Project 1 - 2D meshing on the instrumental Panel

Aim- For the given component, check for the geometrical errors and mesh with the given element Quality criteria. After meshing the component the thickness has to be assigned.

Quality parameters-

Methodology-

1.Import cad model to ansa.

2.Geometry cleanup.

3.Midsurface generation

4.Assigning quality criteria and mesh parameter.

5.Meshing and refining of meshing.

6.Quality issues clearing.

1.Import cad model to ansa.

Measure all the features so that when you assign PID’s, it will be easy to define different thicknesses for features like small ribs, big ribs, dog houses.

2.Clean the geometry using checks manager. Enable unchecked faces, collapsed cons, triple cons, needle faces, overlapped faces, cracks, single cons. Clear all these issues until no error is found. One can use fix option in ANSA to clear all the errors automatically. However, sometimes manual intervention is required for fixing some errors.

The unchecked faces are not linear to geometry, the faces are deleted and recreated and the cons are released to obtain the proper faces.

The single cons are created with the surfaces to have double cons and missing surface.

3.Midsurface generation

There are 3 various methods of midsurface generation.

Manual midsurfaing

casting method.

skin midsurfacing method

Casting and skin options haven’t generated best results in mid surface generation. Therefore, I have done the mid surface generation manually.First generate mid surface for bigger part so that other small features can be extended on to it. Using offset option, pick the bigger surface using feature area to generate mid surface.

 

Mid Surface Generation for small Rib

Use middle option and select both sides of the rib. Then a mid-surface will be formed. Like this generate mid surface for all the ribs. Don’t forget to give separate PID and thickness for all the features.

Mid Surface Generation for long Rib

Mid surface for long ribs on the geometry can be generated using Faces à offset option. Measure the thickness and give offset value in the desired direction.

Mid Surface generation for dog houses

The dog houses consist of cylindrical surfaces. For these cylindrical type surfaces, we can’t generate exact mid surface and volume mesh is not preferred as these dog houses are more in this geometry. So, I have captured these cylindrical surface as two intersecting rectangular ribs.Using Cons2Curve option, I have connected the curve which is created on the cylindrical feature of parent geometry and the rib using Faces a Fitted Surface option.

Meshing and Improving mesh flow

The Ansa has different types of mesh algorithms Spot mesh, Free mesh, and BEST mesh. For the dashboard component, I have done with spot mesh and BEST mesh option to obtain the proper mesh flow with fewer numbers of trias.

The component is started with the first phase of dashboard subparts, the part has the ribs with the dog house and the small surface with number cons, so to avoid the minium failing element size, the cons are removed and mesh with the surface.

Learnings

• Able to do topological clean-up with no errors.
• Assigned separate PIDs for different surfaces.
• Able to generate mid surface for complex geometry with varying thicknesses.
• Aware of all the quality criterias and quality parameters during mesh generation.
• Understood about mesh generation and implemented mesh generation for complex geometry.
• Learned how to improve mesh flow and remove trias to achieve better mesh flow.
• Understood all the concepts regarding mid surface generation and meshing in ANSA

Conclusion-

        In this project, I have generated mid surfaces using different options available in ANSA. Able to defeature and do line adujstments in some areas. Did topological clean up. Understood about transparency mode and the concepts related in generating mid surface for different features. Able to achieve better mesh flow using smooth,reconstruct,swap,paste,move options. Eliminated kinks and raised edges. Successfully generated mid surface and meshed whole Instrument panel usinh ANSA.