Project 1 : CFD Meshing for Tesla Cyber Truck

Link:-  https://drive.google.com/drive/u/1/folders/1i56v0VpMFqFiktuGFG_FhzUmvihIBS4m

Aim:- For the given model we need to check and solve all geomentry errors and needed to assign appropriate PIDs and perform meshing with the suitable target element length and quality criteria

Procedure:- 

• In this Final Project-1 we are splitting it into three parts and we completing this model to the end. the three-part they are,

1. First, Topological cleanup.
2. Second, Surface meshing.
3. Thirdly, Volumetric meshing.

• So now firstly we need to Topological clean up the model after that symmetry of our model and then create a wind tunnel and assign appropriate PIDs.

•  In this week we will work with the TESLA Cybertruck model and we will also try to fix with volumetric mesh for this TESLA Cybertruck model for CFD application.

• First we need to check the TESLA Cybertruck model is present in single cons. If the model is single cons we need to apply TOPO. For this, we need to select the entire car and the middle click. now it is converted into double cons.

• This model is pretty much symmetry to another side apart from a few features remaining all the features are pretty much symmetry. so now we used the universal delete option for deleting half of the model do select half of the model and then the middle click to delete the selected part.

• Now almost half of the part has been deleted. so, the remaining half part is here we need to correct that model. Once we corrected half of the part entirely, we will reflect half side to the other side by using the symmetric option.
• so, before correcting that model the adjanda is we get to create a few volumes inside this main car and then the four tires and we will create the wind tunnel. so the volume is between a car and a wind tunnel. so, first inside the car second to fifth are the four tires, and finally the sixth one is between the car and the wind tunnel.
• we are not much bothered about the inside feature of the car but we are considered about the surface or features outside of the car. so, we will check the single cons and triple cons individually.
• Now we need to delete the unnecessary feature of the inside of the car like the front side of the car. we need to do some topological cleanup.

• we don't have the outer surface of the triple cons and that front surface. so, delete that surface and we don't need that instead of that surface we will create another surface using some option.
• Now we need to patch the using some New options & surfaces of the outside of the car. In the bottom of the window region, we need to create some surface to patch that hole.
• And also in that outside of the tire region we need to create a surface to patch that hole. so, to patch that hole first select the "NEW Option" and select the face in this model, and then the middle click.

• On the right-hand side of the car there is a single con presented. so, first, we need to delete the double cons and also the surfaces presented in that area then we can create the surface in that area.
• And on the front side of the car there are no smooth and flat surfaces presented so, we can delete that entire surface and recreate the surface using some "NEW OPTIONS".

• There isn't a proper surface shape and there is an extra surface presented so, first we need to delete the surface and cut the extra surface using some cut option. And we need to recreate the new surface between the front car panel.
• similarly we need to recreate the surface in their frontside corner surface. In that area, many surfaces don't intersect properly. so Firstly, we need to intersect that and delete that unwanted surface.

• After successfully intersecting the two surfaces then we need to delete some unwanted surfaces over there. so, now we need to create some footprint before deleting the surface. why because those surfaces look important so that's why we are creating some footprint using some "CREATE OPTION" in that curves section and after selecting the create option select the line option in that create section.
• so, now delete the surface and recreate the surface again.

• First isolate the tyre part alone and lock that part. In this center of the tire surface, there is a cylindrical surface presented, and that cylindrical surface is penetrating with another cylindrical surface which is in the car body region. so, we need to delete both cylindrical surfaces which we don't need of it. And then we need to patch that center hole using "NEW OPTION". Also, repeat this same process in another tire. 

• On the back right side of the car surface there is a small surface presented. so first, we need to cut that small surface into two parts and then delete the small surface and patch the hole. Again repeat the same process for another small surface.

• There is a very tyne surface presented at the beginning of the wheel so, we need to delete the small surface and also that neighbor surface also. now recreate the surface again. why because during the surface mesh, there may occur unwanted meshing errors like skewness off-element. so if we should avoid those errors then we have to delete these kinda small and very tyne surfaces.

• Now on the front side of the car surface there is a mess of unwanted cons and multiple hotpoints presented in a single area. so to clear this kind of error first release those cons and delete the unwanted hot points and cons and then patch that surface and cut some surfaces and delete some surfaces and recreate the surface finally we got a clean and accurate surface shape.

• After completing the topological cleanup we need to do the symmetry of another half side for this first, we need to select the transform option on the top of the GUI and in that select the COPY option. now drag to select the overall entity of our half model and then middle click to select the entities.
• now another window will pop up in that window there is a  distance needed for X1, X2, X3, and Y1, Y2, Y3, and Z1, Z2, and Z3 is coming up.
• After that define any three hot points in the center of the edge surface. 
• Now click apply button and then in another tab we need to select the no-offset option and the same part. that's selected in default then just click OK. Now another half of the car position has been created successfully. and finally, click "FINISH".

• Now after the symmetry of our model we can see there is a gap or there are two single cons which is not joined with other. so, now our task is to merge both single cons into double cons. For this just create the footprint of the surface presented on the front car panel.
• Just create the footprint and then delete the entire surface and now we can very well create a new surface using "NEW Option". now we got a new and smooth surface in that area so, now there are no single cons presented.
• And now to patch the hole in their tailgate we need to create a surface that is nothing but the back top side of the car. After completing a symmetry this is our final model of the entire "TESLA Cyber truck" car. 

• Now we need to create a wind tunnel for our TESLA Cyber truck model. So, for creating a tunnel, there is a certain standard for wind tunnels. The face of the wind tunnel would be 4X the distance which is nothing but "2865 + (4 x 5730) = 25,785mm" from any point of our front car model.
• The Rear face of the wind tunnel would be 6X the distance which is nothing but "2865 + (6 x 5730) = 37,245mm" from our rear side point. And the Top face of the wind tunnel would be 3X the distance which is nothing but "1530 + (3 x 5730) = 6120mm" from any between side points.
• The Bottom face of the wind tunnel would be near the wheels. so, to create a surface we should create so many points first. and then we can create a surface indirectly. so, select a relative for creating a point for the surface. 
• And both sides of the wind tunnel would be the actual distance alone which is nothing but "5730mm" 
• Select "RELATIVE" in the points section of the topo mode. select the bottom middle of the hot point in the car and then the middle click and enter the value in either dx, dy, dz anyone of this with the correct symbol.

• After completing creating a base surface then now we need to offset a top side surface using "OFFSET OPTION" so, click the offset option and then enter the distance which is nothing but "-18720mm". now the top surface has been created and does not delete the base surface. After creating a base and top side surface we need to create a side and front and rear side surface. so close the wind tunnel completely.
• And Create and apply the appropriate PIDs for the wind tunnel and the TESLA Cybertruck model. then only we can apply surface mesh for the particular surface.

• So now Secondly we need to inspect our model and then Surface meshTag the model including the wind tunnel. 
• SO, before going to surface mesh we need to inspect the PIDs of all the parts. that means we need to check whether the parts have a proper minimum target length or not. If not then we need to cut the cons and then measure the distance between one cons to another cons or node hot points.
• So, during this inspection we need to do so topo clean-up work in part. That's if needed. after completing the inspection that means the distances are satisfied with the minimum target length we can proceed with the meshing process.
• And there is a certain quality criteria we need to follow accordingly. 
• After completing the inspection so as per the given quality criteria we need to perform the surface mesh of this model. So first give the quality criteria distance between the minimum and maximum target length after that select the mesh parameters that apply the target length and minimum distance and then click OK.
• After that apply the parameter and macro target length and then go to the mesh generation section and select the spot mesh visible option. now our Light region has been meshed but there is very few amount of off-elements are presented. so to clear that few off-elements go to the shell mesh section and select the Reconstruct visible option and execute that option. Now our off-elements are got cleared.

• We need to perform the surface mesh of this window PIDs. So first give the quality criteria distance between the minimum and maximum target length after that select the mesh parameters that apply the target length and minimum distance and then click OK.
• After that apply the parameter and macro target length and then go to the mesh generation section and select the spot mesh visible option. now our Window PIDs have been meshed but there is very few amount of off-elements are presented. so to clear that few off-elements go to the shell mesh section and select the Reconstruct visible option and execute that option. Now our off-elements are got cleared.

• We need to perform the surface mesh of this wheel and tire PIDs. So first give the quality criteria distance between the minimum and maximum target length after that select the mesh parameters that apply the target length and minimum distance and then click OK.
• After that apply the parameter and macro target length and then go to the mesh generation section and select the spot mesh visible option. now our wheel and tire PIDs have been meshed but there is very few amount of off-elements are presented. so to clear that few off-elements go to the shell mesh section and select the Reconstruct visible option and execute that option.
• Now our off-elements are got cleared but still few off-elements are presented. so to the GRIDS section and select the "MOVE Option" and select surface now we can move manually using our mouse once the off-element has cleared then middle-click the mouse. now the off-elements are cleared in this wheel and tire PIDs there are zero off-elements.

  

• We need to perform the surface mesh of these Body PIDs. So first give the quality criteria distance between the minimum and maximum target length after that select the mesh parameters that apply the target length and minimum distance and then click OK.
• After that apply the parameter and macro target length and then go to the mesh generation section and select the spot mesh visible option. now our Body PIDs have been meshed but there is very few amount of off-elements are presented. so to clear that few off-elements go to the shell mesh section and select the Reconstruct visible option and execute that option.
• Now our off-elements are got cleared but still few off-elements are presented in that side mirror area. so go to the GRIDS section and select the "MOVE Option" and select surface now we can move manually using our mouse once the off-element has cleared then middle-click the mouse. now the off-elements are cleared in this wheel and tire PIDs there are zero off-elements.

• We need to perform the surface mesh of the Base Surface wind tunnel PIDs. So first give the quality criteria distance between the minimum and maximum target length after that select the mesh parameters that apply the target length and minimum distance and then click OK.
• After that apply the parameter and macro target length and then go to the mesh generation section and select the spot mesh visible option. now our Base Surface wind tunnel PIDs have been meshed. here the off-elements aren't presented. so, no need to use a reconstruction option.

• We need to perform the surface mesh of the TopSurface wind tunnel PIDs. So first give the quality criteria distance between the minimum and maximum target length after that select the mesh parameters that apply the target length and minimum distance and then click OK.
• After that apply the parameter and macro target length and then go to the mesh generation section and select the spot mesh visible option. now our TopSurface wind tunnel PIDs have been meshed.
• but there is very little amount of off-elements presented. so to clear that few off-elements go to the shell mesh section and select the Reconstruct visible option and execute that option.
• Now our off-elements are got cleared but still few off-elements are presented in that Corner area of the wind tunnel. so go to the GRIDS section and select the "MOVE" option and select surface now we can move manually using our mouse once the off-element has cleared then middle-click the mouse. now the off-elements are cleared in this TopSurface wind tunnel PIDs there are zero off-elements.

• We need to perform the surface mesh of the Side Surface and the front & rear Surface of the wind tunnel PIDs. so now go to the Perimeter section and select "SPACING OPTION". now we need to give the spacing input first geomentry in that tab and the Factor is 1;1 and select the Dstart and give the value as 20. and select the Dlimit and give the value as 100. Now select the Dend/Dstart and give the value as 100/20 = 5.
• Select all the show steps and labels and Now select the 4 corner cons in this wind tunnel. and then the middle click to confirm the meshing length. now the mesh length is created in the front and rear corner surfaces after that go to the mesh generation section and select the spot mesh visible and the mesh has been created in this surface.

• So now Thirdly we need to perform Volumetric mesh on our model Between the wind tunnel and the TESLA Cybertruck model.
• Now we successfully assigned PIDs and the surface meshing process has been completed. so, we can very well go for the volumetric section. for this process, we need to go first to the volumetric section and then click the "DEFINE OPTION" and select the "Whole database option" in that define option and click ok. now the ANA software has detected a total of 6 volumes.
• so, our task is to keep only one volume. so, keep the 1st volume alone and then delete the remaining 5 volumes. so, now select the entire car volume and then right-click to mesh and the mesh should be in Tetra CFD. 

Learning Outcome:- 

So, In this Project-1 I have learned how to clear the advanced topological clean-up in this TESLA Cybertruck model. And the surface mesh and the creation of a wind tunnel with the distance calculation.

Result:-

Hence all the geometric errors and assigning the PIDs and the surface meshing with the target length and the quality criteria and the symmetry of the other sides are successfully done with the Checks Manager.

Conclusion:- 

Finally, the topology was been cleared with all the double cons which are needed for the volume to create and the different mesh sizes for all the PIDs were assigned and surface meshed by refining the mesh as well as errors.

So, Here our Project-1 has been completed successfully...