Tool Test-2

Aim :

For the given Intake Manifold component, check for the geometrical errors and mesh the Surfaces with the given 2D element Quality criterias given below.

S.No	Quality Criteria	Value
1	Target/Average length	3
2	Minimum Length	1
3	Maximum Length	5

Use tetra elements to mesh the Volumes defined in the model and check for the below quality after Volume meshing.

S.No	Quality Criteria	Value
1	Tet collapse	0.2

Solution :

First we will discuss few theories related to solid meshing :

In this we will apply solid mapping .In solid meshing, the ability to be meshed is referred to as mappability. Mappability is
directional and can be likened to putting a surface mesh on one face of the solid, then
extending that mesh along a vector through the solid volume.

Now we will discuss the term tetra collapse :

Tetrahedral is a four- nodded solid element which can be generated through the tria element by creating a volume and also through the existing volume of the geometry. These elements are used where the geometry has high thickness and complexity. The below attached image is a representation of a Tetra element. Tetra element will have 4 triangular faces with four nodes joining them together .

Tet collapse is one of the quality parameters, which will be checked while generating Tetrahedral elements. It can be calculated by measuring the distance of a node from the opposite face, then each of the four values will be divided by the Square root of the opposite face’s area. The minimum of four resulting values is then normalized by dividing it by 1.24.

We have create solid meshing of the following component :

Now we will use topo command so that all the single cons are coverted into double cons meaning the surfaces are connected :

Now we have connected all the surfaces as shown using the topo command :

Now we will do geometry check on the following part :

As you can see the part has no geometric errors and we can proceed with meshing .

Before meshing we can see that the following areas have the small fillets and hence have to be defeatured :

Now in order to make these areas better we will use dach command and in that we will use divide face as shown below :

We have divided the fillet areas as shown below :

In this manner we have applied the required dachs at the required faces .Now we will apply the meshing criteria as shown below :

We will use ortho trias for the highly curved and trias for the rest of the region:

We have meshed the highly curved regions with ortho trias as they capture these areas very accurately.

Now we will mesh the above region curves as shown below :

As you can see elements are failing in this region as shown below :

We have applied split to remove this .

Now we have meshed the neck region with ortho mesh as shown below :

We have meshed the external region and now we will mesh the internal region as shown below :

As you can see the inner region are unmeshed as they are not visible ,by double clicking on umeshed we can view them and mesh them:

Now we remesh the elements which are failing for quality as shown below :

After cleaning the mesh we get the whole component as surfaced meshed :

Now we will create solid mesh by defining the solid volume :

After meshing we get :

As you can see it is passing the quality check as shown below

Conclusion:

Therefore we have meshed the given component by defeaturing ,geometry clean and mesh cleanup