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

AIM:

Aim to Generate Mid-Surface, Create Mesh and Run Quality Checks on Rear Wheel Holder

Procedure:

1. opening .iges file
2. Fix Free Edges in Geometry
3. Generate Mid-Surface
4. Assigning Properties w.r.t Thickness of Part
5. Giving Quality Criteria
6. Generating Mesh with better mesh flow and proper geometry capturing
7. Improving Quality of Mesh
8. Perform Quality Check

1- Opening .iges file:

• Click on Import file Icon Loacted in menu bar
• From Drop Down List Click on import geometry icon
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• Given File is in .iges Format
• Select STEP from list and select model
• click on import
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• Different Views of Model
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2-Fix Free Edges in Geometry:

• First we need to find free edges in the given model manually
• Now Fix Free Edges in Geometry by using below mentioned tools
• Geom->Edge Edit->Replace(by giving cleanup tool value as distance between two edges)
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• Geom->Edge Edit->Toggle
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• Geom->Surfaces->Ruled(This Tool Helps us to create new surfaces w.r.t lines/nodes)
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• 2D->Spline->Surface only(This Tool Helps us to create new surfaces w.r.t lines/nodes/points)
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• In above image area the free edges can be fixed by using toggle (or) replace tools
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• But here in above image area we need to delete this surfaces and create new surfaces using Surface->Ruled (or) 2D->Spline Tools

3-Creating Mid-Surfaces:

• First we need to measure thickness of Given Model
• To Measure Thickness, First we need to Deploy Some random nodes on one surface of model
• To Deploy temp nodes randomly on either areas of given Model, use Tool Geom->Temp Nodes-> Hold Left Mouse Button on surface and Click on add to Deploy Nodes
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• Now Using Project Tool we can duplicate this nodes and project on other side
• go to Tool->Project->To Surface Select Nodes and right mouse click on nodes and duplicate them
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• Select the nodes and Duplicate them
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• now select surface on which we want our Nodes to be projected
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• Along Vector should be Suface Normal
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• Now click on Project
• Now By using Tool Geom->Distance->two Nodes Tool we can measure thickness of Given Model
• for Better Visualization i have converted the Geometry from shaded mode to wireframe mode and measure the thickness
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• As it is a sheet metal Part, it has Constant Thickness of {0.75} throught out the model
• To Generate Mid-Surface use tool Geom->MidSurface
• select auto midsurface->auto-extraction->surfs->Displayed->Extract
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• In Extraction Options Check all Given options mentioned in below image
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• Here In this case,i use Offset options Because it gives better capturing of Mid Surface
• Generated Mid-Surface Successfully and can be viewed in red Color in below image
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• Run Auto Cleanup on Extracted Mid-Surface using Geom->Autocleanup Tool
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• Select Surface->Displayed->Autocleanup
• While Extracting Mid Surfaces, sometimes Geometrical errors were found
• with this HyperMesh will try to clean Geometrical errors in Mid Surface
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4-Assigning Properties w.r.t Thickness of Different Parts:

• Before assigning property to any component, first we need to measure thickness of part
• To Measure thickness follow aboe procedure mentioned in Creating MidSurface Column
• here in this case thickness is 0.75mm
• Now Right Mouse Click on Menu tab to create new property
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• Now assign The same property to component
• To Assign Property select Component
• New Tab will PopUp in Status Bar Area
• click on property and select property from property Tab
• Below Image can refer
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5-Giving Quality Criteria:

• Now before going for meshing we need to give some Quality criteria to HyperMesh
• To apply Quality Criteria go to Title bar->Preferences->Criteria File Settings
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• Enter Required values and save the Criteria file for future use
• click on apply
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6&7-Generating Mesh with better mesh flow and proper geometry capturing & Improving Quality of Mesh:

• Now to Generate Mesh consider only Mid-Surface
• Mesh should be generated on Mid-Surface
• To Mesh consider part and use Tool 2D->AutoMesh
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• Select surface and Click on Mesh
• Mesh will be Generated Shown Below
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• We Should Keep in Mind While Deploying mesh on midSurface that out Geometry Capturing and flow of mesh should be proper
• To Improve Mesh Quality use tools
• a-2D->Quality Index->Cleanup Tools
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• b-2D->Rebuild Mesh>Select Elements and click on Rebuild
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• Our Mesh Should Pass all Quality and there should be no Failed Quality Elements
• Images of Given Model After mesh
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8-Perform Few Quality Checks:

1. Check for free edges using tool

• Tool->Edges->Elements->all->Find Edges
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• there should be no free edges in between elements
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b.Check for Normals:

• Use Tool
• Tool->Normals->Elems->Select all Elems->Display
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• all the elements on surface side should be in same color
• if some elements found different color on same plane select that elements and make them reverse
• Repeat same for remaining Parts

Learning Outcomes:

• Learned how to generate mid-surface with Different Manual Options
• Learned how to generate mesh on mid-surface
• Learned how to assign property with thickness to mid-surface and mesh
• Learned how to perform several checks on meshed parts

Time Taken to Complete This Challenge: 17 Hours