Tool Test 1

Tool test for first model

Quality checking for a Switch Panel

Aim:

To check the quality of the given switch panel by meshing it with a specified quality criteria.

Abstract:

The given switch panel has to be given mid surface which has provision of screw fitting holes, ribs to be locked at a fixed position and to maintain a good mesh flow with less triangle elements and off elements. During the meshing process there will be many off elements due to the complicated areas in between which are to be removed using different tools.

Methodology:

• The given plastic model should be given mid surface and mentioning the PSHELL property card simultaneously so that the thickness can be mentioned in converting from shell to solid mode.
• A geometry check up must be done so that there may not be any kind of unchecked faces collapsed cons and unnecessary hot points which will disturb the mesh flow.
• A good mesh flow must be created on the mid surface so that there may be no off elements and less triangle percentage, and the model must be converted from shell to solid so that the actual thickness is given to the meshed model.

Introduction:

A switch panel in a car is mounted on the inside part of the door which helps for a easy access for opening of closing the window and acts as a hand rest in some cases. The given switch panel is no different with a little complications in between near the screw fitting area.

Procedure :

• A geometry check must be done for a safer side so there may be no errors and for a good mid surface creation. Start creating a mid surface for every component of the model using the tools such as offset , middle single or multi. The mid surface must be attached near the fillet area by creating a new surface and extending them.

• While creating the mid surface, each and every part must have an individual PSHELL card mentioning the thickness of the original surface so that to given the final look when the mesh is completed. The card must be applied to the respective part for an easy identification.

• The mid surface must be checked so that there may be no off elements produced due to the errors such as cracked surfaces, collided cons, unnecessary hot points etc. The distance between two cons or hot points should be more than the target length, which the user should mention in the quality criteria.
• A specified quality criteria should be mentioned so that for a good mesh quality created on the mid surface.

The quality criteria is being set for this particular model as shown in above windows.

• After setting the quality criteria the target length must be set to 4 in the mesh mode for this particular tool test.
• The meshing process can be started for the mid surface using the tools in the general mesh panel. During mesh process, lot of off elements are created in critical areas due to interaction of two cons of near the fillet areas. The produced mesh can be reconstructed by the option reconstruct be selecting a area of off elements or parts. The mesh can also be manually corrected by the user by using the tools such as aplit, swip, move, paste etc and can spread the mesh uniformly after correcting the mesh using the tool smooth. The meshed component will be as shown below.

• There are few off elements formed in the critical or complicated regions due to interaction of two surface cons. The mesh flow should be checked such that no part is deformed due to non-uniform mesh flow.
• After completing the mesh flow the meshed model must be converted from shell to solid mode in the presentation parameters so that to make the mid surface identical to the original plastic component.

Result:

Thus the creation of mid surface and meshing the given plastic model is completed.

Before meshing After meshing

Learning Parameters :

• Learned to use different tools for respective operations
• Learned to create mid surface for complicated parts
• Learned to mesh the surface for complecated parts.

Tool Test for second model

Quality checking for a given Sheet Metal

Aim:

To check the quality for the given sheet metal by creating a mid surface and meshing the component as per the specified quality criteria.

Abstract:

The given component is a sheet metal for which a mid surface must be created, specfing the quality criteria, and should be meshed without any off set elements and maintaining less triangle element percentage. The thickness should also be mentioned and the component should be converted from shell to solid mesh.

Methodoligy :

• The given sheat metal should be given mid surface and mentioning the PSHELL property card simultaneously so that the thickness can be mentioned in converting from shell to solid mode.
• A geometry check up must be done so that there may not be any kind of unchecked faces collapsed cons and unnecessary hot points which will disturb the mesh flow.
• A good mesh flow must be created on the mid surface so that there may be no off elements and less triangle percentage, and the model must be converted from shell to solid so that the actual thickness is given to the meshed model.

Introduction:

A sheet metal is a metal which is converted to sheet so that it can be gaven a perticular shape such as a car hood, car door, car floor etc as per the manufacturers requirment. As converting the sheet metal to required form, the main importance is given to the functionality or the metal as well as the built quality, so that the inner components covered by the sheet metal are protected from external forces.

Procedure :

• A geometry check must be done for a safer side so there may be no errors and for a good mid surface creation. As a sheet metal is one component the mid surface is created at one by using the tool known as mid surfacing. The mid surfaceing has an option known as skin which creates the mid surface taking referace of the top, bottom and side measurements, and uses three different colours that are red, blue, green for easy identification of the user. The ANSA software warns the user is there are any errors on the mid surface. If not the mid surface is created in a couple of seconds.

Top view

Bottom view

Side view

Mid surface

• The created mid surface must be given a PSHELL card with a specified geometry. By using the tool mid surface the PSHELL property card is automatically created in the property manager.
• A specified quality criteria should be mentioned so that for a good mesh quality created on the mid surface.

The quality criteria is being set for this particular model as shown in above windows

• After setting the quality criteria the target length must be set to 4 in the mesh mode for this particular tool test.
• The meshing process can be started for the mid surface using the tools in the general mesh panel. For this particular mesh process, a tool known as Batch is used where the mesh part is completed using the visible option. Many off elements are created during this process. By using the tools reconstruct, smooth, split, swap, paste etc the mesh quality can be improved and off elements can be removed.
• The mid surface must be converted from shell to solid after the completion of mesh process.

Result:

Thus the mid surfacing and meshing the given sheet metal is completed.

Before Meshing After meshing

Learning parameters:

• Learned to mid surface a entire sheet metal at once.
• Learned to improve the mesh quality.

https://drive.google.com/file/d/1V4SeZiPNHeqD-snRWdPL0FKgEFPMwcn-/view?usp=sharing

https://drive.google.com/file/d/1PvBxBdc6Ow-Xu6x5XsMPJ-Ta-Pycyr6J/view?usp=sharing