Challenge

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

OBJECTIVE:

To do geometry cleanup and meshing on the given side door panel of car which is a plastic component with the given quality criteria.

Target Element Length = 4 Units

PROCEDURE:

1. ANALYSIS OF THE COMPONENT

the given component is the side door panel of a car.
the component is a plastic component consisting of many sub components with varying thickness.
the component consist of many ribs ,clips and a circular area where speakers are placed.
the given component has many deformations.

2. GEOMETRY CLEANUP

model has to be uploaded to hyperworks and has to be checked for deformations.
gaps found has to be filled using filler surface option or possible gaps can be toggled or surface can be created.

while checking ribs we have noticed that the ribs have different thickness and have fillets.

we can defeature the fillets to get a good midsurface.
go to geomtry settings >defeature>surface fillets>assign minimum and maximum length of fillets >select the surface>press find.
this will indicate the fillets in the given range.
press remove fillets to defeature the required ones.

we can observe that some surface has been not created we have to create the surface by ruled option.

3.MIDSURFACE GENERATION

we can use auto midsurface to extract the midsurface but it may not give proper midsurface so we go for manual one.
since this is a plastic component it has different thickness so we have to be carefull while taking manual midsurface.
thickness has to be measured and assigned seperately.
thickness at the edge can be taken easily but at the inner side it will be difficult.
press F4 and measure the distance.
go to surface edit>offset>assign thickness>select surface to be offsetted>press offset.

while assigning offset thickness it should be half of the original components thickness.
before offsetting duplicate the required surface to the current component.
check for vector normal to see the direction of the offset if its wrong reverse it.
In manual midsurfacing we have to take midsurface of each component seperately.
for ribs also we can offset the surface but in some case the midsurface wont be perfect.
In that case we can take the mid line and trim it get the midsurface.
geometry>lines>midline.

4.CLEANING OF MIDSURFACE

deformations can be corrected by using toggle line option or by replacing points option from quick edit panel.
if there is no connection between midsurfaces obtained we can extend it and trim it to make connections.
if any area fail for minimum length we can even toggle some lines.

5.QUALITY CRITERIA

6.MESHING

mesh obtained will have trias.
we should reduce maximum possible trais.
we can drag the possible ones out or combine the opposite trias.
no trias should be there at the corners and free edges in our mesh.
opposite trias shouldnt be there in our mesh.
no trias should be there at the fillets and hemmings if there reduce it to minimum.
no rotational quads should be there in our meshed parts.
connectivity of elements has to be ensured.
for good mesh flow and proper mesh we should do smoothing.
2D>quality index>smooth.
QUALITY INDEX option is used to make our mesh a better one and to reduce errors and trias.

Place node: Used to manually move a node.
Smooth: Used to smooth the elements to get better mesh flow.
Swap edge: To swap the edges of the element.
Node optimize: Place the node in an optimize position in order to reduce the errors.
Element optimize: Optimize the elements in order to reduce errors.
Split\collapse edges: Used to split the elements.
Drag tria elements: To move the trias in the mesh.
Split quad elements: To split the quad elements.
Combine tria elements: Used to combine two tria elements.

7.CONNECTIONS

if there is no connectivity between two surfaces we have to provide connectors.
go to 1D and create 1D connector to establish a connection between two components.
1D>RB3>SELECT NODES ON BOTH SURFACE >ASSIGN WEIGHT>CREATE.

8.NORMALS AND FREE EDGES

go to tools >normals>displayed 2D elements>colour display >press display.
if any one side has a combination of colours then we have to press adjust for adjusting it.
by doing so almost all errors will be cleared if not select manually and clear it.
press reverse to exist the normals.

9.ASSIGNING THICKNESS

after the meshing is done we can assign the thickness.
components with same thickness can we grouped and assign thickness in one go.
others has to be seperated before assigning thickness.
create new components and rename with the thickness that has to be assigned.
from tools>organise>move the required components to the respective thickness.
after moving all the components we need to assign the property for it.
create a property card and rename it with the respective thickness that has to be assigned to the respective components.
then press on the property card and assign the thickness of the component.
to assign this property to the component right click on the component and press assign and select the respective thickness and press apply.
in order to see the thickness assigned switch the view to 2D detailed element representation.

RESULT:

Geometry cleanup and meshing was done on the given side door panel of car which is a plastic component with the given quality criteria.

FINAL MODEL

Ship work like this
in your own course.