MDW2 Surface Developments

Page 1 of Chapter W2 Surface Developments
WEB CHAPTER 2 SURFACE DEVELOPMENTS
Surface development is a full size layout of an object drawn on a plane. Some objects are made of flat
sheet metal. When the sheet is cut as per this layout, folded and joined together, it takes the shape of
an object. Orthographic projections of the object are drawn first and then the development is drawn.
Parts made of thin sheet are some times reinforced by embedding a wire in its open edge called
Wiring. Alternately single or double hemming is done for stiffening the edge. Allowances are to be
provided for joining or hemming etc.. The edges are joined together by soldering a lap joint or by flat
lock seaming.
Flat surfaces like that of a box or singly curved surfaces as those of cylinder or cone, which can be
developed are called developable surfaces. Following are some well known development methods
for these surfaces. The development method to be used depends upon type of surface and what data is
available.
Straight line development: It is used if surfaces of the object are flat and true size of each side is
known e.g. a box or a prism. Sides of the object can be laid in successive order.
Radial line development: It is used if true length of an edge is shown in front view and top view
shows the lengths of edges of base line e.g. a cone.
Parallel line development: It is used for singly curved object. The curved surface is opened to form a
flat plane e.g. a cylinder.
Doubly curved surface like that of a sphere is non-developable. These surfaces can be
approximately developed by any one of the following methods:
Zone method: The surface is divided into horizontal zones and each zone is developed as a frustum of
a cone.
Gore method: Surface is divided into a number of equal vertical sections. Each section is considered
as an arched segment.
Triangulation method: Surface is divided into small triangles joined at their sides e.g. a football is
made by joining many hexagonal pieces. A hexagon is a set of 6 triangular pieces.
Surfaces in AutoCAD are shown by many contour lines along the edges to form a mesh. System
variables SURFTAB1 and SURFTAB2 are used to set the number of lines for axes of the mesh.
Following commands can be used to create some predefines surfaces practically in no time. The name
of command is indicative of what it can create. AI_ is to be prefixed before every name e.g. AI_BOX,
AI_WEDGE, AI_PYRAMID, AI_CONE, AI_SPHERE, AI_DOME, AI_DISH and AI_TORUS.
Following commands can be used to create a surface by different methods:

3DMESH Creates a surface through the specified coordinates of each node point of the mesh.
REVSURF Creates an axis symmetric surface by revolving a path curve about an axis.
RULESURF Creates a surface connecting two straight or curved defined edges.
TABSURF Creates a surface by moving a path curve along a direction vector.
EDGESURF Creates a surface connecting four straight or curved defined edges.
Following commands can be used as drafting aids and inquiry:

MEASURE To put marks on an object at specified distance
AREA To find the area and perimeter of a specified boundary
DIST Provides information about distance and angle between two specified points
Surface development using a AutoCAD system is almost same as manual drafting method. However
computer provides easy procedures for construction and hence takes lesser time than manual drafting.
W2.1 INTRODUCTION
Many objects like metal boxes, tin cans, funnels, ducts, elbows etc. are made from flat sheet, which is
cut, folded and joined to give the required shape. To get the exact size, orthographic projections of
the object are first drawn, then a surface development is made to show the shape of the complete
surface called development. The required shape called as pattern is first drawn on a thin sheet to
the actual shape. Materials used for making patterns are card board, plastics, fiber board, wood and
metal sheets. This pattern is then traced along the outer profile and pasted on the metallic sheet from
which the part is to be made. When the material is cut out of the developed shape and bent at the lines
marked, an object similar to the desired object is obtained. For example, the development of a
cylinder is a rectangle. Wrap a rectangular sheet to join any two opposite sides and a hollow cylinder
is formed. Thus in the process of development, the true size of all the faces is found so that all the
lines lie in one common plane and then bent and joined at their common edges to form a three
dimensional object.
To understand the process of making a development, take an example of a triangular box open at top
as shown in figure W2.1A and its orthographic views in figure W2.1B. It has three rectangular faces
A, B and C and a triangular base D. This box can be opened out from any one of the edges so that all
the faces lie in one plane. When opened at edge formed by faces A and C, it appears as shown in
figure W2.1C. This is known as surface development. The dashed lines shown in the development are
the lines where the bending is to be done.
(A)Pictorial view (B) Orthographic views (C) Surface development
Figure W2.1 A triangular hollow box
The base D can be attached at the bottom edge of any face A, B or C. Figure W2.2 shows development
if the base is attached to base A or Base C. Choice has to be made for the one which gives minimum
material waste when many parts are to be cut from a big sheet.
Figure W2.2 Alternative locations of the base of a triangular hollow box
The open edges are then joined by sheet metal joints (Section W2.2), soldering or brazing.
W2.2 JOINTS USED IN SHEET METAL

In addition to soldering and brazing, special joints as shown in figure W2.3 can also join sheet metals.
It can be seen that in all the joints, a seam of bend is given to the plates and then hooked together to
form a joint. Any convenient method can be selected.
Figure W2.3 Sheet metal joints
W2.3 REINFORCEMENT OF FREE EDGES

Sheet metal is of very less thickness and has sharp edges, which can cause injury to the worker or user.
Hence hemming is done by single or double bend at the free boundary edges (figure W2.4). This bend
reinforces the sheet and also safeguards against injury. Sometimes wiring is done in which a wire is
embedded while bending the free edge to impart more strength and thickness. An allowance of 2.5
times the wire diameter can be provided extra at the free end for making this wired bead (figure
W2.5).
Figure W2.4 Reinforcement in sheet metal parts
W2.4 JOINT AND REINFORCEMENT ALLOWANCES

No allowance for the material required for the joint has been indicated in the developments shown in
figure W2.1. In an actual development, allowance of extra material has to be provided at the edges to
form a lap joint. Refer figure W2.5 showing the allowance for a lap joint and for hemming.
Figure W2.5 Joint allowance in developments

NOTE: No joining allowance has been shown in all the problems of developments discussed
hereafter. In actual practice it has to be taken into consideration.
W2.5 TYPES OF DEVELOPMENTS

Flat surfaces like that of a box or singly curved surfaces as those of cylinder or cone can be exactly
developed. Such a surface is called a developable surface. For doubly curved surfaces like sphere
exact surface development is not possible, hence approximate development is done. Such a surface is
called non-developable surface.
W2.6 DEVELOPABLE SURFACES

Following are some well known development methods for developable surfaces:
Straight line development

Radial line development
Parallel line development
W2.6.1 STRAIGHT LINE DEVELOPMENT

This method is used if surfaces of the object are flat and true size of each side is known e.g. a box, a
prism and a pyramid. The sides of the object are laid in successive order in one plane.
Figure W2.6 shows a rectangular prism having four sides, a top and a bottom. The base is of size
LxW and sides are of height of H mm. When all the four faces are opened in one plane, it has a total
length of (2L + 2W) and height H mm. The top and bottom of each of LxW size can be attached to
any common edge.
Figure W2.6 Development of a rectangular prism
EXAMPLE 1 (HEXAGONAL PRISM)

Draw development of a hexagonal prism closed at both ends having each side 50 mm width and length
100 mm as shown on left side of figure W2.S1.
SOLUTION
Each face of the prism is of size 50x100 mm. Draw six rectangles all in a line and attach the hexagonal
end to any one edge at front and back of a face as shown on right hand side of figure W2.S1.
Figure W2.S1 Development of a hexagonal prism
EXAMPLE 2 (FIVE SIDED PRISM)

Draw development of a five sided prism closed at both ends having vertical faces of 50 mm height,
base 100 mm, inclined height 70 mm and length 80 mm as shown on left side of figure W2.S2.
SOLUTION
Draw each face of the prism of size mentioned in figure. The total length of all the faces when opened
out in one plane is (W + 2G + 2H) and width as L. The two ends of the pentagonal shape can be
attached to any face as shown in figure W2.S2.
Figure W2.S2 Development of a pentagonal prism
EXAMPLE-3 (SQUARE PYRAMID)

Draw development of a square pyramid that has a square base of each side 100 mm with four isosceles
triangles sloping faces that form an apex at top at 100 mm centrally above the base (figure W2.S3A).
SOLUTION
It may be noted that the triangular face shown in the front view does not show its true length of the
inclined edge due to its inclination. Hence, the actual shape is found by drawing an auxiliary view.
The slant height (SH=110) is the distance of the apex from its base line for its auxiliary view. Since
the development has to carry the true shape of each face, therefore the triangles for each face have
their vertical height as the slant height and not the vertical height of front view.
Its development is a square base of each side 100 mm and four isosceles triangles of base 100 mm and
height 112 mm. These faces can be joined at each edge of the square base as shown in figure
W2.S3B. Dashed lines indicate the position of the bend.
Alternatively the inclined faces can be placed side by side and bent along the dashed lines as shown in
figure W2.S3C. The base can then be attached to any edge of the inclined face.
Figure W2.S3 Development of a square pyramid
EXAMPLE 4 (OBLIQUE PYRAMID)

An oblique pyramid has its base 150x100 mm and vertical height 150 mm. Its apex lies vertically
above at 30 mm from long edge and 50 mm from short edges of the base (figure W2.S4). Draw its
development.
SOLUTION
For a right pyramid, the fore-shortening effect of the inclined edges due to their inclination is the same
for all, but for oblique pyramid it is different for each face as its apex is not above the geometric centre
of the base.
To draw the development of such a pyramid, the actual length of each inclined face is required. To get
these distances, draw a horizontal line XX in the top view passing through the apex O (figure W2.S4).
With O as centre and 01 as radius, draw an arc from point 1 to XX line to cut XX at 1. Take the
projection of 1 in the front view at the base line to cut at 1. Join apex in front view O to 1.
Distance 01 is the true length at edge O1. Repeat this process for all the points 2, 3 and 4 to cut the
base line in front view at 2, 3 and 4 respectively.
Transfer the triangular faces 1, 2, 3 and 4 to the rectangular base of the development in the orientation
as shown in figure W2.S4B. Apex point O1 can be found by cutting the arcs of actual lengths O1
and O2 from points 1 and 2 respectively. Triangle 012 is the development of face 1. Repeat this
process for all the other 3 faces to get the full development.
Figure W2.S4 Development of an oblique square pyramid
W2.6.2 RADIAL LINE DEVELOPMENT

This method is used if true length of an edge is known in front view and top view shows the size of
base e.g. a cone. A cone has a circular base with an apex vertically above the base centre. Since the
base is circular, it cannot be attached to the slanting face, hence it has to be cut separately and then
attached. Also the body of the cone cannot be like the development of the pyramid but it is as shown
in figure W2.7. The radius of the development is equal to the slant height (SH), which is the true
length of the inclined face. The actual length of the base is (2R) as shown in figure W2.7. When the
fan shaped development is bent, a cone is formed. The angle of the sector 1O1 () of the developed
view can be found by simple mathematics as:
= 360 R/SH (where SH is slant height of the cone and R is the base radius).
Alternatively, the circular base can be divided into twelve equal parts. The length of each small arc
may be cut on the circumference. This is known as triangulation. The development is created by
joining all the small triangles side by side e.g. triangle 1O2 with triangle 2O3 and so on.
Figure W2.7 Development of a right circular cone
EXAMPLE 5 (OBLIQUE CONE)

Draw development of an oblique cone having elliptical base of major axis 115 mm and minor axis 100
mm. Its vertical height is 150 mm and axis is inclined at 60 from vertical axis in vertical plane
shifting its apex 31 mm away from the extreme edge of the major axis as shown in figure W2.S5A.
SOLUTION
An oblique cone does not have its apex above the base centre and hence the slant height changes
continuously. Also, the base line is not circular due to unequal lengths. Method of triangulation is
used to consider small triangular elements of this cone. The base is an ellipse of major axis X-X and
minor axis Y-Y. To draw the development of an oblique cone, follow the steps given below:
1. Draw Front and top view of the cone with elliptical base (figure W2.S5A)
2. Divide the base in 12 parts at 30 interval and number only the lower half from 1 to 7.
3. With O As center and radius as 0-2, draw an arc on major axis to cut X-X at point 2. Repeat
this process for points 3, 4, 5 and 6. Points 1 and 7 are already on the axis and hence are not
affected.
4. Project these points on the base in the front view as 2, 3 .6. Join all these points from
the apex O to form small triangular elements.
5. Line 0-1 and 0-7 show the true length and hence can be measured directly for the purpose of
the development. For other elements, find the true length of each element by rotating parallel
to the picture plane, i.e., line XX and then take vertical projection to front view. These true
lengths are shown as 0-2, 0-3,0-7 etc.
6. With 0 as the center for the development (figure W2.S5B), draw arcs of radii as true lengths
to transfer them on the developed view. Make a triangle 012 in which 0-1 and 0-2 are
the lengths equal to length 0-1 and 02 of front view and 1-2 is equal to arc 1-2 of top
view.
7. Measure the actual distances of the base from top view and true inclined lengths from front
view to create each triangle of the development. All the 12 triangles joined side by side show
the development of the cone (figure W2.S5B).
Figure W2.S5 Development of an oblique cone
EXAMPLE 6 (HEXAGONAL PYRAMID)

Draw development of a hexagonal pyramid. Base edge is of 50 mm and height 110 mm.
SOLUTION
1. Draw top view of pyramid as a hexagon with each edge 50 mm and join the corner points with the
center 0. Number the corners as 1, 2, 3, 4, 5 and 6.
2. Draw front view with height 110 mm. Measure the slant height of the inclined edge 0-1.
3. For development draw an isosceles triangle 0-1-2 with lines 0-1 and 0-2 equal to slant height and
one side equal to edge (figure W2.S6B).
4. Copy 5 more triangles of same size keeping one edge common to the previous triangle.
5. Attach a hexagonal base to any edge.
Figure W2.S6 Development of hexagonal pyramid
W2.6.3 PARALLEL LINE DEVELOPMENT

When a cylinder is opened along its axis, its development is a rectangle. While opening, the two ends
of cylinder form two parallel lines hence it is called parallel line development
A cylinder has a diameter D and length L. Its top and bottom faces are circular and therefore they
cannot be joined to the main body to make it integral. They are to be cut circular separately as shown
in figure W2.8. Its curved face when unfolded in one plane is a rectangle of length equal to the
circumference of the cylinder (D) and width same as that of the cylinder length L.
Figure W2.8 Development of a cylinder

W2.7 NON- DEVELOPABLE SURFACES (SPHERE)

Sphere is an object, whose surface is curved in both planes, hence, exact development cannot be made,
but it can only be approximated. These surfaces can be developed by any one of the following
methods discussed below.
W2.7.1 ZONE METHOD:

The surface is divided into horizontal zones marked A, B, C and D and each zone is developed as a
frustum of a cone as shown in figure W2.9A. The method to draw each frustum of cone is same as
given in section W2.6.2. Slant height of the cone is taken as the size of the zone e.g. 1-2. The center
C1 is the intersection of extenension of line 1-2 with the central axis. The radial distance R1 is shown
zig zag as the center C1 is not the actual center but far off from here. Similarly C2 is intersection of
extension of line 2-3 and central axis and so on. The development of each zone is shown in figure
W2.9B.
(A) Sphere divided in 8 zones (B) Development of each zone
Figure W2.9 Development of a Sphere
W2.7.2 GORE METHOD

Surface of the sphere is divided into a number of equal sections say 12 equal parts of 30 intervals in
the vertical plane and in 6 divisions in horizontal plane (figure W2.10A). Each section is an arch
shaped sector as shown in figure W2.10B. Mark the points as per the distance given in figure W2.10.
Join all the points by a smooth curve. Twelve such elements are needed to form a sphere of the given
radius. Only three are shown here.
(A) Sphere (B) Development
Figure W2.10 Development of a sphere
W2.7.3 TRIANGULATION METHOD

Surface is divided into small triangles joined at one of its side e.g. a football is made by joining many
hexagon pieces. A hexagon is a set of 6 triangular pieces (figure W2.11)
It is divided into small elements for the purpose of development. Smaller the elements, closer it is to
the actual shape. Some types of elements that can be considered are shown in figure W2.11. Such
type of elements can be seen in a football that is composed of small elements of typical shapes.
Figure W2.11 Elements for a sphere

W2.8 OBJECTS CUT BY A PLANE

Development of prisms is not affected if the cutting plane is at right angle to the axis, except that its
length gets reduced. But if a prism is cut by an inclined plane, the development gets changed.
W2.8.1 RECTANGULAR PRISM

When a rectangular prism is cut by an inclined plane, its development depends upon as to how it is
placed. The easiest case is when face of the prism lies in the principle plane (figure W2.12).
Development of a prism with inclined top is shown in figure W2.12. Draw the base line of length (2L
+ 2W). Draw vertical lines as edges of the prism at distances L and W. The smaller faces have height
h1 and bigger faces h2. The other two faces have top lines as inclined lines. The rectangular base can
be attached at the bottom of any face. The actual shape of the top face is a rectangle but length is
more due to its inclination. This can also be drawn with any of the top face of the development. If the
object is open at the top, the top face need not be drawn.
(A) Prism (B) Development

Figure W2.12 Rectangular prism cut by inclined plane (one face aligned with picture plane)
If the face of the prism is not parallel to the principle plane as shown in figure W2.13, the cutting
plane cuts each vertical edge of the prism at different heights as h1, h2, h3 and h4.
Procedure for the development of an inclined prism is similar as discussed in sectionW2.8.1.

1. Draw the base line and mark points 1, 2, 3, 4 and 1 again at the joining edge. These points are
to be marked at distances of W and L alternately.
2. Draw the vertical lines at these points. Since the vertical edges of the prism are parallel to the
principle plane, the heights shown in the front view are the true heights at the cutting point.
3. Take horizontal projections from the front view to cut the vertical lines on the development.
Mark the intersections of the respective points as 1, 2, 3, 4 and 1.
4. Join all these points to form the four sides of the prism. Attach the rectangular base of size
LxW to any of the bases at the bottom line.
5. Draw the auxiliary view of the top face and then copy the same at any top edge, say 2-3.
Alternately, taking 2 as centre and 1-2 as radius, transfer the length of the inclined edge 1-
2 for the top view. Similarly, transfer the distance 3-4 for the top view as shown by
arrows.
(A) Prism (B) Development
Figure W2.13 Rectangular prism cut by inclined plane (face not aligned with picture plane)
EXAMPLE 7 (HEXAGONAL PRISM CUT BY INCLINED PLANE)

A hexagonal prism with each edge of the base as 50 mm is cut by an inclined plane such that it
cuts the extreme edges at a slant height of 95mm and 40 mm (left side of figure W2.S7). Draw its
development.
SOLUTION
The procedure for the development of a hexagonal prism is the same as that for a rectangular prism.
Draw the orthographic views first and then transfer the heights of each edge. The top auxiliary view is
not exactly hexagonal. Draw the auxiliary view in the direction of A for the development of the top
view and then attach at any of the top edges as shown in figure W2.S7.
(A) Hexagonal prism (B) Development
Figure W2.S7 Development of a hexagonal prism cut by an inclined plane
W2.8.2 RECTANGULAR PYRAMID

When a pyramid cut by a horizontal plane at height H from the base the slant height becomes the
height of development at the center line. Solved example 8 demonstrates the development of such a
pyramid.
EXAMPLE 8 (RECTANGULAR PYRAMID CUT BY A PLANE)

A pyramid with base 160x120 mm has vertical height of apex as 142 mm, It is cut by a plane parallel
to its base at a vertical height of 95 mm. Draw its development.
SOLUTION
To draw the development, follow the steps given below:
1. Make a rectangular base of size 160x120 mm (figure W2.S8A).
2. Make isosceles triangles at each line of the base of height equal to slant height of the pyramid
for the respective edges. It may be noted that the apex is not at an axial height 142 mm from
the base in the developed view but equal to the slant height.
3. Cut these triangles at a slant height from the base (location of cutting plane of each inclined
face).
4. Draw the other boundary of the inclined faces by drawing lines at right angles to the axes up to
the inclined edges.
Figure W2.S8 Rectangular pyramid cut by a horizontal plane
EXAMPLE 9 (SQUARE PYRAMID CUT BY INCLINED PLANE)

A square pyramid with base of 160x80 mm and slant height 170 mm is cut by an inclined plane at
slant height of 50 mm at one face and 15 mm on other face as shown in figure W2.S9. Draw the
orthographic views and its development.
SOLUTION
1. Draw the square base PQRS of size 160x80 mm with dashed lines. Dashed lined indicate the
position of the bend.
2. Draw four isosceles triangles X1PS, Y1PQ, X2QR and Y2SR of height 170 mm at each side of
the base. Note that the slant height is taken as axial height for development.
3. Mark points 1 and 2 on X1-X2 line at distance h1 and h2 from the dashed lines of the base.
4. Draw vertical lines AB and CD passing through points 1 and 2 respectively to cut these isosceles
triangles to give two short opposite faces of this pyramid PSAB and QCDR.
5. With P as centre and AP as radius, transfer the length of this edge to cut the adjacent face at A.
With QC as radius and Q as centre, mark C. Similarly, mark points B and D with centers as S
and R respectively. Join AC and BD
6. To draw the top inclined face, mark point 3 on X1-X2 at a distance equal to h3 from point 2.
Draw a vertical line EF of the same height as AB. Join CDEF to give the development of the top
inclined face.
Figure W2.S9 Development of a square pyramid cut by an inclined plane
EXAMPLE 10 (PYRAMID CUT WITH TWO PLANES)

A pyramid has a base of 160x80 mm and slant height 175 mm whose top is not straight, but partially
inclined from slant height of 100 mm up to center and the rest is flat at slant height of 40 mm as shown
in figure W2.S10. Draw its development.
SOLUTION
First draw the orthographic views of pyramid. For the development,
1. Draw the base PQRS as shown by dashed lines. Draw isosceles triangles on each side of the base
with altitude as slant height of 175 mm. Draw center lines X1-X2 and Y1-Y2 (figure W2.S10)
2. Mark point 1 on X1-X2 line at distance 100 mm from line PS and draw a vertical line AB through
it. Mark point 2 on line X1-X2 at distance 40 mm from line QR and draw a vertical line CD
through it. Draw trapeziums ABPS and CDRQ.
3. Transfer lengths PA, SB, QC and RD for the other two faces and mark points A, B, C and D.
4. Draw horizontal lines through C and D of length L2 up to center line.
5. Since face 6 is flat for length L2, draw horizontal lines from C and D of length L2 to form face 5 as
CDEF. Let EF cut line X1-X2 at point 3.
6. Mark point 4 on line X1-X2 distance h3 which is the true length of the slanting face. Draw a
vertical line AB through point 4.
7. Draw lines parallel to the inclined face from E and F to cut the vertical line at A and B. Distance
AB can also be taken from top view and divided equally on both sides of the centre line.
Trapezium EFBA is the development of face 6
8. Join the boundaries of each face by thick lines and bend along the dashed lines to form the
required pyramid.
(A) Pyramid (B) Development
Figure W2.S10 Square pyramid cut by two planes
EXAMPLE 11 (TRUNCATED PYRAMID)

A hexagonal pyramid has a base of each side 60 mm and slant height of 210 mm at one edge. It is cut
by an inclined plane at slant height of 120 mm at one edge and at 45 mm at diagonally opposite edge
(figure W2.S11). Draw its development.
SOLUTION
If a pyramid is truncated by an inclined plane as shown in figure W2.S11, then the initial procedure is
the same as that explained for pyramids in Examples 3 and 4. In front view line 01 and 04 are the only
true lengths. The rest are not true because of the inclination of the faces. The top face has to be drawn
by drawing the auxiliary view as discussed in chapter 9 of the book. Rest of the procedure is same as
described earlier, except that the base is hexagonal instead of square or rectangular.
Alternate method - Radial line method

In this method, it is assumed that all the faces are integral at the inclined faces. Let O be the centre for
development.
1. With O as centre and O1 as radius draw an arc. Mark 6 points on this sector, each of length L and
number them from 1 to 6 and 1 (figure W2.S11).
2. Join 1-2, 2-3, etc. to represent the base of development. Draw radial lines from centre O to join
these points 1, 26 etc.
3. Get the actual slant distances of the edges by drawing and transfer to development view marked as
point 2and 3.
4. Mark points 5 and 6 by symmetry on the radial lines. Join 1, 26 and 1 to give the
boundary of the top inclined face.
Figure W2.S11 Development of a truncated pyramid
EXAMPLE 12 (CONE CUT BY INCLINED PLANE)

A right circular cone of base diameter 120 mm and slant height 210 mm is cut by an inclined plane as
shown in figure W2.S12. The plane cuts the cone at slant height of 125 mm and at 55 mm on the other
side. Draw its development.
SOLUTION
Draw the orthographic views and divide the top view circle into 12 equal parts. Number these points
as 1, 212. Project these points in the front view and number them from 1 to 7. Points 8 to 12 are on
the backside and hence not visible in the front view. Join all these points with apex in the front view.
These lines cut the inclined plane.
Draw the development of full cone on the side of the front view by the method discussed earlier in
section W2.6.2. Let one edge of the development be parallel to the slant height of the cone for the
ease of transfer of the radial distances. The boundary of the development for the base may also be
numbered as 1, 2 ,3 12 and 1.
To draw the development of the top inclined face, draw horizontal lines in front view from intersecting
points to touch the slant edge. Transfer these true lengths for getting points of intersection of the
arctual lines with the radial lines for the respective points. Join them by a smooth curve to give the
boundary of the top inclined face.
Alternately, if the numbers on the arc for the base are changed from 1-1 to 7 - 7 then the development
shape is different. Although the area is the same, but while cutting many pieces from one sheet, one
development may lead to lesser wastage than the other. Hence the best development is the one, which
gives minimum wastage of material.
Figure W2.S12 Development of a right circular cone cut by an inclined plane

EXAMPLE 13 (CONE CUT BY A STEEP INCLINED PLANE)

A right circular cone with base diameter 120 mm and slant height 205 mm is cut by a steep inclined
plane at 125 mm on one side and the other side cuts the base 20 mm from the extreme end (figure
W2.S13). Draw its development.
SOLUTION
If the cutting plane is at a steep angle, it cuts the base as shown in figure W2.S13. Line AB in top
view shows its extreme boundary due to the cutting plane. Procedure to draw its development is
same as for solved example 12 except there is no material between the points A and B. These
points A and B have to be marked in development in the same proportion as in the top view.
Figure W2.S13 Development of a cone cut by a steep plane

W2.8.3 CYLINDER CUT BY A PLANE

EXAMPLE 14 (CYLINDER CUT BY AN INCLINED PLANE)
A cylinder of diameter 110 mm is cut by an inclined plane at a height of 60 mm on one side and 130
mm on opposite side (figure W2.S13). Draw its development.
SOLUTION
1. Draw a horizontal line 1-1 of length as the circumference of the cylinder and divide in 12
equal parts. Number them 1 to 12 and 1.Draw vertical lines on each point
2. Divide top view also into 12 equal parts and number them as 1 to 12
3. Draw vertical projections from the top view to the inclined plane to cut at points 1, 2, etc.
4. Draw horizontal projections from this inclined plane to cut the vertical lines of development at
1, 2, etc. Draw a smooth vertical curve joining all these numbers.
Figure W2.S14 Development of a cylinder cut by inclined plane
The bottom is exactly circular of radius R. The top elliptical end can be drawn as an auxiliary view by
the method discussed in chapter 10. It is an ellipse of minor axis as D and major axis as the length of
the inclined face.
EXAMPLE 15 (CYLINDER CUT BY TWO PLANES)

A cylinder of diameter 110 mm and height 95 mm is cut by two inclined planes. Both planes pass
through center and one slopes down by 30 degrees while the other at 45 (figure W2.S15). It is
desired to draw the development of the curved surface of cylinder.
SOLUTION
First draw the orthographic views. For the development, follow the following procedure.
1. Divide the top view into 12 equal parts and number them from 1 to 12.
2. Draw vertical projections from these points to cut the inclined faces at 1, 2, etc.
3. Draw the base line of length D. Divide it into equal parts and mark them as 1, 212, 1 and
draw vertical lines over them.
4. Take horizontal projections from points 1, 2, etc. from the front view. Wherever these lines
cut the vertical lines of the development view, mark the intersections as 1, 2, etc.
5. Join all these points by a smooth curve to show the boundary of the top edge for the curved
face.
Figure W2.S15 Development of a cylinder cut by two inclined planes
W2.9 DEVELOPMENT OF TRANSITION PIECES

Transition pieces are used to connect two openings of different shapes, say, rectangular, circular or
elliptical to circular, rectangular or square etc. in the same axis or any inclined axis. Ends of these
pieces can have typical shape and hence they are developed by method of triangulation.
Figure W2.14 shows a transition piece whose top is a rectangle and bottom is a circle. The object can
be divided into 8 inclined faces. Faces 1, 3, 5 and 7 are isosceles triangles while faces 2, 4, 6 and 8 are
triangles with curved boundary at one edge.
Before drawing the development, following facts may be noted:
1. Its total periphery at the top is 2L + 2W (L is length and W is width of rectangular opening).
2. Its total periphery at the bottom will be 2R. (R is the radius of circular opening)
3. Height of faces 1 and 5 is the slant height Hs which is different than height of faces 3 and 7.
To draw the development of the transition pieces, first draw the orthographic views. Divide the top
view into 8 parts as shown in figure W2.14. Divide the top circle into 12 equal parts and number
them. Find the true length of each point, as each point is inclined at a different angle. It is shown by
the side of the front view. It is drawn by rotating each point up to line X1-X2 and then taking
projections up to front view. Draw each face in its true shape with their sides as common sides in the
same sequence.
The top rectangular band of uniform height of P can be attached to the faces 1, 3, 5 and 7 as shown in
the development.
Figure W2.14 Development of a transition piece

W2.10SURFACESANDAUTOCAD
AutoCAD has many commands to create surfaces, but there is no command to
directly create the development of surfaces. This section is included here to
appraisethestudentsaboutthetoolsavailabletocreatedifferenttypesofsurfaces.
However, the tools described in Chapter 2 can be helpful to draw developments
easilyandquicly.
In CAD, flat surfaces are displayed by edge lines, while curved surfaces are
displayedintheformofsegmentsoramesh.Thenumberoflinesinthemeshare
set by SURFTAB1 and SURFTAB2 system variables. Commands for drawing
surfacescanbegivenbyanyoneofthefollowingmethods:
On the Menu bar, click Draw and from a pulldown menu choose the option
Surfaces. A submenu on the sideof thepulldown menu appears. Click on the
requiredoption.
OntheSurfacestoolbar,clickonthedesiredicon(FigureW2.15).
Onthecommandline,typeacommandandpressEnter.
W2.11SURFACESTOOLBAR
Thereare16iconson thesurfacestoolbar(FigureW2.15).Thefunctionof each is
mentionedbelow.Thefirsttwoiconsareforcreatingonlyfacesinspace.

12345678910111213141516
FigureW2.15Surfacestoolbar
1.2DSOLID Createsaflatthreeorfoursidedfaceinaplaneofthe
curentUCS.
2.3DFACE Createsathreeorfoursidedflatfaceinthespace.
Predefinedstandard3Dsurfacescanbedrawnbyclickingonthefollowingicons
(FigureW2.16):
3.BOX Drawsa3Dboxofsixflatsurfaces
4.WEDGEDrawssurfacesofarightangledwedge,onefacetaperingalongthe
Xaxis
5.PYRAMIDDrawssurfacesofapyramidwithathreeorfoursidedbaseand
sideswithanapex,oraridgeorafoursidedtop
6.CONEDrawssurfaceofaconeorataperedorplanecylinderofspecified
baseandtopradiiandheight
7.SPHEREDrawsasphericalsurface
8.DISH Drawsthelowerhalfsurfaceofasphere
9.DOME Drawstheupperhalfsurfaceofasphere
10.TORUS Drawsasurfacelikeatubeofacar
Nonstandardsurfacesaregeneratedbyothermethods.Selectaniconaccordingto
theinformationavailableforthesurface.

11.EDGE Doesnotdrawanysurface,buthidestheedgesontherearsideof
object
12.3DMESHDrawsasurfacefromthespecifiedverticesofthenodalpoints
ofthemesh
13.REVSURFDrawsanaxisymetricsurfaceofbyrevolvingaprofile
aboutanaxis
14.RULESURFDrawsasurfacefromtwospecifiededgesofthesurface
15.TABSURFDrawsasurfacebymovinga2Dobjectalongaspecifieddirection
16.EDGESURFDrawsasurfacefromfourspecifiededgesofthesurface
W2.12PREDEFINEDSURFACES
ThereareeightpredefinedsurfaceswhichareshownbelowinFigureW2.16below:

Box Wedge Pyramid Cone

Sphere Dome Dish Torus

FigureW2.16PredefinedsurfacesinAutoCAD
W2.12.1 BOX
Clicktheboxiconshownabove.Specifyacorneroftheboxfollowedbyitslength,
width, height and a rotation angle. The prompt sequence to create a box with one
cornerattheoriginandof120mmlength,80mmwidthand60mmheightisshown
below:
Command:AI_BOX TypecommandorclicktheBoxiconshown
above.
Specifycornerpointofbox:0,0,0 Specifycoordinatesofonecorner.
Specifylengthofbox:120 Specify length of the box along the X axis and
pressEnter.
Specifywidthofboxor[Cube]:80 Specify width of the box along the Y axis
(defaultoption)or
typeCforCubeoptionandpressEnter.
Specifyheightofbox:60 Specify height of the box along the Z axis and
pressEnter.
SpecifyrotationangleofboxaboutZaxisor[Reference]:0
Iftheboxistoberotated,typeanangleotherwisetype0
andEnter
NOTE: ThecommandforallsurfacesaretobeprefixedbyAI_.Forexample,aBOX
command is to create a solid box and AI_BOX command is used to create
onlyoutersurfaceofabox.
W2.12.2WEDGE
AI_WEDGEcommanddrawsarightangledwedgewithslopedfacetaperingalong
the X axis. Type the command at command line or click the Wedge icon shown
above. The following is an example of prompt sequence for a wedge of 60mm
length, 40mm width and 30mm height. The corner of the wedge is specified as
(100,100,0). The lengthis alignedalongtheXaxisandrotationangleisspecifiedas
zero.
Command:AI_WEDGE Type command or click the Wedge icon

shownabove.
Specifycornerpointofwedge:100,100,0 Specifycoordinatesofthecorner.
Specifylengthofwedge:60 SpecifylengthofwedgealongXaxisand
pressEnter.
Specifywidthofwedge:40 Specify width of the wedge and press
Enter.
Specifyheightofwedge:30 Specify height of the slanting face and

pressEnter.
Specify rotation angleofwedgeaboutZaxis<0>:0
W2.12.3PYRAMID
Apyramidusuallyhas4sideswithanapexpointabovethebase.AutoCADoffers4
types of pyramids shown in Figure W2.17. Using AI_PYRAMID command or
clickingonthePyramidiconshownabovecancreatefourdifferenttypesofpyramid
surfacesmentionedbelow:
`
a. Pyramid Afoursidedbasewithanapexatthetop(FigureW2.17A).
b. TetrahedronAtriangularbasewithanapex(FigureW2.17B)
c. RidgedpyramidAfoursidedbasewitharidgeonthetop(FigureW2.17C)
d. TruncatedPyramidAfoursidedbasewithafoursidedtop(FigureW2.17D)

(A)Pyramid (B)Tetrahedron (C)Ridgepyramid
(D)Truncatedpyramid
FigureW2.17TypesofPyramids
Command:AI_PYRAMID TypecommandorClickthePyramidicon
Specifyfirstcornerpointforbaseofpyramid:Specifycoordinatesofpoint1and
pressEnter.
Specify second corner point for base of pyramid: Specify coordinates of point 2 and
pressEnter.
Specifythirdcornerpointforbaseofpyramid:Specifycoordinatesofpoint3and
pressEnter.
Specifyfourthcornerpointforbaseofpyramidor[Tetrahedron]:
Specify coordinates of point 4 and press
Enter or type T and press Enter for
Tetrahedron.
Specifyapexpointofpyramidor[Ridge/Top]:TypeTforToporRforRidgeoption
andpressEnter.
IfTistypedforTopoption(Points5,6,7and8arepointsontopsurface)AutoCAD
prompts:
Specifyfirstcornerpointfortopofpyramid:Specifycoordinatesofpoint5and
pressEnter
Specify second corner point for top of pyramid: Specify coordinates of point 6 and
pressEnter.
Specifythirdcornerpointfortopofpyramid:Specifycoordinatesofpoint7and
pressEnter.
Specifyfourthcornerpointfortopofpyramid:Specifycoordinatesofpoint8and
pressEnter.
W2.12.4CONE
TypeAI_CONEcommandorclicktheConeiconshownabovetocreateaconewith
a circular base. (Figure W2.18). The curved surface is shown by a number of
converging lines. The number of lines are specified by the number of segements at
the last prompt of the command. If the top radius (R2) is given as zero, a cone is
drawn(FigureW2.18A).Ifthetopradiusisspecified,afrustrumofaconeisdrawn
(FigureW2.18B).Ifthetopradiusissameasthebaseradius(R1),itdrawsacylinder
(Figure W2.18C). Specifying the top radius greater than the base radius inverts the
frustrumofacone(FigureW2.18D).
R2=0 R1>R2 R1=R2 R1<R2
A.Acone B.AfrustomofaconeC.AcylinderD.Aninverted
frustrumofacone

FigureW2.18A3Dconewithdifferentoptions
The following is the prompt sequence to draw a right circular frustrum of a cone
withaheightof60mmandthecenterpointofitsbaseat(0,0,0).Baseandtopradii
are30mmand10mmrespectively
Command:AI_CONE Typecommandorclicktheconeicon.
Specifycenterpointforbaseofcone:0,0,0 Specify coordinates of center of the
base.
Specifyradiusforbaseofconeor[Diameter]:30 Specify base radius (R1) and
pressEnter.
Specify radius for top of cone or [Diameter]: <0>: 10 Specify top radius (R2) and
pressEnter.
Specifyheightofcone:60 Specifyheightofthetopandpress
Enter.
Enter number of segments for surface of cone<16>: Press Enter to accept 16
segments.

W2.12.5SPHERE
AsphericalsurfacecanbedrawnbytypingAI_SPHEREcommandatthecommand
lineorbyclickingtheSphereiconshownabove.Thedisplayisintheformofsmall
segements. The number of these segements in longitudinal (joining north to south
pole) and latitudinal (circumferential) directions are to be specified at the prompts.
Thefollowingpromptsappear.
Command:AI_SPHERE TypecommandandpressEnterorclicksphere
icon.
Specifycenterofsphere: Specifycoordinatesofcenterofthesphere.
Specifyradiusofsphereor[Diameter]: SpecifyradiusorandpressEnter.
Enternumberoflongitudinalsegmentsforsurfaceofsphere<16>:
PressEnterortypeanewvalueandpressEnter.
Enternumberoflatitudinalsegmentsforsurfaceofsphere<16>:
PressEnterortypeanewvalueandpressEnter.
.
Prompts for DOME and DISH command are similar to SPHERE command except
that the latitude segments are half in number than the sphere. The Dome is the
upperhalfofspherewhileDishisthelowerhalfofthesphere.
W2.12.6TORUS
Torusisashapesimilartothatofatubeofacar.Itisdefinedbytworadiivalues;
onefortheradiusoftoruswhichisfromthecenterofthetorustotheoutsideofthe
tubeandtheother,astheradiusofthetube(FigureW2.16).Thepromptsequence
forthiscommandis:
Command:AI_TORUS TypecommandandpressEnterorclicktheTorusicon.
SpecifycenterofTorus: Specifycoordinatesofthecenterandpress
Enter.
Specifyradiusoftorusor[Diameter]: EntervalueofradiusoftorusortypeDto
specifydiameter.
Specifyradiusoftubeor[Diameter]: EntervalueofradiusoftubeortypeDto
specifydiameter.
Enternumberofsegmentsaroundtubecircumference<16>:
PressEntertoacceptthedefaultnumberofsegments.
Enternumberofsegmentsaroundtoruscircumference<16>:
PressEntertoacceptdefaultnumberofsegments.
W2.13NONSTANDARDSURFACES
Surfaces other than predefined standard can be created by other commands as
showninFigureW2.19.Thecommandtobeuseddependsuponastowhatdatais
available.Thefollowingsectionsdescribesuchcommands.

A.3DMESHB.REVSURFC.RULESURFD.TABSURF E.
EDGESURF

FigureW2.19Nonstandardsurfaces
W2.13.13DMESH
Withthiscommand,irregularsurfacescanbecreatedwhichareopeninbothMand
N directions (Figure W2.19A). . First, specify M and N values to determine the
numberofthevertices(MxN).Theverticesarenumberedinthematrixformatfrom
(0,0)to(M1,N1).ThenAutoCADpromptsthecoordinatesofeachvertexasshown
below.ForM=4andN=4thereare16vertices.Specifycoordinatesofeachvertex
in3Dformat,i.e.,X,Y,Z.

Command:3DMESH TypecommandandpressEnterorclickonthe3DMesh
icon.
EntersizeofMeshinMdirection:4TypeanumericalvalueforMinthemesh.
EntersizeofMeshinNdirection:4 TypeanumericalvalueforNinthemesh.
Specifylocationforvertex(0,0): Specifycoordinatesofthevertex,e.g.0,0,5.
Specifycoordinatesofeachvertex.
Goonspecifyingcoordinatesofvertices
Specifylocationforvertex(3,3): Specifycoordinatesofthelastvertex.
Asurfaceisgeneratedpassingthroughallthespecifiedvertices.
13.13.2AXISSYMMETRICREVOLVEDSURFACE(REVSURFCOMMAND)
Arevolvedsurfaceiscreatedbyfirstdefiningapathcurveoraprofileandthenthe
same is rotated about an axis. The path curve is swept about the selected axis to
createasurface(FigureW2.19B).
Specifying a start angle begins the surface of the revolution at an offset from the
generating path curve. The included angle is the distance through which the path
curveisswept.Enteringanincludedanglethatislessthanafullcirclepreventsthe
curve from closing. The point used to select the axis of revolution affects the
directionofrevolution.Selectingoneendoftheaxisofrotationcreatesthesurface
in the clockwise direction while selecting at other end creates the surface in the
anticlockwisedirection.Thecommandsequenceisasunder:

Command:REVSURF TypecommandandEnterorclickRevsurficon
Selectobjecttorevolve: Select a line, arc, circle, or 2D or 3D
Polyline.
Selectobjectthatdefinesaxisofrevolution: Selectaline
Specifystartangle<0>: TypeavalueoftheangleorpressEnter.
SpecifyincludedAngle(+=ccw,+cw)<360>: PressEnterforrevolvingsurfaceby360
degrees
NOTE:Specifyapositivevalueoftheanglefromthestartangleifthepathcurveis
to be rotated in a counterclockwise direction and negative value for the
clockwiserotationdirection.
W2.13.3RULEDSURFACE(RULESURFCOMMAND)
WithRULESURFcommand,asurfaceiscreatedbetweentwospecifiededges.Pairs
oftheobjecttobeusedasedgesmustbothbeeitheropenorclosed.Apointcanbe
pairedwitheitheranopenoraclosedobject.
Tocreatearuledsurface,firstdrawthetwoboundaryedges(FigureW2.19C).Then
clickanywhereoneachedgetocreatethesurface.Foropencurves,AutoCADstarts
constructionoftheruledsurfacebasedonthelocationsofthepointsselectedonthe
boundaries. For edges, as closed curves you can specify anytwopoints. It may be
noted that this command is to be used after drawing the two boundary edges. The
promptsequenceis:
Command:RULESURF TypecommandandpressEnterorclickRulesurficon
Selectfirstdefiningcurve: Clickatoneoftheedgeatoneend.
Selectseconddefiningcurve: Clickattheotheredgeatsameoroppositeside.

W2.13.4TABULATEDSURFACE(TABSURFCOMMAND)
Atabulatedsurfaceiscreatedbyfirstdefiningapathcurveandthenalinecalledas
directionvectorshowingthedirectionofmovementofthiscurve((FigureW2.19D).
The path curve could be a line, an arc, a circle, an ellipse, or polyline. AutoCAD
draws the surface starting from this base curve along the path defined by the
directionvectorline.

Command:TABSURF Type command and press Enter or click Tabsurf
icon.
Selectobjectforpathcurve: ClickonPathcurve.
Selectobjectfordirectionvector:Clickonthedirectionvector.
W2.13.5SURFACECREATEDFROMFOUREDGES(EDGESURFCOMMAND)
TheEDGESURFcommandconstructsathreedimensionalmeshfromfouradjoining
edges.Firstdrawfouradjoiningedgesthatdefinethesurfacepatch.Theedgescan
be lines, arcs or splines. The edges must touch at their endpoints to form a closed
path.Selectionofthefouredgescanbeinanyorder.Thepromptsequenceis:

Command:EDGESURF Typecommand&pressEnterorClickEdgesurf
icon
Selectobject1forsurfedgeedge: ClickanywhereonEdge1.
W2.14DRAWINGAIDCOMMANDS
Thefollowingcommandshelpinconstructionsandgiveusefulinformation.
W2.14.1MEASURE
Thiscommandputsapointmarkorablock(asetofentities)ataspecifieddistance.
Itspromptsequenceisasunder:
Command:MEASURE TypethecommandandpressEnter
Selectobjecttomeasure: Clickontheobjecttoputmarks
Specifylengthofsegmentor[Block]: SpecifydistanceandpressEnter
W2.14.2DIST
This command provides information about the distance and angles between two
specifiedpoints.Thepromptsequenceisasunder:
Command:DIST TypethecommandandpressEnter
Specifyfirstpoint: Clickonapointfromwheretomeasure
Specifysecondpoint: Clickonapointuptowhichtomeasure
AutoCADdisplaystheinformationinthecommandarea.Forexample,thedisplayis
asunder:
Distance=107.2151,AngleinXYPlane=41,AnglefromXYPlane=0
DeltaX=81.4691,DeltaY=69.6984,DeltaZ=0.0000
DeltaXandDeltaYarethedistancesinXandYdirectionsrespectively.
Note: If the information is not visible, bring mouse on the upper side of the
command area. When a double line marker appears, drag it upwards to
increasethisarea.
W2.14.3AREAANDPERIMETER
AREA command calculates the area of a boundary and its perimeter. Its prompt
sequenceisasunder:
Command:AREA Typethecommandandpress
Enter
Specifyfirstcornerpointor[Object/Add/Subtract]: Clickonapoint
SpecifynextcornerpointorpressENTERfortotal: Clickonnextpoint
.. Thispromptrepeats
SpecifynextcornerpointorpressENTERfortotal:PressEnterwhenspecifythelast
point which is the same as the
firstpoint.
AutoCADdisplaysasunder:
Area=2998.8346,Perimeter=269.4932
EXAMPLE16(PERIMETERANDAREA)
AIM:Demonstratetheuseofdraftingtoolsandthemethodforsurfacedevelopment.
Calculateareaandperimeterofthesheetmetal.

A90elbowistobemadebyjoiningtwopipescutat45.UsingAutoCADcommands,draw
development of cylinder with a diameter of 100 mm, and a height of 150 mm as shown in
FigureW2.S16.
SOLUTION
Anelbowismadebycutting2pipesat45degreesandthenjoiningattheirinclined
edge.Developmentofboththepipesisshowninthefigurebelow.
A.Drawcrosssectionofapipe
1. Draw a circle using CIRCLE command. Click anywhere on the screen as center
andspecifytheradiusas50mm.
2. Use DDPTYPE command to select a point style. Select cross type (third in top
line).Choosepointsizeas2unitsandselectradiobuttonasSetsizeinAbsolute
units.
3. UseDIVIDEcommandtodividethecirclein12parts.Selectthecircleasobjectto
divide.Specifynumberofsegementsas12.Crossesaremarkedonthecircle.
4. Drawline17asdiameterusingLINEcommandandcompletetherestofthetop
view.

FigureW2.S16Developmentsforanelbow
B.DrawFrontview
5. PutOrthoONbypressingF8key.IfalreadyON,ignorethisstep.
6. UseCOPYcommandtocopyline17verticallyabovethecircle,asthebaseofthe
frontview.
7. UseLinecommandtocompletetherestoftheoutlineofthefrontviewasshown
inFigureW2.S16.Drawaninclinedlineshowingthecuttingplane.
C.Drawconstructionlines
8. UseXLINEcommandwithVerticaloptiontodrawlinesfrompointsmarkedon
thecircleontheupperhalf.
9. UseTRIMcommandtodeleteunwantedconstructionlines.Selectboundariesto
trimascircleabovetheline17andinclinedplaneinthefrontview.Forobjectsto
delete,selectconstructionlinesbelowthecircleandabovetheinclinedlineofthe
frontview.
10. Use XLINE command and Horizontal option to draw lines from points where
verticallinescuttheinclinedline.
11. UseTRIMcommandtodeleteunwantedconstructionlines.Selectboundariesto
trimasinclinedlineoffrontview.Forobjectstodelete,selectconstructionlines
ontheleftoftheinclinedplane.
D.Drawdevelopment
12. Drawahorizontallineasdevelopmentofcircumferentiallength(D)314.16mm
justoppositetobaseoffrontview.
13. UseDIVIDEcommandtodividethisin12parts.Selectthelineasobjecttodivide.
Specifynumberofsegementsas12.Crossesaremarkedontheline.
14. UseXLINEcommandandVerticaloptiontodrawlinesonallpointsonthisbase
horizontalline.
15. UseFILLETcommandwithRadiuszero,andfillettherespectivehorizontaland
verticalconsturctionlinestopoints1,2,..12and1.
16. Use SPLINE command and select all the points 1, 2,..12 and 1 to get the
developmentoftopfaceofthelowerpipe.
17. Use COPY command and copy the SPLINE slightly above the previous curve.
CompletetherestoftheoutlineasshowninFigureW2.S16fortheupperpartof
thepipe.
E.Gettingareaandperimeterofdevelopment
18. Use AREA command and start selecting all the corner points and development
points in a cyclic order , e.g., 1 (Left)1 2 3. 12 1(right) 1(right)
1(left).Thelastpointshouldbethestartpoint.PressEnter.AutoCADdisplaysthe
informationas:
Area=31400.0000,Perimeter=794.5275
THEORYQUESTIONS

Q1. Whatismeantbydevelopment?Explainbygivingexamples.
Q2. What are joining allowances in sheet metal work? How do they affect the
development?
Q3. Whatiswiringandhemming?Whyitisdone?
Q4. Differentiatebetweendevelopableandnondevelopablesurfaces.
Q5. Whatarethedifferentmethodsfordevelopment?Describeanyonemethod.
Q6. Describethemethodtodrawthedevelopmentofahexagonalprism.
Q7. Differentiatebetweentheshapesofdevelopmentforapyramidandprism.
Q8. Howcanyoudrawthedevelopmentofasphere?Describeanyonemethod.
Q9. Explaintheproceduretodrawthedevelopmentofasquarepyramidcutby
aninclinedplane.
Q10. Arightcircularconeiscutbyaninclinedplane.Giveanytwopossibleshapes
ofitsdevelopment.
CAD
Q11. NamethepredefinedsurfacesinAutoCAD
Q12. Whatarethevariouscommandstocreatesurfacesotherthanpredefined?
Q13. HowdoyoucreateacylindricalsurfaceinCAD?
Q14. Whatisatorussurface?Writethevariousdatatobespecifiedincreatingit.
Q15. DescribetheuseofMEASURE,DIST,AREAandPERIMETERcommands.

FILLUPTHEBLANKQUESTIONS
Filluptheblanksbyappropriateword(s).

1. Developmentforalargesheetmetalobjectiscreatedofthe____________sizeas
theobject.
2. Puttingawireonthefreeedgeofasheetmetaliscalled___________.
3. Seamingisdoneto___________thefreeedge.
4. Allowancesforjoiningandseamingare___________tothedevelopment.
5. Aspherehasa___________surface.
6. Themethodfordevelopmentofaconeis___________development.
7. Straightlinemethodofdevelopmentcanbeusedfor___________.
8. Acylinderisdevelopedby___________lineprojectionmethod.
9. Inzonemethodtodevelopasphere,thesurfaceisdividedinzonesof
___________ofcone.
10. In___________methodsurfaceofasphereisdividedinarctualshape.
11. Apiecewhichjoinsopeningoftwodifferentcrosssectioniscalled___________.
CAD
12. Commandtocreatesurfaceofacylinderis___________.
13. Torusisasurfacelike___________ofacar.
14. Symmetricsurfacescanbegeneratedby___________command.
15. Thecommandtocreateasurfacefromfourdefinededgesis___________.
16. TABSURFcommandcreatesasurfacebymovinga2Dobjectinspecified
___________.
17. Anobjectcanbedividedinspecifiednumberofsegmentby
___________command.
18. MEASUREcommandisusedtomarkanobjectatspecified___________.
19. Thecommandtocalculatetheareaofaclosedboundaryis___________.
20. Surfacecommandsareprefixedby___________beforetheircommandname.
MULTIPLECHOICEQUESTIONS
Q1. Developmentofanobjectisdoneto
a. increaseitssize
b. reduceitssize
c. gettheshapeofthesurfaceareainoneplane
d. tocalculatesurfacearea
Q2. Forthedevelopmentofobjectsmadebyjoiningsheetmetaljoints,
a. thetypeofthejointshouldbeknown
b. thetypeofjointdoesnotmakeanydifference
c. thetolerancesshouldbeknown
d. onlyshapeisrequired
Q3. Number of pieces to make an open rectangular tank of sheet metal with
minimumjointsis
a. one
b. two
c. four
d. five
Q4. Tomakeasquarepyramidofthinplates,thereisonlyoneshapewhich
willmakeapyramid.Isthisstatementtrue?
a. Yes
b. No
c. Dependsuponthemethodofmanufacturing
d. Dependsupontheskillofthetechnician
Q5. Developmentofaspherecannotbemadebyusing
a. triangularelements
b. trapezopidalelements
c. circularelements
d. hexagonalelements
Q6. If a prism is cut by an inclined or curved plane near apex, its development
will
a. notbeaffected
b. changeaccordingtobothpositionandangle
c. changeaccordingtopositiononly
d. changeaccordingtoangleonly
Q7. Aboxcannotbemadebythegiven:
a. length,width,heightandcenter
b. basesizeandheight
c. surfacearea
d. corner,length,widthandheight

Q8. Atetrahedronismadebyusing
a. thePYRAMIDcommand
b. theRULESURFcommand
c. theCONEcommand
d. noneoftheabove
Q9. Theslantfaceofthewedgewith0degreerotationtapersalong
a. theXaxis
b. theYaxis
c. theZaxis
d. canbealonganyaxis
Q10. Heightofthewedgeis
a. alongtheXaxis
b. alongtheYaxis
c. alongtheZaxis
d. automaticandproportionaltothelength

Q11 Surftab1systemvariableisusedto
a. createsurfacemodels
b. createonlyonesurfacemodel
c. createtabulatedsurfaces
d. definenumberofsegementsinonedirection

Q12. Tubediameterofatorushastobe
a. smallerthanthetorusdiameter
b. equalormore
c. halfofthetorusdiameter
d. onethirdofthetorusdiameter

Q13. Atruncatedpyramidismade
a. directlybythepyramidcommand
b. by just making the pyramid and then by truncating it using another
command
c. bydefininganegativeheightofthepyramid
d. byinclinedheightsandverticalheights

Q14. Asurfaceismadebyselectingfouredgesbyusingthecommand
a. EDGE
b. EDGESURF
c. 3DMESH
d. POLYFACE
Q15. Axissymmetricobjectsarecreatedbythecommand
a. TABSURF
b. 3DMESH
c. RULESURF
d. REVSURF

Q16. Coordinatesoftheverticesaregiveninthecommand
a. RULESURF
b. EDGESURF
c. 3DMESH
d. TABSURF
AnswerstoFilluptheblankquestions
1.same 2.wiring 3.strengthen 4.added
5.undevelopable 6.radial 7.prisms 8.parallel
9.frustom 10.Gore 11.transitionpiece 12.AI_CONE
13.tube 14.REVSURF 15.EDGESURF 16.direction
17.DIVIDE 18.distance 19.AREA 20.AI_
Answerstomultiplechoicequestions:
1c 2a 3a 4b 5c 6b 7c 8a 9a 10c
11d 12a 13a 14b 15d 16c
ASSIGNMENTONSURFACEDEVELOPMENTS
Q1. Figure W2.P1A shows a prism having the top face inclined. Draw its
development.
Q2. Figure W2.P1B shows a cone with its bottom cut at an angle. Draw its
development.
Q3. Figure W2.P1C shows a pyramid having top face inclined. Draw its
development.
Q4. FigureW2.P1Dshowsacylinderhavingtopfaceinclinedasshown.Drawits
development.
Q5. Figure W2.P1E shows a transition piece having top and bottom rectangular
coaxially.Drawitsdevelopment.

FigureW2.P1Assignmentonsurfacedevelopments
CADASSIGNMENTONSURFACEDEVELOPMENTS
Q6. Figure W2.P2A shows a cone cut by two planes at the top. Draw its
development.
Q7. FigureW2.P2BshowsacylinderwithitstopcutinasemicircularshapeofR
=30.Drawitsdevelopment.
Q8. Figure W2.P2C shows a pyramid having top face inclined at 30. Draw its
development.
Q9. FigureW2.P2Dshowsahexagonalprismhavingtopfaceinclinedasshown.
Drawitsdevelopment.
Q10. Figure W2.P2E is of a transition piece having top and bottom rectangular
havingonlyoneedgeinverticalaxisasshown.Drawitsdevelopment.

FigureW2.P2CADassignmentonsurfacedevelopments
HOMEWROKONSURFACEDEVELOPMENTS
Q11. Figure W2.P3A shows a cylinder cut by a curved plane on top. Sketch its
development.
Q12. FigureW2.P3Bshowsaconewithitsbottomcuthalfasshownandtopcutat
anangle.Sketchitsdevelopment.
Q13. FigureW2.P3Cshowsasquarepyramidhavingthetopfaceinclined.Sketch
itsdevelopment.
Q14. Figure W2.P3D showsapentagonalprismhavingtopfacecurvedasshown.
Sketchitsdevelopment.
Q15. Figure W2.P3E shows a transition piece having top inclined and elliptical
whileitsbottomissquare.Centerpointoftopliesverticallyaboveacornerof
thebase.Sketchitsdevelopment.

FigureW2.P3Homeworkonsurfacedevelopments
PROBLEMSFORPRACTICEONSURFACEDEVELOPMENTS
Q16. Figure W2.P4A shows a triangular prism cut by an inclined plane on top.
Drawitsdevelopment.
Q17,18FiguresW2.P4BandW2.P4Cshowtwocones.Onehasaholeandtheotheris
cutby2curvedplanes.Drawtheirdevelopments.
Q19,20.FiguresW2.P4DandW2.P4Eshowtwocylinders.Onehasacutononeside
and the other has the top face inclined and the bottom face curved in half.
Drawtheirdevelopments.
Q21. Figure W2.P4F shows a hexagonal pyramid with the top inclined up to the
centerlineandtheninaflatposition.Drawitsdevelopmentusingradialline
developmentmethod.

Figure16P4Problemsforpracticeonsurfacedevelopments

Q22. FigureW2.P5Ashowsanobjectwithacurvedtopandinclinedside.Drawits
development.
Q23. Figure W2.P5B shows a cone with its top cut by a curved plane. Draw its
development.
Q24. FigureW2.P5Cshowsanobliquecone.Drawitsdevelopment.
Q25. Figure W2.P5D shows a transition piece with a circular top and a square
bottomverticallycentrallybelow.Drawitsdevelopment


Q26. Figure W2.P6A shows a cone with top and faces cut as shown. Draw its
development.
Q27. FigureW2.P6Bshowstwocones,oneovertheothercentrallyabove.Drawthe
development.
Q28. FigureW2.P6Cshowstwocylinders,oneovertheothercentrallyabove.Draw
thedevelopment.
Q29. Figure W2.P6D shows a transition piece with a circular top and bottom
eccentrically.Drawitsdevelopment
Q30. FigureW2.P6Eshowsafunnel.Drawitsdevelopment.
Q31. Figure W2.P6F shows a cylinder with a hole of 50mm diameter centrally.
Drawitsdevelopment.
PROBLEMSFORPRACTICE
PRISMS
Q32. A triangular prism with bases of lengths equal to 60 mm, 75 mm and 85

mmandaheightof100mmistobemade.Drawitsdevelopment,ifthetop
istobekeptopen.
Q33. Drawthedevelopmentofarectangularprismwithbaseof120mmx80mm
andheightof120mm.Showthetopandbottomalso.
Q34. Ahutistobemadeofthinsheetswithwidthanddepth=200mm,heightin
centre=250mm,heightonsides=175mm.Anopeningof100mmwidthand
150mmheightistobekeptinthefrontside.Drawitsdevelopment.
PYRAMIDS
Q35. Draw the development of a rectangular pyramid with a base of 90 mm x 60

mmandaheightof120mm.
Q36. Arectangularpyramidwithbaseof70mmx40mmandaheightof100mm
iscutbyaninclinedplaneinthelongersidepassingatthemidheightatan
angleof30degrees.Drawitsdevelopment.
CYLINDERS
Q37. Acylinderwithdiameterof130mmiscutby2planesinthecentre.Boththe
plane make angles of 30 degrees with the vertical at height of 120 mm such
thatthesidesaresmallerthanthecentralheight.Drawitsdevelopment.
Q38. Averticalcylinderwithadiameterof200mmandaheightof150mmhasto
support another cylinder with a diameter of 150 mm at a height of 100 mm
from the base by making a circular cut in the vertical cylinder. Draw the
developmentfortheverticalcylinder.
CONES
Q39. A cone with a base of 120 mm and a height of 150 mm is to have a solid
horizontalcylinderwithadiameterof30mmthroughitscentreatitsmiddle.
Drawthedevelopmentofthecone.

Q40. Afunnelistobemadebyjoiningtwopieces.Itstopandbottomdiametersare
100mmand20mmrespectivelywithaverticalheightof80mm.Itsbottom
pipeistaperedfroma20mmtoa10mmdiameterwithalengthof100mm.
Drawthedevelopmentofeachpart.

Q41. Drawthedevelopmentofarightcircularconewithabasediameterof80mm
andaheightof100mmifitiscutbyaninclinedplaneataverticalheightof30
mmfromtheapex.
(a)Theangleofthecuttingplaneis20degreeswiththehorizontal.
(b)Theangleofthecuttingplaneis60degreeswiththehorizontal.
SPHERES
Q42. Asphericalballwithadiameterof150mmistobemadebyjoining12arched
elements.Drawtheshapeofatleastthreeelements.
Q43. Asphericalballwithadiameterof200mmistobemadebytheZonemethod.
Drawthedevelopmentfortheupperhalfportiononly.

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Page 1 of Chapter W2 Surface Developments

WEB CHAPTER 2 SURFACE DEVELOPMENTS

Following commands can be used to create a surface by different methods:

Following commands can be used as drafting aids and inquiry:

(A)Pictorial view (B) Orthographic views (C) Surface development

Figure W2.1 A triangular hollow box

Figure W2.2 Alternative locations of the base of a triangular hollow box

W2.2 JOINTS USED IN SHEET METAL

Figure W2.3 Sheet metal joints

W2.3 REINFORCEMENT OF FREE EDGES

Figure W2.4 Reinforcement in sheet metal parts

W2.4 JOINT AND REINFORCEMENT ALLOWANCES

Figure W2.5 Joint allowance in developments

W2.5 TYPES OF DEVELOPMENTS

W2.6 DEVELOPABLE SURFACES

Straight line development

W2.6.1 STRAIGHT LINE DEVELOPMENT

Figure W2.6 Development of a rectangular prism

EXAMPLE 1 (HEXAGONAL PRISM)

Figure W2.S1 Development of a hexagonal prism

EXAMPLE 2 (FIVE SIDED PRISM)

Figure W2.S2 Development of a pentagonal prism

EXAMPLE-3 (SQUARE PYRAMID)

Figure W2.S3 Development of a square pyramid

EXAMPLE 4 (OBLIQUE PYRAMID)

Figure W2.S4 Development of an oblique square pyramid

W2.6.2 RADIAL LINE DEVELOPMENT

Figure W2.7 Development of a right circular cone

EXAMPLE 5 (OBLIQUE CONE)

Figure W2.S5 Development of an oblique cone

EXAMPLE 6 (HEXAGONAL PYRAMID)

Figure W2.S6 Development of hexagonal pyramid

W2.6.3 PARALLEL LINE DEVELOPMENT

Figure W2.8 Development of a cylinder

W2.7 NON- DEVELOPABLE SURFACES (SPHERE)

W2.7.1 ZONE METHOD:

(A) Sphere divided in 8 zones (B) Development of each zone

Figure W2.9 Development of a Sphere

W2.7.2 GORE METHOD

(A) Sphere (B) Development

Figure W2.10 Development of a sphere

W2.7.3 TRIANGULATION METHOD

Figure W2.11 Elements for a sphere

W2.8 OBJECTS CUT BY A PLANE

W2.8.1 RECTANGULAR PRISM

(A) Prism (B) Development

Procedure for the development of an inclined prism is similar as discussed in sectionW2.8.1.

(A) Prism (B) Development

EXAMPLE 7 (HEXAGONAL PRISM CUT BY INCLINED PLANE)

(A) Hexagonal prism (B) Development

Figure W2.S7 Development of a hexagonal prism cut by an inclined plane

W2.8.2 RECTANGULAR PYRAMID

EXAMPLE 8 (RECTANGULAR PYRAMID CUT BY A PLANE)

Figure W2.S8 Rectangular pyramid cut by a horizontal plane

EXAMPLE 9 (SQUARE PYRAMID CUT BY INCLINED PLANE)

Figure W2.S9 Development of a square pyramid cut by an inclined plane

EXAMPLE 10 (PYRAMID CUT WITH TWO PLANES)

(A) Pyramid (B) Development

Figure W2.S10 Square pyramid cut by two planes