Tool Test-2

TOOL TEST – 2

VOLUME MESH GENERATION FOR INTAKE MANIFOLD USING ANSA (UNSTRUCTURED MESH)

OBJECTIVE:

• Import the CAD geometry of Intake Manifold
• Clean up the geometry until no topological error is found
• Mesh geometry with target/average length of 3mm with no errors.
• Assign closed volume and generate unstructured volumetric mesh using the given quality criteria.

S.NO	QUALITY CRITERIA	VALUE
1	target/average length	1
2	Minimum length	3
3	Maximum length	7
4	Tetcollapse	0.2

ABSTRACT

In this tool test-1 am going to generate volume mesh for Intake Manifold using tools of ANSA. There is no need to generate any mid-surface for this geometry. The given geometry must be meshed on the surface and then the model should be assigned as a closed volume to generate unstructured volumetric mesh. Also, we need to remove tetcollapses after generating volume mesh.

METHODOLOGY

1. Import the CAD Geometry and do Geometry clean-up with no topological error.
2. Assign the property ID (PID)
3. Setup Quality criteria and generate mesh.
4. Assign closed volume for the given geometry.
5. Generate volumetric unstructured mesh.

INTRODUCTION:

Intake Manifold is the part of an engine that supplies the fuel/air mixture to the cylinders. This manifold can be designed in various ways but the function of this for all models is same. Historically it has been manufactured from aluminium or cast iron, but use of composite plastic materials is gaining popularity these days. The main function of this intake manifold is that it distributes air evenly for each cylinder. Even distribution is important to optimize the efficiency and performance of the engine. It may also serve as a mount for the carburetor, throttle body, fuel injectors and other components of the engine.

Intake Manifold Intake Manifold

PROCEDURE:

1.Geometry Clean-up

• After importing the geometry into ANSA there will be many topological errors. In order to prevent this, we do a geometry clean-up which is in the check’s manager.

Cheks Manager Dialog box Cheks Manager Dialog box

• The errors in the above figure can be fixed automatically using FIX option or if the errors are not rectified, we must clear them manually.

Cheks Manager Dialog box

• After all the error are rectified,if you check the geometry the exceution will be 100% then you can move forward.

2.ASSIGN PROPERTY ID (PID)

Every part in the geometry has it’s own property. We can assign PID using ANSA. We have to select the part and click Apply, then we have to select the whole part using window selection to apply the PID.

PID ASSIGNED FOR INTAKE MANIFOLD

3.MESHING AND IMPORVEMENT OF THE MESH

• After assigning all the quality criterias and mesh parameters,one has to do meshing for geometry.
• Meshing should be done at smaller regions in the beginning and continue on to the falt areas, so that kinks and raised edges can be avoided.
• Use ortho tria mesh or tria mesh for the model. Which ever mesh gives better results,continue that mesh in that required region.
• Here average length for mesh is 5, minimum length is 3, maximum length is 7 and tetcollapse is 0.2.

Mesh generated for geometry

IMAGES OF MESH GENERATED IN SOME AREAS

Mesh generated at some regions

Mesh generated at some regions

Mesh generated at some regions

4.Generating Volume Mesh

• Volume mesh can be created in ANSA only if it recognizes the geometry as a closed volume. Therefore, we must manually update our model to closed volume.
• To convert our model to closed volume one must define volume.

Defining Volume for Geometry

• ANSA might crash if you generate volume mesh for the whole geometry. So, define individual closed volumes for different PID’s.
• Defined volumes can be checked under list option under volume dialog box.
• One can give either Tetra Rapid or Tetra FEM under unstructured mesh dialog box for closed volume.

Volumetric mesh generated

Unstructured volumetric mesh generated for whole geometry

• After the completion of volume mesh, 1)tria elements-19062 2)Tetra elements-27941.There are no tetcollapses,kinks,raised edges.

Volumetric Mesh Done for Intake Manifold

Learning Outcomes:

• Able to do topological clean-up with no errors.
• Aware of all the quality criterias and quality parameters during mesh generation. Understood about mesh generation and implemented mesh generation for complex geometry.
• Rectified 3D errors using align,move and other tools in ANSA
• Learned how to define closed volume and use of volumetric mesh

Conclusion:

Solid meshing is successfully generated for Intake Manifold using the given quality criterias mentioned under the challenge. There are no raised edges,kinks and tetcollapses. I understood how volumes are defined and meshed.

Intake Manifold Model of ANSA file link :

https://drive.google.com/file/d/1s9H_ice56Gglh1LqQrenu-m6OQ3gKOwp/view?usp=sharing