Project 2 - 2D meshing on the instrumental Panel

Report on 2D mesh generation and mid-surface extraction using casting method after geometrical and topological clean-up of IP- Substrate model as per the mesh quality criteria by using ANSA software (Project 2).

Aim:

The main aim is to generate the 2D mesh and take mid-surface for IP-substrate model after correcting for the geometrical errors and topological clean up using casting method in ANSA Software. Also the PID and thickness assignment has to be done for all the mid-surfaces, and meshing the same with given quality criteria. And also to achieve better mesh flow in less period of time.

Procedure with CAD model images:

• The given CAD model of component.

Fig. 1: GIVEN CAD MODEL.

• After importing .ansa file in ANSA, the observation found that many areas where geometry needs to be check for topological clean-up and geometrical errors.
• By Starting with checking single, double and triple cons. I have used topo command to clear unnecessary single cons.

FIG.3. MODEL AFTER TOPO CLEAN-UP.

• The achieved geometry of model after using topo command is checked for the errors in check manager by executing it for single cons, cracks, overlap faces, Needle faces, triple cons, collapsed cons and unchecked faces etc. as shown in fig.5 below.

Fig.5 GEOMETRY PRESENTATION WITH CHECK MANAGER EXECUTION.

• CASTING METHOD FOR TAKING MID-SURFACE AND GENERATING 2D MESHING OF COMPONENT.

• Here automatic mid-surface mesh generator is used to generate mid-surface as shown in Fig.16. Below.

FIG.6. AUTOMATIC MIDDLE-SURFACE MESH GENERATOR METHOD.

FIG.7. ACHIEVED MID-SURFACE USING AUTOMATIC MIDDLE-SURFACE MESH GENERATOR METHOD.

• After observing the achieved mid-surface using casting method, it has been found that some warpage and surface dislocation near dog points and feature areas are presents which needs to be modified manually. The figs shows below a closure view of the some areas of dog points, feature and ribs.
• Here the images are presented below in a sequence like first achieved mid-surface, second achieved mid-surface with outer geometry and third modified mid-surface.
• For 1^st dog point :-

Here the modification is done by deleting elements at warpage areas of mid-surfaces and filling it using fill option available in shell mesh group. Also the new cross ribs are generated by creating curves over cylindrical geometry and then filling it with elements by using fill command. Also cut and project commands are used for modification process.

Similar process is used to reconstruct the mid-surface at multiple dog point locations.

FIG.8. ACHIEVED MID-SURFACE NEAR DOG POINT 1.

FIG.9. ACHIEVED MID-SURFACE NEAR DOG POINT 1 WITH OUTER GEOMETRY.

FIG.10. MODIFIED MID-SURFACE NEAR DOG POINT 1 WITH OUTER GEOMETRY.

• 2^nt dog point :-

FIG.11. ACHIEVED MID-SURFACE NEAR DOG POINT 2.

FIG.12. ACHIEVED MID-SURFACE NEAR DOG POINT 2 WITH OUTER GEOMETRY.

FIG.13. MODIFIED MID-SURFACE NEAR DOG POINT 2 WITH OUTER GEOMETRY.

• 3^rt dog point :-

FIG.14. ACHIEVED MID-SURFACE NEAR DOG POINT 3.

FIG.15. ACHIEVED MID-SURFACE NEAR DOG POINT 3.

FIG.16. MODIFIED MID-SURFACE NEAR DOG POINT 3.

• 4^rt dog point :-

FIG.17. ACHIEVED MID-SURFACE NEAR DOG POINT 4.

FIG.18. ACHIEVED MID-SURFACE NEAR DOG POINT 4 WITH OUTER GEOMETRY.

FIG.19. MODIFIED MID-SURFACE NEAR DOG POINT 4.

• 5th dog point :-

FIG.20. ACHIEVED MID-SURFACE NEAR DOG POINT 5.

FIG.21. ACHIEVED MID-SURFACE NEAR DOG POINT 5 WITH OUTER GEOMETRY.

FIG.22. MODIFIED MID-SURFACE NEAR DOG POINT 5.

• 6th dog point :-

FIG.23. ACHIEVED MID-SURFACE NEAR DOG POINT 6.

FIG.24. ACHIEVED MID-SURFACE NEAR DOG POINT 6 WITH OUTER GEOMETRY.

FIG.25. MODIFIED MID-SURFACE NEAR DOG POINT 6.

• 6th dog point :-

FIG.26. OUTER LEFT VIEW OF ACHIEVED MID-SURFACE.

FIG.27. OUTER LEFT VIEW OF ACHIEVED MID-SURFACE WITH OUTER GEOMETRY..

FIG.28. OUTER LEFT VIEW OF MODIFIED MID-SURFACE.

FIG.29. OUTER RIGHT VIEW OF ACHIEVED MID-SURFACE.

FIG.30. OUTER TOP RIGHT VIEW OF ACHIEVED MID-SURFACE.

FIG.31. OUTER TOP RIGHT VIEW OF MODIFIED MID-SURFACE.

FIG.32. FRONT VIEW OF ACHIEVED MID-SURFACE.

FIG.33. FRONT VIEW OF ACHIEVED MID-SURFACE WITH OUTER GEOMETRY.

FIG.34. FRONT VIEW OF MODIFIED MID-SURFACE.

• After completing manual modifications over achieved mid-surface the checks manager is executed for single cons, cracks, overlap faces, needle faces, triple cons, collapsed cons and unchecked faces.
• 35. Shows that there is no error found in mid-surface of Ip- substrate model after manual modifications.

FIG.35. CHECK MANAGER EXECUTION OF MODIFIED MID-SURFACE.

• For getting better mesh flow some modifications are done using multiple commands like reconstruct, smooth, split, swap, cut and project etc. in mesh module.
• Following images shows below mesh flow pattern after manual modification.

FIG.36. MODIFIED MESH FLOW PATTERN OF IP-SUBSTRATE MODEL.

FIG.37. MODIFIED MESH FLOW PATTERN OF IP-SUBSTRATE MODEL.

FIG.38. MODIFIED MESH FLOW PATTERN OF IP-SUBSTRATE MODEL.

FIG.39. MODIFIED MESH FLOW PATTERN OF IP-SUBSTRATE MODEL.

FIG.40. MODIFIED MESH FLOW PATTERN OF IP-SUBSTRATE MODEL.

FIG.41. MODIFIED MESH FLOW PATTERN OF IP-SUBSTRATE MODEL.

FIG.42. MODIFIED MESH FLOW PATTERN OF IP-SUBSTRATE MODEL.

FIG.43. MODIFIED MESH FLOW PATTERN OF IP-SUBSTRATE MODEL.

• After completing manual modifications for getting better meshing results over achieved mesh using a same method, the checks manager is executed for single cons, cracks, overlap faces, needle faces, triple cons, collapsed cons, unchecked faces, unmeshed macros and sharp edges etc.
• 44. Shows that there is no error found in mid-surface of Ip- substrate model after manual modifications.

FIG.44. CHECK MANAGER EXECUTION OF MODIFIED MID-SURFACE.

FIG.45. ACHIEVED MESH MODEL OF IP-SUBSTRATE USING CASTING METHOD.

• The ‘Draw shell as solid’ is activated in quality criteria-presentation parameter which is available in utility menu.

LEARNING OUT COMES:

A casting method (Automatic mid-surface generator method) gives results in less time comparatively other methods but the output of mid-surface shows some errors like warpage, dis-location and missing of surfaces form their original position, hence I needed to fix this errors manually by using multiple commands in topo and mesh modules. Here the learning has to be carried out in modification process of mid-surfaces manually at locations like dog points, feature areas and some ribs. Also the learning has to be done to get smooth and better mesh flow with achieving quality criteria by doing manual modification using mesh module.

CONCLUSION:

The mid-surface extraction and meshing of the given IP substrate model has been carried out using casting method. The remarks are based on the observation of a time taken for process execution and the result outcome.

• In this case the mid-surfacing and 2D meshing are carried out using casting method i.e. automatic mid-surface generator method. It took less time for generating mid-surface and 2D meshing compare to other methods, but the mid-surface and meshing needs to be reconstructed for getting better mesh flow and to remove off elements manually by using topo and mesh module.

NOTE: KINDLY REFER ATTACHED PDF FILE FOR IMAGES. PFA.

GOOGLE DRIVE LINK FOR ANSA FILE. :-