Tool Test 1

TOOL TEST OF COMPONENT BY USING ANSA

AIM:

The main objective of this project is to do the MESHING of given component within Quality criteria.

ABSTRACT:

In this project we are going to do the tool test of the component with out the help of support engineer,and that should follow the quality crteria.We are going to do the Pre processing by using ANSA which is first step in CAE process.

METHODOLOGY:

• Import geometry
• topological clean up
• midsurface extraction
• meshing within the quality criteria.

PROCEDURE:

• After opening ANSA the component should be imported from file command to ANSA interface.

• The model which have to be meshed is imported to ANSA interface.
• Now check for errors,if there are any errors rectify it by using automatic or manual method.
• Do topo and again check for the errors.

(a) (b)

• In the above images we can see that there are errors in the first image.
• But after rectifying it we can see that there are no errors in the second image.
• Make sure to rectify errors because they will effect in results.

MIDSURFACE EXTRACTION:

• To extract midsurface there are some methods,but as it is a uniform thickness component we can go with OFFSET method.
• Mesure the thickness of the component in different parts and store them.
• Take the offset method go with feature angle option for distance it is half of the thickness of the compnent.
• If all the components does not get midsurface then do rest of them with offset entity option.
• This procedure gives the exact midsurface for the component.
• Check that mid surface is extracted for total component,and then lock the model.

• The above image shows the midsurface of the component.

ASSIGN PID:

• After extracting mid surface,seperate it from OR NOT option and assign PID for both midsurface and main part.
• To assign PID go to properties,right click the mouse go to new-pshell-pshell.
• After creating go to apply and apply the PID for mid surface.
• Do same process for the main part.

ORIENT:

• After assigning PID check Orient in entity mode.This is because any distractions we can notice.
• In ansa Grey colour is Positive and yellow colour is negative.
• After doing orient the model looks like as seen below.

QUALITY CRITERIA:

• The quality criteria which has to be followed is given below.

• The above mentioned QC should be followed throught out the model.

MESHING:

IMPORTANT POINTS IN MESHING:

1. Mesh each part seperately,which gives us good mesh flow.
2. If any projected line are created remove them after meshing.
3. No two trias should be opposite to each other.
4. Trias should not be present at the edges of the component.
5. Instead of rotating Quads,replace them with trias.
6. Make sure every part is meshed.

• After doing best mesh we can see that the component is havig so many off elements which should not be present and the component is failing for Quality criteria issues.
• Do reconstruct and work on mesh by using the above rules or important points to attain good mesh flow.

• As we can see there are no off elements in the model,and every part is meshed.

PASTE:

• This is used to move the tria backward.
• The sequence should be correct.

• In the above case the tria can be rectifies by using paste option.

SPLIT:

• This is used to move the tria in the forward direction.

• In the above case using split edge option the forward tria can be rectified.
• The pink line shows the way of new lines.

NOTE:Likewise,we need to rectify most of the tias for the good mesh flow.

GOOD MESH FLOW:

(a) (b)

• The above images shows some good mesh flow,because there are no
• Trias near to each other
• no tria is at the edge.
• no rotating Quads.etc

DRAW SHELL AS SOLID:

• After finishing the mesh make sure to tick draw shell as solid in Quality criteria.

• This gives thickness for the midsurface which is extracted.

MODEL BEFORE AND AFTER:

• The above images shows the complete model after topological clean up and meshing.

LEARNING OUTCOMES:

• Able to do topo clean and fix errors
• extract mid surface for any kind of 2d element
• assigning pid can be done
• Able to mesh the component with good mesh flow
• Able to clear off elements

CONCLUSION:

• The above component has done meshing without the help of Support engineer,where there are no errors in the model and attain good mesh flow.But,we need to compromise for some errors when they occor ,if there are two cons near to each other and that cons cannot be removed,if we do so the geometry may change.So the meshing of the component is done,but majoriy of the element should accept the Quality criteria.

LINK OF THE PROJECT: https://drive.google.com/file/d/1LWGz3uLS-Y5c7OmdPB6LyAM02e5MeBa9/view?usp=sharing

TOOL TEST OF CAR SWITCH PANEL BY ANSA

AIM:

The aim of this project is to do meshing of a car switch panel which is of varing thickness(plastic model) and attain good mesh flow which accepts the Quality criteria.

ABSTRACT:

• Switch panel is used in the car for remort control to the windows of the car.As it is a PLASTIC MODEL,we are going to see the difference in the thickness of the switch panel and we are going to assign the PID and mid surface for difference surfaces and obtain a mesh flow.

METHODOLOGY:

• Import geometry
• check for the errors
• topological clean up
• extract midsurface for different thickness
• Assign pid
• Meshing the component with Quality criteria.

PROCEDURE:

• Open the ANSA,import the geometry by using file command.

• The above is the model we need to mesh,which has difference in thickness.
• After importing check for errors in the model.

• Above we can see that there are errors in the model.
• Do remove the errors by automatic or by manual methods.

• In the above image we can see that there are no errors in the model.

METHODS OF MID SURFACE:

OFFSET:This method is used when there is non uniform thickness of the model.Which means this can be used when the part is not identical.Measure the thickness of the model and give the offset value half of the thickness.Negavtive sign depends when there is yellow colour(orient)in the model.

MIDDLE:This method is used when there is uniform thikness in the model.Which means when the part is in identical shape.Select the two surfaces to get the mid surface.This can be use at a time for many identical parts by selecting middle multy option.

• In the above image as the selected faces are of not identical but of same thickness,so we can go with both middle and offset method,i went with offset method.And assign thickness for the faces.

• In the above image as the parts are identical we can do middle which is easy way to extract mid surface for the identical components.
• Likewise,in the model if there are any identical surfaces we can use middle multi option to save time.

NOTE:Extract the mid surface for each and every component in the model by using Offset and Middle options and parallelly assign PID for the model,which will be easy for the user to identify.

• This is the midsurface of the model,the above image shown is in entity mode.

ORIENT:

• In ANSA grey colour is positive and yellow colour is negative.
• Make sure that top surface is of grey colour.

• Above we can see that top surface is of grey colour and bottom surface is of yellow colour.

ASSIGN PID:

• Assign PID for each and every face.
• To assign PID,go to properties-right click the mouse button-go to new-pshell-pshell.
• After assigning the PID apply it to the component.
• Assign thickness to the component parallelly which will be easy for us to identify.

• These are the PIDS assigned to the component for every faces.
• The component in PID mode is shown as below.

• In the above image we can observe that the switch panel is assigned with different Pids.

NOTE:In some cases when two faces of different thickness are joined by the third face then third thickness is taken as Average of two thickness.

EXAMPLE:

• If thickness of first surface is T1 and thickness of second surface is T2,then third thickness T3 is taken as (T1+T2)/2.

• In our model we can observe that the first face is of thickness 1.8
• second one is of 1.5 then
• third thickness is of (1.8+1.5)/2
• which is 1.6.
• Therefore T3=1.6

EXTEND:

• After extracting midsurface make sure each and every mid is connected to each other.
• If not connected make use of extend option and connect them.
• Only single cons can be extended.

QUALITY CRITERIA:

• The Quality criteria which is to be followed is given below.

• Open quality criteria and make sure every Quality is as defined above .
• Most of the elements should accept the quality criteria.

MESHING:

RULES IN MESHING:

1. Mesh each component seperately
2. no two trias should be near to each other
3. no tria should be at the edge of the model
4. There should not be any rotating quads.
5. Do reconstruct after doing best mesh.
6. Smoothing the mesh is a good practice.

• We can observe that after best mesh there are so many off elements and each elements is failing for Quality criteria.
• Do reconstruct and follow above imortant points for better mesh flow.

• Here we can see that so many off elements are reduced and most of the elements are satisfied for Quality criteria.
• Now manually work on the off elements which are not satisfying for QC.
• For better mesh flow use paste and split option.

• Here we can see that model is free of off elements and accepting the Quality criteria.

NOTE:If there are TRIPLE cons very near to each other,definately there will be off elements.If we try to remove the cons then the geometry of the model changes which is not acceptable.

GOOD MESH FLOW:

• As there are no off elements,no trias near to each other and no rotating Quads the mesh flow is good.

DRAW SHELL AS SOLID:

• Go to quality criteria and tick draw shell as solid .
• This gives us thickness for the midsurface which is extacted.

MODEL BEFORE AND AFTER:

LEARNING OUTCOMES:

• able to fix errors
• able to do topological clean up
• able to extract mid surface for plactic models
• Assign PIDS for plastic models'
• Meshing for Quality criteria.

CONCLUSION:The mid surface is extracted for Plactic model and meshing is done.Extracting mid surface for any plastic model is same.However if some elements fail for Quality Criteria,if we are not supposed to remove the cons then we need to proceed with that elements.Majority of the elements should accept the Quality parameters.The rool test is completed without the help of support engineer.

LINK OF THE PROJECT: https://drive.google.com/file/d/1xvYqJFkTp0JVGEDGr9kXhL7a1u_quIdu/view?usp=sharing