Cross Car Beam Assembly Mesh with Connections in ANSA.

AIM :

To Check for the geometrical errors, take mid-surface and mesh with the given element Quality Criteria for the given Component and perform suitable connections.

OBJECTIVE :

For the given CCB CAD model, Check for the Geometry cleanup (if required), Take the mid surface, and Mesh it with the below 2D element Quality criteria.

THEORY :

A method for manufacturing a cross-car beam assembly for use with a vehicle includes joining first and second support brackets to opposite ends of a cross-car beam using an adhesive, such that the adhesive is a primary attachment means for joining the support brackets to the cross-car beam. Furthermore, the support brackets are attachable to the vehicle so as to support the cross-car beam in the vehicle.

PROCEDURE :

IMPORTING CAD MODEL AND GEOMETRY CLEANUP :

Import the given CAD Model in ANSA by using File-->Open.

After Importing the CAD Model in ANSA, Go to Tool-->Checks-->Geometry for Geometry Clean up.

In the above Checks Manager window click Execute to check any error occurred in Hood Model and fix the Error and Cleanup the Geometry.

In The above window, an error has occurred in the given Geometry model. Check the error showing in the Model and fix the issue and clean up the Geometry.

While resolving the error, Right Click on the error which is going to resolve and click Show only option.

It will show only that Unchecked Faces. Using Face-->Delete Option to delete the Unchecked Faces.

After deleting the Needle Face, that error has been resolved. Similarly, all errors have to be fixed, and again Click Execute in the Checks Manager, and 100% Geometry Cleanup is to be verified.

CREATING MID-SURFACE :

After geometry Cleanup and Mid-surface has to be created separately for each component.

Go to Topo-->Midsurface option and select the face and Create Midsurface.

After creating a Mid-Surface, Click Faces--> Set PID option and create New PID for Each component in the properties.

MESHING :

After Creating a Mid-Surface, set the given Quality Criteria for the Component. Go to

Utilities-->Quality Criteria Option and assign the given Quality Criteria Values.

After assigning the Quality Criteria for the Component, Go to Utilities-->Mesh Parameters and assign the Average Value, Minimum, and Maximum Value for Meshing.

Go to Mesh-->Perimeters--> Length Option and Select the Component to Mesh and enter the Value of Perimeter Length and Macro Length for Meshing.

Go to Mesh-->Mesh Generation Option and Select the Mesh type to mesh the component. Select the Mesh type in the Mesh generation and Select the Faces to mesh and Mesh will be generated.

Use Shell Mesh-->Reconstruct option to rearrange the Mesh and Use Shell Mesh-->Smooth Option to arrange Mesh lines equally within the Selected Surface and solving the Quality criteria issues.

Use Grids-->Paste or Elements-->Split / Swap / Joint Option to eliminate or reduce the trias and get better mesh flow.

Check if there are any off elements is present and reduce the off elements and some areas of off elements will be acceptable.

Parent Surface thickness Value is to be Provide for the Mesh Component. Go to

Lists-->Properties option and Assign the Thickness Value.

Go to Quality Parameter-->Presentation Parameters and select Draw shell as solid, click Apply and Ok.

PERFORMING SUITABLE CONNECTIONS :

Go to Topo-->Points-->On the COG option and select edge to create a point.

After Creating a point, Go to the Convert option and select a point and Select a Bolt connection type.

Go to the Connection option and Select the Bolt point and Click ok, Connection Manager window will open.

In the Connection Manager window, select the part to make a connection and set it as FE Rep type as Bolt, Search Distance as 20, and Zones as In/out.

After setting all in the connection Manager window, click apply & Realize.

SeamWeld Connection :

Go to Topo-->Curves-->Cons2Curve option and select edge to create a curve.

After Creating a Curve, Go to the Convert option and select a curve, and Select Seam line connection type.

Go to the Connection option and Select the Seam Weld point and Click ok, Connection Manager window will open.

In the Connection Manager window, select the part to make a connection and set it as FE Rep type as Overlap shell (or) Y joint shell, Search Distance as 20, Base Sheet as P2, Step Length as 2, Width as 3.

Create & select Weld PID property and click apply & Realize, above same steps to be followed for Y Joint Shell Connection.

RBE2 Connection :

Connecting all other parts by using RBE2 connection.

Go to NASTRAN DECKS-->Elements-->RBE2-->Many nodes Option and select the nodes and Create an RBE2 connection.

RESULT :

Checked for the geometrical errors & taken mid-surface for CCB Assembly and meshed with the given element Quality Criteria for the given Component and performed Bolt connection, Seam Weld Connection, and RBE2 connection.