Project 1 : CFD Meshing for Tesla Cyber Truck

https://drive.google.com/file/d/1SBcDQAx5Suo0XAuSAMxfulP27f4hIElv/view?usp=sharing

PROJECT – TESLA CYBERTRUCK

Aim :

To solve all geometrical errors on half portion and assign appropriate PIDs, perform meshing with the given Target length and element Quality criteria. Creating a wind tunnel according to the car dimensions

Procedure : -

1. Open the ANSA model file and check for the geometric and intersection errors
2. Hit the TOPO option to see whether it can fix the single cons and solve the errors.
3. Divide the car into two equal parts , we can use TRANSFER option and replicate same thing to another by symmetry.
4. This makes our work less and more accurate, so delete the one part of the car using UNIVERSAL DELETE option.
5. Using PLANE CUT option , select three random points on the model and middle click .
6. Now go to LEFT VIEW point and delete the other part of the car.
7. Hit TOPO to check autoclear of any single cons.
8. Fill the missing faces with NEW option with COONS .
9. Check for any geometric and intersection errors using CHECK MANAGER.
10. For intersection errors, delete the unnecessary faces and create small faces so that there wont be any intersection of two surfaces.
11. After solving intersection errors , again go for errors check for confirmation.
12. Thus geometric cleanup can be done.
13. 

ASSIGNING PIDs AND SURFACE MESHING :

Thus the geometric clean up can be completed we need to assign PIDs to the parts of the car and start surface meshing.

1. Open the PROPERTIES MANAGER and we can see many PIDs which are present over there.
2. Use COMPRESS option to forcefully delete the unnecessary PIDs.
3. Now starting creating new PIDs lights , windows , tyres&rims, and body.
4. Start assigning them to the part by right clicking on the PID and selecting APPLY .
5. Select the entites which are required and press middle click.
6. Repeat the same procedure for each component.
7. After completing the assigning PIDs, we can go for meshing.
8. 

SURFACE MESHING :

1. As we are going for quality criteria , we need to assign some parameters in this model i.e SKEWNESS , MINI LENGTH and MAX LENGTH.
2. Make sure that SKEWNESS is 0.5 applied and lengths can be from 0.5 to 6 .
3. The mesh lengths for components are :

Lights = 4mm

Body = 3mm

Windows = 2mm

Tyres = 2mm

4. Now isolate the one part of the car i.e Grills using OR option , assign the mesh parameter ranging from 0.5 to 2.
5. Its always preferable to start meshing the parts from the small rang to high range for good meshing.
6. Go to MESH and long press on SPACING option , select AUTO CFD.
7. Assign the mesh parameters to MACROS and PARAMETERS.
8. Now mesh the part using CFD VISIBLE option.
9. Check for many off elements in the component by enabling HIDDEN option .
10. If there are any off elements , right click on it and select RECONSTRUCT option .
11. Run it and we can see many of the off elements are done.
12. For remaining off elemenst , we can use MOVE option in the GRIDS section to remove those elements.
13. After finishing this , make sure to freeze the component and for preventing unmeshing surfaces after FULL MESHING.
14. Repeat the same procedure for each and every component of the car.
15. Thus surface meshing of the car is finished .

SYMMETRY :

1. Now we need to replicate to other part of the car so we need to use TRANSFER option.
2. Click on transfer option and select COPY .
3. Select the all the entities of the car and middle click.
4. A dialgoue box appears, go to SYMMETRY section and select MIRROR 3 POINTS plane .
5. Select three hot points of the car from one end to another end .
6. Click apply and finish .
7. Thus mirroring of the car can be done.
8. Now again go for error check and hit TOPO for autoclearing.

WIND TUNNEL :

1. We need a create a wind tunnel to do a external flow analysis and keep the car inside it.
2. For that we need measurements of the wind tunnel , for that we choose the parameters which are present in the above figure .
3. Fo creating this wind tunnel we need a reference point, so use RELATIVE option in the curves section .
4. First create a point in the bottom of the car , select the middle hot point and distance of 1500 mm in required direction.
5. Now taking this point as reference , we can create base surface and do offset to create top surface.
6. Measure the distance from the refernce point to front part of the car and also length of the car using MEASURE option.
7. Now create a point in the front portion of the car with the value of (4x of car length + distance from reference point to front portion of the care)
8. Repeat the same procedure for rear and side parts of the car with respective measurements provided based on the above figure.
9. Now using OFFSET option we can replicate same surface above the car with the value of ( 3x of car length + car height ).
10. Using FACE option with COONS selection , create new faces around the formed surfaces.
11. Assign PIDs to the created surfaces with new names and apply them on to the wind tunnel using PROPERTIES MANAGER.
12. 

VOLUMETRIC MESHING OF WIND TUNNEL :

1. Go to MESH section , we can omit Quality Criteria for wind tunnel and assign length parameters ranging from 250 to 350
2. For top surface and bottom surfaces targeted lengths are 350 and 250 mm respectively.
3. Go to SPACING option and assign AUTO CFD lenth parameters.
4. Now select CFD VISIBLE MESH.
5. Repeat the same procedure for bottom surface too.
6. Now coming to rear and side surfaces, we need to do GEOMETRIC MESH ranging from 250 to 350 with length factor of 1.2 apart .
7. Go to SPACING,select MANUAL and give GEOMETRIC MESH ranging from 250 to 350 with length factor of 1.2 apart .
8. Thus surface meshing can be completed.
9. Now go to VOLUMES section, select DEFINE option with wholedatebase parameter.
10. This auto generates the volumes present in the model.
11. If there are any duplicate elements or volumes , autofix them .
12. Now select the require volume from the created volumes and edit mesh criteria.
13. Select TRIADS and CFD mesh .
14. Now right click on the volume and select REMESH.
15. Thus Volumetric Meshing can be completed.

CONCLUSION :

Thus the given car model can be meshed for external flow analysis with the help of wind tunnel.