Meshing an interior plastic component of a side door in a car using ANSA

Objective:

To Mesh the interior plastic component of the side door of a passenger vehicle with given quality criteria.

1. To Extract the mid-surface manually & mesh the geometry with quality.
2. To Extract mid-surface Automatically and mesh the geometry with quality.
3. Then Finally with the combination of both Extract auto mid-surface and manually mid surface and then mesh the geometry with quality.

After meshing assign thickness and check if the geometry is captured properly.

PROCEDURE:

The following procedure will be followed :

1. GEOMETRY CLEAN-UP
2. EXTRACTING THE MID-SURFACE
3. ASSIGNING PID\'S & THICKNESS
4. MESH GENERATION
5. QUALITY CRITERIA

GEOMETRY CLEANUP:

• When the model is imported, it has a lot of topological errors.
• The model is checked for any errors by checks manager, Hence it is found that there are a lot of single cons, triple cons, needle faces & cracks.
• All those errors are corrected systematically one by one.

UNCLEANED MODEL

CLEANED MODEL

CASE 1. EXTRACTION OF DOOR(MIDSURFACE) BY MANUAL METHOD

GEOMETRY CHECKUP:

MID SURFACE:

1. First, we will create the mid surface by manual method. To do this we can use the middle option in the faces menu for small parts and for large continuous surfaces we can use offset option in the faces menu.
2. We have to use the necessary tools to create the middle surface one by one for all the entities in the geometry. Once we have created all the middle surfaces and assigned thickness, we will get the final result as shown below.

PID

Mesh parameters

Now we will mesh the middle surface. Before meshing the surface we have to set the meshing parameters and mesh quality criteria. Below are the images for mesh parameters and mesh quality criteria.

MESH QUALITY CRITERIA

MESHING:

For meshing, we are using the \"best\" meshing option in the mesh module. After meshing we will get the final result as shown below.

After clearing all mesh errors, the results are shown below without any off elements.

SURFACE MESH CHECK

CASE 2. EXTRACTION OF DOOR(MID SURFACE) BY AUTO & MANUAL METHOD

Now we will use the same door inner panel to create the mid surface by auto and manual process. For large and simple entities we can use auto mid surface generation option in the faces menu. But for complex parts, we can use the manual method. The use of both methods will save time in creating the mid surface.

MIDSURFACE:

1. The mid surface shown below is created by the auto method.
2. The auto mid surface generation will generate the mesh elements but we can get the required surface from the mesh elements by using the \"to surface\" option in the elements menu in the mesh module.

Then, the mid surfaces for the remaining entities are created by manual method.

MESHING:

In the above image, we can see that there are no remaining OFF elements

Surface mesh checks:

CASE 3. EXTRACTION OF DOOR(MID SURFACE) BY AUTO METHOD

1. Now we will use the same door inner panel to create the mid surface by entirely by the auto process.
2. This method is the fastest for creating the mid surface, but it has some downsides too. The mid surface created entirely by the auto method has some issues, it does not create the mid surface properly for the complex geometries.
3. To create the mid surface by auto method, select Mid surface option in the faces menu.

PID:

Meshing:
We will use the same mesh parameters and mesh quality criteria for mesh generation.
After clearing meshing errors we will get the final result as shown below

In the above image, we can see that there are no remaining OFF elements.

CONCLUSION:

1. In this project, the mid surface for the car door inner panel was generated by three different strategies, namely Manual, Auto & Manual, and Auto method.
2. Among the three different techniques, most accurate in generating mid surface was the Manual technique.
3. The fasted method was the Auto method but the mid surface generated was not completely similar to the parent surface, especially for the complicated geometries.

drive link :

https://drive.google.com/open?id=1a9INgsOtwEOGWGFANU-D9a6HWrpu-tcm