Project 1-Meshing of Rear Wheel Holder challenge

Project 1

Meshing of Rear Wheel Holder challenge

Aim : Follow the below-mentioned quality criteria, mesh the component given and assign thickness

Target Element Length = 5 Units

Quality Criteria Value

Aspect Ratio 5

Skewness 45

Warping 15

Taper 0.5

Min. Length 2 Units

Max. Length 8 Units

Min angle Quad 45

Max angle Quad 135

Min angle Tria 20

Max angle Tria 120

Tria % 10

Procedure :
Geometry cleanup

• Imported the Rear wheeel holder component into hypermesh .
  
• The CAD geometry had a lot of improper surfaces and gaps.
• Deleted the unwanted surfaces.
• Filled the gap using Quick edit > Filler tool and Surfaces > spline , ruled , skin option.
• Used the Quick edit > Toogle edge to make surfaces proper.
  
  Midsurface :
• Extracted Midsurface using Midsurface > Extraction option > Offset + Planes + Sweeps, as the geomaetry was very complicated with more surfaces.
  
• Midsurface generated had surfaces missing and improper surfaces.
• Did not do the autoclean up because it was making the parts improper, so did clean up manually
• Used the Quick edit > filler surface, toggle edge options and Surfaces > spline, ruled , skin to get it fixed.
• Deleted some unwanted surfaces too, covered the holes which was below the min size.
• Midsurface was ready for meshing.
  
  Meshing
• Started meshing the surface from the middle.
• Used the Clean up tools from quality index to decrease the trias formed.
• swap tria , combine tria , split quad element , smooth , optimize element and place node were some of the cleam up tools used from quality index to improve the mesh quality.
• Used the nodes align option to align elements.
• Used the reflect option to reflect elements from similar surfaces.
• Stitched the reflected elements using Edges > Equivalence option and by pasting nodes using F3.
• Meshed the whole Rear wheel midsurface.
• Checked for free edges , and did the Equivalence option in the end.
  
  
  Assigning Thickness
• Assigned thickness for the meshed elements by creating a new component and property card and entering the value of thickness which was 0.75 .
• Assigned the elements under the property with the thickness value 0.75.
• Shrinked the elements and changed the the elements to 2D detailed representation with thickness 0.75.
  
  
  Conclusion
• The mid surface has been extracted from the parent geometry.
• There are no surface deformations in the geometry.
• Proper connectivity has been established between the surfaces.
• The features have been captured properly.
• Good mesh flow have been achieved with the zero elements failing for quality
• Hence tria percentage with 1.2 % have been achieved.
  
  Learning Outcome
  In this project,I came to know how,
• To mesh a complex sheetmetal component.
• To extract the mid surface manually for the complex sheetmetal components.
• To clean complex geometry .
• To generate a proper mesh flow with low tria percentage.
• To assign thickness to the components.
• 
  Note: As the Model is not able to be uploaded because of the size, the link for the model is pasted in the text file uploaded.