Performing "Surface Re-meshing" On A Dirty Ford Engine Using STAR-CCM+ Software

Surface Remeshing is one of the steps in the STAR CCM+ workflow. This feature can only be used once the Pierced Face, Open Edge & Non-manifold errors are resolved using the Surface Repair or Surface Wrap feature. Other errors such as the Face Quality & Proximity errors are resolved using this technique. Step by step process of the Surface Remeshing methodology is shown below.

Step 1:- Importing the geometry that has gone Surface Wrapping technique, which means the geometry is free of Pierced face, Open edge & Non-manifold errors as shown below. Before we proceed with this step, we must make sure that geometry is free of all the edges & is left with only face quality errors like the Face Proximity & Face Quality errors. The below image shows one such geometry file upon which we can perform the Surface Remeshing technique. 

Step 2:- Creating a new "Automated Mesh" from the operations feature. Next, select all the geometry parts upon which the base mesh should be generated.

Step 3:- Once we create a new Automated Mesh operation, it gets added to the Simulation tree under "operations". Inside this feature, there are several parameters that need to be defined. We start by defining the Base size of the mesh (0.05m) & we make sure our CAD projection is turned on. 

Step 4:- The next step involves navigating to the Custom Controls where we will create a new surface control, which will allow us to generate finer mesh at certain locations of the geometry. 

Step 5:- Under surface control, we start by marking the parts we want to generate this refined mesh. We would also want to add a custom mesh size to these locations. 

Step 6:- The final step involves us specifying the value of the custom mesh that will be refined in particular areas. These are user-defined inputs defined in the form of percentages. For our case, the mesh size at the target location should be 15% of the original or parent base size of 0.05m i.e. 0.0075m with the lowest quality cell of 0.0025m i.e. 5% of the parent size.

Step 7:- Generate the mesh & check the results.