Project 1 : CFD Meshing for Tesla Cyber Truck

Objective:

The main objective of this task is to check the geometry for the error on a half portion, assign the PIDs, and generate the surface mesh for the entire Tesla Cyber truck model with the given mesh parameters.

Geometry Details and Clean-up:

The given Tesla Cyber truck model has to be split into 2 halves, for which:

• The hot points were created using the Parametric option (0.5)
• Cons were created at the center part which is shown below:

• The model is deleted one half in a symmetric plane (x-axis) as shown below:

The single cons, triple cons, and missing faces were found and solved on the rims, Tyres, and body of the model and the cleaned geometry was ready for the surface with any errors on the faces of the entire body. The cleaned geometry is shown as a wireframe view below figure:

Then, the model is copied onto the other side to make the entire model using copy --> symmetric using the 3-point plane option as shown below:

The geometry check-up was made for single cons and triple cons which was found as correct (green tick) without any errors as shown below:

PID Assignment:

In the next step, the PIDs were assigned for the different parts of the model as per the requirement of a challenge to make the surface mesh.

The PIDs created are:

1. Body
2. Rims and Tyres
3. Windows and Glasses

Then, the extra existing PIDs were deleted using the compress option. PIDs are shown below:

Mesh Parameters Details:

Target lengths for the different parts of a model are as follows:

Rims and Tyres:

Target length= 5 mm;

Min. Length = 2 mm;

Max. Length = 7 mm;

Body:

Target length= 10 mm;

Min. Length =5 mm;

Max. Length = 15 mm;

Windows:

Target length= 15 mm;

Min. Length = 10 mm;

Max. Length = 20 mm;

The surface was generated using the spot mesh for all PIDs created as per the mesh quality parameters. The final surface mesh without offset is shown below:

No. of Surface cells for Tyres ~ 1 Millions

No. of Surface cells for Body ~ 1 Millions

The surface mesh was checked for the unmeshed face and single cons, the status was found as correct without any errors as shown:

The total number of surface cells was found as ~ 2 million.

Windtunnel Section:

The wind tunnel test section is created using the point creation option, then the curve is created on the points with which the face was created.The face is made on the opposite side with an offset option. The test section is to be made as 10L X 3L X 2L.

The test section is shown below:

Volume Mesh:

The volume mesh has to be created for the volume over the model (inside the test section). The available volume for the entire database model is checked using the define option.

As the volume mesh takes nearly more than a day, it is not enclosed with this task.

Conclusion:

• The geometry check for the complicated model was resolved and the different ways were learned to remove the single and triple cons.
• The creating curve with points and cons was also learned in this challenge.
• The total number of surface cells was found as ~ 2 million.