Meshing of Chassis Assembly Housing and Crank Housing using 3D Tetra Mesh Element

OBJECTIVE:

1. To create the tetramesh for housing model using the criteria given below:

Target Element Size: 5mm

Minimum element size: 2mm

Maximum element size: 7mm

Tet collapse: 0.15

2. To create tetramesh for chassis assembly and other model using the criteria given below:

Target Element Size: 6mm

Minimum element size: 2mm

Maximum element size: 7mm

Tet collapse: 0.15

PROCEDURE:

For housing model the procedure is given below:

1. Go to Import solver deck>>Import geometry>>File type: STEP>>select the file>>Import.

2. Hide the component and wire frame \"Model 2\" from the components view tab. Keep component \"Model\" as current component. Go to delete>>solids>>displayed>>delete.

3. Change the geometry colour mode to \"By Topo\" to clearly analyse the gemetry. Now go to Geom>>defeature>>surf filets>>Fillet range: 0.1mm to 8mm>>select surface>>find>>remove. This would remove all the fillets in the geomtry. (autocleanup can also be used)

4. Manually check for errors over the geometry and fix the erros using defeature option or manually remove the fillets by picking the surface individually.

5. Go to 2D>>sizing and bias>>elem size: 5mm>>elem type: trias>>surfs>>select displayed>>mesh. This would create 2D mesh over the surface as shown in the figure below

6. Go to 2D>>quality criteria>>check for element length failure>>save failed. Go to 2D>>rebuild mesh>>elems>>retrieve>>enter the given criteria>>rebuild.

7. Go to 2D>>elem cleanup>>elems>>retrieve>>edit criteria (enter the given criteria)>>cleanup. This step to be done if the erros are not fixed even after rebuilding the mesh. The mesh is cleaned until the quality criterias are achieved. This is shown in the figure below.

8. Go to 3D>>tetramesh>>Tetramesh parameters>>tet collapse: 0.15>>Tetra mesh>>elems>>displayed>>mesh. 3D tetramesh is created. This is checked by using mask option in the Tools menu. This is shown in the figure below.

9. Go to Tool>>check elemns>>3D>>tet collapse: 0.15>>check if all the elements pass the criteria. If not manually fix the error by saving the failed elements and retrieving them after masking the other elements.

10. The final meshed model is shown in the figure below.

11. Hide the component and wireframes of \"Model\" and \"auto001.1\"from the components view tab. Make the component \"Model1\" as current component. Go to delete>>solids>>displayed>>delete.

12. Change the geometry colour mode to \"By Topo\" to clearly analyse the gemetry. Now go to Geom>>defeature>>surf filets>>Fillet range: 0.1mm to 8mm>>select surface>>find>>remove. This would remove all the fillets in the geomtry. (autocleanup can also be used)

13. Manually check for errors over the geometry and fix the erros using defeature option or manually remove the fillets by picking the surface individually.

14. Go to 2D>>sizing and bias>>elem size: 5mm>>elem type: trias>>surfs>>select displayed>>mesh. This would create 2D mesh over the surface as shown in the figure below

15. Go to 2D>>quality criteria>>check for element length failure>>save failed. Go to 2D>>rebuild mesh>>elems>>retrieve>>enter the given criteria>>rebuild.

16. Go to 2D>>elem cleanup>>elems>>retrieve>>edit criteria (enter the given criteria)>>cleanup. This step to be done if the erros are not fixed even after rebuilding the mesh. The mesh is cleaned until the quality criterias are achieved. This is shown in the figure below.

17. Go to 3D>>tetramesh>>Tetramesh parameters>>tet collapse: 0.15>>Tetra mesh>>elems>>displayed>>mesh. 3D tetramesh is created. This is checked by using mask option in the Tools menu. This is shown in the figure below.

18. Go to Tool>>check elemns>>3D>>tet collapse: 0.15>>check if all the elements pass the criteria. If not manually fix the error by saving the failed elements and retrieving them after masking the other elements.

19. The final meshed model is shown in the figure below.

20. The final housing assembly is shown below.

For Crankhousing model the procedure is given below:

1. Go to Import solver deck>>Import geometry>>File type: Model>>select the file>>Import. Go to delete>>solids>>displayed>>delete.

2. Change the geometry colour mode to \"By Topo\" to clearly analyse the gemetry. Now go to Geom>>defeature>>surf filets>>Fillet range: 0.1mm to 8mm>>select surface>>find>>remove. This would remove all the fillets in the geomtry. (autocleanup can also be used)

3. Manually check for errors over the geometry and fix the erros using defeature option or manually remove the fillets by picking the surface individually. Also, use toggle edge option to fix the surfaces near holes. The final cleaned up geometry is shown in the figures below.

                BEFORE CLEANUP                                            AFTER CLEANUP

4. Go to 2D>>sizing and bias>>elem size: 6mm>>elem type: trias>>surfs>>select displayed>>mesh. This would create 2D mesh over the surface as shown in the figure below

5. Go to 2D>>quality criteria>>check for element length failure>>save failed. Go to 2D>>rebuild mesh>>elems>>retrieve>>enter the given criteria>>rebuild.

6. Go to 2D>>elem cleanup>>elems>>retrieve>>edit criteria (enter the given criteria)>>cleanup. This step to be done if the erros are not fixed even after rebuilding the mesh. The mesh is cleaned until the quality criterias are achieved. This is shown in the figure below.

7. Go to 3D>>tetramesh>>Tetramesh parameters>>tet collapse: 0.15>>Tetra mesh>>elems>>displayed>>mesh. 3D tetramesh is created. This is checked by using mask option in the Tools menu. This is shown in the figure below.

8. Go to Tool>>check elemns>>3D>>tet collapse: 0.15>>check if all the elements pass the criteria. If not manually fix the error by saving the failed elements and retrieving them after masking the other elements.

9. The final meshed model is shown in the figure below.

For Chassis Assembly the procedure is given below:

1. Go to Import solver deck>>Import geometry>>File type: Model>>select the file>>Import.

2. Hide the component and wire frame \"Imported 12-1\" from the components view tab. Keep component \"Model\" as current component. Go to delete>>solids>>displayed>>delete. Since the component is symmetrical with respect to y-axis delete the other side component after creating base point using distance>>select points>>points between.

3. Change the geometry colour mode to \"By Topo\" to clearly analyse the gemetry. Now go to Geom>>defeature>>surf filets>>Fillet range: 0.1mm to 8mm>>select surface>>find>>remove. This would remove all the fillets in the geomtry. (autocleanup can also be used)

4. Manually check for errors over the geometry and fix the erros using defeature option or manually remove the fillets by picking the surface individually. The final cleaned up geometry is shown in the figures below.

                                                   BEFORE CLEANUP

                                                     AFTER CLEANUP

5. Go to 2D>>sizing and bias>>elem size: 6mm>>elem type: trias>>surfs>>select displayed>>mesh. This would create 2D mesh over the surface as shown in the figure below

6. Go to 2D>>quality criteria>>check for element length failure>>save failed. Go to 2D>>rebuild mesh>>elems>>retrieve>>enter the given criteria>>rebuild.

7. Go to 2D>>elem cleanup>>elems>>retrieve>>edit criteria (enter the given criteria)>>cleanup. This step to be done if the erros are not fixed even after rebuilding the mesh. The mesh is cleaned until the quality criterias are achieved. This is shown in the figure below.

8. Go to 3D>>tetramesh>>Tetramesh parameters>>tet collapse: 0.15>>Tetra mesh>>elems>>displayed>>mesh. 3D tetramesh is created. This is checked by using mask option in the Tools menu. This is shown in the figure below.

9. Go to Tool>>check elemns>>3D>>tet collapse: 0.15>>check if all the elements pass the criteria. If not manually fix the error by saving the failed elements and retrieving them after masking the other elements.

10. Since the component is symmetrical with respect to y-axis, go to reflect>>elems>>select elems>>duplicate>>current component>>y-axis>>select base point>>reflect. This is shown in the figure below

11. Similarly repeat the steps 1-10 for the rest of the components by making them respective current component and meshing them. This is shown in the figures below:

12. The final meshed assembly model is shown in the figure below.