Project 2 - 2D meshing on the instrumental Panel

AIM:

For the given component, check for the geometrical errors and mesh with the given element Quality criteria. After meshing the component the thickness has to be assigned.

GIVEN DATA:

Steps involved in the procedure:

1. To check all the geometry error and to fix them.
2. Mid surface to be made for all the geometrys.
3. To generate mesh with good flow in the given quality criteria.

PROCEDURE:

• Open the Ansa work bench ANSA v22.1.0.
• Import the given model from the downloads
• In ANSA we can import all the CAD Software file formats like IGES,STEP,etc.
• And we have to define the material and to orient the components.
• The model consists of the component listed below.

Given model:

The given cad model consists of 1 component.

STEP 1:

• Before doing the geometry checkup we have give the length for every component to mesh properly.
• Mesh Module >> Perimeters >> Length.

• Then the length of the perimeters and macros should be given 4.

STEP 2:

• We have to fix the geometrical errors in the parent component,Then only we will be able to do midsurface using skin and offset.
• Tool Bar >> Checks >> Geometry.

• After clicking on the check geometry and executing it,The geometric errors will be displayed.
• We can fix that geometric errors by manually or automatically by using the auto fix option.

• after fixing the errors, we have to run another check then it will show no errors .

STEP 3:

• Before middle mesh generation the given data is added to the quality criteria of the components and the target length

• And in presentation parameters element percentage and all details are turned on for better visibility.

STEP 4:

MIDDLE MESH GENERATION:

• The CAD geometry had prepared. Now the Midsurface has to be create for the component.
• There are two methods to create the midsurface for plastic model. They are,
• Manual Method Topo Module >> Faces >> Offset
• Automatic Method

• At here the Casting option is used in Automatic method to create the midsurface.
• Casting option will save lots of efforts in extracting midsurface at various thickness areas.
• To perform Casting select Topo module-->Faces-->Mid.Surface-->Casting.
• In that provide values for minimum thickness and Target element length click on handle as single solid then give Ok to extract the meshed midsurface.

EXTRACTED MIDDLE MESH :

• this mid surface contains distorted features and the alignments of some surface has changed.

the above image is the distorted feature

Redefining and correcting the surfaces and features:

The Align manager tool is used to correct the wrong definition or undefined areas and perimeters for the distorted surfaces.

Topo-->Faces-->Mid.surfaces-->Align manager.

after correcting the features and aligning the surfaces

after fixing the features we have to improve the mesh quality

MESHING:

• To apply mesh use << BEST MESH < MESH GENERATION>> and to remove the mesh use<< ERASE < MESH GENERATION >>.
• To increase the quality of the mesh use <>RECONSTRUCT,<>SMOOTH options.
• To increase the qual;ity manually <> SPLIT /SWAP / JOIN
• the below images are the meshed images of the main component, the component file is shared.
• tria percentage is achieved at 4.46%

Note:
There might be some Failed elements near Triple CONS or at smaller regions that are bounded by two Triple CONS. Keep those OFF elements as it is if not possible to solve.

STEP 5:

Assign PID and THICKNESS:

• For manual mid generation PID has to assign manually. For auto mid generation (Skin/cast) PID & thickness will be assigned automatically.
• Go to topo module --> Faces --> Set PID --> Faces/shells (In selection window) ---> select the mid surface geometry --> Now property window will open & the PID will be created for the mid surface.
• Assign thickness in thickness tab (T)
• Since it is a plastic part there will be a varrying thickness. For parts having varying thickness the average thickness can be given or multiple thickness can be given for a part by assigning seperate PID to the same parts.
• I have taken average thickness for the ribs since they are having varrying thickness.
• Avg thickness = (Max. thickness + Min. thickness) / 2

LEARNING OUTCOMES:

• Now i am able to use all the methods without any doubts.
• I was able to learn new tools and their functions
• understood how to do mesh for complex geometry

CONCLUSION :

Hence, the geometrical errors and mesh, with the given element Quality criteria has been performed successfully for the given plastic component. Also after meshing the component thickness has been assigned.