Project 1 - 2D meshing on the instrumental Panel

AIM : For the given CAD of a component, check for GEOMETRICAL ERRORS and rectify it,which is to be followed by MIDSURFACE EXTRACTION and 2D MESH the same using ANSA.

INPUT : The given CAD is of INSTRUMENT PANEL ( IP ) CONSOLE. It is an important interior part of an Automobile. An IP also known as DASHBOARD, DASH or FASCIA is a control panel set within the central console of a vehicle. Usually located directly ahead or a driver, it displays instrumentation and controls for the vehicle operation. The IP CONSOLE of a vehicle is usually made up of MODERN PLASTICS such as ABS (acrylonitrile-butadine-styrene), PPE (polyphenylene ether), SMA (styrene-maleic anhydride).

The given input is shown below;

WORKING PROCEDURE :

• GEOMETRICAL/TOPOLOGICAL CLEANUP :

• The imported CAD is made run through geometrical check using CHECKS MANAGER > GEOMETRY.
• The following was the report shown by ANSA;
• 
• In above report, about 2000 geometrical errors has been identified by ANSA, in which some were AUTOFIXABLE and for other MANUAL INTERVENTION was required.
• After AUTOFIXATION, rerun is performed and the errors shown was reduced to 82, which has to be fixed manually.
• 
• Some of the operations performed in order to clean geometry is shown below;
• 
• In above shown snaps, DUPLICATE SURFACES has been identified, which is then fixed using FACES > DELETE.
• 
• In above shown snaps, UNCHECKED FACES were detected, which is fixed using FACES > DELETE and FACES > NEW.
• After all existing errors are fixed, the CAD is then brought to assign PIDs.

• ASSIGNING PIDs:

• The thickness of the component were measured and stored and suitable PIDs assigned.
• 
• After assigning the PIDs accordingly, the result is shown below;
• 
• As the PIDs are assigned , the CAD is then forwarded for MIDSURFACING.

• MID-SURFACE EXTRACTION :

• The MIDSURFACING is done manually using FACES > OFFSET, and FACES > MIDDLE.
• For the base panel as the thickness was uniform about 0.6mm, is offset to 0.6/2 = 0.3.
• CURVES > MIDDLE and FACES > NEW is also used in order to define the dog houses and rib's tips properly.
• Some of the operations are shown below;
• 
• In above snaps, the surface is created using these curves and intersected also, thus forms a triple cons.
• After all the surfaces are stitched the model is again made to run for geometrical checks by keeping single and triple cons off, the final results are shown as follows;
• 
• Afterwards, the MIDSURFACE is taken forward to 2D MESH DECK to mesh.

• 2D MESHING :

• The meshing of the midsurface is done using BATCH MESH.
• Firstly, the midsurface is assigned as a part in MODEL BROWSER. Shown below;

• 

• As the parts are assigned, these contents are now selected in BATCH MESH MANAGER.
• The MESH PARAMETER and QUALITY CRITERIA is then fed to it.Shown below;
• 
• As the RUN command is given, ANSA works to give a defined meshing of the component.
• The above shown snaps shows exclamation which denotes that there are some QUALITY VIOLATIONS.
• Some of the surface deformation is cleared using GRIDS > ALIGN in MESH DECK. Shown below;
• 
• The given result is modified manually in order to reduce OFF ELEMENTS ans TRIA CONCENTRATION to some extent.
• As the OFF ELEMENTS can not be eliminated because there are TRIPLE CON INTERSECTIONS.
• After MANUAL INTERVENTIONS, the final result is shown WITH and WITHOUT ENABLING THICKNESS.
• 
• 
• The final result is shown below;
• 

In this project, almost every concepts and technique learned regarding the same is applied, here we have encountered with almost every kind of surface errors, and had been taken care manually using various operations, and majority of time is utilized in that. MIDSURFACING of DOGHOUSES and RIBS which was new had been learnt. Learnt to compensate quality in order to capture feature properly, as this was a large part to be meshed with number of complex features.

CONCLUSIONS :

• The CAD is imported to ANSA and geometrically cleaned using various techniques involved AUTOFIXATION and MANUAL INTERVENTIONS.
• PIDs are assigned in order to ease in analysis.
• MANUAL MIDSURFACING is performed using various methods.
• 2D MESHING is done over the EXTRACTED MIDSURFACE by BATCH MESHING.
• The result is then somewhat modified in order to reduce OFF ELEMENTS and TRIAs by not compromising feature distortion.
• The OFFs are reduced to about 0.80% in total and TRIAs with nearly 5%.
• The thickness is then assigned to the model by checking DRAW SHELL AS SOLID.

FOLLOW THIS LINK TO ACCESS THE MODEL :

https://drive.google.com/file/d/1Y7Tn8tjsvMiIaJnxJKbJ3Wx84tPilbqx/view?usp=sharing