Project 1 : CFD Meshing for Tesla Cyber Truck

Aim: To perform 2D and volumetric Mesh on the given model

Procedure:

1. As there are lots of single cons present topo is given
2. It seems like the resolution of the con is perfect. As there is no change after using fine and setting length as 1mm in mesh
3. The model looks symmetrical. So project the hotpoints in the plane of symmetry create cuts and delete the half portion
4. Six volumes must be created, the volume inside the car, the Volume inside 4 wheels, the volume between the car and the wind tunnel
5. Create faces to fill in the holes
6. All the surfaces or features on the inside are deleted
7. Remove all triple cons
8. Do geometry checks for checking any single cons, double cons, etc.
9. The only single cons present must be the ones on the plane of symmetry
10. All triple cons must be removed as they may create extra volumes
11. The bubble can be removed by releasing the hotpoints
12. Remove close cuts
13. Do not create small surfaces instead delete and create a bigger surface
14. Delete all needle surfaces too
15. Create new PIDs
16. Property manager>New>PSHELL: To create a new PID
17. Create PIDs namely Lights, Windows, Wheels, and body
18. And parts are assigned appropriately
19. Delete the rest of the PIDs directly or use the compress option
20. Quality criteria as the same as the Challenge 4
21. Import the quality criteria saved before
22. Measure the smallest distance in each PID and give max and min length for meshing
23. Window 2 mm target length, 1 mm min length, and 3 mm max length in quality criteria
24. Body 3 mm target length, 1 mm min length, and 5 mm max length in quality criteria
25. lights 4 mm target length, 3 mm min length, and 5 mm max length in quality criteria
26. Wheels 2 mm target length, 1 mm min length, and 3 mm max length in quality criteria
27. Tri-element type is chosen
28. Give target length in length>macro and perimeter
29. Each PIDs are meshed separately
30. Mesh generation>Sopt mesh>Visible: To generate mesh
31. Reconstruct is used to reduce the off elements
32. Deleting the hot points in mesh mode is favored over topo as it doesn't delete the mesh
33. Smooth option can be used to remove the off elements
34. Body PID is meshed at last
35. The cons that come in contact with 2 PIDs are removed and the perimeter is given as 3 mm to mesh the body PID
36. Make sure the already meshed components are still meshed after giving length> Perimeter to the body PID
37. Get rid of all the off elements
38. The symmetry option is used to complete the model
39. Set the model in left view, Transform> Copy> Entities> Symmetry> Mirror 3 point plane> Select 3 points to define the symmetry> finish
40. Paste single cons in the plane of symmetry
41. Do geometry checks enabling unmeshed macros and single cons. Make sure no error exists
42. The next step is to create a wind tunnel and give a volumetric mesh
43. The length of the car is 5906.1 approximating 5900 and going ahead with the calculation
44. The front face of the wind tunnel is 4x times the distance from the front-most point of the car(x is the length of the car)
45. Rear surface x distance from the back end of the car
46. The side surface is x distance from the side ends of the car
47. The top surface is 3x distance from the top of the car
48. The bottom surface is made close to the wheels as not much CFD behavior happens there
49. Create PIDs namely TopSurface_Tunnel, SideSurface_Tunnel, FrontFace_Tunnel, RearFace_Tunnel, and BaseSurface_Tunnel
50. Points are made, curves are created joining them, Faces are made and assigned to appropriate PIDs
51. Curves and points are deleted
52. The control volume is made
53. Remove quality criteria
54. Mesh bottom surface with 20 mm target length and top surface 100 target length
55. 15 and 25 are min and the max lengths for the bottom surface
56. 80 and 120 are min and the max lengths for the top surface
57. Wind tunnel must be meshed in finer elements near the car
58. To give variable mesh length along the side surfaces, Perimeter> Spacing> Geometric> Factor 1.1> Dmin 20> dlimit100
59. Mesh the side surfaces too
60. For volumetric Mesh, volumes> Define> Autodetect
61. Only interested in the volume between the wind tunnel and the car body. Delete other volumes
62. To mesh volume: Right click> Remesh

Learning Outcome: Learned how to do surface cleanup. Learned to do surface and volumetric mesh with varying mesh lengths and for different PIDs with different mesh lengths. And to create a wind tunnel.

Result: The CFD analysis is conducted on the wind tunnel volume.

Conclusion: It is easy to use the symmetric option if surfaces are symmetric. It saves a lot of time doing topo cleanup. Wind tunnel volume is meshed to understand the CFD applications. Use smooth, reconstruct, split, move, and join if off elements are present while meshing due to quality criteria.

*The screenshots when added in this text space are causing trouble in loading and uploading. So they are attached below. Kindly look into it.

**The result file: https://drive.google.com/file/d/1piZRSf4xa8e4O3CvloC-V9LhPlkAvLTP/view?usp=sharing