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

MESHING OF REAR WHEEL HOLDER USING HYPERMESH:

OBJECTIVE:

A back wheel panel (floor panel) component is given for mesh and to get the quality output as per given quality parameters and then assign them the thickness. 

Following the above quality criteria and meshing the component with zero errors and proper mesh flow.

PROCEDURE:

• The floor panel component is given for the meeting, the component has small parts that are saved in different component files which has been organized to the single whole component and remaining has been deleted. 

• Floor panel did not have a solid part, so directly worked on the topology cleanup, the panel has many missing surfaces and or the surface are overlapping, particularly for such case a surface has been masked and checked for the proper surface deleted unwanted surface and to unmasked them.
• Small circles that will not meet the quality condition, so such surfaces are deleted and the big circle has some glitched to the surface so they are deleted and recreated.

• There are some minor issues in the surface which are deleted and created the new surfaces and toggled them properly. After getting the proper surface, deleting unwanted surfaces the geometry cleanup is done on the parent component. 

        Command: [Geometry+ Quick edit panel]

• Completing the geometry cleanup, the floor panel has a single surface and various small parts but they attached to it, the whole component is uniform because of it the auto mid-surface is done on the component. 

• But taking the auto mid-surface, some of the surfaces are having glitches which are fixed manually but at some surface fixing them was not giving proper surfaces, so the particular parts are deleted and offset them (Manual mid-surface) from the parent component.

        Command: [Geometry+ Surface edit+ offset+ continious offset(duplicate surface)+ vector+ offset]

• Fixing the surfaces glitches in the mid-surface, the floor panel is the big component and has small severe parts on them to have the proper mesh flow while meshing the component the mesh is started from the right side top part of the component with the element size 5mm and following the elements with their trias management rule and quality parameters. 

        Command: [2D+ automesh+ size+ align+ connectivity+ mesh]

• Meshing on the side part, the trias is fixed at the corner on some of the elements that are failing for the small size and then following the mesh flow the side part is a mesh when there is a continious surface and also it is rectangular in shape so there are minimum elements that are trias are found but rather than that perfect quad elements are created. 

        But at corners, the trias is merging the feature line due to the small surface. 

• In the middle part of the floor panel, there are few parts with narrow edges and the circle having the issue of warpages and the edges failing for minimum size trias, such an issue is fixed by toggling the line at a certain distance and then joining them again. 

        Those warpage are fixed by giving some trias at a distance or on the particular warpage element.

• While meshing the components there are several fail elements at narrow edges or small surfaces, elements that are failing for angle quad, skewness, taper minimum and maximum size but fixing them as well there are unwanted trim surfaces which are toggled to have one single surface.

• Between the two surfaces at the sharp edge, there are few maximum angle quad or minimum angle quads going theme the right angle as mention in the quality parameters by placing the nodes or moving the particular node at a distance, maximum or minimum angle quad is fixed. 
• The same process is followed for the minimum element size and maximum element size they manually distance to fix these errors and the same is followed to the skewness.

        Command: [Geometry+ distance+ select nodes(give distance)]

        Few of the elements are overlapping these elements deleted and recreated them again. 

• Meshing the surface after getting the mesh, checking for the edges between two surfaces, and they are fixed by given the equivalence value of 2 and the edges which are not fixed by the equivalence value of 2 and the edges which are not fixed by the equivalence they are manually fixed by the replacing nodes to a particular node of other surfaces.

• At the circular surface after getting mesh the two trias are touching at the feature line which is split and then fixed into the quad element.

        Command: [2D+ edit element+ split+ combine]

• Due to the surface glitches and some small surfaces, there are many warpages in this component which is fixed by the new methods checking the degree of the element and then translate the particular element by giving the value around 0.1 to 0.5, by these methods some of the warpage is fixed and some of them are by giving distance to the direction they follow or split the quad into the tria. 
• On the same surfaces, due to the warpage, the element is not capturing the feature line but in such a condition, it can be used for better quality output. 
• Greeting the quality output, now a component is assigned to the thickness of the parent component which around 0.8 mm, so the property is created and then thickness is given to the component. 

RESULT:

The floor panel is the one component but has many several small parts and some surface are not offset properly in the auto or manual mid-surface due to that the element is having the warpage issue but they are fixed by 'translate or moving' the nodes at the given direction, other issues the edges are narrow so they are fixed by toggling the line and getting at a better distance so the element will not fail but due to the warpage fixing there is element which is not capturing the feature line. 

Overall the floor panel is capture with the quality result. 

CONCLUSION:

Floor panel is the different concept of hypermesh which gives detail idea about meshing and how to follow the mesh quality and flow as per the given quality parameters, also the mid surface is an important concept that understood in both automatic and manually, as checking the quality of mesh there were many warpages but they fixed by several methods, finally getting the quality output of the floor panel mesh. 

Project Link: https://drive.google.com/file/d/1AzJOJxunGXmqu0_n_w7U17fQf-sFQ53b/view?usp=sharing