Challenge

Project 1 : CFD Meshing for Tesla Cyber Truck

AIM:

OBJECTIVE:

To open the given geometry in ANSA and to clean up the geometry appropriately.
To carry out triangular meshing on the surface of geometry with different target lengths.
To create a wind tunnel with the appropriate geometry and to do surface meshing of the same.
To perform the volumetric meshing (CFD Meshing) of wind tunnel and car geometry.

PROCEDURE:

Open the geometry in the ANSA software and increase the resolution of the geometry by providing Length and Macros from the Meshing session.

As the geometry is symmetric with the centre it is advised to delete half the geometry and work on the remaining part as shown below and finally do a symmetric approach.
Isolate every part of the geometry such as the Wheel and Rim, Window and body. Then perform surface cleanup of each part by deleting overlapped, unwanted surfaces and penetrated surfaces by using the universal delete option, fill the gaps present by creating a new surface from the New option on the left tabular column followed by selecting either Existing Surf or COONS or FITTED option. After cleanup check whether any triple cone or single cone exists if any single or double cones are there so a necessary step to eliminate those. (NB: Single cone will be present on the central axis as the remaining surface is deleted as per symmetry.
Use Cons2Curve or Create curve option to get the traces of deleted faces which helps to recreate those faces in future.
Remove small faces, and unwanted hot points and delete unwanted cuts on the surface of each part.

After the geometry cleanup checks the geometry for any crack, single cone, overlap faces, penetration etc.. by using check manager. If any errors are encountered resolve those.

After completing the cleanups provide each part with a suitable PID name by selecting the Property from the top tabular column and creating new PIDs and by renaming existing PIDs. Then assign each PID appropriately.

Now move to the meshing tab. On the meshing, the tab set the perimeter and macro length. For this project the considered target length for each part is

a. Body - Target Length = 4, Min and Max Target lengths are 2 and 6 respectively.

b. Window - Target Length = 4, Min and Max Target lengths are 2 and 6 respectively.

b. Rim and Tyres - Target Length = 2, Min and Max Target lengths are 1 and 3 respectively.
From the Mesh parameter drop-down set meshing type as triangular and target length, Minimum and Maximum Target length. Set minimum and maximum target length in quality criteria also.
On the left tabular column click on spot mesh under the Mesh generation section and select each PID and do meshing enable hidden mode and verify any OFF elements are present if so reconstruct mesh by using Reconstruct option under Shell Mesh. Again if any off elements are present check the geometry and do the necessary cleanup.
Repeat steps last three steps with the appropriate target size, minimum and maximum target size for each PID. The surface meshing of each PID is shown in the Result session.

After completing the surface meshing of one half click Transform > Copy > Select the entities > Symmetry > Mirror 3 Point Plane > Select 3 points check the preview and click Finish. Remove if any single cons present and do a geometry check. The figure shown below is the final meshed car geometry.

Now create the wind tunnel by using creating points, and curves and by creating different faces of the wind tunnel using those curves in such a way that the front face of the tunnel should be at a distance of 4X, and the rear face of the tunnel should be at a distance of 6X, the top face of the tunnel should be at a distance of 3X, the bottom face of the tunnel should be very close to the wheel, the Side face of the tunnel should be at X distance from the car geometry. Where X represents the total length of the truck geometry.

After completing the surface meshing move to the volume meshing tab, select Define and select auto-detection. Here delete the unwanted volumes like a car inside the volume, wheel volume, and silencer volume. Maintain the volume between the car geometry and wind tunnel as shown in the figure shown in the Result session. Then Ramesh the selected volume with the Tetra CFD option.

RESULTS:

a. Tyres and Rims:

b. Windows:

c. Body:

d. Final meshed geometry after applying symmetry:

e. Volume selected to perform volumetric meshing:

CONCLUSION:

The given geometry is studied and a topological cleanup and surface meshing of the same is carried out. A wind tunnel is constructed and the surface of meshing is also done on it. As volumetric meshing will require an advanced system, as the number of elements is very large volumetric meshing is neglected for this project.
Doing this project it helps to gain more about topological cleanup, constructing new surfaces, surface meshing and volumetric meshing by using different sets of tools in ANSA software.

UPLOADED MODEL:

As the size of the model is too large to upload directly, the 'google drive' link is been shared to access the corrected model.

Ship work like this
in your own course.