Week 3 Challenge : CFD meshing on Turbocharger

Aim :- Do a Volumetric meshing of  a turbocharger.

Procedure : -

• Import the file
• Tolology cleanup
• Check for visible errors
• Check geometry and intersection errors
• Remove unwanted faces
• Prepare the model for volumetric meshing.
• Do surface meshing of each part
• Define volumetric mesh
• Perform volumetric mesh

Change view to PID

Check geometrical errors. Checks manager > geometry > execute.

 

Select the overlapping surface > Delete the overlapping surface

 

Create a new surface using Faces > coons > Loop > confirm to form correct face

Removal of overlapping surfaces. Go to PID , select the unwanted by colour of the overlapping surface part and delete the unwanted overlapping faces.

Again check for geometry check and check for single coons

Create new surfaces to make the single coons to doble coons.

Use OR function to isolate the single coons

 

Create curves to create a new face

Curves  > transform > select the curve > confirm > select nodes confirm in the direction of curves and confirm.

 

Create new face using Faces > new > entity > select entities > confirm   

and then delete the curve after creating the new face curves > delete

to create face on the compressor casing create a hot point on the middle on the single coon

hot points > insert

Use transform function in the top bar to create a symmetrical copy of the compressor casing on the side

Transform > copy > entities > select casing > confirm > symmetry > mirror 3 points plane > select hot points >  confirm > ok > finish

 

use Cons > fill hole , to fill the hole

Use Faces > Topo to correct the double cons appearing as single cons error.

Check again for penetration and intersection errors

USE intersect to remove unwanted parts I the turbine casing

Faces > intersect > select firs and second faces >delete unwanted faces.

Next check for penetration and intersection errors.

 

                Select an error

Use not function to hie faces to find the intersection error

Faces  > delete intersection faces.

In PID menu name each part with their respective part names

Use compress function to remove un allocated PIDs

Use Cons > project > select cons > select faces > confirm

After projecting cons delete unwanted surfaces Faces > delete ( or universal delete)

  

Use PID manager to display required parts

 

Lock screen using lock function

Check  for geometry error

Use not function to hide unwanted face and delete intersecting and overlapping faces.

Use topo function to correct the double coons.

To solve the overlapping error on the rotor shaft and the turbine blade 2 project the cons onto the rotor shaft and then delete the overlapping surface

Unlock the geometry Check for geometry error

Isolate the compressor casing, impeller and the rotor shaft

Use not function to identify the overlapping faces and delete overlapping faces

 

 

Project the rotor shaft cons onto the top of impeller then delete the impeller surface

Delete the impeller surface and then undo the not function on the rotor shaft and use topo function on the impeller and rotor

 

Check geometry error again

Triple cons on the surface is unavoidable proceed with the intersection-penetration checks

Delete the unwanted faces

Check for errors again.  Then close the entire turbo charger for meshing

 

Use faces > new coons to close the inside opepening of the turbine

 

After closing all the opening start surface meshing

Mesh turbo casing compressor casing and inlet casig cover to  5mm mesh length

Surface mesh > Perimeters > spacing> auto cfd > perimeter > maximum length 6 mm> minimum length 4mm > macros max length 6 mm > mnimum length 4 mm

Mesh generartion > CFD> visible

Surface mesh impeller to 2mm target length

Minimum length for perimeter 1.5 and maximum  length 3

Mesh generation > CFD >visible

MACROS > freeze each PID after meshing to avoid losing surfacea mesh when varying meshes intersect.

 

Surface mesh blade stage 1, blade stage 2 and shaft rotor having target length 1mm

Minimum length .5 an maximum length 1.5

 

In MACROS > freeze each PID after meshing to avoid losing surfacea mesh when varying meshes intersect.

 

After completion of surface meshing select volume meshing

Volumes > Define > ok

Delete the unwanted outer volume and define the internal volume

Mesh internal volume with Tetra CFD

Select the mesh to complete volumetric meshing

 

Use cut plane function to cut the meshed turbo charger I a certain plane and view the cross sectional view

Cut plane > new > default xy plane > select the point > new part