Objective

In this project meshing of interior plastic component of a side, door is done with a comparison of mid extraction of component by manual mid surface extraction, automated mid extraction, automated mid extraction with manual mid surface extraction tool present in ansa software.

following quality criterion is used

Target Element Length-4mm

S.N	Quality Criteria	Value
1	Aspect Ratio	3
2	Skewness	45
3	Warping	15
4	Taper	0.5
5	Min. Length	2mm
6	Max. Length	6mm
7	Min angle Quad	45
8	Max angle Quad	135
9	Min angle Tria	30
10	Max angle Tria	110
10	Tria %	15

procedure

1. Taking mid manually
2. check geometry errors
4. removing geometrical errors by following tools

• release - used for to disconnects two surfaces
• topo - to join two surfaces
• new - to make a new surface

below image shows all geometry errors are removed

1. checking different thickness in geometry

manual mid thickness extraction model 1

1. mid extraction using the following tools
2. offset - By giving proper mid thickness value
3. use troppo module - faces section - middle multi or single

4. assigning thickness to all PID

5. use the extent to extend the surface to create ribs and cylindrical surfaces

below image shows triple con is in between circular surfaces and flat surfaces

6.set PID- select entity - then create a new shell with assigning the thickness to it

Automated mid surface mesh generation model 2

1. use of topo section - surface section - mid extraction - casting
3. after that following FE is generated

Fixing quality

1. use of mesh module
2. grids section - move surf is used to repair the quality
3. shell mesh section - reconstruct, smooth, fix quality is used to set quality

Automated and manual mid surface extraction model 3

1. use of an automated tool from - topo module - faces - mid extraction - casting
2. if some surface are not aligned
3. then use of following tools to set correct surface assignment
4. use align manager to set empty surfaces to correct plane, middle, offsets

fixing cylinder using align manager - cylinder

after fixing cylinder by assigning it to a new cylinder

fixing quality mid extraction

1 by giving meshing by quality criterion in below image

1. use of mesh module
2. grids section - move surf is used to repair the quality
3. shell mesh section - reconstruct, smooth, fix quality is used to set quality
5. above image shows all quality fixes.

conclusion

In this project, mid extraction is done on interior plastic component of side door by manual , automatic mid extraction and automatic mid exaction with manual extraction and its found that automated mid extraction is not good on this type of complex part rather that for this type of complex part and manual process is also so much complex and take huge time, So for this process mid surface extraction with manual handling of mid surface extraction is the best procedure.