-Hill, Inc. New York San Francisco Washington, D.C. Auckiand Bogota Caracas Lisbon London Madrid Mexico City Milan ' Montreal New Delhi San Juan Singapore Sydney Tokyo Toronto Contents

The Solid Modeling Adviser Master Table xix The Solid Modeling Adviser Contributors List xxxv Contributors xxxvii Preface xxxix Acknowledgments xxxix

Section 1 Overview

Chapter 1. Read This First 1.3

1.1 What This Handbook Is / 1.3 1.2 What This Handbook Is Not / 1.3 1.3 The Solid Modeling Adviser / 1.3 1.4 Handbook Structure / 1.4 1.4.1 Categorical Icons / 1.5 1.4.2 Handbook Sections / 1.5 1.4.3 Reader Participation / 1.6 1.4.4 Reader Registration / 1.9 1.4.5 Reader Correspondence / 1.9 1.5 The Purpose of This Handbook / 1.9 1.5.1 In a Nutshell / 1.10 1.5.2 Additional Roles / 1.10 1.5.3 Defining Limitations / 1.11 1.6 Using This Handbook / 1.11 1.6.1 Who Can Benefit? / 1.11 1.6.2 A Deskside Reference / 1.12 1.6.3 A Problem Solver / 1.12 1.6.4 For Implementation / 1.12 1.7 Conclusions / 1.12

Chapter 2. Introducing Solid Modeling 2.1

2.1 3D Geometrie Forms / 2.1 2.2 Why Is Solid Modeling Important? / 2.2 2.3 Types of Solid Modeling (SM) Systems / 2.3 2.3.1 Constructive Solid Geometry (CSG) / 2.3 2.3.2 Boundary Representation (B-Rep) / 2.3 2.3.3 Spatial Enumeration (Octrees) / 2.4 2.3.4 Hybrids / 2.4 2.4 A Brief History / 2.4 2.5 Applications / 2.5 2.5.1 Layout, Design, and Drafting / 2.5 2.5.2 Industrial Design / 2.5 . 2.5.3 Analysis / 2.5 2.5.4 Manufacturing Engineering / 2.6 2.6 Current Limitations / 2.6 2.7 The Future of SM / 2.7 References / 2.8

Section 2 Techniques

Chapter 3. Solid Modeling Concepts 3.3

3.1 Basic Concepts / 3.3 3.2 3D Coordinate Systems / 3.3 3.2.1 Global, World, and Local Coordinates / 3.4

vii 3.2.2 Cartesian Coordinates / 3.4 3.2.3 Cylindrical and Spherical Coordinates / 3.5 3.2.4 Reference Planes / 3.6 3.3 Construction Concepts / 3.7 3.3.1 Construction Planes I 3.7 3.3.2 Building Blocks / 3.7 3.3.3 Creating Solids from 2D Geometry / 3.9 3.3.4 Groups and Assemblies / 3.9 3.4 Other Concepts / 3.9 3.4.1 Translations and Rotations / 3.9 3.4.2 Copying, Scaling, and Mirroring / 5.70 3.4.3 Layers / 3.11 Reference I 3.14

Chapter 4. Solid Modeling Database Structures

4.1 Reviewing CAD Databases / 4.1 4.1.1 High versus Low-Level Design / 4.1 4.1.2 CAD Generations / 4.1 4.2 Requirements I 4.3 4.3 Basic Database Concepts / 4.3 4.3.1 The SM Database / 4.3 4.3.2 Representing Geometrie Elements / 4.4 4.3.3 Classifying Geometrie Elements / 4.5 4.3.4 Bounded versus Unbounded Objects / 4.6 4.3.5 Geometry versus Topology / 4.6 4.3.6 Evaluated Representations I 4.7 4.3.7 Manifold versus Nonmanifold Objects I 4.7 4.3.8 Primary versus Secondary Models I 4.7 4.3.9 Display Models / 4.8 4.3.10 Model Portability / 4.8 4.4 Mathematical Methods / 4.9 4.4.1 Exact versus Inexact Mathematics / 4.9 4.4.2 Analytical versus Numerical Methods / 4.9 4.4.3 Computational Complexity I 4.10 4.4.4 Graphs and Trees / 4.10 4.5 SM Database Considerations / 4.11 4.5.1 Representational Capability / 4.11 4.5.2 Performance I 4.12 4.5.3 Reliability / 4.12 4.6 Constructive Solid Geometry (CSG) / 4.12 4.6.1 Multiple Use of Subtrees / 4.12 4.6.2 Point Classification / 4.12 4.6.3 CSG Pros and Cons / 4.15 4.7 Boundary Representation (B-Rep) / 4.15 4.7.1 Winged-Edge Data Structure / 4.15 4.7.2 Euler's Formula I 4.17 4.7.3 Boolean Operations with B-Rep / 4.18 4.7.4 Polygonal Representations / 4.18 4.7.5 B-Rep Pros and Cons / 4.19 4.8 Other Database Representations / 4.19 4.8.1 The Octree Database / 4.19 4.8.2 The Hybrid Database / 4.21 4.9 The Parametric Parametric/Relational Database / 4.21 4.9.1 CSG / 4.22 4.9.2 B-Rep / 4.22 4.9.3 Variational Design / 4.22 4.9.4 Feature-Based Design / 4.22 Suggestions for Further Reading / 4.24

Chapter 5. Curves and Surfaces for Solid Modeling

5.1 Curves, Surfaces, and Computers / 5.2 5.2 Curve and Surface Usage / 5.2 5.3 Curves and Splines / 5.3 5.3.1 Bezier,B-Splines,andNURBS / 5.4 5.3.2 Curve Functions / 5.4 5.3.3 Curve Representations / 5.4

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5.4 Surfaces / 5.7 5.4.1 Surface Representations I 5.7 5.5 Solid Modeling Considerations / 5.11 5.5.1 Geometrie Progression / 5.11 5.5.2 Levels of Integration / 5.12 5.5.3 Preferred Geometry / 5.12 5.6 Conclusions / 5.13 References / 5.16

Chapter 6. Modeling Strategies 6.1

6.1 Attributes / 6.1 6.2 Solid Primitives / 6.1 6.3 Geometrie Operations / 6.3 6.3.1 Blends or Transitions / 6.3 6.3.2 Extrusions / 6.4 6.3.3 Revolutions / 6.4 6.3.4 Sweeps / 6.4 6.3.5 Formula-Defined Shapes / 6.6 6.4 Boolean Operations / 6.6 6.4.1 Combining Solids / 6.6 6.4.2 SubtractingSolids / 6.7 6.4.3 Intersecting Solids I 6.7 6.5 Modeling Guidelines I 6.9 6.5.1 Minimum Modeling Time / 6.9 6.5.2 Model Size and Complexity / 6.13 6.5.3 Clean Modeling / 6.13 6.6 Navigating Errors / 6.17 6.6.1 Modeling Errors / 6.17 6.6.2 Intersection Errors / 6.20 6.6.3 Accuracy Errors / 6.22 6.6.4 Modeling Work-Arounds / 6.23 6.7 Cautions and Needed Improvements / 6.23 6.8 Conclusions / 6.24 Reference / 6.27

Chapter 7. Editing Strategies 7.1

7.1 Occurring Types of Change / 7.1 7.1.1 Geometry Changes / 7.1 7.1.2 Topology Changes / 7.2 7.1.3 Cosmetic Changes / 7.2 7.2 Editing Solids / 7.2 7.2.1 Editing Geometry / 7.2 7.2.2 Editing Topology / 7.2 7.2.3 Editing Dimensions / 7.3 7.2.4 Editing Surface Intersection Accuracy / 7.3 7.3 Editing theCSGTree / 7.3 7.3.1 Editing Order of Shapes / 7.4 7.3.2 Adding or Removing Shapes / 7.4 7.4 Editing Solid Primitives / 7.5 7.5 Editing Solid Geometrie Operations / 7.5 7.5.1 Editing Blends / 7.6 7.5.2 Editing Extrusions / 7.6 7.5.3 Editing Revolutions / 7.6 7.5.4 Editing Sweeps / 7.6 Reference / 7.8

Chapter 8. Parametric/Relational Solid Modeling 8.1

8.1 The History of Parametrics in Solid Modeling / 8.2 8.2 Parametric/Relational versus Variational Solid Modeling / 8.2 8.3 Anatomy of a Parametric/Relational Solid Modeling System / 8.3 8.3.1 The Sketcher / 8.4 8.3.2 The Solid Modeling System / 8.5 8.3.3 The Dimensional Constraint Engine (DCE) / 8.7 8.3.4 The Feature Manager / 8.10 8.3.5 The Assembly Manager / 8.13

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8.4 Dimension-Driven Editing / 8.15 8.4.1 Value Editing / 8.15 8.4.2 Reference Editing / 8.15 8.4.3 Appearance Editing / 8.15 8.5 Bidirectional Associativity / 8.16 8.6 Example Parametric/Relational Design Process / 8.16 References / 8.25

Chapter 9. Solid Modeling and Knowledge-Based Engineering 9.1

9.1 Knowledge-Based Engineering (KBE) / 9.1 9.1.1 ATypical Application i 9.2 9.1.2 Process or Geometry? / 9.3 9.1.3 Object-Oriented / 9.4 9.1.4 Two Types of KBE Engineer / 9.4 9.1.5 Jargon / 9.5 9.1.6 Who Can Benefit from KBE? / 9.5 9.2 CAD and KBE / 9.7 9.2.1 Geometry Construction / 9.8 9.2.2 Topology / 9.9 9.2.3 Solid Modeling Kernels / 9.9 9.3 Future Developments I 9.10

Chapter 10. Viewing and Displaying Solid Models 10.1

10.1 Hardware and Display / 10.1 10.2 Wireframe Display / 70.2 10.2.1 Hidden-Line Removal / 10.2 10.2.3 2D on 3D Displays / 10.2 10.3 Color-ShadingTechniques / 10.2 10.3.1 CPU Time / 10.3 10.3.2 Lighting / 10.3 10.3.3 Polygon Sort Shading / 10.4 10.3.4 Antialiasing / 10.5 10.3.5 Dithering / 10.5 10.3.6 Translucency / 10.5 10.3.7 Reflectivity / 10.5 10.3.8 Phong and Gouraud Shading / 10.5 10.3.9 Ray-Tracing / 10.5 10.3.10 Radiosity / 10.6 10.3.11 Texture Mapping / 10.6 10.4 Comparison of Shading Performance / 10.6 10.5 Computers, Video, and Film / 10.6 10.5.1 Computers to Videotape / 70.7 10.5.2 Making the Connection / 70.7 10.5.3 Computers to Film / 70.9 Reference / 70.9

Section 3 Applications

Chapter 11. Solid Modeling for Assemblies 11.3

11.1 Assembly Modeling / 77.5 11.1.1 Assembly Components / 77.3 11.1.2 Building the Assembly Hierarchy I 11.4 11.1.3 Component Libraries / 77.5 11.1.4 Performance Issues / 77.6 11.1.5 Visualization Issues / 77.6 11.1.6 Additional Advantages / 77.7 11.2 Interference Detection / 77.7 11.2.1 Static Detection / 77.S 11.2.2 Dynamic Detection / 77.S 11.2.3 Tolerance Analysis / 11.8 11.3 Applications / 77.S 11.3.1 Ease of Assembly (Fit and Form) / 77.9 11.3.2 Mass Properties / 77.9

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11.3.3 Documentation / 11.10 11.3.4 Rapid Prototyping / 11.10 11.3.5 Mechanism Modeling and Manufacturing Processes / 11.11 11.3.6 Finite Element Analysis (FEA) / 11.12 References / 11.15

Chapter 12. Solid Modeling and Mass-Properties Analysis 12.1

12.1 Operational Approach / 12.1 12.2 Mass / 12.1 12.3 Volume / 12.2 12.4 Materials and Densities / 12.2 12.5 SurfaceArea / 12.3 12.6 Moments of Inertia / 12.3 12.7 Centroid / 12.4 12.8 RadiiofGyration / 12.4 12.9 Products of Inertia / 12.5 12.10 Principal Axes / 12.5 12.11 Principal Moments / 12.5 12.12 Cautions and Needed Improvements / 12.5

Chapter 13. Solid Modeling for Kinematic and Dynamic Analysis 13.1

13.1 Defining Kinematic and Dynamic Analysis / 13.1 13.1.1 Kinematic Analysis / 13.2 13.1.2 Dynamic Analysis / 13.2 13.1.3 Inverse Dynamic Analysis / 13.2 13.1.4 Force / 13.2 13.2 Methods of Kinematic and Dynamic Analysis / 13.3 13.2.1 Conventional Approach / 13.3 13.2.2 Computer-Aided Approach / 13.3 13.3 Computer-Aided Kinematic and Dynamic Analysis / 13.4 13.3.1 Solid Modeling Integration / 13.4 13.3.2 Kinematic Analysis / 13.5 13.3.3 Dynamic Analysis / 13.5 13.3.4 Operational Approach / 13.5 13.3.5 Cautions and Needed Improvements / 13.6 13.4 Analysis Examples / 13.6 13.4.1 TheV-8 Engine / 13.7 13.4.2 Windshield Wiper Mechanism / 13.7 13.4.3 Vehicle Suspension System / 13.7 13.4.4 Conclusions / 13.9 References / 13.12 Suggestions for Further Reading / 13.12

Chapter 14. Solid Modeling for Finite Element Analysis (FEA) 14.1

14.1 Operational Approach / 14.1 14.2 FEA Basics / 14.2 14.3 Preprocessing / 14.2 14.4 The Finite Element Mesh (FEM) / 14.2 14.4.1 Mesh Elements / 14.4 14.4.2 Automatic Mesh Generation / 14.4 14.4.3 Model Types / 14.4 14.5 Meshing the Solid Model / 14.6 14.5.1 Mesh Density Controls / 14.7 14.5.2 Relative Mesh Density / 14.8 14.5.3 Editing the Mesh / 14.9 14.5.4 Material Properties / 14.10 14.5.5 BandwidthandWavefront / 14.10 14.5.6 Calculating Final Mesh Size / 14.11 14.5.7 Mesh Checks / 14.13 14.5.8 Detail Removal / 14.13 14.6 Case Loads and Boundary Conditions / 14.18 14.6.1 Mechanical Loads / 14.18 14.6.2 Mechanical Boundary Conditions / 14.19 14.6.3 Thermal Loads / 14.19 14.6.4 Thermal Boundary Conditions / 14.20

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14.7 Analysis / 14.20 14.7.1 Estimating Time Requirements / 14.20 14.7.2 Estimating Storage Requirements / 14.20 14.7.3 Internal Solvers / 14.21 14.7.4 External Solvers / 14.21 14.8 Postprocessing / 14.21 14.8.1 Concept Design / 14.21 14.8.2 Interactive Query / 14.22 14.8.3 Model Simulation / 14.22 14.9 Cautions and Needed Improvements / 14.22 References / 14.25 Suggestions for Further Reading / 14.26

Chapter 15. Solid Modeling for Numerical Control 15.1

15.1 Part Shape / 15.1 15.2 Solid Modeling and Numerical Control (NC) / 15.2 15.3 Change Propagation / 15.2 15.4 Solid Modeling versus Numerical Control Features / 15.4 15.5 Tolerances / 75.5 15.5.1 Tolerance Balancing / 15.5 15.5.2 Gap Tolerance / 15.6 15.6 Dimensions / 15.8 15.6.1 Reference Geometry / 15.8 15.7 Manufacturing Considerations / 15.8 15.7.1 Holes / 15.9 15.7.2 Surfaces / 15.9 15.7.3 Solids and Surfaces / 15.10 15.8 Solid Modeling and Numerical Control Software Compatibility / 15.11 15.8.1 Compatibility Group I / 15.11 15.8.2 Compatibility Group II / 15.12 15.8.3 Compatibility Group III / 15.12 15.9 How Solid Modeling Benefits Numerical Control / 15.12 15.10 Solid Modeling Improvements Needed for Numerical Control / 15.13

Chapter 16. Customizing the Solid Modeling System 16.1

16.1 Needs Analysis / 16.1 16.2 Macros / 16.1 16.3 Intelligent Programming / 16.6 16.4 Adding Functionality / 16.6 16.4.1 Adding Commands / 16.7 16.42 Adding Menüs / 16.7 16.4.3 Adding Programs / 16.7 16.5 CustomizationTechniques / 16.7 16.5.1 Presentations / 16.7 16.5.2 Simulations / 16.7 16.5.3 Animations / 16.8 16.5.4 Automation / 16.8 16.6 Cautions and Needed Improvements / 16.8 16.7 Cönclusions / 16.8

Chapter 17. Solid Modeling and Documentation 17.1

17.1 Detail Drawings / 17.1 17.1.1 Levels of Associativity / 17.1 17.1.2 Space Relationships / 17.3 17.2 Desktop Publishing / 17.4 17.2.1 Graphic Formats / 17.4 17.2.2 Applications / 17.5 17.2.3 Integrated Databases I 17.7 17.2.4 Screen Shots / 17.10 17.3 Hardcopies / 17.11 17.3.1 Printing Concerns / 17.12 17.3.2 Plotting Concerns / 17.13 17.4 Network Considerations / 17.13 17.4.1 Remote Plotting / 17.14 17.4.2 Queue Management / 17.14 17.5 Cönclusions / 17.14

xii Contents

Section 4 Interfaces

Chapter 18. Graphical User Interfaces (GUIs)

18.1 Solid Modeling and GUIs / 18.3 18.2 Windowing Systems / 18.4 18.2.1 Macintosh / 18.4 18.2.2 NextStep / 18.4 18.2.3 OpenLook / 18.4 18.2.4 OSF/Motif / 18.5 18.2.5 Microsoft Windows and OS/2 Presentation Manager / 18.5 18.2.6 Custom GUIs / 18.6 18.3 Windowing System Architectures / 18.6 18.3.1 Kernel-Based Architecture / 18.6 18.3.2 Client-Server-Based Architecture / 18.6 18.4 Window Management / 18.7 18.4.1 TUedWindows / 18.7 18.4.2 OverlappingWindows / 18.7 18.4.3 CascadingWindows / 18.7 18.5 Windowing System Components / 18.7 18.5.1 Windows / 18.8 18.5.2 Menüs / 18.8 18.5.3 Controls / 18.8 18.5.4 Dialogue Boxes / 18.8 18.5.5 Modeless Dialogues / 18.8 18.5.6 Modal Dialogues / 18.8 18.5.7 Control Panels / 18.9 18.5.8 Query Boxes / 18.9 18.5.9 Message Boxes / 18.9 18.5.10 Mouse and Keyboard Interface / 18.9 18.6 Conclusions / 18.9 References / 18.17 Suggestions for Further Reading / 18.18

Chapter 19. Solid Modeling and Rapid Prototyping 19.1

19.1 How Most Rapid Prototyping Systems Work / 19.1 19.2 The StereoLithography Apparatus (SLA) / 19.1 19.2.1 Part Modeling / 19.2 19.2.2 Support-Structure Modeling / 19.2 19.2.3 The STL Interface / 19.3 19.2.4 Processing / 19.4 19.2.5 Production / 19.4 19.2.6 Finishing / 19.4 19.3 The CAD Interface / 19.4 19.4 Inside an STL File / 19.5 19.5 STL Alternatives / 19.5 19.5.1 The Cubital Facet List (CFL) / 19.7 19.5.2 StereoLithography Contour Format (SLC) / 19.7 19.6 Selective Laser Sintering (SLS) / 19.8 19.7 Solid Ground Curing (SGC) / 19.9 19.8 Laminated Object Manufacturing (LOM) / 19.10 19.9 Fused Deposition Modeling (FDM) / 19.11 19.10 Conclusions / 19.12 19.11 Additional Resources / 19.13 19.11.1 Articles and Technical Papers / 19.13 19.11.2 Newsletters / 19.13 19.11.3 Books / 19.13 19.11.4 Associations / 19.13 19.11.5 Conferences / 19.13 19.12 RP System Manufacturers Outside the United States / 19.14 References / 19.19

Chapter 20. Preparing for Data Exchange

20.1 Data Exchange Options / 20.1 20.1.1 Direct Database Translation / 20.1 20.1.2 Neutral File Exchange / 20.1 20.1.3 Data Sharing / 20.3

xiii 20.2 Data Exchange Surveys, Studies, and Trends / 20.3 20.2.1 Automotive Industry Action Group (AIAG) / 20.3 20.2.2 North American Manufacturing Technology Survey / 20.3 20.2.3 Report to the President of the United States / 20.4 20.2.4 Continuous Acquisition and Life-Cycle Support (CALS) / 20.4 20.3 Data Preparation / 20.5 20.3.1 Characteristics of SM and Translators / 20.5 20.3.2 Design for Data Integrity (DFDI) / 20.5 20.3.3 Data Delivery Mechanisms / 20.6 20.4 Measuring Success / 20.7 20.4.1 Functional Equivalence / 20.8 20.4.2 Visual Equivalence / 20.8 20.4.3 Criteria Judgments / 20.8 20.5 Needed Improvements for Data Exchange / 20.8 References / 20.17 Suggestions for Further Reading / 20.18

Chapter 21. Solid Modeling and the Initial Graphics Exchange Specification (IGES) 21.1

21.1 IGES in Production / 21.1 21.2 The IGES Evaluation Process / 21.2 21.3 Anatomy of an IGES File / 21.3 21.3.1 Start Section / 21.4 21.3.2 Global Section / 21.4 21.3.3 Directory Entry / 21.4 21.3.4 Parameter Data / 21.5 21.3.5 Terminate Section / 21.5 21.3.6 IGES Entities / 21.5 21.4 IGES Entity Mapping / 21.7 21.4.1 Entity Subsets / 21.10 21.4.2 Approximations / 21.11 21.4.3 Mapping Solids to Other Data Types / 21.11 21.5 Fiavoring an IGES File / 21.11 21.5.1 Procedural Fiavoring / 21.12 21.5.2 Programmatic Fiavoring / 21.12 21.5.3 Fiavoring Approaches / 21.12 21.6 IGES Utilities / 21.12 21.6.1 Utilities That Do Not Change the IGES File / 21.12 21.6.2 Utilities That Do Change the IGES File / 21.13 21.6.3 Other Translators and Utilities / 21.13 21.7 IGESTesting / 21.14 21.7.1 InteroperabilityTesting / 21.14 21.7.2 Test Preparations / 21.15 21.7.3 Test Cases / 21.16 21.7.4 Running Interoperability Tests / 21.17 21.8 Emerging Functionality Enhancements to IGES / 21.22 21.8.1 Application Protocols (APs) / 21.22 21.8.2 IGES Subsets / 21.22 21.9 Improving Solid Modeling for IGES / 21.23 References / 21.26 Suggestions for Further Reading / 21.27

Chapter 22. Solid Modeling and Product Data Exchange Using STEP (PDES/STEP) 22.1

22.1 PDES/STEP History / 22.1 22.1.1 PDDI and GMAP / 22.1 22.1.2 ANSI and ISO / 22.2 22.1.3 MST and USTAG / 22.2 22.1.4 IGES/PDES Organization (IPO) / 22.2 22.2 STEP Structure / 22.2 22.2.1 Geometrie and Nongeometric Data / 22.2 22.2.2 The Parts of STEP / 22.3 22.2.3 A Solid Basis / 22.5 22.2.4 Functional Goals / 22.5 22.2.5 Why Not IGES? / 22.5 22.3 Solid Modeling and STEP / 22.6 22.3.1 WhoShouldUse STEP and Why? / 226 22.3.2 Preparing for STEP / 22.7 22.3.3 Implementing STEP / 22.7

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22.4 Benefits and Pitfalls of STEP / 22.7 22.5 Life After STEP / 22.7 22.6 Conclusions / 22.7 References / 22.12

Section 5 Implementation

Chapter 23. Solid Modeling Implementation Strategies 23.3

23.1 WhoShould Read This Chapter, and Why? / 23.3 23.1.2 First-Line Managers / 23.3 23.1.2 Middle Managers / 23.4 23.1.3 Executive Managers / 23.4 23.2 Solid Modeling and Change Management / 23.4 23.2.1 Moving from 2D Drafting to 3D Solid Modeling / 23.4 23.2.2 The Emotional Cycle of Change / 23.5 23.2.3 How Long Should the Implementation Take? / 23.6 23.3 Preparing for Solid Modeling / 23.8 23.3.1 Needs and Productivity Analyses / 23.8 23.3.2 Topics for Analysis / 23.9 23.3.3 Three Phases of Analysis / 23.9 23.3.4 Implementation Planning / 23.10 23.4 The CIM 12 Productivity Indicators and Benchmark / 23.10 23.4.1 Competence / 23.11 23.4.2 Integrity / 23.11 23.4.3 Management / 23.12 23.5 Training and Continued Education / 23.14 23.5.1 Computer-Based Training (CBT) / 23.14 23.5.2 Self-Paced Manuals / 23.14 23.5.3 Instructor-Led Training / 23.14 23.6 Continuous Improvement / 23.15 23.6.1 Software / 23.15 23.6.2 Hardware / 23.15 23.6.3 Liveware / 23.16 23.1 Opportunities and Potential Benefits / 23.16 23.8 Where Can the Implementation Go Wrong? I 23.17 23.9 Conclusions / 23.18

Chapter 24. Solid Modeling and Design 24.1

24.1 Introduction: Solid Modeling Becomes the Mechanical Design Tool / 24.1 24.2 Solid Modeling in Government / 24.2 24.2.1 PRC's Project 2851 / 24.2 24.2.2 Fairchild Space Improves Speed and Quality of Proposais with SM / 24.3 24.3 Solid Modeling in Academia / 24.4 24.3.1 Solid Modeling in Education at FAMU/FSU / 24.4 24.3.2 The Purdue Quick Turnaround Cell: Integrating Design and Process Planning with Solid Modeling 7 24.5 24.4 Solid Modeling in Industry / 24.6 24.4.1 Solid Modeling and Analysis Contributes to Better Convertible Top Stack Design / 24.6 24.4.2 Solid Modeling Aids Development of New-Generation Amtrak Passenger Seating / 24.6 24.4.3 Computer Modeling Produces World's First Artificial Ear by Machine / 24.8 24.4.4 MCAE Helps Ford Motor Company Compress Product Development Lead Time / 24.9

Chapter 25. Solid Modeling for Manufacturing 25.1

25.1 Product Design / 25.1 25.1.1 Solid Modeling / 25.1 25.1.2 Feature-Based Design / 25.2 25.1.3 Starting with the Assembly / 25.2 25.1.4 Design for Assembly (DFA) / 25.2 25.1.5 The Principal Axis / 25.4 25.1.6 Design for Manufacturing (DFM) / 25.5 25.1.7 Design for Cost Reduction / 25.5 25.1.8 Data Management / 25.6

xv /

25.2 Product Manufacturing / 25.6 25.2.1 Manufacturing Operations / 25.6 25.2.2 Feature-Based Manufacturing / 25.7 25.2.3 Process Planning / 25.8 25.2.4 Machining Considerations / 25.11 25.3 Solid Modeling Applications / 25.13 25.3.1 Robotics / 25.14 25.3.2 Inspection / 25.14 25.3.3 Physical Modeling / 25.16 25.3.4 Rapid Prototyping (RP) / 25.16 25.3.5 Tool Design / 25.16 25.3.6 Coordinate Measuring Machines (CMMs) / 25.17 25.4 Solid Modeling Improvements Needed / 25.17 25.4.1 Integration / 25.18 25.4.2 Automation / 25.19 25.4.3 Design for Manufacturing (DFM) and Concurrent Engineering (CE) / 25.19

Chapter 26. Volumetrie Sojid Modeling 26-1

26.1 Geometrie versus Sampled Information / 26.1 26.1.1 Volumetrie Datasets / 26.2 26.1.2 Properties / 26.3 26.2 Volumetrie Methods / 26.3 26.2.1 Format Translations / 26.4 26.2.2 Object Storage / 26.4 26.2.3 Display / 26.4 26.2.4 Measurements / 26.7 26.2.5 Dataset Processing / 26.7 26.2.6 Representations / 26.8 26.3 Volumetrie Applications / 26.10 26.3.1 Finite Element Modeling (FEM) / 26.10 26.3.2 Robotics / 26.11 26.3.3 Medical Applications / 26.11 Suggestions for Further Reading / 26.13

Chapter 27. The Role of Solid Modeling in Concurrent Engineering 27-1

27.1 The Road tp Concurrent Engineering (CE) / 27.1 27.2 Effective Implementation / 27.2 27.3 The Road Map for CE / 27.2 27.3.1 Six Perspectives on CE / 27.2 27.4 Processes Before Tools / 27.4 27.5 The Role of SM in the New Manufacturing Enterprise / 27.4 21.SA Customer Focus / 27.4 27.5.2 People and Teamwork / 27.5 27.5.3 Systems for Shared Knowledge / 27.6 27.5.4 Processes / 27.6 27.5.5 Resources and Responsibilities / 27.9 27.5.6 Manufacturing Infrastructure / 27.9 27.6 Summary / 27.10

Chapter 28. Managing Solid Modeling Data 28.1

28.1 Maintaining Standards / 28.1 28.2 Component Libraries / 28.1 28.3 Database Organization / 28.2 28.3.1 Relational Databases / 28.2 28.3.2 Object-Oriented Database Management Systems (OODBMS) / 28.3 28.4 Network Considerations / 28.4

Section 6 In the Field

Chapter 29. Solid Modeling at Sony Corporation 29.3

29.1 Innovation / 29.3 29.2 Design Process / 29.4

XVI Contents

29.2.1 Traditional Design Process / 29.4 29.2.2 New Design Process Based on CAE / 29.5 29.3 Case Study Application / 29.5 29.3.1 Objective / 29.6 29.3.2 Rotating Drum Evaluation Device (RDED) / 29.6 29.3.3 Tape Path System and Feedback Loop / 29.9 29.3.4 Avoiding Interference Problems / 29.9 29.3.5 Checking Manufacturing with Solid Modeling / 29.9 29.3.6 Conclusions / 29.10 29.4 Solid Modeling Payoffs / 29.11 29.5 Future Goals with Solid Modeling / 29.11 Suggestions for Further Reading / 29.16

Chapter 30. Solid Modeling at Volkswagen Automotive Group

30.1 Company Background / 30.1 30.2 CAD/CAM Capability Review / 30.2 30.3 Solid Modeling Applications / 30.3 30.3.1 Die Design / 30.3 30.3.2 Part Transport Simulation / 30.4 30.3.3 Robotics / 30.4 30.3.4 Numerical Control / 30.4 30.4 Information Systems Integration / 30.4 30.4.1 AWK-GWorkingProcedure / 30.5 30.4.2 Preparations and Parameter Assignment for Cast Parts / 30.5 30.4.3 Die Modeling / 30.5 30.4.4 Creating Cast Parts / 30.6 30.4.5 The Standard Parts Concept / 30.7 30.4.6 Using a Relational Database / 30.7 30.4.7 Producing Drawings and Data Output for NC / 30.8 30.4.8 Making Patterns / 30.8 30.4.9 Cost/Labor Calculations / 30.10 30.4.10 Numerical Control Programming / 30.10 30.5 Solid Modeling Difficulties / 30.10 30.6 Solid Modeling Benefits / 30.11 30.7 Future Goals / 30.11 References / 30.13 Glossaryof Terms / 30.14

Chapter 31. Solid Modeling at Hewlett-Packard

31.1 Mechanical Engineering at Hewlett-Packard / 31.1 31.2 Design / 31.2 31.2.1 Common Design Tools / 31.2 31.2.2 Interactivity and Visualization / 31.2 31.2.3 Reduction in Drafting Effort / 31.3 31.2.4 Completeness and Reuse of Design Data / 31.3 31.2.5 Design Summary / 31.5 31.3 Analysis and Simulation / 31.5 31.3.1 Computational Fluid Dynamics / 31.5 31.3.2 Tolerance Analysis / 31.5 31.3.3 Structural Analysis and Shape Optimization / 31.6 31.3.4 Sheet-Metal Cost and Manufacturability Analysis / 31.6 31.4 Prototyping / 31.7 31.4.1 Typical Prototyping Process / 31.7 31.4.2 Prototyping Summary / 31.7 31.5 Release to Manufacturing / 31.8 31.5.1 Product Data Management (PDM) / 31.9 31.5.2 Technical Illustrations / 31.9 31.6 Hewlett-Packards Vision for Better Mechanical Engineering / 31.9 31.6.1 Hewlett-Packard's Visionary Plan / 31.10 31.7 Conclusions / 31.11 Glossaryof Terms / 31.15

Chapter 32. Solid Modeling at Eaton Corporation, Supercharger Division

32.1 Company Background / 32.1 32.2 CAD Capability and Network Overview / 32.1

xvii Contents

32.3 Why 3D Solid Modeling? / 32.2 32.4 Design Process Case Study / 32.3 32.4.1 Application Overview / 32.3 32.4.2 Initial Design Parameters / 32.3 32.4.3 Developing the Housing Casting / 32.3 32.4.4 Significance of Application / 32.4 32.4.5 Modeling Related Parts / 32.5 32.4.6 Assembly Modeling Process / 32.5 32.5 Interfacing Solid Modeling with Manufacturing / 32.6 32.6 Solid Modeling Payoffs / 32.8 32.7 Future Goals with Solid Modeling / 32.8 32.7.1 Integration / 32.8 32.7.2 Four-Week Quick Delivery / 32.9 32.7.3 Rapid Prototyping (RP) / 32.9 32.7'.4 Coordinate Measuring Machines (CMM) / 32.9

Chapter33. Roundtable Discussion 33.1

33.1 Not Who Needs SM, but Why? I 33.1 33.2 Going Beyond Concurrent Engineering: Developing an Enterprisewide Vision / 33.2 33.3 Selecting New Technology: The Bait and the Benchmark / 33.3 33.4 Out of the Mechanical Engineering Department / 33.3 33.5 What Technology Will Evolvefrom SM? / 33.4

i Glossary G.1 Index 1.1

XVIII