Identifying and quantifying inefficiencies within industrial parametric CAD models

Parametric CAD software is the primary development tool for the design engineer during the product development process. However, industrial parametric CAD models are often constructed in a manner that leads to inefficiencies during subsequent product development activities. Despite the availability of Model Quality Tools (MQTs) these ‘poor’ quality models can currently only be accurately identified using time-consuming and subjective auditing from experienced users. The project aims to develop a more robust solution, using measurable part characteristics, to predict the efficiency level of these CAD files

Are we training our novices towards quality 2D profiles for 3D models?

In the history-based, feature-based, parametric CAD approach, 2D profile sketches are the basis for 3D models. Fully-constraining profiles is mandatory to create robust profiles. At present, neither CAD applications nor Model Quality Testing Tools usually check whether 2D profiles contain redundant constraints. Besides, our experience shows that novices tend to introduce redundant constraints. We hypothesize that 2D profiles over-constrained with redundant relations are more difficult to edit than those that avoid redundancies. In the present work―and as a first step to demonstrate this hypothesis―an experiment was conducted. Students of the subject “Graphics engineering” were taught on the creation of constrained 2D profiles. Then, they were asked two questions. On the one hand, novices had to identify and reason whether a simple given profile was fully-constrained, over-constrained or under-constrained. On the other hand, they had to identify and point out the types of the constraints. The results showed that in spite that novices received a specific training, roughly half of them failed to say if the 2D profile sketch was fully-constrained and which type of constraints it contained. Furthermore, the results of the second question revealed that more than the half of students did not recognize perpendicularity as a geometric constraint. As future work, we will try to demonstrate whether a reinforced training through simple exercises and a quick and effective feedback, will allow novices to improve the identification and removal of redundant 2D constraints when drawing 2D profile sketches (thus helping to produce robust profiles)

A survey on 3D CAD model quality assurance and testing

[EN] A new taxonomy of issues related to CAD model quality is presented, which distinguishes between explicit and procedural models. For each type of model, morphologic, syntactic, and semantic errors are characterized. The taxonomy was validated successfully when used to classify quality testing tools, which are aimed at detecting and repairing data errors that may affect the simplification, interoperability, and reusability of CAD models. The study shows that low semantic level errors that hamper simplification are reasonably covered in explicit representations, although many CAD quality testers are still unaffordable for Small and Medium Enterprises, both in terms of cost and training time. Interoperability has been reasonably solved by standards like STEP AP 203 and AP214, but model reusability is not feasible in explicit representations. Procedural representations are promising, as interactive modeling editors automatically prevent most morphologic errors derived from unsuitable modeling strategies. Interoperability problems between procedural representations are expected to decrease dramatically with STEP AP242. Higher semantic aspects of quality such as assurance of design intent, however, are hardly supported by current CAD quality testers. (C) 2016 Elsevier Ltd. All rights reserved.This work was supported by the Spanish Ministry of Economy and Competitiveness and the European Regional Development Fund, through the ANNOTA project (Ref. TIN2013-46036-C3-1-R).González-Lluch, C.; Company, P.; Contero, M.; Camba, J.; Plumed, R. (2017). A survey on 3D CAD model quality assurance and testing. Computer-Aided Design. 83:64-79. https://doi.org/10.1016/j.cad.2016.10.003S64798

On the effects of the fix geometric constraint in 2D profiles on the reusability of parametric 3D CAD models

[EN] In order to be reusable, history-based feature-based parametric CAD models must reliably allow for modifications while maintaining their original design intent. In this paper, we demonstrate that relations that fix the location of geometric entities relative to the reference system produce inflexible profiles that reduce model reusability. We present the results of an experiment where novice students and expert CAD users performed a series of modifications in different versions of the same 2D profile, each defined with an increasingly higher number of fix geometric constraints. Results show that the amount of fix constraints in a 2D profile correlates with the time required to complete reusability tasks, i.e., the higher the number of fix constraints in a 2D profile, the less flexible and adaptable the profile becomes to changes. In addition, a pilot software tool to automatically track this type of constraints was developed and tested. Results suggest that the detection of fix constraint overuse may result in a new metric to assess poor quality models with low reusability. The tool provides immediate feedback for preventing high semantic level quality errors, and assistance to CAD users. Finally, suggestions are introduced on how to convert fix constraints in 2D profiles into a negative metric of 3D model quality.The authors would like to thank Raquel Plumed for her support in the statistical analysis. This work has been partially funded by Grant UJI-A02017-15 (Universitat Jaume I) and DPI201784526-R (MINECO/AEI/FEDER, UE), project CAL-MBE. The authors also wish to thank the editor and reviewers for their valuable comments and suggestions that helped us improve the quality of the paper.González-Lluch, C.; Company, P.; Contero, M.; Pérez Lopez, DC.; Camba, JD. (2019). On the effects of the fix geometric constraint in 2D profiles on the reusability of parametric 3D CAD models. 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Design space exploration of a jet engine component using a combined object model for function and geometry

The design of aircraft and engine components hinges on the use of computer aided design (CAD) models and the subsequent geometry-based analyses for evaluation of the quality of a concept. However, the generation (and variation) of CAD models to include radical or novel design solutions is a resource intense modelling effort. While approaches to automate the generation and variation of CAD models exist, they neglect the capture and representation of the product’s design rationale—what the product is supposed to do. The design space exploration approach Function and Geometry Exploration (FGE) aims to support the exploration of more functionally and geometrically different product concepts under consideration of not only geometrical, but also teleological aspects. The FGE approach has been presented and verified in a previous presentation. However, in order to contribute to engineering design practice, a design method needs to be validated through application in industrial practice. Hence, this publication reports from a study where the FGE approach has been applied by a design team of a Swedish aerospace manufacturers in a conceptual product development project. Conceptually different alternatives were identified in order to meet the expected functionality of a guide vane (GV). The FGE was introduced and applied in a series of workshops. Data was collected through participatory observation in the design teams by the researchers, as well as interviews and questionnaires. The results reveal the potential of the FGE approach as a design support to: (1) Represent and capture the design rationale and the design space; (2) capture, integrate and model novel solutions; and (3) provide support for the embodiment of novel concepts that would otherwise remain unexplored. In conclusion, the FGE method supports designers to articulate and link the design rationale, including functional requirements and alternative solutions, to geometrical features of the product concepts. The method supports the exploration of alternative solutions as well as functions. However, scalability and robustness of the generated CAD models remain subject to further research

Revisiting the design intent concept in the context of mechanical CAD education

[EN] Design intent is generally understood simply as a CAD model¿s anticipated behavior when altered. However, this representation provides a simplified view of the model¿s construction and purpose, which may hinder its general understanding and future reusability. Our vision is that design intent communication may be improved by recognizing the multifaceted nature of design intent, and by instructing users to convey each facet of design intent through the better-fitted CAD resource. This paper reviews the current understanding of design intent and its relationship to design rationale and builds on the idea that communication of design intent conveyed via CAD models can be satisfied at three levels provided that specialized instruction is used to instruct users in selection of the most suitable level for each intent.Otey, J.; Company, P.; Contero, M.; Camba, J. (2018). Revisiting the design intent concept in the context of mechanical CAD education. Computer-Aided Design and Applications. 15(1):47-60. https://doi.org/10.1080/16864360.2017.1353733S476015

CAD-Based Automated Design of FEA-Ready Cutting Tools

The resources of modern Finite Element Analysis (FEA) software provide engineers with powerful mechanisms that can be used to investigate numerous machining processes with satisfying results. Nevertheless, the success of a simulation, especially in three dimensions, relies heavily on the accuracy of the cutting tool models that are implemented in the analyses. With this in mind, the present paper presents an application developed via Computer-Aided Design (CAD) programming that enables the automated design of accurate cutting tool models that can be used in 3D turning simulations. The presented application was developed with the aid of the programming resources of a commercially available CAD system. Moreover, the parametric design methodology was employed in order to design the tools according to the appropriate standards. Concluding, a sample tool model was tested by performing a number of machining simulations based on typical cutting parameters. The yielded results were then compared to experimental values of the generated machining force components for validation. The findings of the study prove the functionality of the tool models since a high level of agreement occurred between the acquired numerical results and the experimental ones

Assessment of parametric assembly models based on CAD quality dimensions

[EN] An approach to convey CAD quality-oriented strategies to beginning users to create bottom-up assemblies is described. The work builds on previous efforts in the area of single part history-based, feature-based parametric modeling evaluation by defining, testing, and validating a set of quality dimensions that can be applied to MCAD assembly assessment. The process of redefining and adapting dimension descriptors and achievement levels of parts rubrics to make them applicable to assemblies is addressed, then the results of two experimental studies designed to analyze the inter-rater reliability of this approach to assembly evaluation are reported. Results suggest the mechanism is reliable to provide an objective assessment of assembly models. Limitations for the formative selfevaluation of CAD assembly skills are also identified.This work was partially supported by the Spanish grant DPI2017-84526-R (MINECO/AEI/FEDER, UE), project CAL-MBE, Implementation and validation of a theoretical CAD quality model in a Model-Based Enterprise (MBE) context. , and the ANNOTA2 project funded by Universitat Politècnica de València.Otey, J.; Company, P.; Contero, M.; Camba, JD. (2019). Assessment of parametric assembly models based on CAD quality dimensions. Computer-Aided Design and Applications. 16(4):628-653. https://doi.org/10.14733/cadaps.2019.628-653S62865316

EZID: A new approach to hazard identification during the design process by analysing energy transfers

Manufacturing machine designers must take into account different aspects of products such as technol-ogy, legislation and occupational safety. European directive 2006/42/CE promulgates machine safetydesign principles to prevent occupational risks. Aimed at machine designers, its objective is to set outthe need to obtain the lowest possible risk level according to the state of the art. Although the designersof catalog machines have access to specific standards to perform a priori risk analyses, this is not the casefor special machine designers. An original approach called EZID is presented in this paper to help allmachine designers in the task of hazard identification. Based on the fact that hazards are linked to thepresence of energies, EZID identifies hazards through the detection of design parameters linked to energysources and flows. It then feeds back organized information to designers on every potential exchange ofenergy between the machine and its operators, bringing to light the need to add risk prevention solutions.The first part provides a detailed classification of energy parameters considered to be the primary indi-cators of hazards. This is followed by an explanation of the logical rules describing how damage is gen-erated by the combination of the other design parameters, increasing the level of detail in hazardidentification. The next part focuses on the characterization of significant hazards. Finally, the resultsobtained from using this approach during the industrial design of a supply line are presented to confirmthat EZID is functional from the earliest stage of design

Does Form follow Function? Connecting Function Modelling and Geometry Modelling for Design Space Exploration

The aerospace industry, representative of industries developing complex products, faces challenges from changes in user behaviour, legislation, environmental policy. Meeting these challenges will require the development of radically new products. Radically new technologies and solutions need to be explored, investigated, and integrated into existing aerospace component architectures. The currently available design space exploration (DSE) methods, mainly based around computer-aided design (CAD) modelling, do not provide sufficient support for this exploration. These methods often lack a representation of the product’s architecture in relation to its design rationale (DR)—they do not illustrate how form follows function. Hence, relations between different functions and solutions, as well as how novel ideas relate to the legacy design, are not captured. In particular, the connection between a product’s function and the embodiment of its solution is not captured in the applied product modelling approaches, and can therefore not be used in the product development process.To alleviate this situation, this thesis presents a combined function and geometry-modelling approach with automated generation of CAD models for variant concepts. The approach builds on enhanced function means (EF-M) modelling for representation of the design space and the legacy design’s position in it. EF-M is also used to capture novel design solutions and reference them to the legacy design’s architecture. A design automation (DA) approach based on modularisation of the CAD model, which in turn is based on the functional decomposition of the product concepts, is used to capture geometric product information. A combined function-geometry object model captures the relations between functions, solutions, and geometry. This allows for CAD models of concepts based on alternative solutions to be generated.The function- and geometry-exploration (FGE) approach has been developed and tested in collaboration with an aerospace manufacturing company. A proof-of-concept tool implementing the approach has been realised. The approach has been validated for decomposition, innovation, and embodiment of new concepts in multiple studies involving three different aerospace suppliers. Application of FGE provides knowledge capture and representation, connecting the teleological and geometric aspects of the product. Furthermore, it supports the exploration of increasingly novel solutions, enabling the coverage of a wider area of the design space.The connection between the modelling domains addresses a research gap for the “integration of function architectures with CAD models”.While the FGE approach has been tested in laboratory environments as well as in applied product development projects, further development is needed to refine CAD integration and user experience and integrate additional modelling domains