Meshing Car spare wheel well in hypermesh (project 2)

Introduction

1. It is an additional tire carried in a motor vehicle as a replacement for one that goes flat, has a blowout, or has another emergency.
2. Although steel is the long-time incumbent in SWWs, for the past decade, European OEMs have been using increasing amounts of composite materials for this application to reduce weight and costs.
3. By virtue of their lower specific gravity, polymer composites have generally had the advantage of lighter weight parts vs. metals.
4. The spare tire is generally or almost all vehicles actually carry an entire wheel with a tire mounted on it as a spare rather than just a tire, as fitting a tire to a wheel would require a motorist to carry additional, specialized equipment
5. Traditionally produced in stamped steel, and more recently in aluminum, this spare wheel well (SWW, also known as a spare wheel baffle) is a large, heavy, tub-like component that also plays a role in vehicle structure and crash safety.
6. Because it is exposed to the elements, its underside is prone to corrosion

SPARE WHEEL WELL

Fig_1

AIM ;

To perform Pre-processing of the wheel tub component, the step involved in the process are

1 geometry cleanup

2 Extract midsurface for a given component

3 performed meshing on the extracted midsurface accounting to the given quality criteria

4 Assign thickness for every component

STEP_1

Import model

• Import that model in hyper mesh

Fig_2

STEP_2

Tune on display fixed point, By using this option for visualizing a corner point

Fig_3

STEP_3

convert; Auto mode to Bytopo mode

Why the need for Converted (Auto mode to By Topo mode) is component surface visual clearly at the same time working comfort

To

STEP_4

Inspection

There is a plastic component thickness of 0.75

Fig_4

4.1_Free edge

Free edge in the parent component

Fig_5

4.2_OPPEN SURFACE

Fig_6

4.3_ More extra surface in the parent component

Fig_7

STEP_5 GEOMETRY CLEANUP IN PARENT SURFACE

5.1_ Delite Extra surface in parent

Fig_8

By Using Tool DELETE (F2) > CHANGE ELEMS TO SURFACE > SELECT SURFACE > DELETE

Fig_9

5.2_ Select surfaces

Fig_10

5.3_ Delete Surface

Fig_11

5.4_ By Using the fillet option fill the surface

Fig_12

STEP_6 CRATE midsurface

What is midsurface?

1. Midsurface modeling is a technique for creating a simplified shell representation of a solid model.

2. Midsurface modeling can reduce the computational expense of analyzing a complete solid model when a shell model with a defined thickness and fewer details is suitable for the required analysis.

6.1_Interior trim panel bottom surface mostly same thickness so I take offset option

By Using Tool (SHIFT+F9) > OFFSET > select surface > in by face option > OFFSET

Fig_13

6.2_ Select surface by using face option

Fig_14

(Fig-15)

6.3_ We need only for offset surface, so hear offset only duplicate in the current component

SURFACE > DUPLICATE > CURRENT COMPONENT

(Fig-16)

(Fig-17)

6.4_ Now done midsurface for interior trim panel inside door component

(Fig-18)

STEP- 7

GEOMETRY CLEANUP IN MIDSURFACE

What is Geometry Cleanup?

• The Geometry Cleanup option allows you to "clean up" the model geometry by merging vertices that are very close to each other into a single vertex, according to a user-definable spacing criterion.

7.1_ In Parent Component some Surface will be open, that type of surface solves to manual

(Fig-19)

7.2_This open surface point replaces the near-surface point (or) delete surface & recreate surface. its open surface solved

By Using [QUICK EDIT > TOGGLE]

(Fig-20)

7.3_Replace project point By Using the replace tool

(Fig-21)

Quick Edit (F11) > replace point

(Fig-22)

7.4_Now Done replace point, now minimum length quality criteria failing is avoid in this surface

(Fig-23)

7.5_ Toggle unnecessary line in the parent component

By Using Toggle tool in (F11) QUICK EDIT > TOGGLE

(Fig-24)

7.6_ Find out the minimum length for given quality criteria because this minimum length failing for element, so toggle the minimum length line

(Fig-25)

STEP_8 Starting Mesh

• Before starting mesh doing some basic steps
• The pathway to create the Criteria File: Preference → Criteria File Settings (ref fig-58).

(Fig-26)

8.1_ Ware to starting mesh on component, which place feel critical or more feature available in a component that places start component

I am starting mesh from this place because this place more features available Eg; (Speaker grid, rib)

Some Conduction for other important parameters in tria management.

* no tria in corners or edge

* no opposite trias

* no back to back trias

* No trias in fillets or hemming (minimal)

* No rotational quads

* No trias should sare a Boundary with Feature line

* connectivity between the element

* Split & perform the mesh

* used mixed type mesh for irregular shaped surface & quads only for rectangular/square surface (opposite side should be parallel & equal)

(Fig-27)

8.2_ This surface is symmetric so I split this surface working on of surface then reflect the element.

(Fig-28)

Reflecting By Using tool

[ TOOL > REFLECT > SELECT ELEMENT > SELECT BASE PONT > REFELT]

(Fig-29)

Select Element

(Fig-30)

Set Axis & base point

(Fig-31)

REFLET ELEMENT

(Fig-32)

8.3_Hemi sphere surfaces, I will use to position tool

1. This position tool advantage, it's one himisphere meshed after position to all Hemi sphere

By Using Tool [ TOOL > POSITIONS > ELEMENT > SET FROM POINTS > SET TO POINTS POSITION]

Select element

(Fig-33)

Set from point & to points

(Fig-34)

Positions The Elements

(Fig-35)

Done Positions

(Fig-35)

8.4_Why Remove All The Tria;

1 when we do analysis the component if you apply the force, but force not properly flow on component

2 Force flow on the direction in between any rotational available that place tria like to be a stiffer

3 main thing is a corner, rotational & opposite tria avoid in meshing time

(Fig-36)

8.5_Some particular surface failing for minimum length failing for quality criteria file setting

(Fig-37)

In this failing element replace by using replace option

F3 > SELECT ELEMENT END LINE 1 & 2 > REPLACE

(Fig-38)

The failing element is solved ref(fig-)

(Fig-39)

8.6_Due to the Meshing Circular surface, the mesh flow is not coming properly. ref (fig-)

(Fig-40)

8.9_ How to Crate smooth Mesh flow in a circular surface

By Using Tool (Darg, Swap, smooth & remesh)

Drag option [QUALITY INDEX]

(Fig-41)

8.10_ Swap Edge option [QUALITY INDEX]

(Fig-42)

8.11_ Smooth [QUALITY INDEX]

(Fig-43)

8.12_ Re-meshing [ 2D, AUTO MESH, SELECT ELEMENT, MESH]

(Fig-44)

STEP-9

9.1_Check the Tria By Using CONFIG TOOL

(Fig-45)

STEP- 10

10.1_FIND THE FREE EDGES

(Fig-46)

10.2_Only free edge

(Fig-47)

STEP-12

ASSIGN THICKNESS

1_ Crate one component in hyper mesh tree ref (Fig_78)

2_ crate current component before creating a new component

3_ move required element in crate new component ref (fig_81)

By Using TOOL > ORGANIZE > SELECT ELEMENT > MOVE

4_ Crate one Property in hyper mesh tree

5_ required thickness assign That property

(Fig-48)

Select an element & organize that element

(Fig-49)

Organize element or move the element to crate component

(Fig-50)

Create one property in tree column then assign thickness for the property

(Fig-51)

Assing thick property in component

(Fig-52)

Done Assing Thickness for all component

(Fig-53)

(Fig-54)

CONCLUSION

performed meshing and assigned thickness to the SPARE WHEEL component

1 From take midsurface for a given component

2 performed meshing on the extracted midsurface accounting to the given quality criteria

3 Assigned thickness for every component