Project 1 : CFD Meshing for Tesla Cyber Truck
Objective
1.For the given model, check and solve all geometrical errors and Assign appropriate PIDs. Perform meshing with the suitable Target length and element Quality criteria.
2.Target lengths for the different parts of a model can be decided by your own. Finer mesh will give good results and will compromise with the longer processing time.
3.Meshing Wind tunnel volume with tetra elements may take upto 2 days of time. So that is not compulsory to perform. As this is a major project, It is advisable to mesh that completely by taking some days of time. Write a detailed report for the same.
Procedure
First i will import geometry
Now this geometry looks as there is not proper connection was established. All over the geometry the red cons seen.so lets hit a topo.for that goto faces-> topo -> box selection of geometry-> hit middle key.
If you click ctrl+shift only few red coons are present
Lets delete this half portion of a car,for that go to universal delete option and select the half portion of a car.Now it has been deleted
Lets check the errors in the geometry.
In the above geometry some red cons are visible.this is due to missing surfaces. Lets try to make surfaces there.for that go to faces-> new-> coons and create new sufrace
One of intersection error occurs at front of the car,to remove this error,we will delete some faces in corners and try to make new surfaces,so that it will eliminate
Lets hide tha face as shown in below by using 'Not' option
So we have removed above intersection error,
Lets clear above errors now which is in wheel part
similarly we will clear another intersection error which is in other wheel part by following the same procedure
After clearing all errors,it will look like below
Let see warnings
These are all conevex,concave cons in tyres due to shape so we are ignoring,Now we will assign PIDs
Now we will go for surface meshing
Lets give universal quality criteria,lets goto quality parameter,Just enabled skewness,min length,max length,Now gives values,Here skewness=0.5,min length=0.1mm,max length=6mm because here the minimum target length = 2mm and maximum target length=4mm
Now we are going to mesh one by one parts.Lets mesh tyres and windows target length=2 for both,Let hide other componenets.for that goto pid manager
After the meshing is done we use hidden tool to find off elements which we reduce by Apply reconstruct, reshape,smooth one by one to reduce the off elements and continued this process until the numbers has reduce to ‘0’,while doing this if off elements has been increased then stops there and do undo. for that select the parameters and click on this '->' until last
Lets see where these off elements came,we will do remove manually
Lets go to topo and see these off elements are coming due to abnormal sharp edges
Finally by modifying the geometry we removed that sharp edge
Lets click on all,hide the body and lights,Go to free mesh --> visible
We have cleared all off elements,freeze it,lets mesh body by target length 3mm
we will freeze now
Similarly we will do lights for target length of 4mm
We have successfully mesh all half parts of a car with zero off elements.now we are able to make a half portion.before going forward let unfreeze thee macros.for unfreeze select the total body with right key of mouse and after that we will do mirroring.
Now it's time to mirror the geometry to produce the other identical half of Tesla car
Transform > Copy > Entities > select entire geometry > select 'Symmetry' > select '3 Points Plane' select any three random points on the edge of the geometry > OK > Apply > Finish
Creating wind tunnel
Go to topo mode.
Here the wind tunnel is closed volume entity like room which is used for simulate the external flow analysis of air over a car,Let
Length of car = x
Front face at= 4x
Back face at = 6x
Top face at=3x
Bottom face = at convenient position that should not be intersect to the car
Left,right faces at = x
First we will calculate x value,It is approximate we will take 6000 mm
Now create the curves between these points. Go to curves->create-> select the points
We will offset this face
We will assign PIDs like bottom face,side face and top face
We will do bottom face for a target length of 60mm,by giving minimum and maximum length as 50 and 70mm
We will do top face for a target length of 300mm,by giving minimum and maximum length as 290 and 310mm
Now its done.Lets go for side faces mesh.Goto pid manager->enable side face.Now here we are giving mesh as grain growth.so Goto perimeter->spacing->manual spacing
Output file
1.Surface meshing of a car with wind tunnel
https://drive.google.com/file/d/1zvIsUyazBCNh0QfBR3FVuJZOoV7GCF17/view?usp=share_link
2.Tesla car surface meshing
https://drive.google.com/file/d/1hdOMEz2VDIz0uiV-xZ-qcOokQ8o-GmZw/view?usp=share_link
Conclusion
1.I have learn how to make wind tunnel.
2.I have learn how we can do surface mesh of car for external flow analysis.
3. Acquired knowledge of various new tools and how to use them to execute operations on given geometry,Construction of the Fluid domain was introduced newl