Week 3 Challenge : CFD meshing on Turbocharger

REPORT:

Aim: To Perform surface mesh and Volumetric mesh.

Objective:

• Perform surface mesh with the given target lengths as per PIDs.
• Blade stage-1 = 1 mm
• Blade stage-2 = 1 mm
• Impeller = 2 mm
• Shaft rotor = 1 mm
• Turbo casing = 5 mm
• Compressor casing = 5 mm
• Inlet casing cover = 5 mm
• Perform Volumetric mesh for the required volumes.

Procedure: 

1. Geometry cleanup and PID Creation:

• The geometry is imported to ANSA software.
• understood the geometry.
• check the errors and over lapping faces.
• cleared the errors and deleted over lapped faces.
• closed the geometry by creating new faces.
• isolated each parts using 'not' command to assign PID's using PID manager as follow

1. Blade stage-1 
2. Blade stage-2
3. Impeller 
4. Shaft rotor 
5. Turbo casing 
6. Compressor casing
7. Inlet casing cover
8. casing inlet
9. casing outlet
10. bottom casing inlet
11. bottom casing outlet

2. Surface Meshing:

• Then isolated  Turbo casing , Compressor casing, Inlet casing cover, casing inlet, casing outlet, bottom casing inlet, and bottom casing outlet for meshing.
• Selected mesh deck and in mesh criteria, target length is given as 5 mm, min length as 3 mm, max length as 7 mm and same in mesh quality as well.
• In length command from perimeters, gives perimeter by selecting surfaces as 5 mm and macros as 5 mm.
• Then selected spot mesh from mesh generation section to create mesh on above mentioned PID's.
• Then isolated 
• Blade stage-1 Blade stage-2, Shaft rotor for meshing.
• Selected mesh deck and in mesh criteria, target length is given as 1 mm, min length as 0.5 mm, max length as 2 mm and same in mesh quality as well.
• In length command from perimeters, gives perimeter by selecting surfaces as 1 mm and macros as 5 mm.
• Then selected spot mesh from mesh generation section to create mesh on above mentioned PID's.
• repeted same procedure for impeller with target length 2 mm, min length as 1 mm and max length as 3 mm.
• At the end, there is no unmeshed face.

3. Volumetric Meshing:

• selected volume mesh deck.
• In that selected 'define' command from volume deck and selected detect on as on whole data base.
• got automatically generated volumes.
• from that volumes, deleted unwanted volumes which are not supposed to be meshed.
• then created 'Tetra CFD' type mesh on each required volumes one by one.
• attachments of files are attached below.

Results and conclusion: model is well studied and understood, PID's are assigned. surface mesh is done with required target lengths. volumetric mesh is carried on required volumes.