Generate volumetric mesh for Turbocharger

OBJECTIVE :

     The perform volumetric mesh on the Turbocharger using different tools available in the ANSA. 

     Different topological errors in the geometry are cleaned up.

     The surface mesh is created using meshing tools.

     The volumetric mesh for the geometry is generated.

PROCEDURE :

Topological Errors 

       The first step is to identify the different topological errors in the geometry, the single cons are the indication of the errors. The errors in the geometry are below

1. Extra part error 

The part is unwanted extrude so simply delete pink PID.

2. Missing part error                                           

Missing parts on the bottom of the turbocharger so faces options is used to create it. Since the faces created always intersect the part so create extra hot points using parameters options under hot points and provide the parameter value and use the coons options to create new faces.

The part missing is simple use fitted option under cons select the entities and click ok.

3. Extra face error 

The red cons are to be deleted, use the intersect option and delete the extra faces. 

The project tool is used to project the face and delete the top surface in the second image.

4. Shaft error

The convert the different PID into a single volume. The different tools like project, topo, cut are used in this. The main step is to convert different separate entities into a single entity. 

CUT - The option under faces cuts the existing face, the two hot points at the boundary where the faces are to be split.

TOPO - The option under faces, the function automatically creates topological conditions between the selected adjacent cons.

PROJECT - The option under cons, the cons to be projected is selected and the surface in which to be projected is selected. 

The PID region for the different surfaces is created and the name for the PID is provided.

Meshing Surface

The Element length for the different PID is given and then the free mesh option is used to create the surface mesh. 

After the mesh generation at the interface of the shaft rotor, the mesh is deleted due to the difference in the element length. So the mesh is again created on the shaft rotor.

The extra surface is created at the shaft & casing so to delete it use the project option & cut under macros used to select two hot points from which patch is created and element length is set at 3.

CFD can be simulated only when all the surfaces are closed, so to create the surface for the inlet & outlet of the compressor & turbo casing.

Surface mesh figure 

Volumetric Mesh

           Click V.mesh option and click on the define option to create the volume for the different regions. 

            A total of eight regions are created, all the regions are not required for the volumetric mesh, delete the unwanted region.

            Use Tetra CFD mesh to create the volumetric mesh.

Tetra CFD - Algorithm is most suited for geometries of thick volume, large domains with significant variation in the length of the surface mesh. 

Cut section of the mesh

Conclusion 

      The different topological errors in the geometry are cleaned using ANSA. Perform the 2D & 3D mesh on the Turbocharger. The mesh is done successfully for model and flow simulation can be made using the volumetric mesh.