Week 3 Challenge : CFD meshing on Turbocharger

AIM:

For given model of an turbocharger check for the geometric errors to make appropriate volumes. create and assign PIDs accordingly also create surface mesh and use that to create volumetric mesh.

OBJECTIVE:

-Performing surface mesh with given target length as per PIDs.

blade stage 1 = 1mm

blade stage 2 = 1mm 

impeller = 2mm

shaft rotar = 1mm

turbo casing = 5mm

compressor casing =5mm

inlet casing cover =5mm

writing the detail report on your surface meshing and volumetric mesh.

STEPS:

-import turbo charger model:

initial model:

- start the topo clean up doing geometry check to find single and triple cons in the geometry

-delete the unnecessary overlaping surface by using the universal delete option.

start filling the surface and cleaning the single cones by creating surface where ever required.

- In certain areas create using new option under faces before that create certain hotpoints and projected then so that samll surface can be created and no over lap can be done and later we can joint them by required geometry.

- here we use intersect option to delete the surface which has no separate entity, therefore sepaerate entity is formed and can be deleted it easily after that.

-the blue circle indicartes triple cons these cons are not eroors and are required to make the geometry water tight.

before going to meshing we just check the geometry for any eoors apart from triple cons this can be done using check manager in to top toolbar go into geometry and execute it.

Assinging relevent PIDs

- to check the surface and to assighn PIDs click on surface that you want to assign make wire option enabled. and click on the list and than click middle button to assign a new PIDs. also repeat the same for other PIDs.

Now surface meshing:

- select the mesh module and than parameter in that length

before that put the max and min limit in mesh quality.

drag the cursor to cover the entire model and click middle mouse button to give the mesh size as 5mm for entire model.

the enitire mesh model is meshed with the appropirate mes size.

here we have mesh of individual parts:

blade stage 1 = 1mm

blade stage 2 = 1mm 

impeller = 2mm

shaft rotar = 1mm

turbo casing = 5mm

compressor casing =5mm

in some areas where the shaft meets the component having different target length the mesh adopts such that there is a connectivity between the two components.

VOLUME MESH:

- For volumetric mesh we go to the right side menu and in the volume defne use the entire database and press ok.

in that it will detect a total 8 volume in those volume we need only 4 volume the fulid region volume not the thickness of the component.

once the required volumes are extracted we right click on these select mesh and select tetra cfd. this generate the volume tetras .

so finaly we have done:

- checking the geometry error and correcting the geometry using different geometry edditing toolss.

- delecting overlapping region to improve mesh quality and avoid while volume meshing

-correcting the triple cons and single cons, givig the finer mesh 

- creating the surface mesh individualy and also maintaining mesh length range at the contact region between 2 different mesh lengths.

-creating the volume mesh only for the fluid region.

CONCLUSION:

The given geometry is volumetric meshed to have tertahedral elements. all the mesh elements have been surface meshed while only the fluid region have been volumetric meshed.