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Sheet Metal DFM Analyzer Example

Table of Contents

Demonstrates how to perform sheet metal design analysis on a 3D model and print information about found issues and their parameters in a console.

Overview

In this example demonstrates how to perform sheet metal design analysis on a 3D model using sheet metal dfm analyzer tool (DFMSheetMetal_Analyzer). For this purpose, used a console application that imports a model, traverses through unique ModelData::Part , creates and runs DFMSheetMetal_Analyzer, groups and prints information about found issues and their parameters into console. Sheet metal design analysis will be performed for each unique ModelData::Part , but only for the scope of accepted geometries.


Application needs 1 input argument to run:

Usage: sheet_metal_dfm_analyzer <input_file>, where:
<input_file> is a name of the file to be read


For more information about sheet metal design analysis visit Design for Manufacturing (DFM) page.

Implementation

PartProcessor class is inherited from ShapeProcessor and overrides ProcessSolid and ProcessShell methods that are used to run DFMSheetMetal_Analyzer on given shapes. Then PrintIssues method is used to print information about found issues and their parameters in a console.
Visit Model Explore Helper Implementation page for more information about base ShapeProcessor class implementation.

class PartProcessor : public ShapeProcessor
{
public:
void ProcessSolid (const ModelData::Solid& theSolid) override
{
auto anIssueList = myAnalyzer.Perform (theSolid);
PrintIssues (anIssueList);
}
void ProcessShell (const ModelData::Shell& theShell) override
{
auto anIssueList = myAnalyzer.Perform (theShell);
PrintIssues (anIssueList);
}
private:
DFMSheetMetal_Analyzer myAnalyzer;
};

To traverse only unique parts of the imported model, the ModelData::ModelElementUniqueVisitor class is used.

PartProcessor aPartProcessor;
ModelData::ModelElementUniqueVisitor aVisitor (aPartProcessor);
aModel.Accept (aVisitor);

After performing design analysis, the object of FeatureGroupManager class is used to group and sort found issues. For this purpose, there is a traverse through all found issues and add each of them to FeatureGroupManager with a specified name.

for (size_t i = 0; i < theIssueList.Size(); ++i) {
const auto& anIssue = theIssueList[i];
if (anIssue.IsOfType<DFMSheetMetal_SmallRadiusBendIssue>()) {
aManager.AddFeature ("Small Radius Bend Issue(s)", "Bend(s)", true, anIssue);
} else if (anIssue.IsOfType<DFMSheetMetal_SmallDiameterHoleIssue>()) {
aManager.AddFeature ("Small Diameter Hole Issue(s)", "Hole(s)", true, anIssue);
} else if (anIssue.IsOfType<DFMSheetMetal_FlatPatternInterferenceIssue>()) {
aManager.AddFeature ("Flat Pattern Interference Issue(s)", "", false, anIssue);
} else if (anIssue.IsOfType<DFMSheetMetal_IrregularCornerFilletRadiusNotchIssue>()) {
aManager.AddFeature ("Irregular Corner Fillet Radius Notch Issue(s)", "Notch(es)", true, anIssue);
} else if (anIssue.IsOfType<DFMSheetMetal_IrregularDepthExtrudedHoleIssue>()) {
aManager.AddFeature ("Irregular Depth Extruded Hole Issue(s)", "Hole(s)", true, anIssue);
} else if (anIssue.IsOfType<DFMSheetMetal_IrregularRadiusOpenHemBendIssue>()) {
aManager.AddFeature ("Irregular Radius Open Hem Bend Issue(s)", "Hem Bend(s)", true, anIssue);
} else if (anIssue.IsOfType<DFMSheetMetal_IrregularSizeBendReliefIssue>()) {
aManager.AddFeature ("Irregular Size Bend Relief Issue(s)", "Bend(s)", true, anIssue);
} else if (anIssue.IsOfType<DFMSheetMetal_LargeDepthBeadIssue>()) {
aManager.AddFeature ("Large Depth Bead Issue(s)", "Bead(s)", true, anIssue);
} else if (anIssue.IsOfType<DFMSheetMetal_InconsistentRadiusBendIssue>()) {
aManager.AddFeature ("Inconsistent Radius Bend Issue(s)", "Bend(s)", true, anIssue);
} else if (anIssue.IsOfType<DFMSheetMetal_SmallLengthFlangeIssue>()) {
aManager.AddFeature ("Small Length Flange Issue(s)", "Flange(s)", true, anIssue);
} else if (anIssue.IsOfType<DFMSheetMetal_SmallLengthHemBendFlangeIssue>()) {
aManager.AddFeature ("Small Length Hem Bend Flange Issue(s)", "Flange(s)", true, anIssue);
} else if (anIssue.IsOfType<DFMSheetMetal_IrregularSizeNotchIssue>()) {
aManager.AddFeature ("Irregular Size Notch Issue(s)", "Notch(s)", true, anIssue);
} else if (anIssue.IsOfType<DFMSheetMetal_IrregularSizeTabIssue>()) {
aManager.AddFeature ("Irregular Size Tab Issue(s)", "Tab(s)", true, anIssue);
} else if (anIssue.IsOfType<DFMSheetMetal_SmallDepthLouverIssue>()) {
aManager.AddFeature ("Small Depth Louver Issue(s)", "Louver(s)", true, anIssue);
} else if (anIssue.IsOfType<DFMSheetMetal_SmallDistanceBetweenFeaturesIssue>()) {
const auto& aSDBFIssue = static_cast<const DFMSheetMetal_SmallDistanceBetweenFeaturesIssue&> (anIssue);
aManager.AddFeature (SmallDistanceIssueName (aSDBFIssue), "Distance(s)", true, anIssue);
} else if (anIssue.IsOfType<DFMSheetMetal_NonStandardSheetThicknessIssue>()) {
aManager.AddFeature ("Non Standard Sheet Thickness Issue(s)", "Sheet Thickness(s)", true, anIssue);
} else if (anIssue.IsOfType<DFMSheetMetal_NonStandardSheetSizeIssue>()) {
aManager.AddFeature ("Non Standard Sheet Size Issue(s)", "Sheet Size(s)", true, anIssue);
}
}

After adding all found issues to FeatureGroupManager, a Print method of the manager is used to print information about found issues and their parameters in a console. PrintFeatureParameters is created to explore and print issue parameters. It uses as an input parameter of Print method.

auto PrintFeatureParameters = [] (const MTKBase_Feature& theIssue)
{
if (theIssue.IsOfType<DFMSheetMetal_SmallRadiusBendIssue>()) {
const auto& aSRBIssue = static_cast<const DFMSheetMetal_SmallRadiusBendIssue&> (theIssue);
FeatureGroupManager::PrintFeatureParameter ("expected min radius", aSRBIssue.ExpectedMinRadius(), "mm");
FeatureGroupManager::PrintFeatureParameter ("actual radius", aSRBIssue.ActualRadius(), "mm");
} else if (theIssue.IsOfType<DFMSheetMetal_SmallDiameterHoleIssue>()) {
const auto& aSDHIssue = static_cast<const DFMSheetMetal_SmallDiameterHoleIssue&> (theIssue);
FeatureGroupManager::PrintFeatureParameter ("expected min diameter", aSDHIssue.ExpectedMinDiameter(), "mm");
FeatureGroupManager::PrintFeatureParameter ("actual diameter", aSDHIssue.ActualDiameter(), "mm");
} else if (theIssue.IsOfType<DFMSheetMetal_SmallDistanceBetweenFeaturesIssue>()) {
const auto& aSDBFIssue = static_cast<const DFMSheetMetal_SmallDistanceBetweenFeaturesIssue&> (theIssue);
FeatureGroupManager::PrintFeatureParameter (
"expected min distance", aSDBFIssue.ExpectedMinDistanceBetweenFeatures(), "mm");
FeatureGroupManager::PrintFeatureParameter (
"actual distance", aSDBFIssue.ActualDistanceBetweenFeatures(), "mm");
} else if (theIssue.IsOfType<DFMSheetMetal_FlatPatternInterferenceIssue>()) {
//no parameters
} else if (theIssue.IsOfType<DFMSheetMetal_IrregularCornerFilletRadiusNotchIssue>()) {
const auto& aICFRNIssue = static_cast<const DFMSheetMetal_IrregularCornerFilletRadiusNotchIssue&> (theIssue);
FeatureGroupManager::PrintFeatureParameter ("expected corner fillet radius", aICFRNIssue.ExpectedCornerFilletRadius(), "mm");
FeatureGroupManager::PrintFeatureParameter ("actual corner fillet radius", aICFRNIssue.ActualCornerFilletRadius(), "mm");
} else if (theIssue.IsOfType<DFMSheetMetal_IrregularDepthExtrudedHoleIssue>()) {
const auto& aIDEHIssue = static_cast<const DFMSheetMetal_IrregularDepthExtrudedHoleIssue&> (theIssue);
FeatureGroupManager::PrintFeatureParameter ("expected max extruded height", aIDEHIssue.ExpectedMaxExtrudedHeight(), "mm");
FeatureGroupManager::PrintFeatureParameter ("expected min extruded height", aIDEHIssue.ExpectedMinExtrudedHeight(), "mm");
FeatureGroupManager::PrintFeatureParameter ("actual extruded height", aIDEHIssue.ActualExtrudedHeight(), "mm");
} else if (theIssue.IsOfType<DFMSheetMetal_IrregularRadiusOpenHemBendIssue>()) {
const auto& aIROHBIssue = static_cast<const DFMSheetMetal_IrregularRadiusOpenHemBendIssue&> (theIssue);
FeatureGroupManager::PrintFeatureParameter ("expected radius", aIROHBIssue.ExpectedRadius(), "mm");
FeatureGroupManager::PrintFeatureParameter ("actual radius", aIROHBIssue.ActualRadius(), "mm");
} else if (theIssue.IsOfType<DFMSheetMetal_IrregularSizeBendReliefIssue>()) {
const auto& aISBRIssue = static_cast<const DFMSheetMetal_IrregularSizeBendReliefIssue&> (theIssue);
const auto& anExpectedRelief = aISBRIssue.ExpectedMinBendRelief();
const auto& aFirstActualRelief = aISBRIssue.FirstActualRelief();
const auto& aSecondActualRelief = aISBRIssue.SecondActualRelief();
FeatureGroupManager::PrintFeatureParameter (
"expected min relief size (LxW)",
std::make_pair (anExpectedRelief.Length(), anExpectedRelief.Width()),
"mm");
if (aFirstActualRelief && aSecondActualRelief) {
FeatureGroupManager::PrintFeatureParameter (
"first actual relief size (LxW)",
std::make_pair (aFirstActualRelief.Length(), aFirstActualRelief.Width()),
"mm");
FeatureGroupManager::PrintFeatureParameter (
"second actual relief size (LxW)",
std::make_pair (aSecondActualRelief.Length(), aSecondActualRelief.Width()),
"mm");
} else if (!aFirstActualRelief) {
FeatureGroupManager::PrintFeatureParameter (
"actual relief size (LxW)",
std::make_pair (aSecondActualRelief.Length(), aSecondActualRelief.Width()),
"mm");
} else {
FeatureGroupManager::PrintFeatureParameter (
"actual relief size (LxW)",
std::make_pair (aFirstActualRelief.Length(), aFirstActualRelief.Width()),
"mm");
}
} else if (theIssue.IsOfType<DFMSheetMetal_LargeDepthBeadIssue>()) {
const auto& aLDBIssue = static_cast<const DFMSheetMetal_LargeDepthBeadIssue&> (theIssue);
FeatureGroupManager::PrintFeatureParameter ("expected max depth", aLDBIssue.ExpectedMaxDepth(), "mm");
FeatureGroupManager::PrintFeatureParameter ("actual depth", aLDBIssue.ActualDepth(), "mm");
} else if (theIssue.IsOfType<DFMSheetMetal_SmallDepthLouverIssue>()) {
const auto& aLDBIssue = static_cast<const DFMSheetMetal_SmallDepthLouverIssue&> (theIssue);
FeatureGroupManager::PrintFeatureParameter ("expected min depth", aLDBIssue.ExpectedMinDepth(), "mm");
FeatureGroupManager::PrintFeatureParameter ("actual depth", aLDBIssue.ActualDepth(), "mm");
} else if (theIssue.IsOfType<DFMSheetMetal_InconsistentRadiusBendIssue>()) {
const auto& aIRBIssue = static_cast<const DFMSheetMetal_InconsistentRadiusBendIssue&> (theIssue);
FeatureGroupManager::PrintFeatureParameter ("expected max radius", aIRBIssue.ExpectedRadius(), "mm");
FeatureGroupManager::PrintFeatureParameter ("actual radius", aIRBIssue.ActualRadius(), "mm");
} else if (theIssue.IsOfType<DFMSheetMetal_SmallLengthFlangeIssue>()) {
const auto& aSLFIssue = static_cast<const DFMSheetMetal_SmallLengthFlangeIssue&> (theIssue);
FeatureGroupManager::PrintFeatureParameter ("expected min length", aSLFIssue.ExpectedMinLength(), "mm");
FeatureGroupManager::PrintFeatureParameter ("actual length", aSLFIssue.ActualLength(), "mm");
} else if (theIssue.IsOfType<DFMSheetMetal_SmallLengthHemBendFlangeIssue>()) {
const auto& aSLHBFIssue = static_cast<const DFMSheetMetal_SmallLengthHemBendFlangeIssue&> (theIssue);
FeatureGroupManager::PrintFeatureParameter ("expected min length", aSLHBFIssue.ExpectedMinLength(), "mm");
FeatureGroupManager::PrintFeatureParameter ("actual length", aSLHBFIssue.ActualLength(), "mm");
} else if (theIssue.IsOfType <DFMSheetMetal_IrregularSizeNotchIssue>()) {
const auto& aISNIssue = static_cast<const DFMSheetMetal_IrregularSizeNotchIssue&> (theIssue);
FeatureGroupManager::PrintFeatureParameter (
"expected size (LxW)",
std::make_pair (aISNIssue.ExpectedLength(), aISNIssue.ExpectedWidth()),
"mm");
FeatureGroupManager::PrintFeatureParameter (
"actual size (LxW)",
std::make_pair (aISNIssue.ActualLength(), aISNIssue.ActualWidth()),
"mm");
} else if (theIssue.IsOfType <DFMSheetMetal_IrregularSizeTabIssue>()) {
const auto& aISTIssue = static_cast<const DFMSheetMetal_IrregularSizeTabIssue&> (theIssue);
FeatureGroupManager::PrintFeatureParameter (
"expected size (LxW)",
std::make_pair (aISTIssue.ExpectedLength(), aISTIssue.ExpectedWidth()),
"mm");
FeatureGroupManager::PrintFeatureParameter (
"actual size (LxW)",
std::make_pair (aISTIssue.ActualLength(), aISTIssue.ActualWidth()),
"mm");
} else if (theIssue.IsOfType<DFMSheetMetal_NonStandardSheetThicknessIssue>()) {
const auto& aNSSTIssue = static_cast<const DFMSheetMetal_NonStandardSheetThicknessIssue&> (theIssue);
FeatureGroupManager::PrintFeatureParameter (
"nearest standard sheet thickness", aNSSTIssue.NearestStandardSheetThickness(), "mm");
FeatureGroupManager::PrintFeatureParameter (
"actual sheet thickness", aNSSTIssue.ActualSheetThickness(), "mm");
} else if (theIssue.IsOfType<DFMSheetMetal_NonStandardSheetSizeIssue>()) {
const auto& aNSSSIssue = static_cast<const DFMSheetMetal_NonStandardSheetSizeIssue&> (theIssue);
const auto& aNearestStandardSize = aNSSSIssue.NearestStandardSheetSize();
const auto& anActualSize = aNSSSIssue.ActualSheetSize();
FeatureGroupManager::PrintFeatureParameter (
"nearest standard sheet size (LxW)",
std::make_pair (aNearestStandardSize.Length(), aNearestStandardSize.Width()),
"mm");
FeatureGroupManager::PrintFeatureParameter (
"actual sheet size (LxW)",
std::make_pair (anActualSize.Length(), anActualSize.Width()),
"mm");
}
};
aManager.Print ("issues", PrintFeatureParameters);

Visit Feature Group Helper Implementation page for more information about FeatureGroupManager class implementation.

Example output

Below is the example output for model from ./examples/models/Power_box_Chasis.stp.

The model Example output 
Model: Power_box_Chasis.STEP

Part #0 ["power box sheetmetal"] - solid #0 has:
    Irregular Depth Extruded Hole Issue(s): 3
        3 Hole(s) with
          expected max extruded height: 1.5 mm
          expected min extruded height: 0.6 mm
          actual extruded height: 2.29072 mm
    Large Depth Bead Issue(s): 1
        1 Bead(s) with
          expected max depth: 0.36 mm
          actual depth: 5 mm
    Non Standard Sheet Size Issue(s): 1
        1 Sheet Size(s) with
          nearest standard sheet size (LxW): 600 x 200 mm
          actual sheet size (LxW): 335.412 x 178.73 mm
    Non Standard Sheet Thickness Issue(s): 1
        1 Sheet Thickness(s) with
          nearest standard sheet thickness: 0.8 mm
          actual sheet thickness: 0.6 mm
    Small Distance Between Extruded Hole And Edge Issue(s): 3
        2 Distance(s) with
          expected min distance: 1.8 mm
          actual distance: 1.5 mm
        1 Distance(s) with
          expected min distance: 1.8 mm
          actual distance: 1.58983 mm
    Small Distance Between Hole And Edge Issue(s): 8
        8 Distance(s) with
          expected min distance: 1.2 mm
          actual distance: 1 mm

    Total issues: 17

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