The Advanced Pre-Processing The Car Backdoor Model using BETA CAE ANSA

TOOL TEST - 2

The Advanced Pre-Processing The Backdoor of the Car using BETA CAE ANSA.

Total time Spending: 6hrs

Objective:

1. Clean The geometrical Error in the Model.
2. Extracting the Mid-surface both the inner and outer panel.
3. Carry out the Hemming process.
4. Mesh generation with suitable Method
5. Clean the Surface meshing error

Abstract:

The door module is preassembly of various components on a carrier plate that can be directly mounted onto the door inner panel. These door modules, when directly shipped to the OEM’s, save assembly time and cost in mass manufacturing. Long fiber reinforced thermoplastic polypropylene (PP-LFT) with glass-filled fiber material is used for various automotive applications as it has improved structural and material properties over conventional materials like steel. Door modules made of PP-LFT material are manufactured using an injection molding method. Although significant work was done on design and analysis of plastic door modules, there was no support information on how the final design of the door module was arrived at. Topology and shape optimization were used in the present investigation to arrive at a design. 30 % glass filled STAMAX® PP-LFT door modules were used to replace the existing steel door module plate. Stress analysis and dynamic door slam analysis were carried out on the door module of the new design to assess its performance under various durability loading conditions. Finally, Mold flow simulation was performed on the door module part to check its manufacturability in mass manufacturing. The final design of the STAMAX® PP-LFT based plastic door module is 33 % lighter than the existing steel door module plate and has improved strength, stiffness, and manufacturability.

Introduction:

Doors are one of the major components in a car which provide easy access for passengers into the car.

With the growing demand for car styling, comfort, safety and other systems integration (window regulator, latch, speaker, motor and electronics) in the door, designing this system is a great challenge to engineers. The door system mainly consists of window glass, window regulator assembly, door latch, sealing and structural components of the door assembly. Traditionally these parts were designed, manufactured and procured separately. A door module is an assembly of functional elements mounted onto a carrier plate. Unlike conventional door systems, where the window regulator assembly was directly attached to the door inner panel, the door module comprises a carrier plate with window regulator assembly, glass motor, and speaker. The window regulator consists of a motor assembly, one or two rails to guide the glass motion, cursor or glass clamps to support the glass, and mechanisms to move the glass up and down. The window regulator, speaker, and other wire harnesses are mounted on the carrier plate using bolts, rivets, and clips. The detailed figure of the door module assembly is shown in Figure 1. The carrier plate is bolted to the inner panel. This module approach helps the car makers in reducing assembly time and hence cost. Thus, the design and manufacture of door modules are very important.

A door module should perform the following

functions

1. Window regulatory function
2. Latch function
3. Speaker function
4. Sealing function

A door module offers several advantages over

conventional door systems. Some important advantages

1. Higher structural strength
2. Better sealing against water vapor and hence door

modules are called “Sealed Carrier Systems”

1. Better noise insulation
2. Dry side mounting of motor and door electronic

components

1. Weight savings and hence cost savings due to
2. the reduced sheet metal on the door inner panel

Methodology:

1. First starting the open the model in software. I can showing the image for open manager. In this step ansa translating the model into ansa file. there are many fomat support in the ansa like .step, .igs, .CATpart, .sldp and many more.

Image 1

2. Now, the model is opened. when i seened this model there are many tripple & single coons are present. This is a translating issue. before performing any meshing first resolve all the issue for a suitable manner. The Tripple coons are formed when more than two faces come in contact in one edge and single coons mean the edge are free means not contacting other faces.

Image 2

3. The Checks manager shows the different types of errors I am attaching the image below. we've got the 180 errors in this model. Some errors I can fix the remesh and reshape method but some complicated error resolving manually.

Image 3

4. After all the Topological error resolved I checked both inner and outer panel into the checks manager geometry check. The checks manager showing me the all error resolved.

Image 4

5. Once I clear the all topological error the model is now set to the lock view. The benefit of this lock view is whenever you required the any geometry you clicked and open it only this geometry.

Image 5

6. Now, I am deleting half of the model because the model is symmetrical in nature so I perform only half of the geometry and after all the procedure done I can copy in another side. Hence, I reduce the time required and the effort also.

Image 6

7. Now I am checking the thickness of the panel for random points. Hence I follow The following steps:
8. Creating Weld Spot > Project to another side > measure the distance > Store the Measurement
9. Now, I got the thickness of the all random point. this thickness is using when I can extracting the mid-Surface using Offset option.
10. Once I am extracting both the panel mid-Surface. I can check the geometry to any geometrical errors present in the model. and resolving all the errors.

Image 7

10. Hemming Process: Hemming and seaming are two similar metalworking processes in which a sheet metal edge is rolled over onto itself. Hemming is the process in which the edge is rolled flush to itself, while a seam joins the edges of two materials. Hems are commonly used to reinforce an edge, hide burrs and rough edges, and improve appearance. Seams are commonly used in the food industry on canned goods, on amusement park cars, in metal roofing (with a roof seamer), and in the automotive industry.

Image 8 Image 9

Now, we have to see the hemming region. In this area, we projecting the clipped outer edge into the inner panel and outer panel and deleting unwanted region. after the pasting both inner panel and outer panel edges. Hence the three surfaces comes in contact in one edge and this is required For hemming.

Image 9

11. After completing all the hemming process. Now, I can mesh the model for suitable Meshing elements. There are many ways to do the meshing like:

Mesh > Mesh generation > Free > Visible

Mesh > Mesh Generation >best > visible

12. Now, I can set the required parameters for the meshing as per the given.
13. After setting up this quality criterion the unfitted element we've automatically seen when I clicked to Hidden option.

Hidden: Hidden mode displaying all the violating elements according to the setting of the quality criteria.

14. Now, I can be resolving violating elements step by step.

First, I can resolving Errors for the following option.

Reshape Advanced mesh quality improvements by mesh reconstruction and automatic perimeters joining of macro areas.

15. Remaining some complicated Elements Resolve by manually for Following option

1. Remesh macros - Remesh macros that ave cost their mesh with some meshing algorithm that had been used on them.
2. Move Surf- Move a single mesh mode on a macro-areas surface.
3. Swap - Swap on edge of two connected elements.

Conclusion

• In this project, The Extracting the mid-Surface using three strategies namely Manual extracting, Auto-Mid Surface and Both Auto-mid Surface and Manually creating some Complicated geometries.
• Among the three different techniques, the most accurate method is the manual extraction method.
• The fastest method is the auto Mid surface extrusion but the mid surface generated is not completely similar to parent surface especially for the complicated geometry. Hence I prefer Manually Extrusion Method For better accuracy.