Week - 4 - 2D meshing for Plastic components

REPORT

Aim: -

The main aim of this challenge is to generate a mid-surface and generate a mesh with good mesh flow according to given mesh parameters and quality criteria.

Procedure: -

1. The Bottle cap model was imported in ANSA.
2. The first step after importing is to apply cons resolution.

Applying Cons Resolution

3. Then it is followed by the cons check-up
4. Then we proceed with the single cons, which is done by hiding the single and double cons.

Single con check-up

5. Then we have to check for the orientation.

Checks Manager for orientation

6. After that we can proceed to the geometry check-up which is done by check manager >geometry >check single cons and other parameters >execute

Geometry check-up using checks Manager

7. If there are errors, they are rectified there only by right click on the error and fix.
8. Since it is a sheet metal component, therefore the thickness is constant, so we begin by taking the offset of the component.
9. To carry out the offset, we begin by taking the thickness and dividing it by half and selecting the property as “auto-create” so that a property is created for the offset solely.

Before offset

After Offset with mid-surface

10. Now, the offset surface is known as the mid-surface.
11. After the mid surface is extracted, meshing has to be performed.
12. To begin with 2D meshing, first step is to go to Perimeter> Length> enter target element length which is 1mm.

Mesh Cons Setup

13. Then we set up the Mesh parameter which has been given

Mesh Parameters Setup

14. Then we set up the quality criteria which has been given

Quality Criteria Setup

15. Then we make the necessary cuts and modifications under the mesh module >macros and topology is done under Topology module>Faces>topology.

Topology

16. While making the cuts, care has been taken to ensure that the feature lines are not removed as they are very important. They are usually on fillets etc.
17. We make these cuts in order to ensure a proper mesh flow
18. Then we begin with meshing under - mesh module>mesh generation>best

Mesh Generation

19. If the mesh generated is not proper, we reconstruct is using the - shell mesh>reconstruct.

Mesh Reconstruct

20. We can also make the necessary changes in elements count and type.
21. This is done by – Perimeter >Num+/- >values

Node Numbering

22. We can also split the elements in order to control the mesh flow

Elements before Splitting Elements after Splitting & Smoothing

23. Smoothing is done after necessary changes in mesh in order to generate good mesh flow by making the elements near ideal.

Elements before Smoothing

Elements after smoothing

24. 2D Meshing is created and it is made sure that there are fewer tria elements as they are stiffer than quads.
25. Thickness is assigned after meshing to the model.
26. Similar steps are incorporated for each and every part.

Learning Outcomes: -

• Learnt about topology clean-ups
• Learnt about offset and extraction of mid-surfacing
• Learnt about the cons resolution which is very crucial
• Learnt about the proper ways of splitting elements in order to get good mesh flow
• Learnt about the element quality criteria

Conclusion :-

It can be concluded that each and every step is very crucial in order to get proper mesh flow results.