Project 1 : CFD Meshing for Tesla Cyber Truck

Aim/Objective

For the given model,

• To Check and solve all geometrical errors and assign appropriate PIDs.
• To perform meshing with the suitable target length and element quality criteria.
• Creating wind tunnel volume and surface meshing.

Procedure

> Primary step is to solve the geometrical errors in Topo mode.

Initial error in the geometry

Error in geometry after hitting topo

> In order to solve geometrical errors and to save time the given geometry is cut into half as it is symetrical and it is mirrored

once the geometrical clean up is finished.

> Major tools used for solving geometrical errors are listed below:

• Faces --> Cut/New/Delete/Topo - Cut - To cut the existing surface and create required one, New - To create new face, Delete - Used to delete unnecessary faces, Topo - Used to auto correct errors in geometry.
• Points --> Relative - Used to create points with respect to nodes.
• Curves --> Create - Used to create curves in between to points, nodes or hotpoints.
• Cones --> Fill Hole - Used to patch open faces.

Geometry without errors

> PIDs are created and assigned for the required volumes after solving geometrical errors.

Geometry afater assigning PIDs

> After assigning PIDs CFD mesh is generated with suitable target length:

• Light - 4 mm
• Body - 2 mm
• Tyres - 3 mm

> Element quality criteria followed:

• Skewness - 0.5
• Minimum Length - 0.5 mm
• Maximum Length - 6 mm

> After meshing the othet part of the geometry is mirrored using: Transform --> Copy --> Entities --> Symmetry -->

Mirror 3 points plane.

> For surface meshing of wind tunnel adopted target length is as follows:

• Bottom Face - 300 mm
• Top Face - 100 mm
• Side Face - 100-300mm (Growth mesh)

> In mesh parameters CFD mesh with tria element as well as minimum and maximum target length is specified.

Results

Mesh generated for cyber truck

Above is the mesh for cyber truck before creating wind tunnel following quality criteria and avoiding off-elements.

Mesh generated for wind tunnel with tria elements

Wind tunnel is meshed with help of growth mesh which is having D-start and D-limit as 100 to 300.

Learning Outcome

• CFD mesh generation with element quality criteria for cyber truck.
• Creation of fluid domain and surface mesh of wind tunnel.

ANSA Model

https://drive.google.com/file/d/1BoAZb6XR_wiy2rtUgMGwIElDHztSKFsT/view?usp=sharing