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

To create the 2D meshing for the car side door panel by eliminating

geometric errors and considering the given elements quality criteria

using hypermesh.

MESH QUALITY CRITERIA :-

Target Element Length = 4 Units

S.N	Quality Criteria	Value
1	Aspect Ratio	5
2	Skewness	45
3	Warping	15
4	Taper	0.5
5	Min. Length	2 Units
6	Max. Length	6 Units
7	Min angle Quad	45
8	Max angle Quad	135
9	Min angle Tria	20
10	Max angle Tria	120
10	Tria %	10

CAD MODEL IMAGE :-

fig. cad model

The component is the inner portion of a car door which is usually made

of plastic.

PROCEDURE :-

After the model is imported, the component needs to be seperated into

multiple sub components considering the complexity of the component.

Different regions have different thickness so we can segregatebased on

thickness.

Certain regions like those shown in question picture can be ignored and

won't be meshed.

Further more , some ribs have thicknesses in excess of 5 mm. Such ribs

won't be midsurfaced and meshed.

Before proceeding, the component needs to be defeature of its fillets.

This can be done by accesing

Gometry > Defeature > Surface > Fillets.

And some time i used Create mid line and project this line on surface panel

and after that create surface.

Moving before midsurfacing we need to assign each region to seperate collector

using the Tool > Organize function.

Before moving, a new collector needs to be created to house the region that is

to be organized. This can be done in the component tree by right clicking and by

accessing Create > Component.

After assigning and seperating them into collectors, we can go ahead and extract

the midsurface on them one by one. There are two ways to extract the midsurface.

We could used the automidsurface option through Geometry > Midsurface but this

many not be ideal in most situations here.

Instead we can use the offset option in Geometry > Surface edit > Offset.

After creating the midsurface we need to attached the to each other as in every

case, the generated offset would be hovering. To do this we can extend the edges

that need to be attached to the corresponding surfaces using

Geometry > Surface Edit > Extend

fig. cylinder using offset

fig. ribs

fig. houses

After the midsurface are generated, we need to carry out cleanup of the midsurfaces

to ensure the minimum length is achieved for all elements of the mesh. Also important

to prevent the formation of trais wherever possible by manipulating surface feature to

facilitate good quality mesh.

This is done by using various quick edit tools like the toggle, replace and split surface

node options. These tools can be accessed via Geometry > Quick > Edit.

Before we can begin meshing, we need to input the required mesh quality criteria through

Prefernces > Criteria File Settings. The mesh quality criteria is entered here.

fig. quality criteria file

After that we can go ahead and mesh each sub component one by one,

ensuring meshes between connecting surfaces are equivalnced properly.

The target element length is 4mm. We can input this in the mesh option

at 2D > Automesh. Select the surfaces that are intended to be meshed

and click mesh.

fig. Mesh whole part

After creating mesh we got some elements failing that time we solve the element failing

using like rebuild mesh and splitting the mesh and element cleanup.

After that assign the thickness of part.

FINAL IMAGE :-

fig. final Part

fig. after assigning thickness

CONCLUSION :-

The given side door panel was meshed as per given quality criteia. Due to

it being a plastic component, different regions having different thicknesses

was prevalent and the component was split into multiple sub component as a

result before meshing and they were assigned their respective thicknesses.