Cross Car Beam Assembly Mesh with Suitable 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.

S.No	Quality Criteria	Value
1	Target/Average length	5
2	Minimum Length	3
3	Maximum Length	7
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

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.

Fig: Cross Car Beam Assembly

PROCEDURE :

IMPORTING CAD MODEL AND GEOMETRY CLEANUP :

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

Fig: Cross Car Beam Assembly Model

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

Fig: Checks Manager Window

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

Fig: Error in CCB Model

4. 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.

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

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

Fig: Deleting Unchecked Faces

7. 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.

Fig: Geometry Cleanup

CREATING MID-SURFACE :

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

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

Fig: CCB Assembly Midsurface

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

Fig: PID for above Mid-Surface Components

MESHING :

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

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

Fig: Quality Criteria

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

Fig: Mesh Parameters

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

15. Go to Mesh-->Mesh Generation Option and Select the Mesh type to mesh the component.

16. Select the Mesh type in the Mesh generation and Select the Faces to mesh and Mesh will be generated.

17. 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.

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

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

Fig: CCB Assembly Mesh with Quality Criteria

20. Parent Surface thickness Value is to be Provide for the Mesh Component. Go to Lists-->Properties option and Assign the Thickness Value.

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

PERFORMING SUITABLE CONNECTIONS :

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

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

Fig: Converting Point to Bolt connection type

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

25. 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.

Fig: Connection Manager - Bolt Connection

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

Fig: Bolt Connection

SeamWeld Connection :

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

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

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

30. 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.

Fig: Connection Manager - Seam Weld

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

Fig: Seamweld (Overlap Shell) Connection

RBE2 Connection :

32. Connecting all other parts by using RBE2 connection.

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

Fig: 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.

Fig: CCB Assembly with suitable Connections