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

Aim:- To mesh a Door Inner Panel for the following criteria.

    

Progression 1:- After carefully observing the geometry properly, the surface has a lot of ribs which helps us to deduce that it is a plastic component.

Progression 2:- The auto mid surface option won't give us a good surface because of the ribs and varying thickness.

Progression 3:- We can delete the unnecessary solid surfaces which are not required to mesh otherwise it will create a bad mesh.
F2>surface>select surface>delete entity

Fill the void surface  Geom>quick edit (F11)> filler surface>select boundary line of the circle

                                          

Toggle the line     Geom>quick edit (F11)> Toggle edge>select boundary line of the circle.

                                

Progression 4:-We can move the surface of the components to another collector so that we can work on the two parts of the side door
panel separately. 

   

Progression 5:- Generating Mid surface of the car’s side door.
The side door panel consists of varying thicknesses so we can’t go through the auto mid surface panel.
We’ve to do it manually by offsetting the surfaces to create a mid-surface.
#1 Geom>surface edit>offset.
#2Select surface
#3Duplicate
#4Current component
#5Give offset distance (T/2)
#6Check normal
#7Click offset

We'll see that the mid surface is being created and this will save in the current component collector.

Progression 6:- It’s impossible to create a mid surface of ribs provided in the component by an auto mid surface panel. The Hypermesh algorithm cant read such complex modeling. 

Progression 7:- After creating the mid surface of all the components we have to proceed for geometry clean up on the mid surface to
get a better mesh result by quick edit panel. 

Geom>quick edit(F11) 

  The Fillets were to be removed for proper smooth mesh flow.

Progression 8:-Creating midline on above and bottom part of the rib.
Geom>lines>midline>select line list 1>select line list 2>create.

Generating the surface on the edge midlines.

Progression 8:- Connecting rib to below component mid surface
There are different methods to connect rib to component mid surface

(A). Extending surface by surface edit extends panel.

(B). Surface drag along with vector panel, trim, and deleting unused surface.

(C). Projecting line to the component surface and follow any one of the above command (A) or (B).

`therefore` I used project lines to complete it. and step (A).

Progression 9:- After cleaning up the geometry and creating mid surface, we can now proceed for 2D mesh on the surfaces one by
one.

2D>automesh>surface>select surface>set element size(4mm)>set element type(Mixed)>mesh

                  

Progression 10:- Quality Check  (Using the Criteria File.)

  

Points to ponder about when checking the criteria of a mesh.

#1 To ensure fewer triangles concentration. 

#2 To ensure proper mesh flow.

#3 To check no element failure.

#4 Mesh connectivity to be proper.

Progression 10:- Thickness assignment (Automatic).

NOTE: In this project, we’ll go through Assigning thickness automatically.

Toolbar>mesh>assign>mid mesh thickness>
Select entities-It helps us to select the entities to assign thickness.

Solid geometry/mesh>Surface>select all the parent component surfaces.

Mid Mesh>Elements>select all the meshed elements.

Thickness output: This option will create a new property collector in the model tree.

Minimum thickness: To define a minimum thickness limiting value

Maximum thickness: To define a maximum thickness limiting value

Maximum search distance: We can restrict the maximum distance from which the desired thickness value is considered for
correcting an incorrect thickness estimate.
Do not assign thickness to the mid mesh outside solid: It controls the thickness assignment outside the given geometry.

Calculate thickness: Assigning thickness to the elements will start and it will take a while to complete it.

It undergoes the following process automatically, seen in the status bar-->
Creating mesh topology, detecting proximity, Initial meshing, meshing, orienting normals, correcting thickness, finding fillets.

Thickness assigned automatically
Viewing Thickness of elements

Toolbar>element color mode (By Thickness)

Toolbar>2D Detailed Element Representation.

Quality criteria check(Final Model)

Mesh Final Model (Thickness assigned)

Mesh Final Model (Thickness un-assigned)

Skills Gained:- 

Extracting the mid surface manually. 
Obtaining midline 
Connecting ribs to component 
Projecting element nodes to feature surfaces. 
Translating element’s node to fix failed elements 
Assigning thickness. (Automatically)