Project 1 : CFD Meshing for Tesla Cyber Truck

AIM:

• To perform mesh for the given TESLA CYBER TRUCK model,

1. Check and solve all the geometrical errors,
2. Assign appropriate PIDs,
3. Perform meshing with an element quality criteria.

PROCEDURE:

• Import geometry from file->open->file location->project_cyber truck.ansa
• Initial model of the cyber truck with the wireframe model.

• Enable shadow mode and labels to show the tool name under the tools.

GEOMETRY CLEANUP:

• Click TOPO->FACES->TOPO to clear some of the small errors automatically.

• Click ctrl+shift to see the model in the wireframe mode shortly.
• From this we can easily find the red coons.

• To close these red coons we can use either the FILL HOLE option or the FACES->NEW option.

• All the red coons have been cleared.

• Go for resolution change and make the shape perfect.

• Resolution has changed.

• Go for a geometry check and see the intersection and geometry errors.
• Here it is showing 5 intersections errors and 1 geometry error,

• We can neglect this single geometry error because still we haven't started the mesh part.
• Remaining all red coon warnings are showing this same unclosed part, so we can close it directly.

• We are only going to focus on the outer surface so we can directly delete the inner surfaces.

• After deleting the inner surface it is making red coon.
• Here we can use the fill hole, New options to create the new surface or either we can delete the upper surfaces to make it a single surface.

• New surface has been created.

• These are the intersection errors shown in the geometry check.

• Give first preference to the intersection errors and clear them.

• To clear all the errors, Either we can work on the full model or we can cut the half section and work on the symmetry model.
• The same intersection error is showing on the other side also.

• After hiding the above surface, we can clearly see how the intersection is happening.
• Here we have to delete the unnecessary surfaces and create the new surface without any intersection.

• The surface has been recreated.

• Now go for a geometry check.
• Ther is no intersection error is shown in the recreated part.
• So do the same procedure for another side.

• Now there is no intersection errors are shown in the recreated section.

• Remaining are showing inside the truck.

• Check inside and clear the intersection.

• All the 4 shafts are intersecting the surface.

• After hiding the surface we can see the difference clearly.

• Delete the extra surface and close the surface using the fill hole option.

• Now it's done for this shaft. Do the same procedure for other also.

• After cleared all the intersection errors to do a geometry check,
• Now it's showing 0 intersection.

• Full body geometry check.

• All the warnings are showing because of the shape.

ASSIGNING PIDs:

• PID->NEW->SHELL PROPERTY->CRAETE NAME->OK.
• PIDs has been created, Do right click->apply->select the surface->ok.

• PIDs has been assigned.

• Clear unassigned PIDs using the compress tool.

WINDOW'S:

TYRES:

LIGHT'S:

BODY:

MESHING PART:

• For meshing we can follow the same target length as given in the BMW challenge.

1. TYRE & WINDOW = 2mm
2. LIGHT = 4mm
3. BODY = 3mm

QUALITY CRITERIA:

• The quality criteria is fixed for the whole CYBER-TRUCK.

TYRE & WINDOW:

• Mesh Parameter:

• Classic mesh->spacing->auto CFD->give perimeter & macros->mesh generation->CFD->visible.

• Still there are 1067 off elements present. Do RECONSTRUCT/RESHAPE to improve the off elements.
• After many improvement also it is showing 4 off elements.

• Delete the part and recreate it in the other 3 sides in the 2 windows.
• After done with the changes we have always go for a FREE MESH->VISIBLE.

• Final mesh output with no off elements.

LIGHTS:

• Do the same procedure as followed above,

• Mesh parameter:

• Meshed with no off elements.

BODY:

• Mesh parameter:

• 3553 off elements are showing, try to improve with reconstruct and reshape.

• After done with many improvement off elements are reconstructed.

TESLA OUTPUT:

CREATING TUNNEL:

• We are going to follow the same procedure as we did in the BMW tunnel,
• Full length we can take it as 5910 and side length as 2040.

• To create relative point in the bottom surface, first create a hot point and take it as a dependent.

• Go to TOPO->POINTS->RELATIVE->and select the mid-hot point.
• For the bottom point I have taken 1500.

• Create the front tunnel,
• [Mid hot point+4x] 2540+23640=26180.

• To create back tunnel give the length as 39,020mm.
• [Mid hot point+6x]

• Now sides we have to take X-full length,
• X=5910mm.

• Do the same with the negative value.

• Create only a single relative point in the upper,
• 3x+1500+2040=21270mm.

• Now create a COONS to connect the points.
• TOPO->CURVES->CREATE->SELECT THE POINTS->MIDDLE CLICK.
• Finally create a new surface and delete the created coons.

• Automatically it will ask for the PID, Create it newly.

• Surface has been created with PID.

• To copy the same bottom surface for the upper point go to TOPO->FACES->OFFSET->FACES.

• Click on the surface and middle click.
• It will ask the upper value to create a surface.
• Give negative value as the direction arrow shows the other direction.

• The surface has been created successfully.

• Now create the other sides and assign PIDs.
• Full Tunnel view with assigned PIDs.

WIND TUNNEL MESH:

• In the mesh parameter also we can follow the same procedure as followed in the BMW challenge.

BOTTOM TUNNEL:

• For the bottom tunnel, the minimum length is 45 and the maximum is 55.
• Mesh Parameter:

• Go to classic mesh->perimeter->spacing->auto CFD->mesh generation->CFD->visible.
• Meshing is completed for the bottom surface tunnel.
• Do the same for upper surface tunnel. But change the length minimum as 250mm and maximum as 350mm.

TOP TUNNEL:

• Here we are changing the length depending upon the side wind tunnels.

• Mesh done for the upper tunnel surface also.

4 SIDE TUNNELS:

• For the sides we are going to use MANUAL CFD to gradually increase the range from the lower to the higher.
• The range we are going to define is from 20 to 100. Before giving an ok we have to select the direction from which should start.
• For that only we have used the smaller range to the bottom surface and higher range to the upper surface.

• Manual CFD limits:

• Select the direction from the lower to the higher range.

• Reference view:

• Go to spot mesh and visible.
• Final mesh view for WIND TUNNEL.

• Used the measure tool to show the gradual limit.

FINAL OUTPUT:

https://drive.google.com/file/d/1rlhEyP8vSlhdso7kQMuoYhbX4aJYXKEH/view?usp=sharing

https://drive.google.com/file/d/1rlhEyP8vSlhdso7kQMuoYhbX4aJYXKEH/view?usp=sharing