SHELL MESHING OF PLASTIC CONTAINER USING HYPERMESH

OBJECTIVE:

To mesh the side door according to the given quality criteria and assign thickness to the component.

Given Quality criteria:

Target element size: 4mm

PROCEDURE:

• A new Hyperwoks file is opened and the given model is imported on the workpage.

• The model is then checked for geometry error and clean up accordingly.

MID SURFACE EXTRACTION AND GEOMETRY CLEANUP:

• The Mid-surface for the component is extracted by using mid-surface tool: Geometry panel>midsurface.
• The model is again checked for geometry error such as duplicate surfaces, missing surfaces, free edges etc which will be shown by coloured lines as per the image shown below.

• Since the auto mid-surface generated for this component by hypermesh gave lot of topology error, some of the mid surfaces were extracted manually by offsetting the surfaces: Geometry panel>surface edit> Offset.
• Defeaturing is done to remove unwanted surface fillets, edge fillets, pin holes etc inorder to avoid failure of elements after meshing.
• Unwanted edges of the surfaces are supressed and combined into one surface and also the surfaces are splitted accordingly to get good flow of mesh.

MESHING:

• The component is then meshed with automesh tool with a target element size of 4mm. 2D panel>Automesh.
• Once the meshing is completed the given quality criteria is checked by using check element tool (F4). Tool panel>check element.
• IF the element didnt follow the quality criteria of particular parameter, it will get highlated and correction is made accordingly.
• The elements can be remeshed to avoid rotational quads and trias present in the mesh.
• The trias are dragged off from the concentrated areas, fillets etc using cleanup tools because trias add more stiffness value which affects the final result.
• Element optimize tool can be further used to heel the element to some extend following the quality criteria.
• The elements are then uniformly arranged by using smooth tool.
• Project tool helps to project the nodes of the element on to the lines which provides better caputring of the features in surfaces.
• Finally the mesh is then checked for any free edges present. Tool panel>Edges>Find edges.
• If any edges are present, it can be corrected by using equivalence option by increasing tolerance and also by further usage of replace tool etc.

ASSIGNING THICKNESS:

• The component is checked for the varying thickness by using distance tool (F4) and then thereby moving each componenet to seperate collector as per the thickness value.
• Property cards are created for each thickness value with P1 card image and thereby assigning these property to the componenet accordingly.
• The thickness assigned can be visualised by using 2D detailed view.

• Save the file.

RESULT:

The given model is meshed as per the given quality criteria and the thickness is assigned.

CONCLUSION:

From this challange, learned about mid-surface extraction, geometry clean up, meshing mid surface, quality check up and assigning thickness to the component.