Project 1 : CFD Meshing for Tesla Cyber Truck

PROJECT 1 : CFD MESHING FOR TESLA CYBER TRUCK

AIM:

• To check and solve all geometrical errors for the given model.
• To assign appropriate PIDs.
• To Perform meshing with the suitable target length.
• Target lengths for the different parts of a model can be decided by your own.
• To make all the 2D elements as trias in the model.
• To create the enclosure for the geometry (wind tunnel) around it.
• To clear the quality criteria.
• To write a detailed report of the project.

PROCEDURE:

1. Patch the missed surfaces:

• First we need to import the geometry model from the source folder.
• The geometry file contains lot of ir-regularities, discontnuities, so we need to patch all the missing and open surfaces in the geometry.
• This can be done by the following procedure;

TOPO → faces → new → here we can select any method → select the cons (this can be done by entity or PID method) → middle click or surface click.

2. Removing overlapped surfaces:

• At some areas of the geometry, we need to clear the overlapped surfaces.
• This can be done by following procedure;

TOPO → delete → select the surface to be deleted by using entity or PID mode.

• Sometimes we need to project the cons to make the single cons into triple cons.
• This can be done by the following procedure;

TOPO → cons → project → select the cons → middle click → select the face where the cons has to be projected → middle click.

3. PID assigning:

• Now we need to create PID (Property ID) for all the surfaces like inlet, outlet, spring, column, base and valve head.
• This can be done by the following procedure;

Properties → right click on the properties screen → new → PSHELL → PSHELL → box pops-up → name has to be given.

• Similarly we need to create as many as required.
• Now we need to assign the created PID 's to the respective surfaces required and we need to make sure that cross-hatches option is enabled.
• This can be done by the following procedure;

Properties → right click on the PID → apply → select the cross hatch present in the surface of the geometry → middle click on the mouse.

• Similarly we need to do for all the required surfaces.

4. Surface mesh process:

Target lengths used for the different parts of a model are as follow:

1. Body - 4 mm
2. Lights - 1 mm
3. Rims and Tyres - 3 mm
4. Wind shields - 3 mm
5. Enclosure - 100 mm

• Now we need to mesh the geometry.
• This can be done in two ways;

1. Meshing the whole geometry in one shot. (only with single element length can be done at a time)
2. Meshing the geometry part by part individually. (each part or component can be given different element length)

• The first method is employed in this challenge, however the second is highly beneficial when meshing distinct pieces with varying target lengths.
• Messhing can be done by following procedure;

MESH (right side on the screen) → perimeters → length → perimeters → give the target length → ok.

MESH (right side on the screen) → perimeters → length → macros → give the target length → ok.

Mesh parameters (Top of the screen) → give the target length, min and max length in that dialog box.

Quality criteria (Top of the screen) → give the target length, min and max length in that dialog box.

Mesh generation (right side on the screen) → spot mesh → select the geometry to be meshed.

5. Enclosure construction:

• Now we need to create a enclosure to the geometry which can aslo be called as wind tunnel.
• We need to take the mesurements of the car.
• Now we need to create a point, from that we need to extend our points.
• This can be done by following procedure.

TOPO → points → relative → select the hot point and middle click → specify the direction (- or +) and distance →click ok.

→

• We need to join the points created using the other tool

TOPO → curves → create → drag from one point to another → middle click → esc.

• Now we need to create the surface using the other tool.
• Now we need to create the similar surface on the top of the car using another tool.

TOPO → faces → offset → select the cons → middle click (arrow appears) → specify the the value.

• Now create the faces in the required places using faces tool.

6. Volume identification:

• Here we need to identify the volumes.

volume mesh → volumes → define → auto detect → work on → whole db → ok

• Totally eight volumes have been detected.
• wind tunnel + car → 1
• wheels → 4
• car body → 1
• We can keep first one and delete the rest all because it is unnecessary.

CLEAN-UP IMAGES:

1. Front door left : Rectangle piece missing

2. Front Near bonnet: Rectangle piece missing

3. Front wheel left: Center piece missing

4. Back of the truck : Rectangle peice missing

5. Right back door : small rectangle peice missing:

MESH IMAGES:

Front and back lights:

Car wheels:

Wind shields:

Car body:

QUALITY CRITERIA:

Whole car

• This mesh has been done by CFD method.
• Here the off elements are 13 in count.
• These 13 elements were unable to clear due to a software error, as the skew, min, and max elements were not observable by even changing their colour to identify them.

Car enclosure:

• This mesh has been done by CFD method.
• Here the off elements are zero in count.

https://drive.google.com/file/d/115UwhSDqlupccyUKKiBDxGauu7h_wQ1B/view?usp=sharing