REPORT ON "IDEALIZATION OF CAD MODEL FOR A

SIMULATION BY A FINITE ELEMENT METHOD"

Introduction
The finite element method (FEM), a numerical methodology, provides an approximate solution
to physical issues. Salih (2016) indicates that FEM was first created to analyze strains in intricate
aeroplane structures, but was expanded and used in a wide range of continuum mechanism
applications, such as fluid mechanics and heat transport [1]. FEM now plays a significant part in
engineering analysis and design because of its flexibility as an analysis tool and its capacity to
address complicated challenges. Meanwhile, the art of taking a fundamental structure and turning it
into an assembly of finite elements is idealization in FEM. At its most basic level, the process
includes creating a single geometric model from CAD and meshing it in a single step. Subsequently,
the critical benefit of FEM is that it works well with problems involving complex geometries since
no specific issues arise when the physical dimension has a complicated geometry [1]. The ease of
scripting programmable computer codes for FEM formulations is another significant benefit.
The necessity to idealize CAD in FEM emanates from historical consideration of design and
mechanical analysis as separate processes. Hamdi et al. (2010) posit that the designer and analyzer
worked independently, where designers utilized specialized design tools, and delivery specifications
and analysts evaluated design concepts based on analytical tools [2]. The approach required the
analyst to frequently recreate the CAD geometry using different tools to assess their functional
effectiveness, meaning that changes in the design required the expert to revive the laborious
preparation of the simulation geometry. Starting with the CAD model supplied by designers depict
an absence of method to apprise the model utilized for scrutiny. In this regard, the length of the
analysis goes out of control at an advanced design stage because a modification severely affects the
analysis. The numerous recessive and accelerative phases between design and analysis lengthen the
product's authentication process, which raises its price.
Goals
The study's goal is to make the mesh preparation stage of CAD models better before its
commencement. Hamdi et al. (2010) note that the aim is to introduce a new stage in creating a CAD
model for idealizing the geometry, which involves removing any details that simulation is thought
unnecessary [2]. These specifics are precincts where the mesh will be spontaneously polished
because they will require a significant amount of processing time without improving the precision of
the simulation's outcomes. Since these features were temporarily removed during the design phase to
prepare for subsequent simulation, significant time can be saved without compromising the
simulation's outcomes.
Hamdi et al. (2010) propose a novel algorithm that can direct the designer during the process of
getting a CAD model ready for a finite element simulation. Hamdi et al. (2010) indicate that the
suggested method is based on the elimination of details on an Iso-zone representation allowing the
designer to see the details that are suitable for reduction based on the severity of the detail to be
eliminated [2]. Eliminating the details can be done automatically or in conjunction with the designer.
The time savings and the difference between the error rate of computation results prior to and after
CAD geometry idealization may be demonstrated on several mechanical parts utilizing a data-
processing employment of the proposed approach using Open CASCADE. This model significantly
shortens the design process and lowers the product's cost. Early idea judgments are simplified using

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FEM, lessening the demand for actual prototypes. It also enables tests of a device's performance and
behavior that are inaccessible in the real world. As a result, a product's CAD model is broken down
into a finite number of components, which creates a simulation model that the computer can use to
do calculations. This model is a virtual prototype that fosters modification and redesign when
necessary.
Gap
Simplification
A period of idealization or simplifying the geometry occurs during the development of a CAD
model. This phase eliminates details whose contribution to simulation extends simulation duration
without improving the calibre of simulation results. According to the type of simplification operators
used in each technique—surface entities, volumetric entities, explicit features, and dimensional
reduction—Thakur et al. (2009) studied existing design and parameterization strategies that are
useful from physics-based modelling and broadly categorized them into four main categories [3]. No
single technique can effectively address the issues associated with model simplification (see Figure
1). Most of the strategies can be used to prepare FEA models, while the others can be used to solve
fluid flow issues, find collisions, or even as pre-processing procedures to identify complicated
features. In this context, choosing a particular technique requires considering the following factors:
the application domain, the types of attributes handled, the input format, the degree of automation,
and the type of operators employed.

Figure 1. Simplification techniques identified by Thakur et al. (2009).

Venkataraman et al. (2002) proposed robust techniques for extracting fillets with a suppression
algorithm for predicting the final topology using the fillet chains' structure and then identifying a
geometric solution based on the overlap of the fillet's support faces [4]. To eliminate the shift

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between two faces and create a convex face, Armstrong et al. (1996) used Euler operators. The
following merge and collapse operators were available for removing 3D geometries' finer details:
merge features, merge borders, kill voids, kill gaps, fall face to the edge, and fall face to the vertex
[5]. Two vertexes were produced on edge to establish a face and begin contracting this face toward
the edge.
To enable mesh creation, Sheffer et al. (1997) used a virtual topology that grouped faces in
specific places, given that the faces defined a large enough plane surface. The flatness of the region,
which permits the elimination of the low-size faces by fusing them with their neighboring facades or
by compressing them in edges, is the main criterion for regrouping faces in a region [6]. As a result,
it cannot be regarded as a geometry-simplification technique but rather as a specific meshing
technique.
In 2008, Foucault et al. published a method for topology simplification for the construction of
finite element meshes. To meet the requirements for sharp corner matching, the authors created a
Mesh Stress Topology (MCT) based on a model simplification technique [7]. MCT entities are
composite topological entities developed to satisfy the mesh mentioned above generating
requirements. The union of the Riemannian surfaces that make up the reference model is what is
referred to as the MC face, which is a poly-surface. In order to simplify their work, Foucault et al.
(2008) constructed graph-based operators that allowed them to delete MC edges and vertices, insert
MC vertices into MC edges, collapse MC edges into MC vertices, and merge MC vertices. The size
and curve of the mesh affect the stress on its quality for MC entities. The distance between its
boundaries determines an MC face's size, but the edge lengths determine an MC edge's size. The MC
delete operator must be used to remove redundant edges located in planar regions.
The purpose of the form features is to couple geometrical and semantic information into a single
entity. These entities support appropriate significances for a trade or a particular application thanks
to their significant geometric components. The attributes can be applied to extraction or modeling.
Hamdi et al. (2010) noted that the existing simplification techniques have significant pitfalls. The
method described in this work is distinctive in this sense and is distinguished by an idealization
process with input and outcome files in the impartial STEP format. The idealization process involves
interaction that ensures an iso-zone model displays the CAD part after treatment, allowing the
designer to choose which details to remove based on criteria. The reconstruction procedure is carried
out without approximation, whereas the idealization process is based on a CAD model. A
hierarchical link is kept between the original and the modified models. Due to the output format
type, the idealized model can be applied to numerous case studies, including finite element analysis,
assembly process, collision detection, and dynamic analysis.
Methodologies
A proposed method by Hamdi et al. (2010) consists of three main interdependent steps. There are
overlapping algorithms in each stage. The suggested approach depends on a neutral file to load the
data of the hypothetical part to be free from the CAD/CAM systems. The idealized CAD geometry
was saved in a neutral format for use with various simulation systems (STEP). The three phases of
the suggested algorithm are shown in Figure 2. The algorithm's first stage is the pre-treatment phase
for CAD models. It enables the part's Boundary Representation (B-rep) description to be reorganized
and stored in a database. The subjects of the data structure in this database are the surfaces, cables,
borders, and vertex, which comprise the part's geometry model. The CAD model's restructuring aims
to explore and simplify the handling of the topological and geometrical data related to each part.

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Figure 2. Algorithm of idealization (Hamdi et al., 2010).
Finding the specific candidates for elimination makes up stage 2. That implies the use of
identification algorithms based on specific parameters. This phase represents the Iso-zones,
equivalent to the portrayal of the Isovalues of tension and deformations in computational tools using
the finite element approach. These Iso-zones are objects (edges, faces) colored per a criticality
gradient. With the help of this novel vision, the designer sees the areas that have the most negligible
impact on the computation results, providing him with the option of manually removing entities with
a high order of criticality or using automatic techniques.
The third stage entails suppressing the detected details before recreating the geometric model. In
this step, the goals are to eliminate the specifics mentioned in the preceding section and reconstruct
the idealized part. After removing faces and edges, reconstructing a CAD model involves looking for
faces close to the deleted entities. Nearby faces are detected based on the dataset portion analyzed in
the first stage. An idealized CAD model with a valid elementary topology is the result of this phase.
The designer has access to an idealized model recorded in STEP format for a simulation using finite
elements at the algorithm's exit.
Major Findings
The proposed algorithm reduces computing time by 68 per cent. The inaccuracy for the
displacement values is 0.9 per cent, whereas the error for the comparable stress is 7.5 per cent. After
using the idealization algorithm, tension and displacements have computation time savings of 62.5
per cent, error related to displacement is 2.13 per cent and relative stress error of 1.36 per cent. This
inaccuracy is regarded as acceptable for an initial dimensioning analysis. If the designer wants to
perform a lot more in-depth research to verify the chosen dimensions, he can use stricter idealization
criteria on the size of the features that will be deleted or on the location of the elements concerning
the loading. This will prevent the concentration stress from being removed. Considering the
idealization loop in the design-analysis chain in every situation leads to a significant reduction in
computing time without a noticeable decline in the results' quality. As a result, compared to the
overall simulation duration, this idealization process takes very little time to complete.

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Conclusions
The idealization algorithm of CAD models is presented in this study for a simulation using the
FEM. The suggested approach involves reading the B-rep modelling of the CAD geometry to locate
and then eliminate any information deemed unnecessary for mechanical analysis. The creation tree
of the CAD model (CSG) is not considered in this work because it is unique and readily escapes a
straightforward transfer of the CAD model between various working programs. The validation
examples demonstrate that an appropriate removal of the features in a CAD model permits saving of
time during the simulation procedure while maintaining high accuracy of the calculation results.
These findings came from performing finite element simulations before and after idealization. This
work complies with current industrialist trends, which show an increasing interest in creating CAD
models during the pre-processing stage. Meanwhile, future idealization criteria must consider factors
like how the detail sits concerning the boundary requirements (BC). Currently, the designer is the
person who must review the list of details that must be eliminated to keep those that are carrying BC
and those that are positioned in the loading direction. Since the design phase, specific information
about BC has been provided, but they do not appear in the STEP export file.
The Relation to CAD/CAM Course
CAD/CAM offers quicker and more effective working systems through improved accuracy,
productivity, and well-organized information flow. As a result, the course improves the design
process's creation, adjustment, and optimization. In addition to time savings due to more
straightforward modification and increased design quality, the research assesses the idealization of
CAD models using FEM. The study advances the course purpose of removing the arduous work
associated with manual pattern design and grading, construction of layouts, and transfer of written
information by utilizing upgraded CAD. The papers allow students to increase corporate
competitiveness and lower product prices in their professional lives. Meanwhile, CAD/CAM courses
encourage students to take part in the automation of repetitive design jobs, productivity optimization,
and the reduction of lead times in the product development process to increase the design process's
efficiency. This article promotes the practical application of CAD/CAM technology by offering the
appropriate technology to meet the requirements of various industries through efficiency
optimization. The paper curbs students' negative attitudes toward CAD/CAM technologies and their
insufficient training.
Contribution
Students Contribution Personal Experience
A Introduction and The paper was crucial in advancing the course outcomes. I
Gap learned how to enhance the accuracy and reliability of CAD
technology. The idealization of CAD using FEM was highly
crucial in combining analysis and design. Hence, the paper
was essential for ensuring that I am not only aware of how
to use CAD/CAM technologies but optimizing them to
deliver accuracy and reliability. The paper guaranteed the
attainment of CAD/CAM benefits, including time saving in
engineering, enhanced control over the production process,
and tasks perfectly and precisely.
B Methodologies, Participating in the CAD/CAM course has made me a better

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Findings, and person in the creation of designs and generation of technical
Conclusion drawings. By creating designs that are more practical,
satisfying, and meaningful, I am able to save a significant
amount of time in this area. Now that I can simply and
comfortably make improvements to current designs, I can
fix flaws and improve designs. Hence, with my superior
CAD skills, I can lessen errors that could happen in manual
designs. Additionally, because I use software to streamline
various activities, I can promise a lower amount of effort
while creating various models. The paper contributed
enormously in the attainment of the course objectives.

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 References
[1] Salih, A. A. (2016). Finite element method. Indian Institute of Space Science and Technology.
[2] Hamdi, M., Aifaoui, N., Louhichi, B., & BenAmara, A. (2010) Idealization of CAD model for a
simulation by a finite element method. European Journal of Computational
Mechanics/Revue Européenne de Mécanique Numérique, 19(4), pp. 419-439.
[3] Thakur, A., Banerjee, A. G., & Gupta, S. K. (2009). A survey of CAD model simplification
techniques for physics-based simulation applications. CAD Computer Aided Design, 41, pp.
65-80.
[4] Venkataraman, S., Sohoni, M., & Rajadhyaksha, R. (2002). Removal of blends from boundary
representation models”, Proceedings of the seventh ACM symposium on solid modeling and
applications, ACM Press, pp. 83-94.
[5] Armstrong, C. G., Donaghy, R. J., & Bridgett, S. J. (1996). Derivation of appropriate
Idealisations in Finite Element Modelling. 3th International Conference on Computational
Structures technology, Budapest.
[6] Sheffer, A., Blacker, T. D., & Clustering, M. (1997). Automated detail suppression using virtual
topology. ASME, pp. 57-64.
[7] Foucault, G., Cuillière, J., François, V., & Léon, J. (2008). Adaptation of CAD model topology
for finite element analysis. CAD Computer Aided Design, 40(2), pp. 176-196.