Challenge

Project 1 : CFD Meshing for Tesla Cyber Truck

Aim: CFD Meshing for Tesla Cyber Truck

Procedure:

First check if model is having single cons, select entire model and apply TOPO from FACES option on it to convert single cons to double/ triple cons, as and where possible

check for cons resolution. set length for perimeter and macros as 1 mm by selecting entire model for obtaining smooth surface
We will use symmetry option so delete half part of the model and keep only components which are not symmetric. for that, first make cut on the symmetric line for diviiding the model in equal halves

We need to make the model topology clean to ensure only one volume is remaining that is the volume between wind tunnel and truck exterior features. Remove all single and triple cons on the truck inside part by part
All errors are resolved, now create and assign PIDs. Remove all unwanted PIDs using COMPRESS option

Measure distances in all PIDs for checking any distance less than minimum length and store the values
Now start surface meshing by selecting each PID, define quality criteria- min length = 1, max length = 3 and target length as 2 for windows PID
Now set same values in mesh parameters
Now select PERMITER and MACROS length as 2 in MESH MODE and then do spot mesh for visible area
Go to HIDDEN drawing style in ENT mode to check for success of quality criteria
Use RECONSTRUCT option from SHELL MESH on visible area to try to reduce number of off elements
Topo clean up to be done for off elements In TOPO mode and then again do spot mesh and reconstruct option and check for number of off elements. If it turns out to be zero, mesh is complete
Similarly do it for all PIDs. Finally it should like this after full surface meshing
use target length as 4 mm for lights PID, 2 mm for tyre and for body 3 mm
Now go to TRANFORM – COPY option in TOP VIEW Mode, shift and left drag mouse click to select entire model and right click on LOGO PID to deselect it. Now do middle click and choose SYMMETRY option with MIRROR 3 POINTS PLANE
We got the entire model, now use PASTE option to get rid of single cons present at the line of symmetry

For creating wind tunnel select RLEATIVE option from POINTS in TOPO mode and set top part distance as 3X from top surface, 4X from front surface, 6 X from back side surface and X mm each on either side and some roughly close distance to bottom surface where X is the approx. length of model
Now close the wind tunnel by using NEW COONS option and assign PIDs to all surfaces of the tunnel
Complete surface mesh on wind tunnel

Go to volumetric mesh, select AUTO DETECT in DEFINE WHOLE DB option. delete all other volumes other than the one between car and wind tunnel
apply volumetric mesh

NOTE: file size is beyond 200 MB. tried compressing also but not reaching near to 200 hence model file not uploaded

Ship work like this
in your own course.