Geometry Cleanup, Mid-surfacing, Meshing, Quality optimization of mesh and mesh quality testing of rear hood of the car

Objective: The objective for the project is to Extract the midsurface, cleanup the geometry, 2D mesh the component and quality check for the elements.

About the component: The component is from rear hood of the car where stepney(replacement wheel) is placed, here is a reference image for better visualisation perspective

Pre-requisites:

1. Cad file of the component

2. Meshing software, here used: Hypermesh 2019

Procedure:

1. Open the Floor_Panel.hm file in the Hyperworks

2. Switch to topo mode for better surface visualisation

3. Clean the geometry using the quick edit menu(F11)

4. Extract the mid-surface using the auto-midsurface option

Note: Used skin offset as extraction option

5. De-feature tiny surface features whose dimensions are less than the minimum element length and cleaned the midsurface using the quick edit menu

6. Split surfaces and washer split holes for better mesh quality

7. Start meshing the component, one surface at a time keeping target length as 5.

8. Now reflecting the mesh for the identical second half surfaces

9. Now equivalencing the nodes to make the proper connectivity between the elements

10. Final Mesh

11. Now updating the 2D quality criteria for element check

12.Quality check

1. Elements were checked and the failing elements were resolved by remeshing and element optimisation technique

2. Check for duplicate

3. Free edge check

4. Check for normals

5. Dependency check

6. Elements comparison to surface

13. Material and the property were created and a thickness of 0.75 was assigned to it

Material: Steel

Property: 0.75

Result

Final model image

2D elements detailed representation

Conclusion:

In this project the midsurface of the floor panel was extracted and the surface was cleaned thus meshed under the given quality criteria,

finally different quality tests were done to verify the quality of the mesh.

Project file link: https://drive.google.com/file/d/1RwT5AJKakNMil-NNn2oM7S-QAJ9FMu_I/view?usp=sharing