Project 1 : CFD Meshing for Tesla Cyber Truck

AIM:-

To performe the surface mesh for the given tesla cyber truck model and also for the fluid domain enclosure which is used for CFD analysis

OBJECTIVE:-

The objective of the project is to do a basic geometric check and to do a surface mesh & volumetric mesh using ANSA on the given model Tesla cyber truck Model

PROCEDURE:-

STEP 1 : Open the given cyber truck model using MENUBAR>FILE>OPEN

• We can see so many single cons in our model

STEP 2: We can just do a TOPO to clean them

TOOL USE :- MENUBAR>TOOLS>TOPO>FACES>TOPO

• After topo some of the single cons are changed into double cons

STEP 3: since the given cyber truck model is symmetric about z-axis simple cut the half part of a model using

TOOL USE MENUBAR>TOOLS>TOPO>FACES>PLANE CUT - SINGLE

STEP 4 : after using plain cut then selected part delet of a given model using

MENUBAR>TOOLS>TOPO>FACES>DELET `

STEP 5: Now check for the geometric error in the remaning region using

MENUBAR>TOOLS>CHECKS>CHECKS MANAGER

• checks manager : This function open the checks manager it is used to execute a number of checks
• Geometry checks : This function locates geometrical problems of the model such as ( uncheck faces . needle faces . collapsed cons . single cons . triple cons . overlap and cracks )

STEP 6: the given model has geometrical error . performe the topological CLEAN-UP first

creating faces filling the missing faces there

simple delet the faces than creating new faces respectively using

MENUBAR>TOOLS>TOPO>FACES>DELET
MENUBAR>TOOLS>TOPO<FACES>NEW>CONS

STEP 7: The given model we can see there are penetraction ( intersection ) error we have to try and solve those errors

STEP 8 : we can see the wheels shaft have overlaping faces that have creating intersection errors simpaly delet that over lapping faces of a shaft

using

MENUBAR>TOPO<FACES>DELET

same as a 2nd wheels of the shaft of a model

STEP 9: After checking and performing topo CLEAN-UP for the entire half part of a model we should do a final geometry check to find if there any remaning small crack and unchecked faces which is not good for geometry

• single and convex cons showing only cut half part of a model
• as we can see there are no any intersection errors present on a half part of a model

STEP 10: after clearing all the topological errors ( geometrical error ) we can go with assining PIDs then Meshing

ASSINING PIDs :

STEP 11: assining PIDs for region of the given model using

MENUBAR>LISTS>PROPERTIES

NEW>SHELLPROPERTY>REMAIN NAME AS PR WE CAN ASSSIGN THE PIDs NAME

BODY:

WHEELS:

WINDOWS:

ROOF:

STEP 12: remaning pids simple compress using compress option

MESHING :

STEP 13: Quality criteria i am giving all the region of a model skewness =0.5

min length of a qality criteria = 0.2

max length = 6

WINDOWS AND WHEELS MESH TARGET LENGTH = 2mm

CFD spacing parameters i give

min =1

max = 3

• freeze that the meshing part using MENUBAR>MESH>MACROSE>FREEZE&UNFREEZE

BODY AND ROOF MESH TARGET LENGTH = 4mm

CFD SPACING PARAMETER I GIVE

min = 3

max =5

STEP 14 : after completing meshing unfreeze the model using unfreeze left click of a mouse show in the above fig

• since the whole half of the model is meshed we can just simply transforme the model to create a whole cyber truck mdel

STEP 15 : select the entities to get transformed press right click choose the mirror 3 points plane under symmetry and select any three points on the end surface of the model and again press right click

STEP 16 : now the car has been transformed

STEP 17 :

WIND TUNNEL :

• Data for wind tunnel as a follow .
• the wind tunnel dimension are if X id the length of car model
• front of wind tunnel is 4x from the car
• rear of wind tunnel is 6x from the car
• top of wind tunnel is 3x from the car
• side wall of wind tunnel are at X from the side potion of the car
• bottom of wind tunnel is in close proximity of wheels
• Points are created by using (Relative option )

MENUBAR>TOPO>POINTS>RELATIVE

STEP 18: Measure the length of a model ( total length of the cyber truck 50906mm) i consider 6000mm

STEP 17: creating a refrance point at a bottom ( insert a hot point in bottom of a model using insert hot point )

using a hot points lest create a node using realative option in a bottom -Z direction ( -1000)

STEP 18 : with the help of refrance point at front nodes -Y direction ( 2700+4X6000 =26700mm in front direction )

front of wind tunnel is 4X of the car

with the help of refrance point at rear +Y rear of wind tunnel is 6X ( 3300+6x6000= 39300 )

STEP 19: creating front and rear nodes using refeance nodes length distance at -x and +x direct at

select the refrance 2 nodes put the distance of +x at 8000

STEP 20: after completing the bottom nodes simplay we select tha center nodes refrance at the top faces to creating top refrance points at a car

+z axis at 20600

then we have to connect the points using curve option to create the walls

MENUBAR>TOPO>CURVES>CREATE

STEP 21: we can offset the bottom surface at the top surface and we can delet the unnessary points and deleting the created curve then with tha top and bottom surface refrance can create the side faces

DEFINING THE PIDS FOR THE WIND TUNNEL
TOP_FACES
BOTTOM_FACES
SIDES_FACES

OFFCET VALUE IS - 20600 at the -z direction

CREATING SIDE FACES USING PLANNER

MENUBAR>TOPO>FACES>NEW>PLANNER

SURFACE MESHING :

WIND TUNNEL : 200mm to 450 qality criteria

BOTTOM_FACE

CFD SPACING PARAMETER LENGTH USING

min= 150

max= 250

TOP FACE

min =400

max= 500

SIDE FACES performe growing mesh

manul cfd spacing

Dstart = 200

Dlimit = 450

THE final mesh

since performing volumetric mesh required 2-3 days so we are not performing it

LEARNING OUTCOMES:

• learn how to create a wind tunnel and using spacing option in surface meshing help in having mesh length along the surface
• learn how to clear any off elemnts created while meshing using reconstract option
• using the mesh modifiying tools like move . split. and smooth option
• identifying & cleanup of the topological / geometrical errors
• use qality cretiria tools also learnt various option under the shell parameter such as skwness, min length , max length
• set up wid tunnel as per given dimesnions for external flow CFD analysis and surface mesh of wind tunnel

CONCLUSION :

• created wind tunnel for external aerodynamic analysis
• surface mesh is generated with the required element size

RESULTS :

complete the tesla cyber truck model with wind tunnel ANSA

https://drive.google.com/file/d/1LflEerm1jvHcYPEo_uEEhdplodBaVQk6/view?usp=share_link