Fastening different components of an assembly using various connectors

3D Tetra Meshing Operation

Objective:

To create appropriate connectors of various kinds to attach the given different components of the frame assembly as per the specified requirements.

Procedure:

Step 1. The given frame assembly surfaces are repaired with topology cleanup methods like adding washers and modify surfaces to avoid failure on meshing.

Step 2. The repaired surfaces are meshed individually with a target element size of 5mm (maximum is 7mm and minimum is 3mm). The symmetry is observed and operations are performed according to reflect the elements to cover the entire geometry properly.

Step 3. The connectors are created as per the given requirements.

• The right rail 2 and the front truss 1 are attached using seam weld with following specifications of tolerance - 4, spacing - 5, cap angle - 65, weld angle - 45 and run off angle - 10 with mesh adjust, quad transition and imprint options.

• The left rail 2 and the front truss 1 are attached using the quad elements from seam welding section, with previous spacing and tolerence specifications.

• The both front truss and the right rail 1 are connected with spot weld of 5mm diameter with 3 layers and 10mm tolerance.

• The front truss 1 and the left rail 1 are connected with hexa adhesives with 3 layers of strips and coats and all spacing, tolerance and width as 5mm. Similarly, the front truss 2 and the left rail 1 are connected with same specs.

• The both right rail 2 and left rail 2 components are connected with the rear truss 2 using the bolt (general) connectors with tolerance as 5mm, in a similar way.

• The both right rails and the left rails components are connected using the spot weld connectors of rigid and spring type of elements respectively, with diameter as 5mm and tolerance as 10mm with 2 layers.

• The reinforcement plate is connected with the front truss memebers using different spot weld elements like CWELD on one side and with PLOT on another side.

• The rear truss members are connected using seam sealing elements and rear truss 2 is connected with the right rail 1 and left rail 1 components are connected using the bolt (CBAR) and bolt (hinge) connectors respectively.

Step 4. The created connectors mesh imprints on the already meshed components modifying the mesh flow. This distortion in the mesh due to the created connectors are rectified. The mesh after creating all the connectors and mesh cleanup operation.

Result:

The given components were attached using the appropriate connectors as per the requirements and all connectors were created and realized properly with no error and no changes to mesh quality post connectors creation.