Project 1 : CFD Meshing for Tesla Cyber Truck

Aim :- CFD Meshing for Tesla Cyber Truck

Objective :- 

1) Checking and solving all geometrical errors

2) Assigning appropriate PIDs

3) Performing surface meshing with suitable target length and element quality criteria.

4) Constucting enclosure around the tesla cybertruck and surface meshing of it.

Tools used :- Faces , Surface , Curves , Cons , PIDs , Delete , Intersect , Perimeters , Grids , Mesh Generation , Shell mesh , Elemets , Geometry checks , V.mesh .

 Procedure :-

Geometry clean-up

1) Import the downloaded geometry in ANSA.

2) Improve the resolution of geometry by reducing the perimeter length.

3) Delete the unnecessary surface which is inside the geometry because that will increase unnecessary mesh elements.

4) Cover all the openings using coons option.

5) Remove all the single cons available by covering openings or using topo option.

6) Remove small surfaces using cut option because that will hinder during meshing.

7) Create different PIDs such as

  a) Lights

  b) Truck Handle

  c) Window

  d) Wheel

  e) Body

8) Now, do geometry check , if any geometry error or intersection error occur then eliminate them.

9) Below figure shows cleaned Cybertruck.

Meshing 

1) Go to Mesh deck.

2) Give suitable max and min target length value in Mesh parameters and quality criteria also give skewness value 0.7 and disable all other options in quality criteria except max and min length.

3) Min and max target length for different PIDs are

PIDs	Target Length (mm)	Mesh Parameters (mm)	Quality Criteria (mm)
Lights	2	1.5 - 2.5	1 - 3
Truck handle	2.5	2 - 3	1.5 - 3.5
Window	6	5 - 7	4.5 - 7.5
Wheel	5	4.5 - 5.5	4 - 6
Body	6	5 - 7	4 - 8

 4) Select one PID ,give mesh parameters and quality criteria as given above.

 5) From perimeters tool , select spacing and select particular PID and provide target length.

 6) For meshing , click on mesh generation and select CFD mesh algorithm.

 7) Meshing is done on one PID now check off elements on that component.

 8) If off element is present then try to remove them by reconstructing mesh using reconstruct option in shell mesh tool or smoothing the mesh also manually we can remove them by moving grids.

 9) Freeze that PID or component using freeze option from macros tools.

10) Select another PID or component and follow meshing procedure  given in "4-9".

11) Meshing is done on car now unfreeze it by selecting unfreeze option and right clicking and do box selection of entire car.

12) Meshing on different PIDs :-

   a) Truck Handle

   b) Light

   c) Wheel

   d) Windows

   e) Body

 Enclosure construction

  1) Make 4 points around the car in rectangular way at given distance from the car.

  2) Create surface using these points.

  3) Do offset below the car and there should be small gap between tha car and surface.

  4) Now offset again for top surface at given distance.

  5) Create remaining surfaces around the car 

  6) Given below dimensions of enclosure, where x is length of Tesla Cybertruck which is 6000mm.  

Front	4x	24000 mm
Rear	6x	36000 mm
Side	x	6000 mm
Top	3x	18000 mm

  7) Do CFD mesh on enclosure surface.

  8) Go to V.mesh and define the volumes.

  9) Delete all the not required volumes as required volumes are only inside the enclosure except Car.

10) Below figure shows

   a) Enclosure around Tesla

   b) Meshing of enclosure

Result :-

1) CFD meshing of Tesla Cybertruck

 

2) Surface meshing of enclosure around Cybertruck.

3) Google Drive Link :- https://drive.google.com/drive/folders/1KQyeAMy0uJ8C_xNRBxpkYmSgtEDEJTW0?usp=sharing