Project 1-Meshing of Rear Wheel Holder challenge

Aim/Objective :
To extract midsurface of rear wheel holder
Meshing the rear wheel holder with proper mesh flow
Obtain the given quality parameters for midsurface

Component : Rear wheel holder

Quality criteria :
Target Element Length = 5 Units

S.N Quality Criteria Value
1 Aspect Ratio 5
2 Skewness 45
3 Warping 15
4 Taper 0.5
5 Min. Length 2 Units
6 Max. Length 8 Units
7 Min angle Quad 45
8 Max angle Quad 135
9 Min angle Tria 20
10 Max angle Tria 120
11 Tria % 10

Procedure :

Steps 1
To import the geometry in hypermesh
Improve the geometry by working on single cons on wire frame mode
Single cons were eliminated by geom quick edit toggle in most places
Toggle length was 1mm in most of the improved geometry
Under geometry surfaces ruled option was used where toggle was not used

Steps 2
Property created Midsurface was extracted geom surface edit offset
Thickness half the value given surface selected by face then duplicate
In someplaces the midsurface was not captured so it was captured again on that areas
Excess surface was trimmed by using surface edit trim with surface plane
And these excess surfaces was then deleted

Steps 3
Feature lines less than minimum length were toggled
Using geom quick edit and toggle around the areas and corners
The large areas were divided to small sections for smooth meshing
Some feature lines were slightly adjusted to avoid failures
Some of the holes less than minimum length were changed surface using spline option

Steps 4
Meshing was done from the edges of one side continued throughout
Under 2D automesh was used for meshing the component
2D rebuild option was used to improve the mesh flow for failing elements
Most of the warpages were check and converted to tria to avoid failing
Holes and fillet were captured in tria to avoid warpage issues

Steps 5
Tool Translate options were used to avoid warpages in possible areas
Under tools edges were checked with applying tolerance 0.1 and find edges equivalence
Tools check elements used to check minimum failure saved failed
Then used retrive under mask reverse unmast adjacent to work on them
Meshing was done with proper flow and quality criteria was obtained
Thickness was assigned to the component through property card

Learning outcomes :
Geometry cleanup of the component for midsurface extraction
Holes capturing where required or converting to surfaces
Midsurface extraction and trimming the unwanted surface
Meshing the component with proper mesh flow thickness assigning
Quality parameters obtained with proper feature lines and mesh flow

Result :
Thus the rear wheel holder midsurface is extraced and meshed to obtain the quality parameters and the file is attached for reference