Week 12:Project-1-Meshing of Door Inner Panel Challenge

Meshing the Side Door Interior Plastic Component using Hypermesh

Aim:-

1. To take the mid surface for the given geometry.

2. To mesh the mid surface and clear all the quality issues according to the given quality criteria.

3. Assign the thickness to the mid surface components according to parent geometry.

Procedure:-

1. We first Import the model using Import ~ Geometry.

                                                              Fig 1. Given geometry

2. After Importing we organize the given component into four Individual Components.

                                  Fig 2. After organizing the given component into four individual components.

3. Then, we defeature the ribs to take a good mid surface, for that we use Geometry ~ Defeature, we select surfaces and give min. radius and max. radius and then click find, the software finds the fillets and then we click remove, to remove the fillets.

                                                         Fig 3. After Defeaturing the ribs using the Defeature option

4. Then, we measure the thickness of the base part, using the Geometry ~ distance option, we use the surface edit ~ offset option to take the mid surface of the component.

                                                   Fig 4. Using Offset option to take the Midsurface of the base part

5. Similarly, we extract the mid surface for all the ribs and other components using the same method i.e. offset method

6. After extracting the mid surface for all the ribs and other components, we need to extend them to the base surface, for that we use the Surface edit ~ Extend command to extend these components to the base surface.

                                                     Fig 5. The mid surface of the given geometry 

7. We, then proceed with meshing the component, we Import the quality criteria given in the aim for meshing the model using the criteria file settings under the preferences tab.

                                       Fig 6. Given quality criteria

8. We start meshing the model Component by component, we first mesh the base surface using the Automesh option under the 2D module, we first enter the target element length as 4 mm with a type of mesh as mixed. and then select the surface to mesh and finally click on the mesh.

                         Fig 7. Auto mesh option with target element length as 4mm, used to mesh the surfaces.

9. We also mesh all the ribs and cylindrical surfaces, and then we go to the quality Index option and use QI cleanup tools and other tools such as element cleanup, rebuild mesh in the 2D module to clear the quality issues.

                           Fig 8. Element cleanup option used to clear the quality issues

10. We, then get a good quality mesh over the entire model with no quality issues as shown in the image given below.

                                          Fig 9. Mid surface meshing after clearing all the quality issues

11. Then, we try to segregate the mid surfaced components according to thickness in the Parent geometry.

12. Then, we try to proceed to create properties and material for all the mid surfaced components, then we assign those properties and material to the mid surfaced components according to thickness in the parent geometry and after assigning thickness to all the components, we use 2D element representation as detailed representation in the visualization tab as shown in the image given below.

                            Fig 10.After assigning thickness to the components and using 2D Element representation 

                                  as detailed representation in the visualization tab.

Conclusion:- 

1. We have taken the mid surface for all the components using the manual offset option.

2. We have meshed the mid-surface components and clear the quality issues using rebuild mesh, element cleanup options.

3. We have finally assigned thickness to the model by creating properties and material for each component. the thickness assignment was done using the 2D detailed element representation option.