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.

S.No	Quality Criteria	Value
1	Target/Average length	4
2	Minimum Length	2
3	Maximum Length	6
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

• Write a detailed report on your meshing process
• Mention which method you used to extract the mid-surface along with the reason

PROCEDURE :

• Import the Instrumentel Panel Model in ANSA
• Check for geometrical Errors using Geometry check manager.
• Fix the errors.

After Geometrical Check-up

• Measure the thickness for each components by using Automatic thickness tool

(Topo>Midsurface>Thickness>calculation)

• By using Automatic Thickness tool we will get thickness of each PID and automatically with seperate PID's.

• Assign the quality criteria as mentioned.

• Define Mesh Parameters.

(F11-Quality criteria)

• Assign element size by selecting LENGTH>TOOL>PERIMETERS.
• Select entities and give element size.

(classic mesh>perimeters>length).

• Since we are using CASTING METHOD for meshing purpose,we can directly get MESHED MIDSURFACE without actual generation of mid surface.

(Topo>Midsurface>casting)

• Result of CASTING has failed to recognise and create proper Meshed Midsurafce with reference to the PARENT GEOMETRY,which has to be checked individually and fix manually.
• Set the base elements in accordance to the PARENT GEOMETRY using the three given tools in Align Manager.
• Areas
• Perimeter
• Direct

(Topo>Midsurface>Align Manager)

• To Merge two surfaces. (Topo>Midsurface>Align Manager>select the required area>right click on selected area>Add to)

• Some of the Dog House and Ribs have not been captured properly, which has to be deleted and recreate using CURVE tool from TOPO Module.
• Create a curve using Cons2curve tool

(Topo>curve>Cons2curve)

• Project this curve to the below surface using project tool.

(Classic mesh>shell mesh>project)

• Use Fill option to fill the hole between the CURVE and Projected Curve(classic mesh>shell mesh>Fill)
• After creating the elements Add them to their respective features (Middle OR Plane) using Align Manager.

BEFORE

AFTER

• Using PERIMETERS in Align Manager.

BEFORE

AFTER

To fix Failed Elements in Quality Criteria, Use :

• Reconstruct
• Smooth
• Fix Quality
• Moving Grids
• Pasting Grids
• Splitting
• Swaping

1. (Classic mesh>Shell Mesh>Reconstruct/Smooth/Improve)
2. (Classic mesh>Grids>Move/Paste)
3. (Classic mesh>Elements>Split)

LEARNING OUTCOMES :

1. Mesh the component using casting method
2. To Use Align Manager.
3. To assign thickness for each PID's automatically.
4. To identify and rectify the failed elements after Casting for complex parts.
5. To improve mesh flow and minimise the number of tria elements to achieve better mesh flow.

CONCLUSION :

• Tried to create Midsurface and Mesh it using Manual method and as well as Auto Midsurface Method.
• Casting method can be used for meshing complex models which results in minimum time and effort which may contain collapsed components.
• Plastic models require considerable effort for modelling the mid surfaces and mesh generation.
• Its very important to know how to use different tools in Align manager while using CASTING method to finish the job within given time frame.