Project 1 : CFD Meshing for Tesla Cyber Truck

Aim:

To check and solve all the geometry errors in the tesla cybertruck model, then assign appropriate PID's. After assigning PID's choose a target length for each PID and mesh them with proper quality criteria.

Procedure:

1. Choose File->Open to open the cybertruck ansa file.

2. After opening the file, check for the geometry errors. There are lot of single CONS which will go away once you choose the 'TOPO' option to establish topology connections between surfaces.

3. After setting topology, fix the remaining single CONS option by creating new COONS surfaces. Then start creating PID's in the property manager. After creating the PID's start assigning PID's to the surfaces using 'Set PID' option.

4. Assign all the surfaces to their PID's and select compress option to remove the remaining unwanted PID's. Check for geometry errors and once you made sure that unwanted errors are removed, go to Mesh deck. Then start assigning length to the surfaces using 'Length' and 'Perimeters' option.

5. The target lengths and quality criteria were selected from previous 4th week assignment. Then start generating the mesh for each PID's separately. Once the surfaces were meshed, quality was checked and the erros elements were corrected using Improve and Reshape option.

6. After maintaining the quality of the elements, the wind tunnel was created first using 4 points and then using the copy option. After copying the created surface, the other surfaces were created using COONS option. The created wind tunnel was assigned to a new PID for mesh creation purpose.

7. After creating the wind tunnel surfaces, they were meshed separately and then combined together with the existing mesh. A cutting plane was created to make sure the car model and wind tunnel is placed properly. Quality criteria for both the car and wind tunnel mesh was once again checked.

8. After creating surface mesh, once can use the volume->define option to extract volumes and then mesh then using Tetra rapid option.

Learning outcome:

Learnt how to approach a meshing problem independently and how to simplify the surfaces without any guiding videos. Chose the target length and quality criteria on my own.

Conclusion:

Was able to create a surface mesh of the cybertruck tesla model along with a wind tunnel. The wind tunnel surfaces were selected to have a coarse mesh in order to avoid size issues. In case of a simulation, we should make sure to have refined surface atleast in the floor of the model.

(And I am unable to upload my mesh model once again because of the file size of 120Mb. Hence I am not uploading the meshed model. I am removing the mesh and uploading only the surfaces. If the mesh is also required, please reach out to me. I will upload the meshed model separately. Thank you.)