Project-2-Meshing of Door Inner Panel Challenge

AIM:

To perform preprocessing on the given car side door [Inner Panel] plastic component using hypermesh preprocessing software.

OBJECTIVE:

To create the shell (2-D) meshing for the Car Side Door Panel by eliminating geometrical errors and considering the given element quality criteria using Hypermesh.

• To import the model into the Hypermesh module and check for geometrical errors and clear them so that we can extract a Mid-surface manually.
• To set the quality criteria and mesh the parts using 2-D Shell mesh.
• Make sure that the flow of mesh is maintained and avoid rotating quads, pattern trias, and opposite.

CAD MODEL IMAGE:

PROCEDURE:

Image- Importing the geometry.

4. Check for the damaged surfaces and try to fix them manually.

5. To fix the required damaged surfaces use the surface tool option and choose the surface through lines option select the required lines to make the proper surface.

(Geom-> surfaces-> ruled->select the lines -> create)

Or

(2D-> spline->lines->surface only ->select the lines->create)

6. For fixing the surface damage quickly use the quick edit tool and use the filler surface option to fill the open or damaged surfaces.

(Geom-> quick edit-> filler surf)

Image- 4 Geometrical errors.

Image- Cleaning the geometrical errors by using quick edit tools.

DEFEATURING FILLETS AND OTHER REQUIRED SURFACES BEFORE MANUAL MIDSURFACING-

1. As we can see here ribs are on the parent component. So now we will move on to component 2 for ribs and try to defeature of surface fillets on it.

(Go to Geometry panel > Select defeature > select on surface fillet > select the surfaces > put the radius limit as 0.1 to 5 now click on find > shown the surface fillets > now click on remove)

• Now proceed for mid-surface extraction Shows the extracted mid surface.

• It has been observed that, auto-midsurface is unable to provide proper mid surface so, go with manual mid-surfacing as shown in below fig.

Image- extraction of midsurface for critical surfaces.

PROCEDURE MESH GENERATION-

1. For creating mesh click on the 2d option in the main menu tool panel and choose the auto mesh option and set the required criteria with elements of 5 units.

2. Before meshing set the conditions as per the given quality criteria. To set the quality criteria choose the option element clean-up from the tool panel and click on the edit criteria and set all the given quality criteria and click apply. After setting the parameters choose the edit parameter option and set all the required values such as element size etc.

• Now, mesh the object. To maintain the proper mesh flow lines use the option Rebuild mesh. During meshing also pay attention towards element connectivity. If elements are connected properly using equivalence proper connectivity can be achieved.
• After meshing, go for quality index checking as shown in fig.

If suppose during quality checking some of the elements failed to achieve the quality criteria, through element clean up tool as shown in fig clean up the elements, this will automatically clean up most of the elements.

• Even after element clean some elements fail to achieve the criteria, using options such as translate, split element, combine element and by remeshing particular surface quality criteria can be achieved as shown in following figs.

Now, assign the material to the model as shown in fig.

Now create & assign the thickness as shown in fig.

FINAL MODEL:

RESULTS:

As per the given criteria, Door Inner Panel has been meshed and achieved all quality criteria.

CONCULUSION:

By doing this project, the following aspects can be learned:
1. Extracting the mid surface.
2. cleaning up the geometry.
3. Generating the proper mesh flow.
4. Reducing tria concentraion.
5. Assigning the thickness to the given Component.