Project 1 : CFD Meshing for Tesla Cyber Truck

Aim:To check and solve all geometrical errors and perform meshing for a given CyberTruck model using the ANSA software.

Hardware Required:Desktop,Mouse,Keyboard,CPU.

Software Required:ANSA v23.0.1x64bit software.

Theory/Description:

• ANSA is an advanced multidisciplinary CAE pre-processing tool that provides all the necessary functionality for full-model build up, from CAD data to ready-to-run solver input file, in a single integrated environment.
• ANSA is the users preference due to its wide range of features and tools that meet their needs. The list of productive and versatile features is long and the alternative tasks and processes to be completed using them are countless.

In case of Meshing, ANSA has integrated Batch Meshing tool,which leads to controllable and effortless optimal results, for both shell and volume meshing. Following the versatile mesh area idealization, geometry can be meshed according to modeling requirements by cutting edge surface and volume meshing and wrapping algorithms.
A unique mesh generation environment is composed by:
- proprietary shell meshing algorithms
- high performance and quality volume meshing algorithms
- state-of-the-art boundary layers elements deployment
- Hexahedral dominant meshing
- Acoustic Cavity mesher and the straight forward Wrapping tool
- one-step mesh generation on automatically extracted middle surface
- numerous mesh handling functions.

Procedure:

1. Open the ANSA software and Import the given CyberTruck model from the files.
2. Check the entire model before getting started work it.
3. Now inspect the model thoroughly and then check the model for topo cleanup.
4. First of all, check whether any single cons are present in the model by selecting the wire frame mode by holding ctrl+shift together.
5. If you found any single cons in the geometry, then check for the problem closely one by one that what need to do to solve the problem in the place that where you found single cons.
6. Try to use all the options available for to solve the problem.
7. If you found any over left surfaces then delete the unwanted surface by selecting the right cross-edge.
8. If any cracks and unfilled surfaces are present, then use coons option to sort out the problem.
9. After solving all the single cons, check whether any triple cons are present.
10. If you found any triple cons, then check for the problem closely by choosing wire frame mode.
11. While sorting out the errors present do not leave any extra surface, it may cause some problem meshing. so, make sure you are giving a single volume while doing topo clean-up.
12. Remove every unwanted surface while doing the topo clean-up.
13. After completion of topo clean up, assign the PID's to each different portion in the car model for the surface mesh sake.
14. After assigning the PID’s, start working on surface mesh by changing the meshing method from NASTRAN to OpenFoam.
15. Set the quality criteria that which are required for better and accurate mesh.
16. For every different part meshing, set the quality criteria and mesh parameters accordingly as per the below mentioned target lengths respectively.

17. Part	Length
    i. Body	5mm
    ii. Fuel_Cap	1mm
    iii. Tires	3mm
    iv. Glasses	4mm

18. After completion of surface meshing with the above given target lengths,we need to create the wind tunnel.To create a wind tunnel, first of all we need to create some reference points.

19. Now use the relative option for to create the reference points to create wind tunnel.
20. Take the reference point at the center and check the measurements of the car to create the six faces of the wind tunnel at the desired locations.
21. By taking the ansa axis as a reference create the first reference point at the base at a distance of ~600mm.
22. Then after that, by taking this point as the reference create the side faces at a distance of 3x of the car radius to the side from the center.
23. Likely to the front create a reference point to the front at a distance of 4x, 6x to rearword direction and 3x to the top of of the car radius.
24. After creating all the refernce points at the desired locations, join them using the cons2curve option.
25. Then mane a face using the coons option. Using Offset option make a mirror face in the opposie direction by taking top view as a reference view.
26. After that join all the faces using the coons and delete the reference points and reference curves.
27. After completion of making the Wind Tunnel, assign PID's to every face and start doing the mesh the base face with the target length of 50mm and top face with the target length of 500mm.
28. After meshing base and top faces, set the max and min lengths for the quality criteria off.
29. To mesh the remain faces in the wind tunnel, use the spacing option and set the starting value and limit value, and choose the faces and direction for meshing.
30. After done with the surface mesh to both BMW car and Wind Tunnel, check for the volumes in volume deck and delete all the unwanted volumes except the one which Wind tunnel along with the car volume.
31. Save the file and close the ANSA software.

Precautions:

1. Do the topo clean up accuretely for to make surface mesh and volume mesh without any errors.
2. Make sure there should not be any geomtrical erros in the model.
3. Set the desired target lengths and make sure everything is perfect while meshing.
4. Wisely delete the unwanted surfaces that which are not useful and make sure that closing the body is neceeeary for volume meshing.
5. While deleting the unwanted volumes, check twice before deleting the unnecessary volumes.

Result: Checking and solving all geometrical errors and Meshing with the given Target length and element Quality criteria for a given CyberTruk model is done using the ANSA software.