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

AIM:

To Generate Manual MidSurface, Deploy Mesh on Generated MidSurface, Assign Thickness & Run Required Quality Checks on Door Inner Panel.

Procedure:

1. opening .stp file
2. Cleaning Up Geometry
3. Creating Mid-Surfaces with Fully Manual Method
4. Assigning Properties w.r.t Thickness of Different Parts
5. Giving Quality Criteria
6. Generating Mesh
7. Improving Quality of Mesh
8. Perform Quality Check

1- Opening .stp file:

• Given File is in .stp Format
• Select STEP from list and select model
• click on import
• Different Views of Model
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• Here i have changed the color of component
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2-Cleaning Up Geometry:-

• At some areas in Geometry we need to fix free edges
• some of the areas are mentioned below
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• we can fix this kind of free edges using different tools like
• 1-Geom->Surfaces->Ruled
• 2-Geom->Quick Edit->Replace
• 3-2D->Spline->Surface only
• Here i have fixed free edges using tool Geom ->Surfaces->Ruled

3-Creating Mid-Surfaces with Fully Manual Method:-

• Given Geometry is Plastic Part so it has irregular shapes and Surfaces.So, hypermesh is not able to generate MidSurface Using AutoMid Tool
• So, i use to Generate Mid Surface Using Fully Manual Method
• First i use to Measure thick of different areas of Given Model
• By Deploying Temp Node on one surface and projecting this nodes on other surface we can accurately measure thickness of any parts
• Above Method is as follows
• First Deploy temp nodes randomly on either areas of given Model using Tool Geom->Temp Nodes-> Hold Left Mouse Button on surface and Click on add to Deploy Nodes
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• Now Using Project Tool we can duplicate this nodes and project on other side
• go to Tool->Project->To Surface Select Nodes and right mouse click on nodes and duplicate them
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• now select surface on which we want our Nodes to be projected
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• Along Vector should be Suface Normal
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• Now click on Project
• Now By using Tool Geom->Distance->two Nodes Tool we can measure thickness of Given Model
• for Better Visualization i have converted the Geometry from shaded mode to wireframe mode and measure the thickness
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• here thickness of given model is 2.8mm
• now i use Geom->Surface Edit->Offset Tool to offset the surface
• Before Offseting create a new Component name as MidSurface and make this component as current component
• by selecting the surface which doesn't have free edges and checking vector direction give offset value and duplicate the surface with current component
• Now click on offset
• Our MidSurface has been Generated succesfully
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• To Generate MidSurface for this kind of Rib Like Areas i use to follow this Method
• Method to generate MidSurface for Rib Like Areas
• a-Create new component named as Lines and make this component as current component
• b-now using Tool Geom->Lines->MidLine create MidLines
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• Similarly Generate MidLines for Bottom area
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• now project this Bottom MidLine on MidSurface using Tool Geom->MidSurface->Final Edit Tool->Imprint
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• select line from line/surf to Imprint Option and select line extend to no extension
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• Select target surfaces to manual setup
• now click on lines and select target surfaces
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• Now Click on Imprint
• Below mentioned image shows line imprinted on selected surface succesfuly
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• now by using Different Tools we can create new Surface
• Tool to create Missurface are
• 1-Geom->Surfaces->Ruled
• 2-Geom->Quick Edit->Replace
• 3-2D->Spline->Surface only
• After Generated MidSurface for this rib area
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• Similarly generate MidSurface for Other Rib like Areas
• Some of the Images of ribs after generating Mid Surface
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• For This Kind of Dock Like areas
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• Generated MidSurface like Mentioned below
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4-Assigning Properties w.r.t Thickness of Different Parts:

• Before assigning property to any component, first we need to Measure thickness of Different areas of Given Model
• now use Tool Geom->Distance->two points/two nodes->select two points/nodes to calculate thickness of any part
• use above mentioned method to measure thickness of different areas of model
• now create new component w.r.t to their thickness
• Now Right Mouse Click on Menu tab to create new component
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• and name them w.r.t their thickness for better understanding
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• Similarly create new property cards by Right Mouse Click on Menu tab
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• and name them w.r.t their thickness for better understanding
• now click on property and assign thickness value in Below tab "T" area
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• For varying thickness ribs assign average thickness
• Some of the properties are mentioned below with their assigned thickness
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• Now assign The same property to component
• To Assign Property select Component
• New Tab will PopUp in Status Bar Area
• click on property and select property from property Tab
• Below Image can refer
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• Repeat same process for remaining parts

5-Giving Quality Criteria:-

• Now before going for meshing we need to give some Quality criteria to HyperMesh
• To apply Quality Criteria go to Title bar->Preferences->Criteria File Settings
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• Enter Required values and save the Criteria file for future use
• click on apply
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6&7-Generating Mesh & Improving Quality of Mesh:-

• Now to Generate Mesh consider only Mid-Surface
• Mesh should be generated on Mid-Surface
• To Mesh consider any area and use Tool 2D->AutoMesh
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• Select surface and Click on Mesh
• Mesh will be Generated Shown Below
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• To Improve Mesh Quality use tools
• a-2D->Quality Index->Cleanup Tools
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• b-2D->Rebuild Mesh>Select Elements and click on Rebuild
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• Our Mesh Should Pass all Quality and there should be no Failing Quality Elements
• Images of Given Model After mesh
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• Our Mesh Should have a proper flow avoid trias as much as possible

8-Perform Quality Checks:

1. Check for free edges using tool

• Use Tool->Edges->find:Free Edges->Elements->all->Find Edges
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• there should be no free edges in between elements
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• Repeat same for remaining parts

b.Check for Normals:

• Use Tool
• Tool->Normals->Elems->Select all Elems->Display
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• all the elements on surface side should be in same color
• if some elements found different color on same plane select that elements and make them reverse

Learning Outcomes:

• Learned how to generate mid-surface with Different Manual Options
• Learned how to generate mesh on mid-surface
• Learned how to assign property with thickness to mid-surface and mesh
• Learned how to perform several checks on meshed parts

Time Taken to Complete This Challenge: 13 Hours

Final Model Images of Model in 2D detailed Element Representation:-

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