Week 3 Challenge : CFD meshing on Turbocharger

week 3 challenge:

volumetric CFD meshing on turbocharger.

Aim:

To create a mesh using a ANSA software, for a given model. with the target length and mesh size of

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

PROCEDURE:

topo manager:

Firstly, import the model in the ANSA software. File>Open>select the path.

using a topo deck manger, cleanup the geomentry.

using faces in topo desck, create a new faces on the region, where it contains a incomplete surface.

for meshing the model should be in a closed surfaces.

after completed the model with the closed surfaces.

the below images shows the topo clean up.

tools>checks>geomentry. this is to check for the incomplete surfaces or single cons icon also used.

after the geomentry is cleaned. the check was performed. it shows some error these error are due to the triple cons used in the model to close the surfaces.

so the error was negligible.

topo>face>new/cut

is to create a new faces and to remove the cons.

pid manager:

now, name the surfaces according to your need by using a PID manager.

property manager is to create a pid region.

here ,new>pshell>pshell. to create a pid region.

mesh:

now, in Mesh Dock,under parametric. click on length to create a mesh length as 1mm, 3mm, and 5mm.

under length it shows two option just like the perimeter and macros.

select the cons and middle click on mouse and length as 1mm.

for other model with 3mm and 5mm. here only we need to change the 1 as 2 and 5.

under macros 3mm. now, click on mesh manger and provide a tria element.

with the target legth as 3mm.

heres, the final 2d surfaces as trigonal element are created is the 2d surfaces.

final step is to create a mesh using a mesh generation. there, it contains some of the meshing algorithm such as free, cfd, spotmesh, best etc.

from that select the spotmesh as algorithm for simple geomentry.

then create a mesh.

mesh parameter:

this is for 1mm. for 2 and 5 mm on the model.change it to 2 and 5.

quality criteria:

this criteria is for 1mm mesh size.

for creating a mesh.

mesh manager> mesh generation> spotmesh(we can use any type of mesh algorithm).

the final output with the mesh is shown below:

mesh size:

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

all the mesh has beeen a tri with 915828 cells.

volumetric mesh:

for volumetric meshing,

volume mesh>volume>define. the ANSA software automatically detects the volume list.

volume mesh, after creating a volume list. delete the unwanted volume which are not used in the fluid body.

then after, creating a volume.

volume mesh>unstructured mesh>tetra cfd.

this was to create a tetra mesh on the volume which was later used for the cfd application. such as ansys, hypermesh etc.

this was the cut view after the volumetric mesh had been created.

there are totally 5979064 tetra cells.

final view:

Learning outcomes:

from, the above challenge. the mesh generation steps has been studied and the genration of mesh and volumetric mesh was done on the turbo charger.

the cell counts are shown below.

tria mesh cell=802330

tetra volume mesh cells=6823988

Result:

mesh generation for volume meshing of a turbocharger using ANSA software was done.

the ANSA file had been provided in below link.

https://drive.google.com/file/d/1i2cVQPXQALoyJlqWH3kObC6rY2u6YGnl/view?usp=drive_link

==========thank you==================