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

2D Meshing – Side Door Inner Plastic Panel

AIM:

            To generate a 2D mesh for the given Side Door Plastic Panel model by taking Mid Surface for each component present in the model after clearing the geometrical errors present in the model followed by meshing with the given Quality Criteria.

PROCEDURE:

Geometry Import:

First, the Hood model has been imported to the Hypermesh software using the IMPORT MODEL option from the IMPORT tab. Figure 1 shows the model imported into hypermesh software.

Fig. 1 The Side Door Plastic Trim model imported into Hypermesh Software

Mid Surface Extraction:

After the model has been imported, the Mid Surface of each component has been extracted using the MIDSURFACE-AUTOMID SURFACE-OFFSET option from the GEOMETRY menu for Front Side, while the Lower Body was extracted using the OFFSET option from the SURFACE EDIT menu. Figure 2 shows the mid surface of the entire model and figures 3 - 7 provide details of the property assigned respectively.

Fig. 2 Mid Surface Extracted for each Component.

Geometry Clean-up:

The model has been cleared for geometrical errors using the AUTO CLEAN UP option from the GEOMETRY menu with the default parameters and criteria followed by manual clean-up. The below figure provides a visual aid for the cleared geometry.

Fig. 3 Auto clean-up performed.

The blue dotted/toggled lines in the model show the geometry clean-up carried out where the unnecessary lines were suppressed to make the model easy to meshing.

Meshing:

After Mid Surface Extraction and auto clean-up, meshing has been carried out on the mid-surface with the following mesh parameters shown in figure 4. Since the given model is complex, it was difficult to mesh the model as a single stretch. So, the model was split into many portions like a box, which helps in meshing the entire model easily while the mesh flow and tria concentration can be easily controlled. Figure 5 shows the entire model split into many portions of boxes for ease mesh.

Fig. 4 Mesh Parameters.

Fig. 5 Model split into many portions.

The mesh was carried out using the AUTOMESH option from the 2D menu bar. Figure 6 shows the mesh created on the mid-surface extracted.

Fig. 6 Mid Surface Meshed.

Quality Checks:

After mid-surface meshed, quality checks have to be performed and the mesh should be free from quality errors. Figure 7 shows the Quality Criteria set for the given model.

Fig. 7 Quality Criteria Check.

The quality check was performed and quality errors were cleared. The mesh model free from quality error is shown the figure 8.

Fig. 8 Quality Checks performed on the mesh.

Fig. 9 Quality cleared on the mesh.

After clearing all the quality issues, elements norma; were checked using the NORMAL option from the TOOL menu.

Assigning Thickness: The model has been provided with respective properties namely Thickness, Name, and Ids. Since the given model is made of plastic, the model had different and varying thicknesses throughout for various profiles. So, separate property cards and component cards were created for each thickness in the model, and the mesh elements were moved to respective cards with their specific property. Finally, the elements were drawn as solids. Figure 14 shows the mesh elements of the entire model drawn as 2D DETAILED ELEMENT REPRESENTATION to reflect the actual CAD geometry. Figure 15 shows the final model along with CAD Geometry.

Fig. 10 Separate Component Card Created for respective property.

Fig. 11 Separate Property Card Created for respective thickness.

Fig. 12 Specific Thickness assigned for each Property card.

Fig. 13 Respective Properties assigned to the components.

Fig. 14 Elements drawn as 2d detailed element representation.

Fig. 15 Final Model with CAD Geometry.

RESULTS:

            The given model has been cleared for geometrical errors and meshed for the specified mesh criteria. Then the model has been cleared for all the quality issues for the given quality criteria. Finally, the model is passed for all the given quality parameters and assigned with appropriate thickness for each component.