SolidModeling Blade

XOR Tutorial
SolidModeling: Blade

July, 2007

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RapidformXOR User Guide & Tutorial

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Rapidform XOR Basic Tutorial 2

1. Overview
Welcome to the XOR Feature modeling with mesh Guide!

Rapidform XOR is New reverse engineering software to build parametric CAD models
directly from 3D scan data with using the skills & UI that you are already familiar with
through the experience of CAD systems.

This tutorial is intended for the user who needs to become quickly familiar with the Rapidform
XOR product. This tutorial has been designed to show you how to create a hybrid mesh fit
surface model.

Reflect Design Intent
XOR helps the user to discover the original design concept & capture it.
The result is an idealized model (the part in its pristine design condition; as it was intended to
be).

Copy the part exactly:
Use the polygon mesh if possible, or fit NURBS surfaces to the polygon mesh to make it
readable in some CAD & CAM systems.
Result is an almost exact copy of the part geometry, including the good and the bad.

SCAN data CAD data



The deviation result between the features modeled part and the original mesh.

2. Data files

Blade_b.stl Raw Scan data of a blade.

Sample data for the following tutorial is provided by INUS Technology. They are the
property of INUS Technology and are used for informational purposes only. Other than to
identify this software and publication, individuals or organizations purchasing the software
are not entitled to use the sample data without INUS Technologys prior written consent.


3. Summary

For this tutorial, we will follow the process in below.

1. Import Mesh data and Auto-Region Segment
2. Interactive Coordinate Alignment
3. Create Plane ,vector using Redesign Assistant
(Intelligent design intent & parameter extraction)
4. Create 2 Mesh sketches
5. Create 2 Base Solid Bodies
6. Create Mesh fit surface and cut by surface
7. Trim surfaces and Boolean Solid
8. Create 4 sketch to Make blade surface
9. Create a blade Solid
10. Add Fillet and Accuracy Analyzer

4. Modeling Process

Step1: Region Segmentation

Click Insert > Import and open blade_b.stl at following location:
~/INUS Technology/rapidformXO Redesign/Sample/SolidModeling.
Click the Region group mode icon to enter Region Group Mode.
Click Auto segment and then click the OK button with the default options as shown below.


Auto Segment information will be displayed as follows.



Step2: Interactive Coordinate Align
Click the Interactive Coordinate Alignment icon in the Align Toolbar.
The Interactive Alignment dialog tree displays on the screen.

Select the blade mesh as the Moving Mesh.

Click the next stage icon to align the mesh to a global coordinate.
It makes two separated view as shown below.
The left view is Source and the right view is Reference.



Select 3-2-1 Method
You can align the mesh using the 3-2-1 method. You need to select each entity for Plane,
Vector and Position. If you click the Flip button, you can reverse the direction of it. You can
also select Ref.Point, Ref.Coordinate, Ref.Vector, Ref.Plane, Poly-Vertex, Curve Point,
Curve, Poly-Face, Region, Sketch, Vertex, Edge or Face.

Click the Plane button and select the side region as shown below.

Click the Vector button and select the upper region as shown below.



Click the Position button and select the bottom region as shown below.

Click the Apply button. You can see that each perpendicular face aligns to the reference plane.


Step3: Create a Plane and Vector using the Redesign Assistant
Click the Ref.plane icon to create a region fitting plane1.
Select the Extract method and select the region as shown below.



Create a plane2 by selecting 2 regions as shown below.

Create a plane3 by selecting the region as shown below







Create a Ref.vector1 to be used for extruding by intersecting plane5 and plane6


Step4: Create 2 mesh sketches
The Mesh Sketch command allows you to extract a polyline of a section or silhouette from a
mesh model and create 2D geometries such as a line, a circle, a rectangle, etc., based on the
created section or silhouette. You can extract design intent and redesign the part.

Click the mesh sketch command and select plane1 as the base plane.
Input 1mm as the offset distance from the base plane.

Tip: If the section polyline is not displayed, click the Flip direction icon .

You can adjust the resolution by moving the slide bar in the Segment Section Polyline.toolbar.


Tip Resolution This operation determines the resolution of a polyline.
are created.

lick the
The further left the cursor is moved, the fewer segments
C button on the Sketch toolbar, or click Tools > Sketch Entities > Line.
Fi
the 3D Model View.
Enable the t Polyline option and select a polyline segment .
Repeat this step until you duplicate the sketch seen below.
Click Accept Fitting or double-click the left mouse button on

lick the C button on the Sketch toolbar, or click Tools > Sketch Tools > Fillet.
t be Add a fille tween lines to apply tangent constraints on them.


Select the Accuracy Analyzer.
button and input the tolerance values as shown below.

Check the Deviation radio check
A deviation that is displayed by the color green indicates that the sketch curve is within an
allowable tolerance to the polyline.

he final Sketch1 is as shown below.

T


Click the Mesh Sketch command and select the plane3 as the base plane.


Click the button on the Sketch toolbar, or click Tools > Sketch Entities > Line.
Click the button on the Sketch toolbar, or click Tools > Sketch Entities > Centerpoint Arc.
Enable the Fit Polyline option and select a polyline segment.
Draw an arc and a line sketch entity. Repeat these steps until your sketch matches the one
shown below.

Click the button on the Sketch toolbar, or click Tools > Sketch Tools > Fillet.
Add fillets between lines to apply tangent constraints on them.


The final Sketch2 is as shown below.

Step5: Create 2 Base solids
Click the button on the toolbar, or click Insert > Solid > Extrude.
Select the Base Sketch as the sketch1. Select Up to Surface as the extrusion method and
select the Plane2.
TIP: If the solid is not displayed, click the Flip button to change extrusion direction.



Extrude1 is created


Click the button on the toolbar, or click Insert > Solid > Extrude.
Select the Base Sketch as sketch1. Select Up to Surface as the extrusion method and select
the Plane4.
Select the Ref.vector1 as Custom direction.
NOTICE Dont check cut or merge in Result Operator option.

Extrude2 is created



Step6: Create a Mesh Fit Surface
1. Create 4 upper Mesh Fit surfaces and cut the solid by those surfaces.
Click the Mesh Fit Surface icon or select Click Insert > Surface > Mesh Fit.
Select the yellow color region as shown below.(The region color may differ from this tutorial)
Click OK with the default options as shown below . Input 0% as V.extend ratio in the
Extend option dialog tree.
Meshfit surface1 is created.

Select the blue color region as shown below. (The region color may differ from this tutorial)
Click OK with the default options as shown below. Meshfit surface2 is created.


Select the violet color region as shown below. (The region color may differ from this tutorial)
Select By no. of control point method in the Resolution Selection Box.
Input 5 by 5 as U,V control point. Input 55% as the U.Extend ratio and 70% as the V.Extend
ratio.
In the Extend option, Select the Curvature Extend method.
Click OK with the options shown below.




Select the blue color region as shown below. (The region color may differ from this tutorial)
Click OK with the default options as shown below. Meshfit surface4 is created.


Extend Mesh Fit surfaces 1, 2, and 4 so that they fully intersect with one another.
Click the button on the toolbar, or click Insert > Surface > Extend.
Select the Mesh Fit Surface2.
Select Curvature as the Extension Method and Input 4mm as the distance.
Repeat this step for Mesh Surface4.

Select the edge of meshfit Surface1 as shown below
Select Curvature as the Extension Method and input 6mm as the distance



Cut the Extrude1 by the Mesh Fit1 surface.
Click the button on the toolbar, or click Insert > Solid > Cut.
Select Mesh Fit1 as the Tool Entities and Extrude1 as the Target Bodies.

Click the Next stage icon.
Select the Remaining body as shown below.
Cut1 is created.



2. Create 4 lower Mesh
it surfaces and cut the solid by the surfaces.
Click the Mesh Fit Surface icon or select Insert > Surface > Mesh Fit.
Select the yellow color region as shown below.(The region color may differ from this tutorial)
Click OK with the default options as shown below. Input 0% as V.extend ratio in the
Extend option dialog tree.
Mesh Fit surface5 is created.


Select 3 color regions as shown below. (The region color may differ from this tutorial)
Click OK with the default option as shown below. Mesh Fit surface6 is created.

Select the green color regions as shown below. (The region color may differ from this tutorial)
Click OK with the default options as shown below.
Mesh Fit surface7 is created.



Select the orange color region as shown below. (The region may differ from this tutorial)
Click OK with the default options as shown below.

Extend the Mesh Fit surface5, 6, 7, and 8 to fully intersect one another.

Click the button on the toolbar, or click Insert > Surface > Extend.
Select the edges of the Mesh Fit Surface6 as show below.
Select Curvature as the extension Method and input 3.5mm as the distance.

Select the edges of Meshfit Surface7as show below.

Select Curvature as the Extension Method and input 4.5mm as the distance.

Select the edges of Meshfit Surface8 as show below.
Select Curvature as the Extension Method and input 4.5mm as distance.

Select the edges of Meshfit Surface5 as show below.
Select Curvature as the Extension Method and input 8mm as the distance.


Cut Extrude1 by the Mesh Fit5 surface.
Click the button on the toolbar, or click Insert > Solid > Cut.
Select Meshfit5 as the Tool Entities and Extrude1 as the Target Bodies as shown below.



Click the Next Stage icon.
Select the Remaining body as shown below.
Cut2 is created.

Offset a surface from Extrude2 as shown below.

Cut the Cut2 solid by the surface offset1.


Step7: Trim surfaces
Click the Show icon of mesh fit 1, 2, 3, and 4 in the model tree to show them.

Click the button on the toolbar, or click Insert > Surface > Trim.
Select all surfaces as Toolbody and all surfaces as Target body.
Select the remaining bodies as shown below.
Tip: You can select all surface Bodies by using the Right Mouse Button menu.


Trim1 is created.


Click the Show icon of meshfit 5, 6, 7, and 8 in the model tree to show those surfaces.

Click the button on the toolbar, or click Insert > Surface > Trim.
Select all surfaces as the Tool Body and all surfaces as the Target Body.
Select the remaining bodies as shown below.


Trim2 is created.

Cut extrude2 by trim1.

Cut extrude2 by trim2. Cut5 is created.


Boolean two cut bodies (Cut3 &Cut5). Cut5 is created.


Step8: Create 5 sketches to Make a blade surface
Click the Ref.plane icon to create region fitting plane7.
Select Extract method and select the region as shown below.

Click the mesh sketch command and select plane7 as the base plane.



Final sketch3 looks like this.

Create an offset plane8 -19mm from plane7.
Create a Mesh sketch4 as shown below.


Create a Mesh sketch5 as shown below.

Create a sketch6 and click the Convert entity icon.
Select all curves in Sketch5 and click OK.
The final sketch6 should look like the one below.


Finally, 4 Sketches are created to create a lofted surface.

Step9: Create a blade Solid
Create a Loft surface.
Click the button on the toolbar, or click Insert > Surface > Loft.
Select Sketch 3, 4, 5, and 6.



Create a Fill surface.
Click the button on the toolbar, or click Insert > Surface > Fill Face.
Select the edges of the Lofted surface and click OK.


Click the button on the toolbar, or click Insert > Surface > Offset.
Select the surface of Solid Cut5. Insert 0.0 mm as the Offset distance.


Click the Trim & Merge icon on the toolbar, or click Insert > Surface > Trim & Merge.
Select the Fillface1 and the offset surface, and click OK.
A solid is created as shown below.


Boolean the solid body.

Create a Plane8 using Extract as the Method.


Select the Plane8 and create a Mesh Sketch7 with a distance of 0.5mm.



Select Sketch7.
Create an Extruded feature using Through All as the Method the Cut option under Result
Operator selected.

The result is as follows.


Step10: Add Fillets and Analyze Deviations

Click the button on the Default toolbar, or click Insert >Modeling Feature >Fillet. Click to
calculate the radius of an entity est. XOR automatically extracts the radius of a fillet from a
mesh model and is useful when modeling with a reference mesh model.
Input 2.5 mm as the Radius and click OK.

Variable Radius Fillet
You can create variable radius fillets by specifying a different radius for each vertex of the edges
you want to fillet. If you check this method, you can see the Profile View in the consol window.
You can add a control point by clicking specific location on the yellow line and set radius by

dragging the blue point or clicking the value to specify a value. If you want to remove the control
point, move the point that you want to remove to another point and overlap it.

Variable Radius Fillet edges as shown below.
Click to calculate the radius on the Mesh Data automatically.

Deviation Analysis using the Accuracy Analyzer.


The Accuracy Analyzer is useful tool for identifying the accuracy of the created entities
against the scan data of the part. You can check curvature, deviation, or environment
mapping using the Accuracy Analyzer.

Now select the Deviation option to view the deviation between the created surface and actual
scan data of the part. If Color Map is selected as the Deviation Type, the result is displayed by
the color map the user defines. If Vector is selected as the Deviation Type, the deviations are
displayed as vectors.

The result of the final solid looks as follows. (minor features have been omitted)




SolidModeling Blade

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