Week 3 Challenge : CFD meshing on Turbocharger

Aim : To do a surface mesh and volumetric mesh for a given Turbocharger.

Procedure :

Introduction:

1. Download the model.
2. First, model is over lapped in some parts so topo clean up was had done.
3. Since many surfaces are unfinished so need to topo claen up and fill the gap, used faces group in new option select the option and clean the surface.
4. In some cases the surface of the unnecessary parts are deleted to avoid this error use in faces group Intersect option and select the 1st surface of purple colour and 2nd surface of blue line colour click on middle button to okay. next delete the extra line surface.
5. In turbo casing the gap cannot be fill by new option so we need to be select hot points group select parameter, the give 0.5 line as measurement in particular direction give around 7 points like that and then by using new option we can fill the surface by small area.

Crate a new PID sections:

1. Before creating new PIDs need to be do geometry checks and want to clear the error.
2. In inner side of the compressor casing the Shaft is overlapped with many surfaces tripple cons are present, so isolate the other surfaces then delete the overlap surface by using delete option.
3. In blade stage 2 and end of the shaft both brown and pink colour surface is overlapped to clear it use project option in CONS and select layer and select face.
4. the shaft pink layer is in unve form to make a correct form use fine option in Auxiolaries group and click to fill it.
5. by selecting a delete option remove the pink over lapped surface by isolating.
6. In impeller region the shaft and impeller part is overlapped so delete the unwanted surfaces but the impeller fins are connected to center part so in order to delete this use cut option in faces group then make a selection of cut region the end points of the fins and centre then after cutting select the cente part and delete.
7. To give a PID name slect a PID option and give a name by selecting the part as Compressor casing, Turbo casing, Rotor shaft, Blade stage 1 & 2, Inlet casing cover and Impeller.
8. After Geometry checks still tripple Cons are present in many part of the model.
9. Since these tripple CONS are necessary should not delete this if remove this the Surface of model is deleted, the tripple CONS are there because in that particular point three different surface layers or parts are connected in different sides so the tripple cons are shown and it is not a problem as a error.
10. The details of the Image as shown in the Google drive link.

Surface Meshing:

To do a surface mesh click on a PID and select a part, Give a different target length to different parts as given :

• Blade stage 1 = 1mm
• Blade stage 2 = 2mm
• Impeller = 2mm
• Shaft rotor = 1mm
• Turbo casing = 5mm
• Compressor casing = 5mm
• Inlet casingt cover = 5mm

1. To do a surface mesh in four different region and need to give lengths.
2. Select a Quality criteria tool in this give Minimum length and Maximum length based on the parts.
3. Then select a Mesh parameter tool in that make a selection of general and select element as Tria element and give Target length, Minimum and Maximum length click on okay.
4. Then select a perimeter tool and select a perimeters select a whole part by draging and give target length, then click on Macros and drag give target length.
5. Finally in Mesh generations tool select a Spot mesh tool and make a select of model click on middle click.
6. In some areas the different parts are connected for example shaft is connected to Turbo casing so in that connectin region the lengths of the part is varies based on the neighbor part to match the both surface.
7. So need not to be give a target length while select in Length tool in perimeters tool it will take autumatic length in that range, the picture is attached in Google drive link.
8. Like the above methods surface mesh has to be done.

Volumetric Meshing :

1. Volumetric meshing is defined as After surface meshing defining a volume that converts 2D elements to 3D elements.
2. To do a Volumetric mesh select a volumes tool and select a Define option select a Auto Detect tool.
3. Then select Whole data base option in Work on, before that delete the some unwanted Auto detected part and keep the part where the fluid has to be flow, so the Vmesh has done to this parts only.
4. Select a particular part click on right click then select a Tetra CFD option click okay.
5. since the number of elements are more then tria element So it will take Few minutes be Patience it will mesh.
6. Like this steps do for all parts to be Volume mesh.
7. To see the colour of the model after Volumetric Mesh Click on Volume option in lower menu tools diable other FE mode and Geometry mode.

The related pictures and Model has attached in this below Google drive link

https://drive.google.com/drive/folders/1dPHdEIv6lWjs21L-tRLGkkuQ77V6mRaE?usp=sharing

Learning Outcomes :

I learnt the new topic of Volumetric mesh and my skills on this topic is Improving.

Result:

The surface meshing and volumetric meshing for the Turbo charger is done base on the differnt parametrs and different target lengths.

Conclusion :

Since the Surface Mesh and Volumetric mesh are two different in sections, to get a particular result both Surface mesh and Volumetric mesh has to be done.