Week 3 Challenge : CFD meshing on Turbocharger

WEEK 3 CHALLENGE : CFD MESHING ON TURBOCHARGER (VINITH)

QUESTION:

For the given model, check for the geometrical errors to make appropriate volumes. Create and assign PIDs as shown in the video. Perform surface mesh with the given target lengths as per PIDs.

1.Blade stage-1 = 1 mm

2.Blade stage-2 = 1 mm

3.Impeller = 2 mm

4.Shaft rotor = 1 mm

5.Turbo casing = 5 mm

6.Compressor casing = 5 mm

7.Inlet casing cover = 5 mm

Perform Volumetric mesh for the required volumes as shown in the videos.
Write a detailed report on your surface meshing & Volume meshing process

OBJECTIVE:

To check for the geometrical errors to make appropriate volumes. Create and assign PIDs as shown in the video. Perform surface mesh with the given target lengths for the different portions of the given geometry as per PIDs.

Also Perform Volumetric mesh for the required volumes as shown in the videos.
Write a detailed report on your surface meshing & Volume meshing process

SOLUTION:

Open the ANSA software and Log on performance 3 mode

Open the new file using options FILE > NEW FILE

Enable the shadow mode & PID to better view of the provided geometry

ENABLE LABELS, SHADOW MODE & PID

GEOMETRY CLEANUP:

Auto fix the existing geometry errors

TOPO > FACES>TOPO

TOPO CLEANUP

Glitches and Multiple surfaces are clearly visibles in enables shadow mode, It confirms that existence of the overlapping surfaces and its to be removed.

Go to PID > Show only overlapped surface > Delete it by universal DELETE from the UTILITIES toolbar

UNNECESSARY SURFACE-UNIVERSAL DELETE

Ensure the deleted part by clicking the PID TAB

Remove the unwanted shell property from PID list

Utilities Tool Bar > Compress option > OK

GEOMETRY LESS PID DELETE

Geometry checkup

identification of the location of geometry and intersection error to clear it one by one

Tools>Checks>Checks Manager>Geometry checkup>Execute

GEOMETRY & INTERSECTION ERROR CHECK

Removing of single cons presented in the geometry one by one. Clear the misaligned and overlap to make the geometry in a perfect shape.

Deleting of unwnated faces from the geometry

Topo>Faces>Delete>Selection of face id number>Delete

SURFACE DELETE

Now new face to be created based the existing coons

Topo>Faces>New>Surface type selection>Coons>Confirm the shape by preview>Create

CREATING NEW SURFACES

Intersection Error removal from the compressor casing part

Topo>Faces>Intersect>Select first part>Select second part> KEEP (Necessary) or DELETE(Unnecessary)

INTERSECTION OF COMPRESSOR CASING

Creating new faces to clear the uneven surfaces

Now create new faces by CUT delete the unwanted faces and surface TOPO > FACE>CUT

CREATE CUT

Now delete the unwanted faces and surface TOPO > FACE>DELETE

DELETE FACE

Creating the new surface TOPO > FACE > NEW > COONS > LOOP SELECTION

CREATE SURFACE

Delete the presented hot points – TOPO > HOTPOINTS > DELETE

REMOVAL OF HOT POINTS

Create new curve face by using transform tool

TOPO > CURVES > TRANSFROM>SELECT COONS>2 POINTS ENITIY SELECTION

CURVE TRANSFORM

Creating the new face after madeup of new curve

TOPO > FACE > NEW> COONS>ENTITY SELECTION OF COONS to make the curve face

CURVE TRANSFORM

DELETE HOTPOINTS

Deleting unwanted curves

TOPO>CURVES> DELETE> selection unwanted curve part

DELETE CURVES

Now copying the turbo casing impeller portion by transform method

Go to utility toolbar TRANSFORM > COPY > ENTITIES > Select portion to copy

Popup box will be go to Symmetry selection > Mirror 3 point plane

TRANSFROM SURFACE ( 3 POINT METHOD)

Close open portion by using fill hole

Go to, Topo>cons > Fill hole

FILL HOLE

Topo cleanup to auto fixing the geometry errors

TOPO > FACES > TOPO CLEANUP

Next is To clear the Compressor casing blades and shaft intersection clear

First hide all the portions exclduing the shaft and Compressor casing blades

Go to PID Enable only shaft and Compressor casing blades , to be locked be starting the cleanup

Delete the multiple sufaces presented in the one location

Topo>Faces>Delete>Selection of face id number>Delete

FACE DELETE

INTERSECTION OF SHAFT TO BLADES

Making the shaft and impeller blades shaft into one surface

Cons to be projected to create boundry as make it two surfaces

Topo>Cons>Project>select cons>selectface

Now excess intersected surface to be deleted

All the intersection errors presente in the shaft and blades portions were cleared

Next impeller casing and shaft intersection errors to be cleared by one by one

INTERSECTION & EXCESS SURFACE DELETE

Delete the excess surface presente turbo casing inlet part

Now confirmty of intersection error fro check manager

INTERSECTION ERROR CHECKUP

Close all the openings aech parts to proceed for surface mesh

Required water type surface created to proceed surface meshing in below pic

WATER TYPE GEOMETRY

Create and Asssign PID for individual parts as per provided part list

Each of parts are renamed as per provided name list and it is applied

ASSIGNING OF PID

SURFACE MESH GENERATION

Mesh Generation setting (SPOT MESHING- Recommended)

1. Blade stage-1 = 1 mm
2. Blade stage-2 = 1 mm
3. Shaft rotor = 1mm

Above mentione portions were separately selected by using PID since all the parts same mesh specification.

SURFACE MESHING SETTING

Specified size of mesh has beed generated for compressor casing blade and shaft portion

1 MM MESH GENERATION

Mesh generation for impeller

Impeller = 2 mm

Setting of mesh parameters Min target length - 1mm Max target lenghth - 3mm

Then setting of Perimeter and Macros to 2mm

IMPELLER - 2MM MESH

Similarlly surface meshing to 5mm for below parts respectively

1. Turbo casing = 5 mm
2. Compressor casing = 5 mm
3. Inlet casing cover = 5 mm

Setting of mesh parameters Min target length - 3mm, Max target lenghth - 7mm

Then setting of Perimeter and Macros to 2mm

5MM MESH GENETRATION

Mesh regeneration to be done in whereever unmeshed part shown.

SURFACE MESHING VIEW

Surface mesh has been successfully completed.

VOLUMETRCI MESH GENERATION

Go to Modeules > Volume mesh > define

VOLUME MESHING STEPS

VOLUME MESHED MODEL

RESULT:

https://drive.google.com/file/d/1ItW3O-3zHagcnymr6SOpNvKXXmffal_-/view?usp=sharing

Thus the provided model check for the geometrical and intersection errors were cleared. PIDs created for the different parts of the model. Surface mesh has been generated with the given target lengths as per PIDs.

Also volumetric mesh also generated tetra rapid algorithm and Above attached Gdrive link is tha ansa file for your reference.