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

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

OBJECTIVE:

The Side door component is given for extracting the midsurface manually or automatic and then follow the quality parameters to get quality mesh and then assign the thickness to assign the component.

PROCEDURE:

1. Meshing:

• First, import the side door inner panel model into HyperWorks.
• Since there are many ribs with surface fillets, it is difficult to create their mid-surfaces. So, these fillets are removed or defeated by going to Geometry > defeature >surf fillets. Then specify minimum radius, maximum radius, select surfaces and click find. The fillets are shown as highlighted, then click remove to remove the fillets.
• Clean up the geometry of the components for obtaining better mid-surface.
• Now, after checking the thickness at various points of the components by Geometry > distance > two points, it is found that the component has varying thickness. So, manual mid-surfacing is done by going to Geometry > surface edit > offset. Then, select the surface and duplicate it, specify offset thickness and click offset and the mid surface is created.
• To create the mid surface of the ribs, go to Geometry > midsurface > final edit tools > surface pair, select the surfaces and click extract.
• To join the ribs with the base surface, go to Geometry > midsurface > final edit tools > imprint. The imprint of the ribs are obtained on the base surface which can be replaced with the ribs free edge by Geometry > edge edit > replace.
• There is also a cylindrical surface which can be done in the same procedure.
• After extracting the mid-surface, perform the geometry clean up. Then, the mesh can be created by 2D > automesh > size and bias. Then, assign element size, mesh type , select surface and click mesh.
• The obtained mesh fails for quality criteria which can be corrected by remeshing with 2D > rebuild mesh ad select edit criteria. A window is opened where quality criteria requirements can de given. Then, select the elements and click rebuild. If the mesh still fails select the elements and remesh it.
• Also check for connectivity by Tool > edges, select the elements and click preview equivalence. This can be corrected either by clicking equivalence in the same menu or by manually through 2D > replace and selecting the nodes to replace.

2. Assign thickness:

• Since there are surfaces and many ribs with varying thickness, arrange the elements with same thickness to the same component by Tool > organize, select the elements and click move.
• Then create property cards for all the thickness and assign it to the respective components.

Result:

Hence the mid surface has been extracted to the parent component. There are no surface deformations in the geometry. A well connectivity has been established between the surfaces. The features have been captured properly. A good mesh flow have been achieved with the zero elements failing for quality .