Batch Meshing and Casting

OBJECTIVE:

• For the given Sheet Metal model, take the mid-surface after checking the geometrical errors.
• Perform the Batch Meshing on the mid-surface with the given element quality criteria.

S.No	Quality Criteria	Value
1	Target/Average length	3
2	Minimum Length	1
3	Maximum Length	5
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
10	Tria Percentage	15

PROCEDURE:

• Import the CAD model into the ANSA interface.

• Perform CONS resolution by using the Length option under the Classic Mesh module. The suggested value is 1 for CONS resolution.

• Check for connectivity between surfaces by visual inspection and use the Topo option.
• By using the Orient option, make sure that all surfaces have normal in one particular direction.

• Perform a geometry check on the given model to eliminate errors like superimposed surfaces, single cons, holes, etc.

• Use the Auto fix option to eliminate the errors.

• Measure the thickness of the model to make sure that it is a sheet metal model.

• Use the Midsurface - Skin option to generate the mid-surface of the given model. Make sure to uncheck the 'Delete Original Faces' option from the list before performing this operation.

• After the generation of the mid-surface, go to Perimeters -> Length and enter the target element length.

• Now open the Batch Mesh Manager from the taskbar. Create a Meshing Scenario from the New option.

• Right-click the Meshing_Sceneario_1, go to Edit, and then open Contents.

• Now select Search for PIDs and choose the mid-surface we have already created.

• Check the Mesh parameters and Quality criteria one more time and then click the Run button.

• The mesh has been generated but the mesh flow is not that good. We will take 2 areas and try to create a good mesh flow.
• The area before is given below

• From observing the above area, we can see a lot of tria elements. we can divide this area by using the Edge2Perimeter option and then reconstruct it.

• Now consider an area with a hole. For proper mesh generation, we can increase the number of nodes to 6.

• Now slide the node in such a way that the edge is parallel to the nearest feature line. After that mark the nodes. We need to create a washer around the hole using the Zone Cut option.

• Convert the edges of the washer to the perimeter and freeze the mesh to avoid any changes while reconstructing.

• Similarly, other areas should also be reconstructed in such a way that there is a good mesh flow.

CASTING

OBJECTIVE:

• For the given plastic model, generate the Casting after checking the geometrical errors with the given element quality criteria.

S.No	Quality Criteria	Value
1	Target/Average length	5
2	Minimum Length	2
3	Maximum Length	7
4	Aspect	5
5	Warpage	15
6	Skewness	45
7	Jacobian	0.7
8	Minimum Quad Angle	45
9	Maximum Quad Angle	135
10	Minimum Tria Angle	20
11	Maximum Tria Angle	120
10	Tria Percentage	15

PROCEDURE:

• Import the CAD model into the ANSA interface.

• Perform CONS resolution on the model using the Length option from the Classic Mesh module.

• Check for connectivity and use the Topo option to make sure that all surfaces are connected.

• Use the Orient option to ensure that the normal is in one particular direction.
• Perform a geometry check on the model to identify any faults or single CON errors. Use the Auto Fix option to eliminate those errors.

• In this method of mesh generation, we don't have to create a mid-surface.
• Select the Mid Surface -> Casting/Extrusion option from the Faces section under the Topo Module.

• Enter the Minimum Thickness and Target element length as per the problem statement.

• Go to the Options tab and uncheck the 'Stop at geometry errors'.

• Click on OK and wait until the entire mesh has been generated.

CONCLUSION:

• The Batch Meshing method was used to generate mesh for the sheet metal model.
• The Casting Method was used to generate automatic mesh for the plastic model.