Project 1 : CFD Meshing for Tesla Cyber Truck
Aim:For the given Tesla cybertruck model, check and solve all geometrical errors and Assign appropriate PIDs. Perform meshing with the suitable Target length and element Quality criteria. create a wind tunnel around the model and deploy volumetric mesh on the volume.
Introduction:
The Tesla Cybertruck is an upcoming battery electric light-duty truck announced by Tesla, Inc. in 2019. Three models have been announced, with EPA range estimates of 400–800 kilometers (250–500 mi) and an estimated 0–100 km/h (0–62 mph) time of 2.9–6.5 seconds, depending on the model.The stated goal of Tesla in developing the Cybertruck is to provide a sustainable energy substitute for the roughly 6,500 fossil-fuel-powered trucks sold per day in the United States.
Cybertruck is built with an exterior shell made for ultimate durability and passenger protection. Starting with a nearly impenetrable exoskeleton, every component is designed for superior strength and endurance, from Ultra-Hard 30X Cold-Rolled stainless-steel structural skin to Tesla armor glass.
Procedure:
step 1: import the geometry
step 2: select all the surfaces and perform TOPO operation in order to solve all the single cones.
step 3: idendify and perform topological cleanup on the model, wire frame mode can be used in order to clearly identify the errors surafces and solve them.
unsolved errors solved erros
step 4: perform geometrical checkup of solved model.
step 5: Create and assign PID's to the components of the model.
step 6: perform surface mesh on all the PID's with the following mesh lengths and quality criteria for each components.
also we need to eliminate off elements, so we need to perform reconstruction operation for each components in order to solve them and freeze those meshed surfaces.
1.Body_mesh length=5mm
quality criteria for body(min length=1mm, max length=7mm)
2.Tyres_mesh length=3mm
quality criteria for tyres (min length=0.2mm, max length=5mm)
3.windows_mesh length=5mm
quality criteria for windows(min length=3mm, max length=7mm)
- windshield_mesh length=5mm
quality criteria for wind shield(min length=1mm, max length=7mm)
step 7: global variable to be defined for whole model in order solve the off elements.
step 8: After eliminating all the off elements, create relative points for wind tunnel as per standard such as let length of car be 'x'mm distance so the distance from front end point is 4x mm,distance from rear end point is 6x mm, distance from top end is 3x mm and width should be length of the car for creating wind tunnel.
step 9: Assign PID's to the surfaces of the wind tunnel.
step 10: peform surface mesh on the surfaces of the wind tunnel with the following mesh length and quality criteria
top surface tunnel mesh length=400mm and quality criteria as per below snap.
base surface tunnel mesh length=200mm and quality criteria as per below snap.
step 11:perform 2D mesh for the side surface tunnel with top suface mesh length =400mm,base surface length=200mm and for side, front, rear surfaces use spacing command to define the range of mesh from bottom to top, considering the factor as 1.1.
step 12: perform volmetric mesh for the wind tunnel.
(In our case we are avoiding performing volumetric mesh, since a huge amount of computational time and effort has to be undergone, which can not be done using a regular personal computer or laptop.)
Learning outcomes:
- advanced Topology cleanup to define volumes.
- Variable Surface meshing part by part
- Solving quality failed elements as per Quality criteria
- Symmetry operation for surface and mesh elements
- Wind Tunnel Creation
- CFD Meshing for Wind tunnel
Results: For the given Tesla cybertruck model, all geometrical errors were checked and solved, appropriate PIDs were created and assigned. Meshing was performed with the suitable Target length and element Quality criteria. wind tunnel around the model was created and analyzed.
https://drive.google.com/file/d/1DLAjK0BOS_3hUX478A0u_LkWA2W5VTxu/view?usp=share_link