Recently, three-dimensional CAD systems based on feature-based solid modeling techniques have been widely used for product design. However, when part models associated with features are used in various downstream applications, simplified models at various levels of detail (LODs) are frequently more desirable than the full details of the parts. One challenge is to generate valid models at various LODs after an arbitrary rearrangement of features using a certain LOD criterion, because composite Boolean operations consisting of union and subtraction are not commutative. This article proposes an algorithm for feature-based multiresolution solid modeling based on the effective volumes of features. This algorithm guarantees the same resulting shape and the reasonable intermediate LOD models for an arbitrary rearrangement of the features, regardless of whether feature types are additive or subtractive. This characteristic enables various LOD criteria to be used for a wide range of applications including computer-aided design and analysis.
Current CAE systems used for both the simulation of the injection molding process and the structural analysis of plastic parts accept solid models as geometric input. However, abstract models composed of sheets and wireframes are still used by CAE systems to carry out more analyses more efficiently. Therefore, to obtain an adequate abstract model, designers often have to simplify and idealize a detailed model of a part to a specific level of detail and/or abstraction. For such a process, we developed a feature-based design system based on a non-manifold modeling kernel supporting feature-based multi-resolution and multi-abstraction modeling capabilities. In this system, the geometric models for the CAD and CAE systems are merged into a single master model in a non-manifold topological representation, and then, for a given level of detail and abstraction, a simplified solid or non-manifold model is extracted immediately for an analysis. For a design change, the design and analysis models are modified simultaneously. As a result, this featurebased design system is able to provide a more integrated environment for the design and analysis of plastic injection molding parts.
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