Tool Test 1

Objective:

To create mid surface mesh for the given sheetmetal and plastic component

Part-1:automotive plastic component- switch panel

geometry:orientation and geometry errors are cleared

midsurface:midsurface is extracted manually using ofset, middle option nad srufaces are patched using extend option.

midsurface mesh:

properties created and assigned:

thickness assigned to features as shown

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Part-2:BIW sheetmetal component

geometry: orientation adn geometry errors corrected.

midsurface extration: since the component has uniform thickness faces offset is used to create midsurface.alternatively aut midsurface->skin can also be used.

preparing midsurface for meshing:

since the component is nearly symmetric, symmetric faces are deleted to save meshing time.

meshing: remaining faces are meshed

transform->symmetry optionm is used to completed the model.and elements/geometries are patched.

Assigning thickness:PSHELL property is created and assigned to midsurface.

Time report for meshing:

observations:

1.presence of many features each taking approximately 15 minutes for mid surface extraction

2.large number of fillets making it difficult to find the parent surface to offset.

3.tricky boss features and its stiffeners

4.first time meshing these kinds of featurtes so have to make a lot of trial and error methods to extract midsurface.

5.target element size is very large compared to features size so capturing geometry was very difficult.

observations:

1.since the part is symmetry and many features are similar time required to clean geometry and mesh is reduced.

2.faced difficulty in meshing the fillet regions.