Tool Test-2

Aim

• To check the given models for geometrical errors and mesh with given quality criteria using tetra elements.

PROCEDURE

The model assigned was that of an intake manifold.

Step-1: To study the areas of the model.

The intake manifold has two different areas.

• The central coloumn
• Intake ducts

The above mentioned parts are mostly curved.

Step-2: To do the standard geometry cleans-up.

Then topo was performed to stitch all the surfaces together. All the surfaces were properly oriented. Then the geometry checks manager were performed. there was no error for this model.

Each surface was manually checked and the regions were cleared to pass the quality criteria for shell meshing. Certain cuts had to be joined and certain new ones had to be introduced accordingly.

Holes on the model was given a even number of nodes so as they would give a better shell mesh pattern.

Step-3: To define and enlist a volume o be solid meshed

The model of intake manifold had to be treated as a single volume entity as everything was single cast. The volume was defined using ‘Define’ tab in volume deck. Then the list of volumes can e seen using ‘List’ tab in the same.

Step-4: To type in the quality criteria and establish the mesh parameters.

When the volume were ready the quality criteria’s in shell tabs and solid tabs were typed in.

• Max length-5.0mm
• Min length-1.0mm
• Target length-3.0mm
• Tet collapse-0.2

Step-5: Meshing and checking.

The meshing is unstructured tetra meshing. That is elements with four edges were used to mesh the component. Capturing of solid features is of prime importance.

The meshing is done initially on the surface using ortho tria and tria mesh. Ortho tria mesh was used in curved areas whereas the tria mesh was used in flat regions. If the mesh creates height differences on the surface it was reconstructed. The process of meshing was completed individually for each volume. It was ensured that a good mesh flow was achieved for each surface.

Step-6: Giving volume to the shell mesh

The volume is selected and initially the status was unmeshed. Then the unmeshed volumes are meshed using any of the available algorithms. Here ‘Tetra rapid’ was used.

Now the shell mesh on the surface is literally grown into the cad’s inside volume. The growth pattern is unstructured and hence the name.

Conclusion

The model was successfully meshed using solid mesh. The models cutaway section reveals the unstructured growth pattern. Unstructured mesh is generally used for non critical components.

As the wal thickness of the componets were small the resulting mesh had some good amount of structured growth along the thickness.

i took nearly 4 hours to complete.

https://drive.google.com/file/d/1ffg5ILkiN7T6vLpbjzFwJOTJIT37jdCc/view?usp=sharing