Project

CROSS CAR BEAM ASSEMBLY USING ANSA V20.1.4

OBJECTIVE:

The main aim of this project is,

QUALITY CRITERIA:

PROCEDURE:

GEOMETRY CLEAN UP AND MIDSURFACE EXTRACTION:

Imported the given .iges file in the ANSA work page.
In order to view the model geometry clearly, the perimeter length of 1mm is applied to the model using the mesh module --> perimeter--> length option.
Checked for orientation i.e. the upper part of the model should be in gray color meaning positive and the lower part in yellow color meaning negative.
The issues with orientation are cleared using the topo module-->faces-->topo.
The model is then subjected to a geometry checkup to check any free edges between the models, duplicate surface, irrelevant CONS using the option tools--> checks-->geometry.
The geometrical errors are fixed by using the Auto option and some are cleared manually.
Since the thickness of the parts remains constant, extracted the mid surface using the topo module-->faces--> mid surface--> skin, while keeping the parent geometry not getting deleted.
Geometry check-up is done and a property ID is created with their respective thickness.
By default, ANSA creates a steel material ID, which is defined so that the material is assigned to the model.

The surfaces are split accordingly to attain good mesh flow and to avoid element failures using mesh module--> macros-->cut option.
1.Mid-surface

MESH GENERATION:

The Quality criteria are applied to the model using utilities--> Quality criteria as shown below,
2.Quality Criteria

Mesh parameters are applied as shown below, using utilities--> mesh parameter.
3.Mesh Parameter

The perimeter elemental length is applied to the model using the mesh module --> perimeter--> length option.
The split surfaces are meshed one by one using mesh module--> mesh generation--> Best option.
During meshing the opposite trias, back to back trias, tias present at the edges, rotational quads can be removed using shell mesh--> reconstruct option.
Trias present at edges, fillet areas, pattern formation, opposite trias can be avoided using split, swap, reconstruct, edge2 perimeter, Num +/- options.
The elements which fail for quality can be viewed by using the Draw mode toolbar --> hidden option and corrections are done for the elements which fail for quality.
4.Meshed Model

THICKNESS ASSIGNMENT:

The thickness assigned to the model can be viewed using utilities--> quality criteria--> presentation parameters --> draw shell as solid.
5.Thickened Model

CONNECTION:

In order to connect the model with appropriate connections, here the bolt connections and seam weld connections are used.

Bolt connection:

The bolts can be represented as rigids, it can be modeled with RBE2 elements.
Here, the automatic blot representation method is used.
To create that, a 3D point has to be created on the hole COG as shown below using Topo>points>on COG.
6.3d Point

Then the 3D point has to be converted as blot representation using convert>3D point>bolts in assembly toolbar as shown below,
7.Bolt Representation

Then the connection manager in the assembly toolbar is used and required inputs are provided for the bolt representation as shown below,
8.Control Manager for Bolt Creation
9.Bolt connections

Manual Bolt connection:

Bolt connections are provided to the holes, where the parts are to be connected with bolts.
That can be identified when the part holes are located next to each other.
It is recommended that the bolt representation to the holes can be captured using a washer split of one layer.
Generally, bolts can be represented as cluster RBE2 as well as two-node RBE2 connecting the master nodes of spider RBE2s.
Generally, these bolt representations are done manually using Nastran deck>elements>RBE2.
10.Manual Bolt Representations

Seam connection:

Seam weld is used to connect the parts in continuous seam line.
It provides more structural rigidity to the system.
To generate seam weld, the seam data has to be obtained and then curve is created along the length to represent the seam length.
Then the curve has to converted into seam line using the assembly toolbar convert>curves> seam line.
Then the seam line can be realized using connection manager from assembly toolbar and inputs are provided as shown below,
11.Control Manager for Seam Weld Connection-y-joint
12. Control Manager for Seam Weld Connection-Overlap joint

The seam weld representation as follows,
Basically, if the parts are parallel to each other, then the FE rep type has to chosen as overlap shell.
13.Seam Weld Representation for Parallel Parts
If the parts are perpendicular to each other, then the FE rep type has to chosen as Y-joint shell.
14.Seam Weld Representation for Perpendicular Parts

RESULT:

Hence,

LINK TO VIEW THE MODEL:

CROSS CAR BEAM ASSEMBLY

Ship work like this
in your own course.