Tool Test 1

Mid Surface Extraction and Meshing of a switch panel and sheet metal component using ANSA.

Objective:

To extract the midsurface and generate 2D mesh for the given models according to the given element quality criteria using ANSA.

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

Introduction:

The models provided for the tool test was switch panel and sheet metal component. The sheet metal component has uniform thickness. The switch panel has many features with varying thickness. Hence, the mid surface is extracted for each feature. Since the mid surface was extracted for the given models, 2D mesh is generated by satisfying the given quality criteria.

Fig.1. Sheet metal component.

Fig.2. Switch panel

Geometry cleanup:

The given component is checked for geometrical errors using checks manager. The errors displayed is cleared using auto fix and tools from hot points, cons, faces & surfaces.

Fig.3. sheet metal component before topo cleanup.

Fig.4. sheet metal component after topo cleanup.

Fig.5. Switch panel before topo cleanup.

Fig.6. Switch panel after topo cleanup.

Midsurface Extraction:

• The midsurface of sheet metal component is extracted using tool offset option. Since it is having uniform thickness.
• The midsurface for switch panel having varying thickness features is generated using tool faces>middle option.
• The midsurface for curved features are extracted using tool curves>middle option.

Fig.7. Mid surface of sheet metal component.

Fig.8. Mid surface of switch panel.

Assigning shell property and thickness

• The midsurface of sheet metal component is assigned with new PID is as shown in fig.9
• The midsurface of switch panel is assigned with new PID is as shown in fig.10

Fig.9. Sheet metal component with PID assigned.

Fig.10. Switch panel with PID assigned.

Meshing:

• The quality criteria & mesh parameters values are entered.
• The perimeter length value assigned is 4 mm.
• Using best mesh option each macro area is selected and meshed.
• The quality criteria are achieved by using tools like cut, join, Num +/-, reconstruct, smooth and split options.
• The tria percentage is reduced by deleting unwanted construction lines without losing the feature.
• The smooth mesh flow is achieved by creating small macro areas and restructuring the mesh.
• The shell to solid feature is enabled to ensure the feature capturing is matching with parent geometry.
• The meshed model of given component is as shown in the following figures.

Fig.11. Meshed model of sheet metal component.

Fig.12. Meshed model of sheet metal component with shell to solid enabled.

Fig.13. Meshed model of switch panel.

Fig.14. Meshed model of switch panel with shell to solid enabled.

Learning Outcomes:

• Learnt the usage of various tools of ANSA software.
• Able to fix the geometrical errors for given models.
• Able to extract midsurface for features with varying thickness.
• Able to mesh the given models by satisfying the quality criteria.

Conclusion:

• The given model is imported to the ANSA software and the geometrical errors are fixed.
• The midsurface for each feature of model is extracted and thickness is assigned.
• The midsurface is meshed successfully by satisfying the quality criteria.
• The time taken to complete the sheet metal component is 5 hours.
• The time taken to complete the switch panel component is 8 hours.