Project 1 : CFD Meshing for Tesla Cyber Truck

Aim :

To clean up and mesh a computational domain for an external flow analysis of a Tesla Cyber Truck.

Methodology:

A.Geometry Cleanup

• Firstly delete half of the tesla model and perform topo cleanup to that half as they are symmetric
• Secondly perform geometry check for single cons, double cons, overlapped surfaces and bad surfaces and rectify it by using the following tools as shown below.

B. Creating enclosure:

• The outer domain was created with a width distance of L measured from the both extreme ends, Length of 6L measured from the rear and 3L measured from the front of the tesla truck and the Height of 4L measured from the top. Where L is the length of the cyber truck ~6m. It was created with the help of Relative points to define the points and the curves to join the created points and the New option in faces to generate the macros/surfaces.

D.Creating Mesh

• A target length of 8 mm was chosen for the body, windshield and window and 3 mm was choosen for tyres

For body, windshield and window :

Minimum length-4 mm, Maximum Length-12 mm & Skewness - 0.5.

For tyres:

Minimum length-0.5 mm, Maximum Length-5 mm & Skewness - 0.5.

Full mesh

• A target length of 450 mm was chosen for the enclosure.
• Mesh quality parameters were: Minimum length-400mm, Maximum Length-500mm & Skewness - 0.5.
• 
• In total there are 25,06,700 elements out of which 24,52,234 are tesla cyber truck surface mesh & 54,466 are enclosure surface mesh.

E. Volumetric mesh

• In volumetric mesh deck using the Auto-Detect feature check for the volumetric errors before proceeding it.
• Under the list tap it will show the list of volumes. Since we are interested in external flow analysis keep the volume common to tesla cyber truck and the enclosure and delete all the remaining volumes.
• Then using the tetra CFD mesh perform the volumetric mesh since it is time consuming and requires reasonable computational power here we stopped with surface mesh itself.

Conclusion:

Topo clean up and meshing a computational domain for an external flow analysis of a Tesla Cyber Truck is successfully done.

Learning Outcomes about course:

• Advanced Topology cleanup
• Advanced tools used in Surface mesh and in Volumetric mesh.
• Different selection techniques and visibility tools

Link : https://drive.google.com/file/d/1CkvFDtkx0yg8uu-rQ2bOiFmr0gexBfj9/view?usp=sharing