Challenge

Week 12:Project 2-Meshing of Rear Wheel Holder challenge

Meshing Of Rear Wheel Holder

Aim

To mesh the given rear wheel holder model according to the given criteria

Procedure

Figure 1

These free edges can be solved if they are simple but if it is a tedious process, it can be faster to simply ignore them and manually generate the mid surface on such locations and patch them appropriately
First we use the auto mid surface option to generate the initial mid surface

Figure 2

It is then necessary to manually check the mid surface for free edges and patch them appropriately before meshing.

Figure 3

Also toggle off any unnecessary construction lines as they may lead to bad mesh flow in those areas.

Figure 4

Certain areas have very small thickness and will fail for quality criteria.It is necessary to defeature such areas

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

In these cases making small changes to the feature to capture it approximately while satisfying element criteria will give a better simulation result
If this is not done, stress singularities will occur in these locations leading to an incorrect conclusion from the simulations.

Figure 10

Areas like in figure 10 were not defeatured as they do not come into contact with significant load and thus will not affect the result of the simulation in any significant manner

Note:These features may be defeatured if required but it is not necessary to do so.

There are 2 possible meshing strategies that can be followed for optimal time save
One is to mesh half the component and then reflect it since the model is mostly symmetrical outside of certain regions that will need to be remeshed after.

Figure 11

The other option is to perform batch meshing on the model and then to manually correct the mesh if needed.
This is preferred if the resulting mesh Quality is acceptable.
For batch meshing,we need to upload a parameter file and criteria file to hypermesh.

Figure 12

As we have already done the geometry clean up, we can upload a dummy parameter file.
In parameter file settings ,in preferences ,disable geometry clean up and upload the file to a folder for access

Figure 13

For criteria file, simply update the values in criteria file settings in preferences to the criteria and upload it in the same folder as the parameter file.

Figure 14

Figure 15

After batch meshing is completed it is necessary to check each surface manually for solvable trias,off elements and rotating Quads.

Note:If the user has decided to not defeature features the off elements for min length are unsolvable.

Figure 16

Figure 17

In the case of figure 18 While it may seem like the trias need to be solved, on viewing the geometry it can be seen that they lie in different planes and hence can be left as is.

Figure 18

Figure 19

It can be observed that in certain areas the mid surface extends over the parent geometry or vice versa.

Figure 20

Figure 21

One option is to extend or trim overlapping surfaces so that the mid surface capture the parent geometry properly
Another option is to create mid lines and project the mesh accordingly so that the mesh captures the parent geometry properly.

Figure 22