MESHING THE SWITCH PANEL AND A SHEET METAL COMPONENT USING ANSA V 20.1.4

OBJECTIVE:

The main aim of this project is to mesh the Switch panel of a car and a sheet metal component as per the quality criteria shown below and to assign thickness.

QUALITY CRITERIA:

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
10	Tria Percentage	15

PROCEDURE:

SWITCH PANEL:

GEOMETRY CLEAN UP AND MIDSURFACE EXTRACTION:

• Imported the given .stp file in the ANSA work page.
• Checked for the orientation i,e. the upper part of the model should be in gray color meaning positive and the lower part in yellow color meaning negative.
• The issues with orientation are cleared using the topo module-->faces-->topo.
• The resolution of the CONS is improved using Auxiliaries--> fine from topo module or perimeters-->length from mesh module.
• The model is then subjected to a geometry checkup to check any free edges between the models, duplicate surface, irrelevant CONS using the option tools--> checks-->geometry.
• Some geometrical errors are cleared using the Auto fix option and some are manually done using options like release hot points, release cons, topo, faces cut, etc. from the Topo module.
• The geometrical errors are fixed and measured the model for different thicknesses using the Utilities-->measure option.
• Since the model is varying for thicknesses, using the options faces-->middle-->single, faces-->offset from topo module, the manual mid-surface extraction is done.
• Also options like curves-->create, CONS-->project,points-->new,faces-->new,cut,topo,transform-->copy-->rotate,etc. for creating the mid-surface.
• By using the Not option from the focus toolbar while selecting the PID region from the features selection toolbar, the mid-surface is viewed separately.
• Geometry check-up is done and a property ID is created, so the mid-surface is organized.
• By default, ANSA creates a steel material ID, which is defined by marking the check box so that the material is assigned to the model.
• The surfaces are split accordingly to attain good mesh flow and to avoid element failures using the topo module--> faces-->cut option.
• To check whether the mid-surface is perfectly captured, the transparency is turned ON to the parent geometry while keeping the Shadow mode ON and draw mode to PID from the drawing styles.
• 

1.Comparison between Mid-surface and parent geometry.

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2.Mid-surface

MESH GENERATION:

• The Quality criteria are applied to the model using utilities--> Quality criteria as shown below,
• 

3.Quality Criteria

• Mesh parameters are applied as shown below, using utilities--> mesh parameter.
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4.Mesh Parameter

• The perimeter elemental length of 1 mm is applied to the model using the mesh module --> perimeter--> length option.
• The split surfaces are meshed one by one using mesh module--> mesh generation--> Best and spot mesh option.
• During meshing the opposite trias, back to back trias, trias present at the edges, rotational quads can be removed using shell mesh--> reconstruct option.
• Trias present at edges, fillet areas, pattern formation, opposite trias can be avoided using split, swap, reconstruct, edge2 perimeter, Num +/- options.
• The elements which fail for quality can be viewed by using the Draw mode toolbar --> hidden option and corrections are done for the elements which fail for quality.
• The smooth-->shell mesh option is used to attain good mesh flow.
• 

5.Meshed Model

THICKNESS ASSIGNMENT:

• By measuring the varying thicknesses, property Ids are created with the thickness values and assigned to the model.
• The thickness assigned to the model can be viewed using utilities--> quality criteria--> presentation parameters --> Draw shell as solid.
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6.Thickned model

SHEET METAL COMPONENT:

• All other procedures are carried out as same as mentioned above for the switch panel except the mid surface extraction process.
• In this component, the mid-surface extraction is done automatically using the topo module-->faces--> mid surface--> skin option.
• Since the thickness of the model remains constant, the auto mid surface extraction method is used.
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7.Mid-Surface

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8.Meshed Model

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9.Thickened Model

RESULT:

Hence, the Switch panel and a sheet metal component are meshed as per the quality criteria given and assigned thickness to it.

CONCLUSION:

From this challenge learned more about geometry cleanup, mid surface extraction, shell meshing and assigning thickness, etc.

Link to view the model:

SWITCH PANEL

SHEET METAL COMPONENT