Challenge

Project 1 - 2D meshing on the instrumental Panel

SSyed Abu Talib27 Jul 2021

ANSA

Objective:-

to check for geometrical errors and fix them
create a mid surface of the given model using appropriate tools
create surface connection in the mid surface between ribs, dog houses, and parent surface to have a proper mid surface.
create a 2-D mesh over the mid surface
assign thickness to the extracted mid surface
assign criteria parameter values
check for the failing elements
fix all the failing elements using required tools for the different kinds of failures

Introduction:-

For this project, received a half part of the model of a dashboard of the car
which is very complex in structure and has a variable thickness
it consists of a lot of ribs, dog houses, and other sections on it
The dashboard of a car is a plastic component that holds a lot of devices such as a speedometer, music system, A.C holes, and sections, storage compartments, etc. It is also called an Instrument Panel, It is a control panel set within the central console of a vehicle or small aircraft. Usually located directly ahead of the driver, it displays instrumentation and controls for the vehicle's operation.
So that's why it consists of that many ribs just strengthen it.

Model Recieved

Theory:-

First imported the given model into ANSA
then by observing carefully found that there is a lot of single cons
so to fix that used the toppo tool
then after that, I used the orient tool to fix all the orientation issues

After fixing all the geometrical issues

I
after fixing all the geometrical issues
Inspected the given Geometry very carefully and then by using the measure tool
Measured the thicknesses at several different positions to know that whether the geometry is of uniform thickness or not
then after checking the thickness at the different positions it came out that the geometry is of non-uniform thickness

thicknesses measured at different positions
after measuring the thickness it came out that the base surface is 0.66 mm thickness
So first I extracted the mid surface of the base surface by using the offset tool
Faces--> Offset
After selecting one side of the face of the base surface did a middle mouse click
then inserted an offset value of 0.3 which is the half of the value of its thickness
Then did a middle mouse click which resulted in the mid surface of the base surface of the IP console
Then after getting the mid-surface first assigned the thickness to the mid-surface
By creating the property Id by using the Lists--> Property--> New--> PSHELL
Then there I assigned the thickness of the mid surface by inserting the value of the thickness as 0.6
Then Applied that property card to the base mid-surface

using the Offset Tool to extract the mid-surface of the base surface

After getting the mid-surface using the checks tool to check for geometrical errors
After getting the base mid-surface extracted the mid surface of the ribs and other components of the geometry
But for every component, the Offset tool is not feasible
So for the ribs which were similar on both sides, I used Faces--> Middle
After selecting one side identical face did a middle mouse click and then again selected the other side identical face
Then it extracted the mid-surface out of it
And for the ribs which were not identical to both sides or using the Middle tool is not feasible neither the Offset tool
So in that case I used the Curves--> Middle tool
Through which I got the curve at the top middle of the top face of the rib
Then By using the Cons--> project tool I projected that Curve over the Base mid-surface
After that by using the curve and the con
Created a new surface using faces--> New--> Fitted or Coons which is the exact mid-surface of the rib.
Then after that for the solid cylindrical surfaces, I used the CONS2CURVE tool to get the outer curve
And then by using those curves I created a new surface which is the mid surface the solid cylinder
And in this way after extracting the mid surface of every component I created a different property card for each having a different thickness.
And for a component I used the transform tool as both of them are identical so I just used the symmetry tool from Transform to get the mid-surface

Using Transform Tool to get the mid surface of two identical components

Using The Faces--> Middle tool to get the mid surface of a rib

Using the Curve--> Middle to get the Curve between the top two end cons of a rib /
Then projecting that curve to base surface and creating a surface between them gives the mid-surface of the rib

Using CONS2CURVE to get the curve out of the solid cylinder and then by creating new surfaces between them got the mid-surface

Applying property cards to all the different thickness Components of the Mid surface
After getting the accurate and complete mid-surface, moved towards meshing the surface
And by using the given quality criteria meshed the whole mid surface
after completely meshing the surface I switched to Hidden mode where all the failing elements were visible then there I fixed all the failing elements