Project 1 : CFD Meshing for Tesla Cyber Truck

Aim:

For the given model of tesla's Cyber truck, check and solve all geometrical errors and Assign appropriate PIDs. Perform meshing with the suitable Target length and element Quality criteria and also create a wind tunnel and perform volumetric mesh.

Procedure:

1. Topo/geometry clean-up:

a. Upload the ANSA file onto screen to perform topo/clean and meshing on the later stages.

b. Go to mesh and choose length and enter 1 mm under perimeters to smoothen the sharp curves of the car and give it a fine look.

c. Since the car is symmetric from the middle to any end, we can delete one-side of the car and perform the necessary operations on the car and use symmetry option to produce the complete car.

Deleting half surface

d. We can now start with the topo clean-up by removing the single and unnecessary triple cons. First click on topo and box select the entire to identify or joins any unjoined single cons or triple cons so that we can identify the required clean-up accordingly.

- After checking and performing topo-clean up for the entire half car model. We need to perform geometry checks to find small cracks are unchecked faces extra which is not good for the geometry, therefore we need to perform checks and clean the geometry accordingly.

Once the geometry is checked and has no errors, we can now assign names to different components using PID.

- Performing symmetry on the car model:

a. Perform symmetry under transform option to create a exact same opposite body of the car to create a full body car.

b. After choosing the model, middle click mouse, we get a window, choose symmetry and choose mirror 3 points plane and choose 3 points on the edge to be performed symmetry.

2. Surface meshing:

We need to mesh the components individually since the given mesh targets are different for each PID regions. Assign the mesh parameters and quality parameters for each PID accordingly, assigning the correct min and max length will reduce mesh failure and off elements.

Following target lengths for the different parts of a model are considered as follow:

1. Body - 5 mm

2. Lights - 6 mm

3. Rims and Tyres - 5 mm

4. Window - 5 mm

Tyres and rims

windows

Lights

body

Wind Tunnel:

To create wind tunnel, the reference points has been created using "Realtive" tool available in Point toolbar. The faces of the wind tunnel have been created using "New" surface creation option.

Size of the wind tunnel

Car elngth (x) = 5880mm

Top = 3x + Distance from referecen point = 19740mm

Bottom Just below the wheel

Front = 4x = 23520mm

Back = 6x + Distance from referecen point = 41160mm

Side 1x 5880mm

To perform mesh, the top face has been assigned the mesh element size of 300mm using "Length" tool to its perimeter & macros.

To perform mesh, the bottom face has been assigned the mesh element size of 80mm using "Length" tool to its perimeter & macros.

- Surafce meshing of wind tunnel:

a. We need to apply surface meshing depending the mesh length near the car and regions far away from it.

b. Therefore we need to apply different mesh lengths at the bottom and top wind tunnel surfaces.

c. We need to use spacing option to have a mesh length varying from the small mesh length size to larger mesh length.

d. Surface meshing can be achieved by doing this accordingly.

Volumetric mesh

Geometry model

https://drive.google.com/file/d/1rQup2jraGHSPj-TK_RfAgn9JC7pWxkbi/view?usp=sharing

Conclusions:

1. Cybertruck car model is topo-cleaned and surface meshed appropriately.

2. Wind tunnel is created and surface meshed with reference to the car model size.

3. Different volumes of the car model is created since the tyres are not connected to the car body.

4. Single volume is created of the car body so that it can be avoided at one go when creating a volumetric mesh.

5. Required physics tests can be performed on the wind tunnel volume model after volumetric meshing successfully.