Manual mid surface extraction of a plastic component

Aim: To generate a manual midsurface for the given side door component and to generate the mesh as per the quality criteria and to assign thickness to it.

S.No	Quality Criteria	Value
1	Aspect Ratio	5
2	Skewness	45
3	Warping	15
4	Taper	0.5
5	Min. Length	2mm
6	Max. Length	6mm
7	Min angle Quad	45
8	Max angle Quad	135
9	Min angle Tria	20
10	Max angle Tria	120
10	Tria %	10

Model:

Procedure:

1. Use RADIOSS profile to import the model.

2. Measure the thickness of the component to extract the midsurface using Tools - Project - nodes option

Project the nodes by duplicating it on both surfaces and measure the thickness as shown.

Measure the thickness at different areas since the component has varying thickness.

3. Extract the midsurface using Geom - Surface edit - offset - surfs option as shown.

4. Defeature the ribs if required using Geom - defeature - surf fillets option and generate the midsurface for the ribs or create a midline using Geom - lines - midline option and go to Geom - surface - trim with lines edit as shown.

Select the surface and free line and trim the surface as shown.

Create a surface using the two lines to for the rib as shown.

repeate the above for all the ribs.

5. extracted midsurface might not be connected to the surface as seen in the parent geometry and has to be extended to for surface connectivity using Geom - surface edit - extend - extend over edges as shown.

using the extend option the surface gets connected as shown above. the same is followed where the surface connectivity is missing for ribs.

6. Extract all the midsurfaces and toggle the free edges where it is required as shown.

7. Go to 2D - automesh as shown.

enter the provided quality criteria in the criteria file settings as shown.

generate the mesh with proper mesh flow as shown.

8. Check for free edges and quality as per the quality criterion.

9. Create and organize the component into different component collector as per the thickness as shown.

10. Create material card for the component, using plastic as material and the values of polypropylene as shown.

11. Create property card for each component and assingn the thickness as per measurement.

12. Assign the material and property to each component as shown.

Result:

Midsurface was extracted manually on the given side door component and mesh was generated as per the quality criterion. Material Card and Property Cards were created and assigned to the component.