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.

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 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

Sol : 

We have been given the following suspension :

As you can see the following assembly has the following parts :

We can do the geometric clean up of the whole assembly by doing it part by part as shown below :

Part 1 : Suspension Assembly 

As you can see the thickness of the following component is more than 5 mm , therefore we will use solid meshing .

Now we will do the geometric check up of the above part as shown :

Now we will work on defeaturing of the given component  as shown below :

Hence we will use dach command over here :

Now we will set the meshing parameters as shown below :

We will seggreate the parts into smaller parts as shown below:

1. Trailing Arm :

We have geometry cleanup of the following part and now we will give it a surface mesh as shown below :

Now after this we will convert the surface mesh into solid mesh :

2.Frame Connector 1 :

Now we will create the surface mesh of this which will be converted into solid mesh later on :

Now we will convert this into solid meshing using tetra rapid as shown below :

3.Sway Arm :

Now we will do geometry cleanup of the following part and now we will do the surface mesh of the sub component with tria meshing:

Now we will convert this into solid meshing using tetra rapid as shown below :

After converting into solid mesh we get the following :

4.Brake  Disc :

Now we will do geometry cleanup of the following part and now we will do the surface mesh of the sub component with tria meshing:

 

Now we will convert this into solid meshing using tetra rapid as shown below :

After converting into solid mesh we get the following :

5.Damper :

Now we will do geometry cleanup of the following part and now we will do the surface mesh of the sub component with tria meshing:

Now we will convert this into solid meshing using tetra rapid as shown below :

After converting into solid mesh we get the following :

In tha above manner we have created the solid meshing for the following parts :

Now we will be creating solid meshing for the tyre :

We have created surface mesh for the tire as shown below :

After converting into solid meshing we get the following :

Now we will apply the same for the rim as shown below :

Now we will convert this into solid mesh as shown below :

Now we will model the spring as an 1D element as shown below :

Now we will convert this into a middle curve as shown below :

We have connected the curves and created a COG as shown below :

We have created a CBAR element as shown below :

Now we will create connectors as shown below :

 For the rim we have made the following :

We have created two node rbe 2 between as shown 

In the above manner we have created the connectors as shown below :

Conclusion :

Hence we haved meshed the suspension assembly and created the connectors