Project 1 : CFD Meshing for Tesla Cyber Truck

Aim: To check and solve all geometrical errors, assign appropriate PIDs and mesh all the surfaces with appropriate length

Objective: To create a meshed model o the Cybertruck with zero off elements

Procedure: 

As I opened the model I noticed that all the surface were showing single con. So I did TOPO and most of the single cons were eliminated. Next I split the model in half with cut and deleted the half o the model. Since the model is symmetric, I can mesh the half and then duplicate the other side.

There was some duplicate surfaces near the wheel shaft and there were some open patches also.

I closed all of the open areas and deleted the duplicate surfaces

There were a lot of surfaces having iregular shapes and cons with very minimal distance between them. We cannot achieve the desired mesh length and shape in these areas. All these surfaces I cleaned up.

After cleaning up the geometry, I performed a geometry check. There were only single cons on the cut side of the model.

Next I assigned PID to the surfaces. I created 3 diferent PID for Body, Windows and Tires.

After assigning PID, I started to mesh the surfaces. or Body I gave mesh length as 20. For windows I gave length as 30 and for tires I initially gave length as 3.

In the body there were surfaces near the door handle and door hinges where the 20 mesh length was not suitable. So I had to vary the mesh length in these areas.

For meshing the tires I gave length as 3.

But after meshing, there were a lot of Off elements forming and could not be solved even with reconstruct and other options. In some areas on the tire, the distance was 0.21

So I reduced the size of mesh length and made it as 1mm.

There were some off elements in near the meeting point of different PIDs. I solved this using reconstruct. I followed this procedure for all the areas and reduced the Off elements as far as I can.

After meshing and solving the off elemnts, I duplicated the other half of the truck with copy command with symmetry option. This created the other half of the truck.

Both the halfs of the model is correctly merged with no single cons forming.

Conclusion: There were a lot of Off elements in the tires wich could not be solved completely by commands like Reconstruct and Reshape. For these areas manually we need to check and solve for it.