Week 3 Challenge : CFD meshing on Turbocharger

Objective:

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 and volume meshing process. 

Solution:

We have received a new geometry called turbocharger and our job is to volume mesh the geometry for simulation.

This is what the geometry looks like with uncleaned parts and surfaces. As we can see here there are a lot of red CONS and our Job is to fill these patches for the cleanup part. Now we are going to use certain tools and steps to resolve this. And here while doing that we have to make sure that every boundary line of the geometry should is YELLOW 

Here we can see it is RED patches in most of the parts of geometry. And the amount of these red lines is quite in number across the whole geometry. We checked for Intersections errors and we saw a whole bunch of it.

Along with all other errors it shows up in the color pink. We can always navigate to see what kind of missing CONS are there and present in geometry. 

Now as we began cleaning up we selected a few parts and used the FILLED HOLE option or NEW SURFACE build option to create new COONS. Now there's a specific part where we encounter geometry with half of the surface part in red lines.

The turbocharger casing is filled with RED lines and we make some HOT points and then CONS creates them one by one.

N now you can see that the empty space is filled.  The reason we choose to create hot POINTS is to give a smooth surface to the casing. No, we proceed to clear the rest of the patches.

As you can see we cleared almost every patch and we processed to get a cleared geometry.

 Now there are chances that not every line will not be cleared up. and if have to use the CTRL+SHFT to see the wireframe mode or we can directly select wireframe mode to view the geometry. Like the one below.

Now you can see how there are a few RED line circles in the geometry overlapping the YELLOW ones. Now we are going to try to remove that from the geometry and make error-less part.

This is the PID mode where we can see the geometry in PARTS mode. Below is the view where we can see the whole geometry as a whole part ENTITY. One can always put this into ENT mode by selecting the icon.

Now we have to mesh the geometry and here's how we process the following steps. And we have to mesh the geometry by PARTS.

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

And creating named parts as PID.

And therefore by parts, we just meshed the whole body.

 as you can see we have meshed the geometry.

Moving on to the Volume meshing part.

as you can see we have meshed one part it shows TETRA MESH CFD

this is how we select the mesh part. Once you start doing everything about the geometry your system will take time. and this is what the result will be.

now you can split this in haf to see the detailed volume tet mesh.

This is the detailed interior view of the compressor casing flow-weighted region.

 Conclusion:

We have learned the new meshing scheme called VOLUME mesh. and the amount of time we required to complete both meshes was significantly not large. And the geometry was cleaned by learning new tools that were in the tool section. The complex case turbocharger of geometry was understand the how to remove single CONS. and we have learned that too.