Project 1 : CFD Meshing for Tesla Cyber Truck
CFD MESHING OF THE TESLA CYBER TRUCK
OBJECTIVE
- Geometry clean-up of Tesla cyber truck.
- Assign appropriate PIDs for meshing.
- Surface Mesh generation on the Model.
- Analyze and correct the quality of the mesh.
- setting up a wind tunnel around the car.
PROCEDURE
As we saw above objectives, so we define the procedure in 4 parts.
Part-1(Cleaning all the errors on the model in topo mode)
-In this model, we have only single cons, so we changed the single cons to double cons using topo mode.
Splitting the model
-After that, we cut the model from the middle as it is symmetry so that we can easily resolve our problem in our model and at the end, we can mirror it to the other side.
Removing the single cons and overlapping surfaces.
Part-2(Generating PIDs)
To Generate the PIDs of the model, we use the properties tab to list them.
Assigned PIDs Table
The car model after being assigned the PIDs
Part-3(Generating a surface mesh on the car body)
The mesh parameters, quality criteria, and length are set according to different PID regions.
For meshing, we use the spot mesh tool and reconstruct the mesh if any off elements are there.
Target Length
Body-5mm
windows-3mm
Rims and tyre-3mm
Mesh parameter
The minimum and maximum length of the mesh do not lie within the required range(in this case it is 0.2-8mm), which results in quality errors. this can be reconstructing the macros region.
Quality criteria are the same for all PID regions with different target lengths.
Surface meshing
Due to different target lengths given for meshing, that's why we mesh the components individually.
In the body, the PID region is in contact with other PIDs so that the mesh length variation at the boundary region of 2 different pids causes the mesh to erase or cause mesh failure in that particular region. Therefore, while entering the perimeter under a length in the mesh. select the region which is not in contact with other PID regions. This helps in avoiding the mesh being erased and can later be edited to erased and can later be edited to erase the off elements.
Meshing Errors
Some errors like (skewness, Max length, and min length) may occur and that can be tackled by using a different tool such as MV surf, split, swap, cut, and mainly reconstruct.
Body mesh
Rims and tires
Windows
art-4(Generating or joining the other half)
As we discussed above this is a symmetry model so we have a tool called transform where we can copy, move and link the model as per required.
But for this model, we 1st use the copy option and then chose three points to join the other half n execute.
The whole car model
Part-5(Creating the wind tunnel and volumetric mesh of the wind tunnel)
Dimension of the wind tunnel
Car length-5900 approx so,
- From the Front of the car is 4x that is 23600mm
- From the Rear of the car is 6x that is 35400mm
- From the Top of the car is 3x that is 17700mm
- from the bottom is 510mm
- From the center plane -the left and right are 1x which is 5900mm
Wind tunnel
Meshed wind tunnel
A geometry spacing is a creat with a factor of 1.1, with the smaller mesh elements increasing from the bottom to the top. This is because the top of the wind tunnel is less important compared to the bottom. finally, the wind tunnel has meshed.
since performing volumetric mesh required 2-3 days so we did not perform it.
CONCLUSION
All 4 parts are concluded successfully, we get a cleaned and improved mesh and the wind tunnel is set up successfully.
Tesla cyber truck Model
https://drive.google.com/file/d/1BWf_utGEPocmCl4so_RFINUvItdhVZi2/view?usp=sharing