Project 1 : CFD Meshing for Tesla Cyber Truck

OBJECTIVE

• To check and solve all geometrical errors and Assign appropriate PIDs and perform meshing with the suitable Target length and element Quality criteria for Tesla Cyber Truck model.

PROCEDURE

• Import the geometry to the ANSA pre-processor.

• Check the model for Single CONS. If the model contains only Single CONS, then do the Topo function (Topo>Faces>Topo).
• Check wether the model given is fine or not i.e., check for CONS resolution.
• CONS resolution can be corrected by selecting the entire model (Mesh>Perimeters>Length). Give the perimeters and macros length as 1mm.
• Since the model is symetrical, the topo cleanup can be done one side only. This one sided topo cleanup will be reflected on the symetrical side.
• Select Plane Cut > 3point plane, Select any three points on where the plane is and apply. We have a symmetric model with double cons dividing it in the middle. Delete one side of the model. Half of the model so obtained is shown in the figure below.

• Fill the holes, apply new faces and remove topological errors if present as shown in the figures below.

• Check for any remaining errors in Checks > Geometry. If there are any errors, fix those as well (single CONS at symmetry are not errors as shown in figure below because we'll execute the symmetry later and join each side's single CONS into double CONS).

• Create new PIDs by asigning appropriate part names and then assign the parts by selecting the model. Aisigned PIDs are shown in the figures below.

• After asigning PIDs for the each parts as mentioned, surface mesh the mentioned parts by setting minimum and maximum target length in the quality criteria and target lengths with the element type as tria in mesh parameters.

• 	Target length (mm)	Minimum length (mm)	Maximum length (mm)
  Windows	2	1	3
  Lights	2	1	3
  Tyres and Rims	2	0.2	3
  Body	3	1	5

• After completing the surface meshing of one half click Tranform > Copy > Select the entities > Symmetry > Mirror 3 Point Plane >  Select 3 points check the preview and click Finish. Symmetric model obtained is shown in the figure below.

• Check for geometrical errors in the symmetrical model as shown in the figure below.

• Now create the wind tunnel by using creating points, curves and by creating different faces of wind tunnel using those curves in such a way that front face of the tunnel should be at a distance of 4X, rear face of the tunnel should be at a distance of 6X, top face of the tunnel should be at a distance of 3X, bottom face of the tunnel should be very close to the wheel, Side face of the tunnel should be at X distance from the car geoemtry. Where X represents the total length of the car as shown in the figures below.

• Mesh all the faces of tunnel and create fine mesh at bottom and course mesh at top using Spacing option which helps to enable to save time as over focus is more to car geometry as shown in the figure below.
• Next mesh the required volume of wind tunnel and the car model volume.

RESULTS

• Surface meshed parts is shown in the figures below with respective target lengths and quality criteria.

Window

• Target length = 2mm
• Minimum length = 1mm
• Maximum length = 3mm
• Element type = tria

Lights

• Target length = 2mm
• Minimum length =1mm
• Maximum length = 3mm
• Element type = tria

Rims and Tyres

• Target length = 2mm
• Minimum length =0.2mm
• Maximum length = 3mm
• Element type = tria

Body

• Target length = 3mm
• Minimum length =1mm
• Maximum length = 5mm
• Element type = tria

Wind Tunnel

• Bottom Surface = 20mm 
• Top surface = 100mm
• Side surface = Spacing from start = 20mm to limit = 100mm

• Required volume for volume meshing is shown in the figure below.

• Volume to be deleted is shown in the figures below.

Attached link : https://drive.google.com/file/d/1UA80XUgPIkYOJaguRG9OlS6a4wVTbdT0/view?usp=share_link