Project 1 : CFD Meshing for Tesla Cyber Truck

AIM

Perform meshing for tesla cyber truck

Objective

Check and solve all geometrical errors and Assign appropriate PIDs. Perform meshing with the suitable Target length and element Quality criteria.

ABOUT TESLA CYBER TRUCK

FEATURES

The proposed truck uses self revealing suspension which compensates for variable load and some models feature all wheel drive The company states that other standard features will include on-board Power invereters or supplying both 120 and 240-volt electricity, allowing use of power tools without a generator An air-compressor for powering pneumatic tools is included. The exterior stainless steel sheet-metal is said to be bullet-resistance All vehicles are also planned to come with tesla autopilot, and they are planned to have the hardware capabilities for fully autonomous operation.

Interior

The interior of the prototype unveiled on 21 November 2019 included a 17-inch center display, seating for 6 using two bench seats with the front middle seat being a fold-down center arm rest, a digital rear-view camera based mirror, a race car style steering yoke and a dashboard with a surface resembling marble.The rear middle seat folds down to allow loading long cargo extending into the cab from the vault (enclosed lockable bed). The "marble look" dashboard of the unveil prototype vehicle was a paper composite material made from "paper, wood-based fibers, natural wood pigments and non-petroleum based resins.''

Vault (bed)

Rear view

The bed of the truck is planned to be a standard-bed size, 6.5 feet (2.0 m) long, similar to a conventional pickup truck bed. It has sloped side walls, similar to a first-generation honda ridge line, and a planned integral motorized roller shutter style tonneau cover to improve the aerodynamics of the vehicle. Because of the additional security this provides, Tesla terms this 100-cubic-foot (2.8 m³) enclosed space "the vault". It includes LED strips along each side, an additional under-floor storage space behind the rear wheels, 120 and 240 VAC outlets, and a compressed air outlet for penumatic tools. While one article claims that there is a pass-through to the cabin for long cargo, the displayed prototype lacks any corresponding opening in the front of the bed. The cabin's climate control was expected to be available in the vault for uses such as camping.

Design

Specifications

The powertrain for the dual motor AWD version is similar to the 2019 and newer "Raven" Tesla model sand model x, all of which have an inductive rear motor and the model 3s permanent-magnet motor in front. Other versions are single-motor rear-wheel drive, or tri-motor with one front and two rear motors.

Geometric clean

Bsically tesla cyber truck design is very simple so the topo cleaning is also a simple process

This is the condition of the model ,here we can see a lot of triple coons.We have to done geometric cleaning on this

• We uses a lot of options to clean up the model
• Here we found an triple coon ,triple coon is beacause the surfaces are missing
• First we can use TOPO option to remove a number of single coons

This is the condition of the model after TOPO

• Then we FILL HOLE option to fix some single coons
• Fill hole option fills the hole between surafaces and removes single coons

• In this topo cleaning we mainly used FILL HOLE and NEW (SURFACE )-COONS to create new surafaces to fix single coons
• Finally we completed the topo cleaning
• Cleaned model is given below

• Once we done the topo cleaning we have to perform geometric check
• We use geometry from Checks to execute geometric checking

• Results of the check shows no errors so we can move the the next stage of the process

Naming & Adding PIDs

• After checking we created new PID to existing list and named them properly
• We given different colors to different PIDs

Surface meshing

Then we started surface meshing

• We done meshing on each PID one by one using spot mesh -Visible option
• We use spot mesh visible option
• We adopted different mesh length for different parts
• Tria is the type of element we selected in qulity criteria

• We faced some problem ,some meshing got erased so we remeshed that part
• We use freeze option to avpid such problems

Like this we meshed all parts and after meshing each meshing we looked for off elements by putting in hidden mode

Quality criteria

• In quality criteria we mainly sets three things
• Skewness- is the measure of equalateral traingularity of mesh elements
• Minimum Length
• Maximum length

This is the off elements cleared head lamp portion

Reasons for off elements

• sharp edges results skewness off elements
• small surafes results off elements of minimum length

Fixing off elements

• We used Reconstruct ,Smooth ,reshape and fix quality Options to fix off elements automatically

• After reconstruct there are some off elements remained for fixing this off elements we used move option in grids to move the mesh edges manually thus we can able to fix skewness and minimum length off elements

Here off element of maximum length is fixed manually by using move option

similiarly we cleared all the off elements

Wind Tunnel Creation

After clearing off elements we have to make wind tunnel

Steps

• First of all we have to create some points around the model
• Wind tunnel dimensions is such that front face of the tunnel is 4x distance from front of the model ,where x is the length of the model
• Rear face of wind tunnel is 6x distance away from back side of model
• Height of the tunnel is 3x + ground clearence of the model
• we used relative option from points to make points to build tunnel

• After point creation we used curve joint the points by lines

• Then we created surafce from the lines

• Then we offset option to make similar surafce on the top

• We created remaining surafces using new option to build tunnel

• Then we assigned PIDs for different surafces of wind tunnel

Surface meshing on wind tunnel

• Then we performed suraface meshing on wind tunnel
• Mesh length for top face is 100 and for base face is 20
• For vertical front and rea faces we adopted biased meshing or varibale meshing with start of 20 and end 100 with a factor of 1.2
• We used Spacing option to perform the variable meshing

• Thus we completed suraface meshing of the tunnel

Conclusion

• Completed meshing of tesla cyber truck and created a wind tunnel
• Performed suraface meshing on wind tunnel
• Understands meshing and ansa in deep
• Got indroduction and ideas about new tools and options in ansa

Link of the model

https://drive.google.com/file/d/1ZyImCXur_REBPp4DTZPrSaxhqfFIbjcv/view?usp=share_link