Project 1-Meshing of Rear Wheel Holder challenge

AIM:-

The below-mentioned quality criteria have to follow, also meshing the component with a target size:

Target Element size - 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
10	Tria %	10

Procedure To Accomplish The Given Task:-

Step1:-

We have to Download the model and import it into Hypermesh software.

Step 2:-

We need to see the object in topo mode so that we can see how the surface of the given component.

Step 3:-

We need to check all over the surface for free edges and how the surface is in the component.

By forming the proper surface we can overcome this error.

Here I used replace command to correct surfaces and for improper surfaces, I used the filler option to rectify it.

The surface is misaligned so I joined them by replacing the points.

here I corrected the surface, I tried to replace points it's not working so I deleted the surface properly and then created a new surface there.

You can see the free edges in the above pic, these all errors are corrected in parent geometry to get a proper mid surface as much as we can. Here I created a new surface to solve the error.

Step 3:-

After solving all the issues in the parent component we have to create a mid-surface for it.

We need to check the mid surface and have to correct the surface.

Here in the mid surface, I found the surface not formed properly so I filled the surface as shown in below pic.

It is rectified by deleting unwanted surfaces and by replacing the points I corrected it.

As suggested in the challenge I removed these small semi-sphere surfaces as it is difficult to capture the area with the elements of the size of 3 as minimum size elements

so I deleted the surface and then filled that area and toggled it.

Step 4:-

We need to mesh the surface so we have to change the criteria file settings according to the given parameters values we have to set it.

I created mesh in the middle surface.

We gonna need to start correcting the geometry for the proper mesh flow in the surfaces according to the given criteria.

After correcting the middle surface. We do this by creating the initial mesh and then smoothing it using the quality index and then by saving the failed elements and masking them to identify where the element is failing and by adding temp nodes to those elements and unmasking all the elements, as we added temp nodes to find the areas to work on we can delete the elements and we have to work on the surface.

Through this, we will identify the areas where the elements are getting failed, by this we can correct them again to get proper mesh flow.

Here the surfaces are minimum size it is difficult to capture the region for the elements so I created mid-lines and toggled the other 2 lines.

Same here also it is a narrow surface to capture by the elements.

Like this, I created the middle lines and solved this issue.

Step 5:-

I checked the mid-surface and correct all the issues and I confirmed it by checking in topo mode and done the auto mesh on the mid-surface.

I tried to correct the mesh as much as I can without getting any element failure as given in the project.

Step 6:-

After correcting the mesh we need to give thickness to the mesh elements.

I measured the parent component thickness it is 0.75 all over, so we need to give a thickness of 0.75 mm to the elements.

We can see the thickness of the elements as it is applied to the mesh.

Result:-

By completing all the corrections we completed the task according to the given 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
10	Tria %	10

This is the final model of the components of satisfying all the given criteria.