Surface Wrap of Engine, Transmission and Gearbox using ANSA

In this challenge, we will perform surface wrap using ANSA on the Engine block, transmission, and gearbox. A surface wrap is an extremely fast method of generating surface mesh for the outer surface only. The surface wrap only covers the outer surface of the geometry. It is like keeping the complete geometry in the airtight bag and then sucking out the complete air from the bag, this will create an almost exact surface mesh elements for the complete exterior geometry. This is a very fast and beneficial method where we only need to examine the exterior fluid flow over an object.

Engine block

• Show only unchecked items. Then go to untrim option in the surfaces menu. Then hold and drag the complete unchecked entities. After that click middle mouse button and click ok.
• Now delete all the unnecessary entities which are not required and can degrade our surface wrap.
• The image below shows many entitie which are just hanging in the air, these kind of entities and many other circular geometries are not needed.

• The pink color sphere is some extra geometry just used by CAD engineer for reference. We also have to delete it.
• Now we have to cover all the open circular ends and orifices before creating surface wrap.
• We have to this because it will generate a smooth surface wrap. if we do not cover the openings then the surface wrap wil distort and try to get inside all the circular openings.
• To do this first click release option in the cons menu. Then left click hold and drag the mouse around the complete geometry to select it. Then click middle mouse button.
• After this click fill hole in the cons menu, the left click and drag around the complete geometry.
• Now click middle mouse button, this will fill all the circular opening and orific.
• After following all the sbove steps we will get the result as shown below.

• Now we have to do the surface wrap. Click on the wrap option in the elements menu and set the required parameters. Set target length as 8 and smooth factor 0.5. And select nodes out of structure, assign properties from structure.
• After following all above steps we will get the final result as below.

• After surface wrap we have to delete the entire geometry because we no longer need it.
• After deleting the geometry compress the file.

Transmission

• We will start with deleting the unnecessary components.
• After deleting all the unnecessary components fill all the holes by fill holes option.
• Now we are ready to do the surface wrap. Click on the wrap option in the elements menu and set the required parameters. Set target length as 5 and smooth factor 0.5. And select nodes out of structure, assign properties from structure.
• Now compress the file.
• After following all above steps we will get the final result as below.

Gearbox

• Now we will start working on the gearbox in the same manner as we did wtih the previous two geometries.
• First check for any unwanted components and close all the holes.
• Now we are ready to do the surface wrap. Click on the wrap option in the elements menu and set the required parameters. Set target length as 5 and smooth factor 0.5. And select nodes out of structure, assign properties from structure.
• Now compress the file.
• After following all above steps we will get the final result as below.

Merge three seperate files into one single file

• Select merge option from file menu and select the files to merge.
• Then we have to divide the three geometries into three different parts in the model browser.
• We will get the merged file as shown below.

Model browser

• We have to divide the three surface wraps into three seperate entities using model browser.
• To do this, make visible all the three geometries one by one and defie the new part from visible.

Deleting the overlapping surface wrap elements.

• To delete the intersecting wall elements, go to mesh mode and select delete under elements menu.
• Then click feature area button adjacent to PID region button and specify the angle as 10 degree.
• Then delete the selected entities by pressing middle mouse button.

• Then make visible The interface between the transmisson and gearbox and lock the view.
• Now we have to delete the elements of transmission at the interface of the wall.
• To do this go to Decks module. Then click release option under the nodes menu.
• And release all the element edges around the boundary of the gearbox.
• After performing the release operation select the elements and delete them.
• After following all the above steps we will get the results as shown below.

• After deleting the intersecting elements a gap is created between the interface. We have to create new elements at this interface.
• To do this we can use three different tools, namely paste, fill and new under mesh module.
• After using the appropriate tools and joining all the gaps we will get the final result as shown below.

• After that, we have to eliminate the intersecting surface wrap elements between transmission and engine block.
• Now we will do this in a different manner than we did earlier above.
• First, we will join the outer interface by creating new elements, this will create triple bound.
• After creating the new joining elements we can simply delete the intersecting surface wrap elements.
• After following all the above steps we will get the final result as shown below.

Final result