Project 1

Aim:

Extract the middle surface from the reduced instrument panel and generate a 2D shell mesh according to the quality criteria.

Objective:

• Clean the reduced IP substrate and clear the errors from the geometry check.
• Extract the middle surface and assign the appropriate thickness property to the middle surfaces.
• Generate a shell mesh according to the quality criteria.

Procedure:

• Import the IGES format file of the IP substrate model into the ANSA workspace.
• Connect the surfaces of the model by topo operations and close the IP model.

• Geometry check is done and the errors are cleared through a suitable action.
• The model is found to have variable thickness. Since the thickness is not uniform throughout the component, auto mid surface extraction is not possible and manual extraction of middle surface is done.
• The base of the IP model is found to have a uniform thickness of the 0.6 mm.
• The middle surface is created by offsetting the surfaces of the parent model.
• Middle surface of the features having different thickness and the thick parts are created by offset or middle options available in the TOPO module.

• The extracted middle surfaces are edited accordingly to represent the parent model.
• The connection between these surfaces and the base is established by extend and intersect surface options available in the TOPO module.

• The fillet features violating the minimum length criteria are divided by face and macros are joined.

• The cons are rearranged and the perimeters are refined with a length of 4mm.
• The quality criteria and the mesh parameters are inserted to the ANSA.
• The surfaces are divided into the small surfaces and the 2D mesh is generated by best mesh algorithm.
• The mesh is reconstructed and the elements are manipulated accordingly to fix the quality of the elements and attain the better mesh flow.

• As the mesh output is satisfied, the mesh generation is proceeded to the next surfaces.

• Elements failing due to structural constraint are allowed to fail as shown below.

 

• The above steps are followed accordingly to generate a 2D shell mesh throughout the middle surface.
• The elements are set to represent 3D by drawing the shel as solid and parent component is kept in tansperancy. 

Result:

The middle surface is successfully extracted and a 2D shell mesh is generated according to the quality criteria.

Model is observed to be having total of 45892 elements out of which 1947 are the tria elements. The model is having 275 elements failing for the given quality and this is due to constraint in the structure.