Project 2 - 2D meshing on the instrumental Panel

Project 1.

Aim- Mid surface extraction and 2D meshing on the instrumental Panel.

Google Drive Link of assignment -https://drive.google.com/file/d/1zWtE_GZENGqz_GOTe5mqbQ6nAQ6bih_g/view?usp=share_link

Procedure-

Step 1- Imported the Geometry

Step 2- Improved cons resolution from mesh module- perimeter- length – 1.

Step 3- Set orientation from Topo module -Faces- orient.

Step 4 – Checked for connectivity between surfaces from topo module – faces-topo.

Fig 1- Part before geometry checks

Step 5- Geometry checks – tools – checks – geometry- fix.

Fig 2 – Errors that Ansa was not able to fix

Step 6 - To fix the geometry error we had worked on it individually, The Unchecked faces error was removed by deleted the unchecked faces, from Topo module- Faces – Delete.

Step 7- Re run the checks geometry, the other error remaining error are cracks between cons, and auto fix error, 5 errors that was not auto fixed. The crack between the faces error is due to the absence of faces. All the error is fixed individually, by LMB - Show only , we get the location of error.

Fig 3 – Location of error

Step 8 - we need to add another surface to fix this error from, Topo module- Faces – New- Cons – Selected the single cons- MMB-ok. Applied the same process for other errors.

Fig 4 – Solved the error

Fig 5 – Part after fixing all geometry error

Step 9- Checked for number of properties – ctrl+P (shown in fig 6)

Fig 6- Property card.

Step 10- Worked on one property by turning off the other cards.

Step 11- Measured the thickness at different location from Utilities- measure, thickness is not same for different locations(shown in fig 7 ). So ,it is casting or plastic components and have to move from one surface for mid surface extraction.

Fig 7- Thickness at different location.

Step 12- Extracting the Mid surface

Step I- To start midsurface extraction, We started from the bottom surface, from Topo module- faces- offset- 0.3. for the type A surface.

Fig 8 - Mid susrface from offset.

Step II - The midsurface at different location is extraced form commands like Midsurface and offset tools.

Step III – Extracting the dog house,

Fig 9- Dog house

Step a-To extract the dog House, First extacted the midsurface of the ribs from Topo module -middle -single.

Fig 10 – Midsurface of Ribs

Step b – The Ribs contais fillet section because of which the actual height is not able to extracted, To get the actual height first we created the curve at the middle of the ribs from topo module – Curves middle selected the cons- MMB. Cut the face for non ribs portion as the middle and created the curve from Cons to curve. Applied the same process for the other ribs.

Fig 11- Middle Curve

Step c – Extended the surface to the curve from Topo module- Faces-new -cons.

Fig 12 – faces added to curve.

Step d- The cylindrical is extended Part is modeled by adding the surface in the middles of the ribs and till the curve.

Fig 13 – Modeling the cylindrical Part.

Step e – Extended the Ribs to the Midsurface from Topo module- Faces – extend- select the surface-MMB.

Fig 14- Complete modeling of the Dog House

Step IV - Applied the same Process for the remaining dog house and ribs.

Fig 15 – Complete Midsurface of the Instrumental Pannel.

Step 13 Meshing

Step I- Added quality criteria as per the assignment.

Step II – Meshed the Mid surface for different portion.

Step III – The required element size is set to 1 from mesh module - perimeter- length – 4.

Step IV -meshed the Part by using Macro area selection and using the Best algorithm form mesh module -shell mesh-best

Step V – generated proper mesh characteristics by using Split, Improve, Reconstruct, Grids Paste, Reshape commands.

Fig 16 – Meshing of complete Part

• 84 Elements are failing for quality criteria and was not able to solve them.

Step 14 - Thickness Assignment to Parts.

1. Created the PID for of different thickness.
2. Separated the two adjacent faces from mesh Module – Macros -Edge to perimeter.
3. Assigned the Face to different PID form mesh module-Macros- Set PID.

Fig 17 – PIDs of different thickness.

Fig 18 - PID for different faces.

Conclusion

• Mid surface Extraction of automobile plastic components.
• Meshing of complicated component.
• Learned about some constraints of software.
• Learned about assigning the thickness to different thickness.