Modeling Rear suspension assembly using ANSA V19 1 2

Project name: Modeling Rear suspension assembly

Objective: To model the given rear suspension CAD model and assemble using connections

Quality criteria:

Quality Criteria for Tria Elements (Tyre and Rim):

S.No	Quality Criteria	Value
1	Target/Average length	7.5
2	Minimum Length	5
3	Maximum Length	10
4	Skewness	45

Quality criteria for Tria Elements (For other components):

S.No	Quality Criteria	Value
1	Target/Average length	4
2	Minimum Length	2
3	Maximum Length	6
4	Skewness	45

Common Quality Criteria for Tetra elements:

S.No	Quality Criteria	Value
1	Tet-collapse	0.2

Quality criteria for Mixed elements (For Midsurface only):

S.No	Quality Criteria	Value
1	Target/Average length	4
2	Minimum Length	2
3	Maximum Length	6
4	Aspect	3
5	Warpage	15
6	Skewness	45
7	Jacobian	0.7
8	Minimum Quad Angle	45
9	Maximum Quad Angle	135
10	Minimum Tria Angle	30
11	Maximum Tria Angle	120

Procedure/ steps:

1. Open the CAD model in ANSA V19.1.2 using the open option under files in the main menu.
2. Refine the model using length option under perimeters in the mesh module to visualize the features properly.
3. To check for geometrical errors, use the geometry check option in the tools menu.
4. Clear all geometric errors present in the model and confirm the same by rerunning the geometry check again. Most of the errors were triple con errors, formed due to close proximity of the different components of the suspension model. For removing these triple cons, each component was separated by using iNOT with PID region selection turned on. Some misalignment was also found in a few components. In those cases, the respective faces were deleted and recreated to eliminate the issue.
5. The next step is to mesh the components. The model has both solid components as well as components of uniform thickness( <5mm). The respective quality criteria were used to mesh each type of component.
6. Tria quality on the surface mesh of solid components:
7. Tria quality on the surface mesh of the tire and rim part:
8. Mixed element quality on mid-surface:
9. Each component was meshed to meet the required quality criteria. In the case of uniformly thick components with a thickness of less than 5 mm, the mid-surface was generated and meshed accordingly. Appropriate thickness was assigned for the mid-surface while defining its PID.
10. In the case of solid components, first, the surface was meshed according to given criteria and then the volume was defined using the 'define volume' option in the V-mesh deck. The volumes were then meshed using tetraRapid or tetraFEM algorithms.
11. To check for quality, change the focus to the hidden option. Quality in most regions was solved.
12. Now that all the components have been modeled, we have to deploy appropriate connections between the components to assemble the suspension model.
13. The mesh elements were released and the FE model of the suspension components was generated after which, RBE2 elements and seam weld was used to connect the parts together.
14. The complete suspension assembly was generated using the mirror option under transform.

Result:

1. The suspension model was cleaned for geometric errors and meshed to satisfy the given quality criteria.
2. All the features were captured properly.
3. The suspension model was assembled using appropriate connections.

Learning outcomes:

1. Modeling solid components and realizing connections on them.

Go to the link below for the Completed ANSA file:

https://drive.google.com/drive/folders/1GLdZaLevCNet0VBaxI01SLFU7LBvfRJQ?usp=sharing