Meshing a Side Door Component of a Car

Objective:

To extract a proper midsurface using manual offset and also to mesh the given side door model respecting all the specified quality criteria.

Procedure:

Step 1. Open the given hypermesh .hm file, the geometry of the side door panel component is studied and divided into five different components to ease the meshing process.

The red coloured components in the above snapshot are the fifth components and they are closed objects with definite dimensions along all three axes. So the midsurface is not extracted for those components.

Step 2. The midsurface is extracted using manual offset method. For surfaces with uniform thickness, the midsurface is extracted. Before midsurface extraction, a geometry cleanup is performed, to get rid of undesired surface features like fillets with radius less than 5mm. The midsurface is then extracted for all the divided components.

Step 3. The midsurface is extracted for the ribs present in the model, in the same method.

The extracted midsurface however is not associated to the main panel of the already existing midsurfcae.

The rib midsurface is then extended to a distance sufficient enough to intersect the main panel midsurface.

Then, the intersecting surfaces were trimmed.

The protuding extra unwanted surfaces (shown in the below picture) are deleted.

The rib midsurface is now properly associated with the main panel's midsurface.

The same process is repeated for all the rib midsurface association procedure. And the midsurface is extracted for the whole side door model.

Step 4. The topology repair operation is again performed on the extracted midsurface, like toggling edges and adding washers and divinding the midsurface into simplified easily meshable surfaces.

Step 5. Then, the midsurface is meshed to the provided specifications, ensuring zero element failure and the tria percentage of the meshed elements is 0.96%

Step 6. The properties are created for components with different thicknesses, and the meshed elements of the corresponding components with respective thicknesses are assigned and moved into different components. The 2D detailed element representation view will display the meshed elements with assigned thicknesses.

Result:

The elements were meshed to meet the specified meshing requirement criteria and no element failure is ensured, also respecting and adhering to the best practices.

The meshed elements are assigned appropriate thicknesses of their corresponding componenets, in 2D detailed representation view, the elements are displayed properly.