Project - 2 - Meshing on the suspension Assembly

Aim:

For the given assembly, check for the geometrical errors and mesh with the given element Quality criteria. After meshing the component the thickness has to be assigned for mid surfaces. Use tetra elements to model non-uniform thickness components. Also use Appropriate connections to connect the component as suggested in the Project-2 video (Use PBAR elements to model suspension spring). At last perform Symmetry command to reflect the half finished model to the other side.

Write a detailed report on your meshing process and also mention which method you used to extract the mid-surface along with the reason.

Common Note:

1. Use Volume mesh for Tyre and Rim with below Quality criteria. (Use Tria Element)
2. Use mid surface only when the thickness is uniform and less than 5 mm. (Use Mixed elements)

Quality Criteria for Surface Meshing of Tyre and Rim (Element type: Tria) :

S.No	Quality Criteria	Value
1	Target/Average length	6.5
2	Minimum Length	5
3	Maximum Length	10
4	Skewness	45

Quality criteria for Surface Meshing of Non Uniform thickness components other than Tyre and Rim (Element type: Tria) :

S.No	Quality Criteria	Value
1	Target/Average length	4
2	Minimum Length	2
3	Maximum Length	6
4	Skewness	45

Quality Criteria for Volume meshing of all Non Uniform thickness components (Element type: Tetra Elements):

S.No	Quality Criteria	Value
1	Tet-collapse	0.2

Quality criteria for Mid surfacing of Uniform thickness part which has thickness less than 5 mm (Element type: Mixed elements) :

S.No	Quality Criteria	Value
1	Target/Average length	4
2	Minimum Length	2
3	Maximum Length	6
4	Aspect	3
5	Warpage	15
6	Skewness	45
7	Jacobian	0.7
8	Minimum Quad Angle	45
9	Maximum Quad Angle	135
10	Minimum Tria Angle	30
11	Maximum Tria Angle	120

• Given CAD model of the suspension Assembly model and topo operation is performed.

• Then the model is checked for geometrical using the checks manager for a given geometry.

Tools--> Checks--> geometry
Where many single cons and unchecked faces appeared as errors
Which I fixed using the fix tool

After fixing all the geometrical errors, used the orient tool to fix all the orientation issues if there was present any
Then after carefully observing the assembly found that it has many components which need different approaches to mesh
So for that, I started with the wheel and rim part
So for that, I isolated the Wheel first by using the iNot tool and locked that wheel component in a different locker using the Lock tool after isolating the wheel

• Then the mesh parameters and quality criteria are assigned

• As given the length parameter, there is no deformation found in the model and double-checked for geometry error.

• Now 2d mesh is performed over the surfaces with element type(tria).
• tria elements were used at the surface like fillets and curvature to capture features.
• First, the fillets, curvature regions were meshed with elements and finally, the remaining plane surface are capture using trias.

• Now the volume of the components was defined and TETRA Rapid mesh command is performed over the defined volume

• It same thing is done for the rim (mesh type is tria) performed too.

• Now 2d mesh is performed over the surfaces with element type(tria).
• tria elements were used at the surface like fillets and curvature to capture features.
• First, the fillets, curvature regions were meshed with elements and finally, the remaining plane surface are capture using trias.

now, for spring PBAR elements to model suspension

- Generate a middle curve for the spring. By using the middle option in the curves.

Connect the curve into a single curve. By using the connect(multi) option in curves.

Create a COG point for the curve to define the orientation.

- Select the CBAR element.

Change the selection type to the curve box

select the orientation node.

specify the element length. In this case, The Element length is taken as 3 mm.

After Specifying the element length as 3 mm, Do the middle mouse click and define a pid by creating a new PID. (As
shown in the below image)

After that, assign the cross-sectional radius of the spring element.

1D bar elements will be created.

Click on apply and ok. The 1D bar element will be represented as a solid element

Use tetra elements to model non-uniform thickness components

QUALITY
The elements failing for tet collapse are optimized using the move option without affecting the mesh on the surface.

Final modal after complete modeling

Conclusions:-
Learned how to model huge geometries with all necessary tools such as 2-D meshing, 3-D meshing, 1-D meshing, making connections, as solids, and line element cross-section as solid.
Learned how to approach meshing for a component.
learned which kind of mesh is feasible for which kind of geometry.
Learned how to make proper connections in the Rear Wheel Assembly.
Learned how to use different options in Transform Tool and do a perfect symmetric reflection.
Learned the complexities of geometry and how to extract exact a mid surface perfectly.
Learned about the different parts of Rear Wheel Assembly.

Model link-

https://drive.google.com/file/d/17PU2GCxXPMczo_GrgFFgEavGHfK1d5O8/view?usp=sharing