Week 3 Challenge : CFD meshing on Turbocharger

Aim: To volume mesh the turbocharger by clearing all the geometrical errors and Meshing each component at an individual mesh size.

Objective:

Surface mesh is performed with the given target length as per PID's

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

Workflow:

• Clear geometrical errors
• Clear single cons from the geometry.
• Assign Target length to individual PID's
• Surface Mesh all the components
• Volume mesh all the components

Geometry:

The model and related parts are shown as Pid's

Wire frame model

PID's:

Blade stage 1,2:

Rotor shaft:

Turbo casing and inlet casing cover:

Impeller :

Geomtrical errors:

The error all corresponds to triple cons and many single cons are rectified by developing a surface by using extend option and new surface option

Care is taken for trimming extra surfaces

The triple cons error may be ignored as the surface are shared.

Intersection error can be elimianted by using intersect option

Intersect:

Intersect option trims the unwanted intersected surfaces which creates errors

Surface mesh:

Surface mesh is applied to all the componets according to the Target length

target length 5mm

element type is tria

surface mesh results:

volume mesh:

After the surface mesh is done we start the volume meshing

this is done by deleting the thickness components

Results:

The Volume mesh is enabled and the define option is selected from the list

auto detect is chosen with whole database as option

The option looks for errors and completed volume and return list of volumes

As in the above we delete thickness components and Volume mesh the remaining Volume or cavity

Below is the volume required

Cross section view of tetra mesh with information about No of trias and tetra.

Conclusion:

The PID plays an important part is differentiating the components with individual target length for meshing.

care should be taken in cleaning the topo to clear all the single cons

Before volume meshing , proper connectivity of components needs to be checked so as to avoid errros

Few errors such as unchecked surface can be eliminated by Autofix option.

Ansa model file:

https://drive.google.com/file/d/1bL5Xv0WiBe7_eZA0D_JiZ5R3RQ4XQ7OV/view?usp=sharing