Frame Assembly Welding using Connectors

OBJECTIVE:

To create connector and Attach the various parts of the given model 

1. Right_Rail_2 & Front_truss_1:- Seam-Quad (angled+capped+L)

2. Left_Rail_2 & Front_truss_1:- Quad elements

3. Front_truss_2, Front_truss_1 & Right_Rail_1:- Spot weld with 3 Layers and 5 mm Diameter

4. Front_truss_2, Front_truss_1 & Left_Rail_1:- Hexa (Adhesive)

5. Rear_truss_2 & Right_Rail_2:- Bolt Connector

6. Rear_truss_2 & Left_Rail_2:- Bolt Connector

7. Right_Rail_1 & Right_Rail_2:- Spot-weld with Rigid Elements

8. Left_Rail_1 & Left_Rail_2:- Spot-weld with Spring Elements

9. Rest all the component left Join them with suitable connectors

PROCEDURE:

• Go to Import Solver Deck>>Import Model>>Select File>>Import
• Change the Geometric Color Mode to \"By Topo\" to check for any erros in the surface.
• Now choose each component midsurface by hiding the rest of the components and mesh it with the quad element of size 5mm. 

Right_Rail_2 & Front_truss_1:- Seam-Quad (angled+capped+L)

1. Hide rest of the surfaces and wireframes except for right rail 2 and front truss 1.

2. Go to 2D>>Connectors>>seam>>type=seam-quad (angled+capped+L)>>spacing: 5>>tolerance: 10>>select nodes>>select components>>create

3. After the above step adjust the mesh by remeshing in those regions. The connectors are created as shown in the figure below

Left_Rail_2 & Front_truss_1:- Quad elements

1. Hide rest of the surfaces and wireframes except for left rail 2 and front truss 1.

2. Go to 2D>>Connectors>>seam>>type=quads>>spacing: 5>>tolerance: 10>>select nodes>>select components>>create

3. After the above step adjust the mesh by remeshing in those regions. The connectors are created as shown in the figure below

Front_truss_2, Front_truss_1 & Right_Rail_1:- Spot weld with 3 Layers and 5 mm Diameter

1. Hide rest of the surfaces and wireframes except for right rail 1, front truss 1 and front truss 2.

2. Go to 2D>>Connectors>>spot>>type=weld>>total: 3>>diameter: 5>>spacing: 5>>tolerance: 10>>select nodes>>select components>>create

3. After the above step adjust the mesh by remeshing in those regions. The connectors are created as shown in the figure below

Front_truss_2, Front_truss_1 & Left_Rail_1:- Hexa (Adhesive)

1. Hide rest of the surfaces and wireframes except for left rail 1, front truss 1 and front truss 2.

2. Go to 2D>>Connectors>>seam>>type=hexa(adhesive)>>strips: 2>>spacing: 5>>tolerance: 10>>select nodes>>select components>>create.

3. After the above step adjust the mesh by remeshing in those regions. The connectors are created as shown in the figure below

Rear_truss_2 & Right_Rail_2:- Bolt Connector

1. Hide rest of the surfaces and wireframes except for right rail 2 and rear truss 2.

2. Go to 2D>>Connectors>>bolts>>type=bolt(general>>tolerance: 10>>create hole if none>>select nodes>>select components>>create

3. After the above step adjust the mesh by remeshing in those regions. The connectors are created as shown in the figure below

Rear_truss_2 & Left_Rail_2:- Bolt Connector

1. Hide rest of the surfaces and wireframes except for left rail 2 and rear truss 2.

2. Go to 2D>>Connectors>>bolts>>type=bolt(general>>tolerance: 10>>create hole if none>>select nodes>>select components>>create

3. After the above step adjust the mesh by remeshing in those regions. The connectors are created as shown in the figure below

Right_Rail_1 & Right_Rail_2:- Spot-weld with Rigid Elements

1. Hide rest of the surfaces and wireframes except for right rail 1 and right rail 2.

2. Go to 2D>>Connectors>>spot>>type=rigid>>total: 2>>diameter: 5>>spacing: 5>>tolerance: 10>>select nodes>>select components>>create

3. After the above step adjust the mesh by remeshing in those regions. The connectors are created as shown in the figure below

Left_Rail_1 & Left_Rail_2:- Spot-weld with Spring Elements

1. Hide rest of the surfaces and wireframes except for left rail 1 and left rail 2.

2. Go to 2D>>Connectors>>spot>>type=spring>>total: 2>>diameter: 5>>spacing: 5>>tolerance: 10>>select nodes>>select components>>create

3. After the above step adjust the mesh by remeshing in those regions. The connectors are created as shown in the figure below

Front truss 2 & Left_Rail_2:-

1. Hide rest of the surfaces and wireframes except for front truss 2 and left rail 2.

2. Go to 2D>>Connectors>>spot>>type=plot>>total: 2>>diameter: 5>>spacing: 5>>tolerance: 10>>select nodes>>select components>>create

3. After the above step adjust the mesh by remeshing in those regions. The connectors are created as shown in the figure below.

Front truss 2 & Right_Rail_2:-

1. Hide rest of the surfaces and wireframes except for front truss 2 and right rail 2.

2. Go to 2D>>Connectors>>spot>>type=plot>>total: 2>>diameter: 5>>spacing: 5>>tolerance: 10>>select nodes>>select components>>create

3. After the above step adjust the mesh by remeshing in those regions. The connectors are created as shown in the figure below.

Rear truss 2 & Rear truss_1:-

1. Hide rest of the surfaces and wireframes except for reartruss 2 and rear truss 1.

2. Go to 2D>>Connectors>>seam>>type=weld>>total: 2>>diameter: 5>>spacing: 5>>tolerance: 10>>select nodes>>select components>>create

3. After the above step adjust the mesh by remeshing in those regions. The connectors are created as shown in the figure below.

Front_truss_2, Front_truss_1 & Reinforcement plate:-

1. Hide rest of the surfaces and wireframes except for front truss 2, reinforcement plate and front truss 1.

2. Go to 2D>>Connectors>>seam>>type=bush>>total: 2>>diameter: 5>>spacing: 5>>tolerance: 10>>select one side of the reinforcement plate>>create. This is shown in the figure below:

3. Go to 2D>>Connectors>>seam>>type=sealing>>total: 2>>diameter: 5>>spacing: 5>>tolerance: 10>>select the other side of the reinforcement plate>>create. This is shown in the figure below:

The final assembly is shown in the figure below:

RESULT AND CONCLUSION:

Therefore, various parts are attached by creating the given connectors. Also, different types of connectors present in Hypermesh is learnt from this challenge.