Modelling, 2D meshing, and CAD extraction from FE model in Hypermesh

SECTION I

Objective: To model the provided design in Hyperworks

Features used: We will be using Generate Nodes, Lines, surfaces, fillets, trim and delete features in order to generate the model.

Design:

Procedure:

1. We start by creating two lines in the XZ plane using the XYZ Coordinates of the points of the lines :

(0,0,0) and (0,0,100)

(0,0,0) and (100,0,0)

2. Then we add a fillet of 5 mm to the line

3. Then we use Drag along vector command to create the surface. The nodes to be selected for giving the vector direction are created by using the temp node feature as shown

4. Then the corners are filleted by a radius of 15mm, as shown:

5. Then in the YZ plane two lines are created using the XYZ command as shown. Since the design input is insufficient, the lines are assumed to be at 30mm distance from the edge. Co-ordinates of the lines are:

(0,0,70) and (0,30,100)

(0,70,100) and (0,100,70)

6. The corners are trimmed by using trim with lines feature, and keeping normal to surface option selected:

7. Three nodes are created at following co-ordinates using the create nodes option:

(0,50,0)

(0,50,40)

(40,50,0)

8. A plane is created using the three points as shown using the Square Size of plane is 40 mm (half)

9. Then the extract parametric option is used to obtain the lines of intersection of the center plane with the rest of the surfaces. Another line is created from the two end points of the newly generated line.

10. A surface is created from the lines, using the Ruled command

11. A circle of radius 5 mm is created at (0,50,75) using the Circle center and radius command

The surface is trimmed to separate the circle from the rest of the surface using the Trim with lines command

The trimmed surface is deleted using the Delete command and selecting the surface option.

14. The corners are filleted with a radius of 10mm, then the surfaces are trimmed and deleted to arrive at the required geometry.

SECTION II

Objective: To mesh the given model for Target size 5mm, Min size 2 mm and Max size 8 mm

Model:

Procedure:

1. Import the model into Hyperworks by clicking on “Import Geometry” and selecting the file.
2. Go to Geom-Autocleanup. Then select all surfaces and click on autocleanup
3. Click on 2D – Automesh
4. Then in the input, select Surfaces and click on select all. Give element size as 5 mm, and elements as
5. Then click Mesh.
6. Following result is obtained:

6. Now click on the node number at the holes to match them with the node number of the washer split:

6. Do the same for all the holes:

8. Go to 2D - Element Cleanup, select all elements, and input following criteria

Then click on Cleanup.

9. Then go to 2D – Quality Index and check that there are no elements failing the quality criteria as shown:

SECTION III

Objective: To extract CAD surface from given FE model

Model:

Procedure:

1. In Hyperworks, click on Import model and select the FE model and click Import.
2. Click on the XZ view plane to get above view.
3. Go to Geom-Surfaces and click on From FE
4. Click on Elements-all and click Create
5. The CAD model will be generated from the mesh: