Clean up & Meshing the Turbo charger unit using ANSA - PART - 1

Objective:

• Create a error free error & free mesh geometry using Advance CFD Meshing using ANSA.

Description:

The following is the model which we need to clean up and meshing has to be perform.

The following is the mesh element size taken into consideration for meshing the geometry.

• Blade stage 1 - 1mm
• Blade stage 2 - 1mm
• Compresssor casing - 5mm
• Impeller - 2mm
• Inlet casing cover - 5mm
• Shaft rotor - 1mm
• Turbo casing - 5mm

And the ELEMENT TYPE will be used is TRIA. Also we are going to do VOLUMETRIC MESHING using TETRA CFD.

Check of Geometry:

1. Set the Geometry in PID mode and enable CROSS HATCHES.

2. Go to CHECK option TICK SYMBOL & do the Geometry check. Check for identifying the errors in the Geometry.

3. After checking the geometry we need to clean the geometry which has the single coons (Red in color) and unwanted surfaces & overlapped surfaces.

Cleaning the surface:

4. Select !-(I NOT OPERATOR) and PID REGION and select the geometry which i have circled in the picture (Cross hatches) and then press middle mouse button for confirmation.

5. Ensure your still in PID Region now delete the unwanted surface (Pink Color) go to FACES option in that DELETE option can selected as per easiness. Then confirm by pressing OK in the dialog box.

6. Now we will clean the surface which has single coons top of the geometry. Select NEW option under FACES module in that select FITTED, now select LOOP option which is in the bottom, select the single coons which is in the RED COLOR, then press middle mouse button for confirmation and then check the proper surface is created by selecting the alt option check and also check it is same as the other side profile then select OK. Then close the NEW FACES OPTION dialog box.

7. Next we will clean the bottom casing which has extra projection of surface which is highlighted by single coons (RED IN COLOR).

8. Now select !-(I NOT OPERATOR) and select the ENT MODE and the select the surface as shown in the picture step-8. and then press middle mouse.

9. After pressing middle mouse button, the surface which we need to clean will be highlighted.

10. Now select PROJECT option under CONS module for projecting the single coons on the top surface. Then press middle mouse button for confirmation, after confirmation we have to select the face on to which it has to be projected then press middle mouse button for confirmation. By doing this extra surface will become different surface which helps in deleting the surface as single entite(separate cross hatches will be generated).

11. Now select the TOPO options under FACES module, select the top and bottom surface single coons to perform topology operation and then press middle mouse button for confirmation. Now we can see triple coons and also the surface is completed separated.

12. Now delete the unwanted surface, go to FACES option in that DELETE option can selected as per easiness. Then confirm by pressing OK in the dialog box. Then press ALL option which is down to go back to entire model.

13. Now we will clean the inlet casing cover.

14. Now we will create HOT POINTS to clean the inlet casing cover.

1. Create a HOT POINT by selecting PARAMETRICAL option and select on the curve area towards downward direction by providing 0.5mm distance valve then press middle mouse botton for confirmation.
2. Again create HOT POINT by selecting PARAMETRICAL option and select on the curve area from the already generated HOT POINT towards upward direction by providing 0.5mm distance valve. Then press middle mouse botton for confirmation.
3. Again create HOT POINT by selecting PARAMETRICAL option and select on the curve area from the already generated HOT POINT towards downward direction by providing 0.5mm distance valve. Then press middle mouse botton for confirmation.
4. Now we can see the HOT POINTS has been created on the single coons when we check in wire frame mode (CTRL+SHIFT) it will visible easily.
5. Repeat the steps 14.1, 14.2 & 14.3 in the other side where the single Coons are present check in wire frame mode (CTRL+SHIFT) it will visible easily. Then close the Param.Input dialog box by pressing OK.

15. Now we will fill the surfaces of Inlet casing cover.

1. Go to COONS under SURFACES select the HOT POINT which are at the top side as shown in the picture step 15.1 then press middle mouse button for confirmation, then select ALT option to create a proper surface and press OK to create the surface.
2. Go to COONS under SURFACES select the HOT POINT which are at the bottom side as shown in the picture step 15.2 then press middle mouse button for confirmation, then select ALT option to create a proper surface and press OK to create the surface.
3. Go to COONS under SURFACES select the HOT POINT which are at the middle bottom side as shown in the picture step 15.3 then press middle mouse button for confirmation, then select ALT option to create a proper surface and press OK to create the surface.
4. Go to COONS under SURFACES select the HOT POINT which are at the middle Top side as shown in the picture step 15.4 then press middle mouse button for confirmation, press OK to create the surface.

16. After this the inlet casing cover is cleaned properly.

17. We will clean the turbo casing cover.

18. Now select the !-(I NOT OPERATOR) and ENT MODE then select the middle portion and the chamfer portion as shown in the picture step-18 and then press the middle mouse button. Now we can see the portion we have selected.

19. Now we are going to INTERSECT the two surface. Select INTERSECT options under FACES and select PID REGION then select the cylinder geometry (PURPLE COLOR) and then press middle mouse button to confirm and then select the taper region (BLUE COLOR) and press middle mouse button to intersect both the surfaces.

20. After intersecting now one dialog box will appear stating FACES DELETE AREA ??. so i will select keep for all surfaces.

21. Now delete the unwanted surface as shown in picture step-21 by selecting the DELETE option which is on the top or we can go to FACES option in that DELETE option can selected as per easiness. Then confirm by pressing OK in the dialog box.

22. After deleting the unwanted surfaces the geometry is cleaned.

23. Select ALL option to bring back the complete geometry.

C: Check of Geometry:

24. Go to CHECK option TICK SYMBOL which is on the top when you select list of options will appear select Geometry and one dialog box will appear press EXCUTE, check for identifying the errors in the Geometry.

25. After checking the geometry If we have any errors in geometry we need to clean.

D: Set the PID for the Geometry:

26. Now assign the PID for each area.

27. Go to SET PID option under FACES and select PID region select one of the faces and press middle mouse button to confirm and in the you will get the option new in the PSHELL select and enter the name or if the property has been assigned as Default PShell Property then just right click on the property name, select the edit option and then we can edit the name for the particular property.

1. Set PID for the Compressor casing.
2. Set PID for the inner part of the blade as Impeller.
3. Set PID for the Inlet casing cover.
4. Set PID for the Turbo casing.
5. In order to set the PID for inner part of the turbo unit we need got !-(I NOT OPERATOR) and select PID REGION and select the Compressor casing then press middle mouse button to confirm.
6. Set PID for the Blade stage -1 for the top blade.
7. Set PID for the Blade stage -2 for the below the top blade.
8. Set PID for the Shaft rotor.
9. Now we will set the PID for the shaft which is present between blade stage 1 & 2.
10. Select the shaft which is between the Blade stage 1&2 and press middle mouse button and select the SHAFT ROTOR property and press OK. The property of SHAFT ROTOR will assigned to that particular shaft. After setting the PID shaft color will be same as the SHAFT ROTOR.
11. Now press ALL to bring back the complete geometry.
12. After setting the PID confirm by going in to the PROPERTY by pressing CTRL+P.

E: Now we will combine the Shaft assembly with all the Blades to make one single unit:

28. Now select !-(I NOT OPERATOR) and select PID REGION then select Compressor casing,Inlet casing cover & Turbo casing and press middle mouse button to confirm.

29. Then the LOCK the geometry which we need to work.

30. Now we will merge the Impeller and Shaft rotor by using TOPO option and selecting the connected area of Impeller and shaft rotor draging at that particular area. Then press middle mouse button to confirm.

31. Now we can see triple coons are generated but near blade connecting area the triple coons are not generated.

32. Now we will undo the TOPO operation.

33. Now we select the !-(I NOT OPERATOR) and select PID REGION then select the Impeller and press middle mouse button to confirm and then again press middle mouse button to work on the Impeller unit.

34. Now we can see the blade connecting area has some gaps. Total there are 8 gap area.

35. In order to fill the gaps go to FACES module in that select the CUT then select the two hot points one by one for all the 8 gap area. Then we can see a circumferenc on that area.

36. Then press ALL option and hit ESC button on keypad.

37. Now we will merge the Impeller and Shaft rotor by using TOPO option and selecting the connected area of Impeller and shaft rotor draging at that particular area. Then press middle mouse button to confirm.

38. Now we can see the triple coons on the entire circumference.

39. Now select the !-(I NOT OPERATOR) and select ENT mode and select the half portion of the Shaft rotor.

40. Now delete the inner surface by using DELETE option select the Impeller surface and Shaft rotor surface and then press middle mouse button to confirm and press OK.

41. Now we can see the Shaft rotor and impeller is merged properly.

42. Then press ALL option and hit ESC button on keypad.

43. Now we are going to merge all the blade which are present in blade stage 1.

44. Now by using TOPO option under FACES module we will select the intersecting area of the all 3 blades and then press middle mouse button to confirm. Now we can see the triple coons are generated which indicates the faces has been merged. Next hit ESC button on keypad.

45. Now select the !-(I NOT OPERATOR) and select PID REGION mode and select the all 3 blades and press middle mouse button to confirm and again press middle mouse button to confirm to see the inner faces of blades. Hit ESC button on keypad.

46. Now we can see inner faces of blade.

47. Now delete the 2 faces by selecting the DELETE option which is on the top or we can go to FACES option in that DELETE option can selected as per easiness. Then confirm by pressing OK in the dialog box. Then press ALL option and hit ESC button on keypad.

48. Now select the !-(I NOT OPERATOR) and select PID REGION mode select the blade stage 1 , now we can see all 3 blades are merged and selected as single entite. Hit ESC button on keypad after confirming. Then press ALL option and hit ESC button on keypad.

49. Now select the !-(I NOT OPERATOR) and select PID REGION mode select the blade stage 2 and select the all 4 blades and press middle mouse button to confirm and again press middle mouse button to confirm to see only 4 blades. Hit ESC button on keypad.

50. Now by using TOPO option under FACES module we will select the intersecting area of the all 4 blades and then press middle mouse button to confirm. Now we can see the triple coons are generated which indicates the faces has been merged. Next hit ESC button on keypad. Then press ALL option and hit ESC button on keypad.

51. Now select the !-(I NOT OPERATOR) and select PID REGION mode select the blade stage 2 , press middle mouse button to confirm.

52. Now we can see inner faces of blade.

53. Now delete the 3 faces by selecting the DELETE option which is on the top or we can go to FACES option in that DELETE option can selected as per easiness. Then confirm by pressing OK in the dialog box.

54. Then press ALL option and hit ESC button on keypad.

55. Now select the !-(I NOT OPERATOR) and select PID REGION mode select the blade stage 1 , now we can see all 3 blades are merged and selected as single entite. Hit ESC button on keypad after confirming.

56. Now we will merge the small lenght shaft rotor with Blade stage 2 by using TOPO option under FACES module. Then press middle mouse button to confirm. Now we can see the triple coons are generated which indicates the faces has been merged. Next hit ESC button on keypad.

57. Now select the !-(I NOT OPERATOR) and select ENT mode and select the half portion of the Shaft rotor. Now delete the inner surface by using DELETE option select the Blade stage 2 surface and Shaft rotor surface and then press middle mouse button to confirm and press OK. Now we can see the Shaft rotor and Blade stage 2 is merged properly. Then press ALL option and hit ESC button on keypad.

58. Now we will project the small lenght shaft rotor to Blade stage 1 as there is different dimensions so we will use the PROJECT options under CONS MODULE. First select the small lenght shaft rotor end double coons by using LOOP option,then press middle mouse button and select the Blade stage 1 end face then press middle mouse button.

59. Now we will merge the small lenght shaft rotor with Blade stage 1 by using TOPO option under FACES module. Then press middle mouse button to confirm. Now we can see the triple coons are generated which indicates the faces has been merged. Next hit ESC button on keypad.

60. Now select the !-(I NOT OPERATOR) and select ENT mode and select the half portion of the small lenght shaft rotor. Now delete the inner surface by using DELETE option select the Blade stage 1 surface and small lenght shaft rotor surface and then press middle mouse button to confirm and press OK. Now we can see the Shaft rotor and Blade stage 1 is merged properly. Then press ALL option and hit ESC button on keypad.

61. Now we will merge the area where the blade stage 2 and shaft rotor is connected.

62. Now go to PROJECT option under CONS and select the Blade stage 2 end surface which consists of Double cons and press middle mouse button to confirm and select the shaft rotor press middle mouse button to confirm. Now we can see the shape has been changed to Hexagonal and hit ESC button on keypad.

63. In order to clean the Hexgonal shape geometry we will go to MESH module in that select LENGHT option under PERIMETER , now select the LOOP option and select the the HEXGONAL area which is Highlight with GREEN in color press middle mouse button to confirm and now the dialog box will appear and will ask for the lenght at which the meshing has to take place so now select upper region of the circumference which is blade stage 2 end face and press OK. Now we can see HEXAGONAL shape will be turned into circular shape.Hit ESC button on keypad.

64.Go back to TOPO module.

65. Now we will merge the shaft rotor with Blade stage 2 by using TOPO option under FACES module. Then press middle mouse button to confirm. Now we can see the triple coons are generated which indicates the faces has been merged. Next hit ESC button on keypad.

66. Now select the !-(I NOT OPERATOR) and select PID REGION mode and select the shaft rotor & Blade stage 2. Then press middle mouse button to confirm.

67. Now delete the inner portion of the shaft by using DELETE option select the shaft rotor and then press middle mouse button to confirm and press OK. Now we can see the Shaft rotor and Blade stage 1 is merged properly. Then press ALL option and hit ESC button on keypad.

68. Now select the !-(I NOT OPERATOR) and select ENT mode and select the half portion of the shaft rotor. Now we can see that the shaft rotor is merged with the Blade stage 2 properly.Then press ALL option and hit ESC button on keypad.

69. Now release the LOCK and press ALL option to go back outer part of the body.

70. Go to CHECK option TICK SYMBOL which is on the top when you select list of options will appear select Geometry and one dialog box will appear press EXCUTE, check for identifying the errors in the Geometry. If there are present rectify it else close the dialog box.

71. Now go to PROPERTY by pressing CTRL+P or the P symbol which is present in the top side. After pressing the option we can see the Property ID in which we can see the the Blub is not glowing fully.

72. Now we will clean the unwanted faces which are still present by using the compress Option, when you select all decks and press OK .

73. Now go to PROPERTY by pressing CTRL+P or the P symbol which is present in the top side. After pressing the option we can see the Property ID in which we can now see the the Blub is glowing fully and deleted the unwanted faces.

F: Now we will mesh the Geometry:

74. Now go to MESH MODULE and go to LENGTH option under PERIMETERS. Drag the mouse and select the entire geometry and press middle mouse button to confirm and enter the 5mm valve in the length option. Then press OK in the dialog box. And then hit ESC button on keypad.

75. Then go to MESH GENERATION option and in that select FREE MESH and under option select TRAI and RECONSTRUCT to be selected. Drag the mouse and select the entire geometry and press middle mouse button to confirm and the mesh is generated on the geometry.

76. Then go to MESH GENERATION option and in that select ERASE option and hold the mouse button and select VISIBLE so that all the mesh which was generated will be erased.

77. Now we will mesh Blade stage 1 , Blade stage 2 & Shaft rotor by 1mm. Now go to PROPERTY by pressing CTRL+P or the P symbol which is present in the top side in that select only Blade stage 1 , Blade stage 2 & Shaft rotor then right click in that select SELECT ONLY option. Then close the PROPERTY window.

78. Now go to MESH MODULE and go to LENGTH option under PERIMETERS. Drag the mouse and select the Blade stage 1 , Blade stage 2 & Shaft rotor and press middle mouse button to confirm and enter the 1mm valve in the length option. Then press OK in the dialog box. And then hit ESC button on keypad. Press ALL option to go back outer part of the body.

79. Then go to MESH GENERATION option and in that select FREE MESH and under option select TRAI and RECONSTRUCT to be selected. Drag the mouse and select the entire geometry and press middle mouse button to confirm and the mesh is generated on the geometry.

80. Now we will mesh Compressor casing , Inlet casing cover & Turbo casing by 5mm. Now go to PROPERTY by pressing CTRL+P or the P symbol which is present in the top side in that select only Compressor casing , Inlet casing cover & Turbo casing then right click in that select SELECT ONLY option. Then close the PROPERTY window.

81. Now go to MESH MODULE and go to LENGTH option under PERIMETERS. Drag the mouse and select the Compressor casing , Inlet casing cover & Turbo casing and press middle mouse button to confirm and enter the 5mm valve in the length option. Then press OK in the dialog box. And then hit ESC button on keypad. Press ALL option to go back all other geometry.

82. Then go to MESH GENERATION option and in that select FREE MESH and under option select TRAI and RECONSTRUCT to be selected. Drag the mouse and select the entire geometry and press middle mouse button to confirm and the mesh is generated on the geometry.

83. Now we will mesh Impeller by 2mm. Now go to PROPERTY by pressing CTRL+P or the P symbol which is present in the top side in that select only Impeller then right click in that select SELECT ONLY option. Then close the PROPERTY window.

84. Now go to MESH MODULE and go to LENGTH option under PERIMETERS. Drag the mouse and select the Impeller and press middle mouse button to confirm and enter the 2mm valve in the length option. Then press OK in the dialog box. And then hit ESC button on keypad. Press ALL option to go back outer part of the body.

85. Then go to MESH GENERATION option and in that select FREE MESH and under option select TRAI and RECONSTRUCT to be selected. Drag the mouse and select the entire geometry and press middle mouse button to confirm and the mesh is generated on the geometry.

86. Now we can see there is a UNMESHED : 2 faces. The face is shaft rotor which is connected between Turbo casing and compressor casing which we need to mesh.

87. Now go to MESH MODULE and go to LENGTH option under PERIMETERS. Select the GREEN line of the Shaft rotor and press middle mouse button to confirm and enter the 1mm valve in the length option. Then press OK in the dialog box. And then hit ESC button on keypad. Press ALL option to go back outer part of the body.

88. Then go to MESH GENERATION option and in that select FREE MESH and under option select TRAI and RECONSTRUCT to be selected. Select the GREEN line and press middle mouse button to confirm and the mesh is generated on the geometry.

89. Now the entire Geometry is Meshed properly.

90. Now we can see that mesh size is 2mm on Shaft rotor at the intersection of the Shaft rotor and Turbo casing.

91. The irregular size of mesh has happened because of the impeller unit as it is intersecting with shaft rotor.

92. And there is irregular size of mesh has happened because of the Compressor casing unit as it is intersecting with shaft rotor.

93. Now go to TOPO module and select !-(I NOT OPERATOR) and ENT mode select the one of the surface of compressor casing where the shaft rotor is intersecting. Now we can see the compressor casing unit is combines with shaft rotor.

94. Now we will delete the surface which is intersecting. Now we will hide the turbo casing and shaft rotor using !-(I NOT OPERATOR) and PID REGION.

95. Now selecting the DELETE option which is on the top or we can go to FACES option in that DELETE option can selected as per easiness. Then confirm by pressing OK in the dialog box. After deleting we can see Single cons.

96. Now go to Property select the SHAFT ROTOR and right click and select show only. Now we can see the Shaft rotor is showing.

97. Now we will Project the single cons on the shaft rotor. Now select the PROJECT option under CONS module. Before select ensure the 3 options are checked which area at the bottom right corner. Now select the single cons on the both surface and press middle mouse button for confirmation and select the Shaft rotor and press middle mouse button for confirmation. We can confirm the projection operation by press SHIFT+CTRL by going in to wire firm the single cons are converted in to triple cons which are in BLUE in color.

98. Now select ALL option now we can see single cons of half of the circumference area of the Shaft rotor. Now again we do to project the single cons on to the shaft rotor. Now select the PROJECT option under CONS module. Before select ensure the 3 options are checked which area at the bottom right corner. Now select the single cons on top surface and press middle mouse button for confirmation and select the Shaft rotor and press middle mouse button for confirmation. We can confirm the projection operation by press SHIFT+CTRL by going in to wire firm the single cons are converted in to triple cons which are in BLUE in color in complete circumference.

99. Select !-(I NOT OPERATOR) and ENT mode select the one of the surface of Turbo casing where the shaft rotor is intersecting. Now we can see the Turbo casing unit is combines with shaft rotor.

100. Now we will delete the surface which is intersecting. Now we will hide the turbo casing surface and shaft rotor using !-(I NOT OPERATOR) and PID REGION. selecting the DELETE option which is on the top or we can go to FACES option in that DELETE option can selected as per easiness. Then confirm by pressing OK in the dialog box. After deleting we can see single cons.

101.Now go to Property select the SHAFT ROTOR and right click and select show only. Now we can see the Shaft rotor is showing.

102. Now select the PROJECT option under CONS module. Before select ensure the 3 options are checked which area at the bottom right corner. Now select the single cons on top surface and press middle mouse button for confirmation and select the Shaft rotor and press middle mouse button for confirmation. We can confirm the projection operation by press SHIFT+CTRL by going in to wire firm the single cons are converted in to triple cons which are in BLUE in color in complete circumference.

103. Now select ALL option now we can see single cons of half of the circumference area of the Shaft rotor. Now again we do to project the single cons on to the shaft rotor. Now select the PROJECT option under CONS module. Before select ensure the 3 options are checked which area at the bottom right corner. Now select the single cons on top surface and press middle mouse button for confirmation and select the Shaft rotor and press middle mouse button for confirmation. We can confirm the projection operation by press SHIFT+CTRL by going in to wire firm the single cons are converted in to triple cons which are in BLUE in color in complete circumference.

104. Now all the unwanted surfaces are deleted. Now we will go to module to mesh the module near the intersection area.

105. Now select the LENGTH under PERIMETER module select the SHAFT ROTOR press middle mouse button to confirm and enter 1mm of element length. Before pressing OK select the REMESH MACROS option to be checked else it will not mesh properly near to intersected surfaces. Then press OK.

106. Now go to mesh generation option select FREE and select the ELEMENT TYPE and RECONSTRUCT option under the option list and under FREE select VISIBLE.

107. Now select ALL option. Now we can see near intersection surface ,it has not meshed so now we will preform mesh generation. Now go to mesh generation option select FREE and select the ELEMENT TYPE and RECONSTRUCT option under the option list and under FREE select VISIBLE.

108. Now it has mesh at all the surfaces.

109. Now we can see near intersection area of compressor casing and Shaft rotor the mesh length in some area are 5mm and near to intersection it is 1mm.

110. Now we will make the mesh size more refine. Now we create a surface surrounding to the intersection area of Compressor casing and Shaft rotor. Now under MARCOS select CUT option and create 4 points.

111. Now we will define the length of the area defined. We will assign 3mm as the length as the area near to the intersection has the length element as 1mm and 5mm. So now go to LENGTH under PERIMETER module select the lines and press middle mouse button and enter the value of 3mm and press OK. Now we can see much more refined mesh near the intersection.

112. Now we will refine the mesh inside the compressor casing near the intersection. Now using !-(I NOT OPERATOR) and ENT MODE select the non working area. Now we will make the mesh size more refine. Now we create a surface surrounding to the intersection area of Compressor casing and Shaft rotor. Now under MARCOS select CUT option and create 4 points.

113. Now we will define the length of the area defined. We will assign 3mm as the length as the area near to the intersection has the length element as 1mm and 5mm. So now go to LENGTH under PERIMETER module select the lines and press middle mouse button and enter the value of 3mm and press OK. Now we can see much more refined mesh near the intersection.

Till now we have compeleted the surfaces meshing.

Now we will carry out Volumetric meshing.

Contiuned in PROJECT PAGE 2..