S14-1 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation SECTION 14 PARASOLID MODELING

S14-2 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation

S14-3 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation PARASOLID MODELING TOOLS n Patran has a set of powerful parasolid modeling tools to help the user create complex geometry in Patran. n The parasolid modeling tools described in this section use the parasolid kernel which requires the Parasolid Modeling license.

S14-4 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation PARASOLID MODELING TOOLS (cont.) n Primitive Creation u Block, cylinder, cone, sphere, torus u Optional on-the-fly (automatic) Boolean operation n Solid Creation Operations u Extrude u Revolve n Solid Editing Operations u Boolean operations: add, subtract, intersect u Edge blend: constant radius, chamfer u Shell: create thin-wall solids u Imprint: solid on solid u Refit to Parasolid u Auto update of CAE data after a solid editing operation

S14-5 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation n A primitive is a solid that can be defined with several parameters. n MSC.Patran has five different types of primitives: PRIMITIVE CREATION BLOCKCYLINDERCONESPHERETORUS

S14-6 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation PRIMITIVE CREATION BLOCK Create a rectangular solid by specifying Side lengths. The direction of the X, Y, and Z length are determined by the coordinate frame listed on the right. Users can also specify a negative side length to get the block defined in the opposite direction. The base origin defines the corner of the block and also depends on the Reference Coordinate Frame.

S14-7 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation PRIMITIVE CREATION CYLINDER Define a cylinder using a Radius, Height, and Location of the base. The height can be defined along the X, Y, or Z axis. This direction is defined on the Axis List.

S14-8 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation PRIMITIVE CREATION CYLINDER (Cont.) By entering a wall thickness, a tube can be created.

S14-9 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation PRIMITIVE CREATION CONE Define a cone by specifying a Base Radius, Top Radius, Height, and Base Center Point. The height of the cylinder can run along the X, Y, or Z axis. The direction is defined on the Axis List box. Height Base Radius Top Radius

S14-10 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation PRIMITIVE CREATION CONE (Cont.) The Cone Primitive also has a Thickness box for making thin walled cones. This option works the same way as the Thickness List option for the cylinder.

S14-11 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation PRIMITIVE CREATION SHPERE Define a sphere by specifying a Radius and Center Point.

S14-12 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation PRIMITIVE CREATION TORUS Define a torus by specifying a Center Point, Inner Radius, and Outer Radius. The centerline of the torus can run along the X, Y, or Z axis. Users can define this direction on the Axis List box.

S14-13 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation PRIMITIVE CREATION MULTIPLE PRIMITIVES On the Center Point List box, users can create multiple primitives at once by entering multiple center points. This example shows 3 spheres created in one operation.

S14-14 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation PRIMITIVE CREATION AUTOMATIC BOOLEAN OPERATION The Boolean Operation menu controls what kind of boolean to perform using the solid that will be modified. This menu comes up when the user first turns on the Modify/Solid option and clicks on the Boolean Operation button on any of the Primitive Solid menus. The resulting solid is added to the target solid. The resulting solid is subtracted to the target solid. The user will get the solid that is common, or the intersection of the resulting solid and the target solid.

S14-15 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation PRIMITIVE CREATION AUTOMATIC BOOLEAN OPERATION In this example, the cylinder created will be automatically subtracted from the target solid, making the hole in one step. Target Solid Newly Created Primitive Solid (Cylinder) Finished Part -=

S14-16 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation SOLID CREATION EXTRUDE Extruding Surfaces: Using this option, any surface can be extruded to create a complex (white) solid. Surface 1

S14-17 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation SOLID CREATION EXTRUDE (Cont.) Extruding Simple Surfaces: This option works only with simple (green) surfaces which are extruded into simple (blue) solids. Surface 1

S14-18 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation SOLID CREATION REVOLVE Revolving Surfaces: Using this option, any surface can be revolved to create a complex (white) solid. Surface 1

S14-19 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation SOLID CREATION REVOLVE (Cont.) Revolving Simple Surfaces: This option works only with simple (green) surfaces which are revolved into simple (blue) solids. Surface 1

S14-20 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation SOLID EDITING n The following parasolid editing tools are available in MSC.Patran: u Boolean operations: add, subtract, intersect u Edge blend: fillet, chamfer u Shell: create thin-wall solids u Imprint: solid on solid u Refit Parasolid

S14-21 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation SOLID EDITING BOOLEAN OPERATIONS OVERVIEW n This solid model represents the top part of a cell phone. It was created using the three types of Boolean operations: add, subtract, and intersect. The holes for the keyboard are made using multiple solids for the subtraction. This is much faster than subtracting the solids one at a time. The main body of this solid can be made by intersecting a thin walled cylinder with a simple block. The tabs on the top of this part can be added using a Boolean Add.

S14-22 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation SOLID EDITING BOOLEAN OPERATIONS (Cont.) Boolean Add option: MSC. Patran allows users to perform this operation on more than one solid at once. This picture shows individual solids before an Add operation is performed.

S14-23 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation SOLID EDITING BOOLEAN OPERATIONS (Cont.) The eight solids have been combined into one solid.

S14-24 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation SOLID EDITING BOOLEAN OPERATIONS (Cont.) Boolean Subtract option: In this example the cylinder is subtracted from the block, which is the target solid.

S14-25 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation SOLID EDITING BOOLEAN OPERATIONS (Cont.) Boolean Subtract option: This is the resulting solid. The Boolean Subtract can also be used on multiple solids at once. This would allow users to easily use multiple solids to create holes or to cut a solid.

S14-26 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation SOLID EDITING BOOLEAN OPERATIONS (Cont.) Boolean Intersect option: Creates a new solid from what was common between the Target Solid and the Intersecting Solids.

S14-27 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation SOLID EDITING BOOLEAN OPERATIONS (Cont.) Boolean Intersect option: MSC.Patran automatically deletes the solids used for this operation. If the user still wants to use these solids, it will be necessary to copy them BEFORE the operation.

S14-28 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation SOLID EDITING EDGE BLEND OVERVIEW n Users can also add fillets and chamfers to a solid using the Edge Blend tool. For this model, an intersection of pipes, edge fillets were added using the Edit/Solid/Edge Blend tool under the Geometry menu. Chamfers were added to this solid using the same menu.

S14-29 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation SOLID EDITING EDGE BLEND (Cont.) Fillet option: With this option the user can add fillet to a single edge on a solid, to all edges on a face or to all edges on the solid. Lets consider this solid and add fillets to all its edges. Single edge on solid All edges on face All edges on solid

S14-30 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation SOLID EDITING EDGE BLEND (Cont.) Fillet option: The All Edges on Solid button was selected and a Constant Radius of 0.05 chosen. The fillets were added in one operation. Filleted edges Multiple fillets blended at a corner

S14-31 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation SOLID EDITING EDGE BLEND (Cont.) Chamfer option: This option works the same as the fillet option. The user can add chamfer to a single edge on a solid, to all edges on a face or to all edges on the solid. The parameters that have to be chosen are the Offset and the Angle. Single edge on solid All edges on face All edges on solid

S14-32 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation SOLID EDITING EDGE BLEND (Cont.) Chamfer option: This model has a few edges chamfered with different offsets and different angles. Chamfered edges

S14-33 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation SOLID EDITING SHELL OVERVIEW n Users can remove the material on the interior of a solid using the Edit/Solid/Shell tool under the Geometry menu. This model was obtained from a solid that was hollowed out using the shell tool.

S14-34 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation SOLID EDITING SHELL (Cont.) Shell option: Lets remove the material from the interior of this solid, leaving a wall Thickness of 0.1 in. The Solid Face List identifies the face or faces which will be pierced to allow the removal of material.

S14-35 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation SOLID EDITING SHELL (Cont.) Shell option: The material is removed from the solid up to the wall thickness.

S14-36 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation SOLID EDITING IMPRINT The Imprint tool imprints one or more solids onto other solids. For example, the cylinder on the right is imprinted onto the rectangular block.

S14-37 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation SOLID EDITING IMPRINT (Cont.) The imprinting broke the larger rectangular face into two faces. This tool is useful for creating congruent meshes across neighboring solids.

S14-38 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation SOLID EDITING REFIT TO PARASOLID n Non-Parasolid geometry can be converted into Parasolid geometry by using the Refit tool. n Once the geometry is converted to Parasolid geometry, the user can take advantage of all the new Parasolid editing tools described in this Section. n Alternatively, the user may choose to let MSC.Patran automatically refit the geometry to Parasolid geometry. This automatic refit occurs whenever a Parasolid editing operation is requested and MSC.Patran detects that the solids involved are not Parasolid solids.

S14-39 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation SOLID EDITING AUTO UPDATE OF CAE DATA n The Auto Update Solid Mesh/LBC toggle from the Preferences/Geometry form re- applies mesh parameters, loads and boundary conditions, and re- meshes after geometry modification (such as a Boolean operation).

S14-40 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation SOLID EDITING AUTO UPDATE OF CAE DATA (Cont.) For example, the Parasolid solid on the right has been meshed with Tet10 elements. We now want to drill a hole through the solid using Boolean subtract.

S14-41 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation SOLID EDITING AUTO UPDATE OF CAE DATA (Cont.) A cylinder is created and it will be used to drill the hole.

S14-42 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation SOLID EDITING AUTO UPDATE OF CAE DATA (Cont.) Use Boolean Subtract to drill the hole. The solid is modified and the Tet mesh is automatically updated.

S14-43 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation NEW SOLID MODELING TOOLS n The following three Case Studies will demonstrate the parasolid modeling tools u Case Study 1: Lamp Housing u Case Study 2: Tension Fitting u Case Study 3: Valve Housing

S14-44 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation CASE STUDY 1 – LAMP HOUSING Model the lamp housing shown below using primitive geometry, shell, fillet, and Boolean.

S14-45 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation Step 1: Model the base geometry using a primitive cone. Step 2: Use a shell operation to hollow out the cone. Step 3: Use a trimmed surface to model the outline of the tabs. Extrude the surface into a solid and use a Boolean Add to combine the tabs to the main solid. Step 4: Add the fillets to the solid. CASE STUDY 1 – LAMP HOUSING

S14-46 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation Define a primitive cone with the dimensions shown. The Thickness List option wont work in this case because it would remove material from both sides of the cone. CASE STUDY 1 – LAMP HOUSING

S14-47 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation Use the Edit/Solid/Shell tool to remove the interior material from the solid, with a wall thickness of 0.25 in. CASE STUDY 1 – LAMP HOUSING

S14-48 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation Defining a surface on the top of the base is easier if a coordinate system is placed on the top of the base. This will make defining coordinates and moving the tabs easier. CASE STUDY 1 – LAMP HOUSING

S14-49 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation CASE STUDY 1 – LAMP HOUSING Define the base points for the tab such that they penetrate into the top of the cone. These coordinates reference the new coordinate system. Point 1Point 2

S14-50 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation CASE STUDY 1 – LAMP HOUSING Define the left and right edges of the tab, 1.1 inch tall. Point 1Point 2

S14-51 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation CASE STUDY 1 – LAMP HOUSING Define the rounded top edge of the tab. The coordinates of the center point are easier to define using the local coordinate system Coord1.

S14-52 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation CASE STUDY 1 – LAMP HOUSING Create the bottom curve of the tab. Without this curve, there will not be a closed loop, which is required for a trimmed surface.

S14-53 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation CASE STUDY 1 – LAMP HOUSING Use the chain tool to link the curves together.

S14-54 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation CASE STUDY 1 – LAMP HOUSING Define the hole for the tab with a radius of in.

S14-55 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation CASE STUDY 1 – LAMP HOUSING Create a trimmed surface. This surface will be extruded to create the tabs.

S14-56 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation CASE STUDY 1 – LAMP HOUSING Extrude the trimmed surface to create the tab using the local coordinate system Coord 1.

S14-57 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation CASE STUDY 1 – LAMP HOUSING There are two tabs on the top of the base. Use the Translate tool to copy the solid you created in the previous step.

S14-58 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation CASE STUDY 1 – LAMP HOUSING Use a Boolean Add to combine all the solids together. Without the Boolean, it will not be possible to add the fillets in the next step.

S14-59 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation CASE STUDY 1 – LAMP HOUSING Apply fillets to the root of the tabs and the bottom lip of the cone.

S14-60 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation CASE STUDY 2 – TENSION FITTING Model the bathtub tension fitting shown below using techniques similar to the last case study.

S14-61 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation CASE STUDY 2 – TENSION FITTING Step 1: Create an outline of the bracket as a trimmed surface and extrude the surface to create the base. Step 2: Use a shell operation to hollow out the bracket. For the shell, remove the top, angled, and front face of the base solid. Step 3: Use a Boolean or the Modify/Solid option to add the hole on the back of the part. Step 4: Add fillets to the solid.

S14-62 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation CASE STUDY 2 – TENSION FITTING Start with a simple rectangular surface (5x2 in). This surface will be cut to create the outline of the bracket.

S14-63 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation CASE STUDY 2 – TENSION FITTING Translate the points shown bellow to create the cutting line for the outline.

S14-64 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation CASE STUDY 2 – TENSION FITTING Connect the two points to create a line. This line will be used with the break tool to create the outline of the bracket.

S14-65 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation CASE STUDY 2 – TENSION FITTING Use the break tool to split the surface.

S14-66 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation CASE STUDY 2 – TENSION FITTING Delete the extra surface. The resulting trimmed surface can be extruded to create the base for the part.

S14-67 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation CASE STUDY 2 – TENSION FITTING Use the extrude Parasolid option on the extrude menu. Since this is a magenta surface, the blue solid option would not have worked.

S14-68 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation CASE STUDY 2 – TENSION FITTING Use the shell tool to remove the interior material from the solid. The shell operation needs to remove material from the top face, angled face, and the front face of the solid.

S14-69 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation CASE STUDY 2 – TENSION FITTING This is the hollowed out bracket.

S14-70 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation CASE STUDY 2 – TENSION FITTING Create a solid cylinder where the hole will be. The height of the cylinder is not important. It only needs to pass through the solid. Alternatively, the Modify/Solid option could be used to skip the Boolean Add operation.

S14-71 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation CASE STUDY 2 – TENSION FITTING Use a Boolean Subtract to remove the cylinder and create a hole on the back face of the fitting.

S14-72 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation CASE STUDY 2 – TENSION FITTING Add the fillets to complete the model.

S14-73 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation CASE STUDY 3 – VALVE HOUSING

S14-74 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation CASE STUDY 3 – VALVE HOUSING The valve housing shown on the previous page can be created in two ways: 1. Generate the cross section of the part and revolve it to create the part. 2. Create the outer solid and inner cavity using primitive geometry and use a Boolean operation to subtract the two solids. This requires less calculation and often less work from the user. We will use method 2 to create this part.

S14-75 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation CASE STUDY 3 – VALVE HOUSING Step 1: Model the outer solid with three primitives: two cones and a cylinder. Use a Boolean operation to combine the three solids into one. Step 2: Model the inner cavity with solids. This can also be done using cones and cylinders. Use another Boolean to combine all the solids. Step 3: Subtract the cavity from the outer solid.

S14-76 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation CASE STUDY 3 – VALVE HOUSING Since the user probably wants to cone to taper in the - Z Direction, use a negative height. Otherwise, the user would have to rotate the cone to get it to face the right direction.

S14-77 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation CASE STUDY 3 – VALVE HOUSING Create the middle portion of the outer solid by extruding the bottom face of the cone into a cylinder (this is to make sure the solids are joined).

S14-78 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation CASE STUDY 3 – VALVE HOUSING The end of the outer solid can be created using another Primitive Cone. But for good practice, to make the solids join exactly, lets extrude the cylinders surface and scale in the same time to create a cone (4 inch high).

S14-79 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation CASE STUDY 3 – VALVE HOUSING Use a Boolean Add to combine all the solids into one part.

S14-80 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation CASE STUDY 3 – VALVE HOUSING Place the outer solid in its own group. This will help with the next set of steps.

S14-81 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation Before creating the inner cavity, define a group for the next set of solids. Use the Make Current option to make sure any solids created join this group, and Unpost All Other Groups to clean up the display. CASE STUDY 3 – VALVE HOUSING

S14-82 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation CASE STUDY 3 – VALVE HOUSING The first part of the cavity is a cylinder. The base of the cylinder is at (0, 0, -4). One alternative is to specify a negative height and an origin of (0, 0, 0).

S14-83 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation Even with the separate groups its difficult to see whats going on with the model. Use the Group Display mode to draw the outer solid in wireframe and the inner cavity in solid shaded mode. CASE STUDY 3 – VALVE HOUSING

S14-84 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation CASE STUDY 3 – VALVE HOUSING Draw the cutting_tool group in solid shaded mode.

S14-85 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation To display the settings on screen, post both groups to the viewport. CASE STUDY 3 – VALVE HOUSING

S14-86 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation CASE STUDY 3 – VALVE HOUSING The next part of the cavity is a cone. This can also be defined using a primitive.

S14-87 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation CASE STUDY 3 – VALVE HOUSING To define the rest of the cavity, use a mirror operation. Defining a coordinate system in the middle of the part will help define the mirror plane.

S14-88 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation CASE STUDY 3 – VALVE HOUSING Use the Z-Axis of the new coordinate system to define the mirror plane.

S14-89 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation CASE STUDY 3 – VALVE HOUSING For the remaining solid, extrude a face of one of the cones to make the cylinder. A primitive could also be used for this step.

S14-90 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation CASE STUDY 3 – VALVE HOUSING Combine all of the inner solids into one part.

S14-91 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation CASE STUDY 3 – VALVE HOUSING Use a Boolean Subtract to remove the cavity from the outer shell.

S14-92 NAS120, Section 14, May 2006 Copyright 2006 MSC.Software Corporation EXERCISE Perform Workshop 15 Parasolid Modeling in your exercise workbook.