Week - 4 - 2D meshing for Plastic components

OBJECTIVE:

To Perform Geometry Clean-Up, Generate Mid-Surface and Meshing of a Plastic component with respect to the below given Quality Criteria:

PROCEDURE:

1. Geometry Clean-Up:

• Once the component is opened in ANSA, perform Faces > Topo in-order to connect the different surfaces.
• Mid-Surface is generated for each feature separately.
• Commands such as Middle > Single, Middle > Multi, Faces > Offset are used to generate surfaces.
• The generated mid-surfaces are attached to each by using option Extend.
• In few complicated areas such as Outer Circular thread, the mid-surface generation is slightly different from the common method.

The following images represent the steps in generating the mid-surface of the threaded surface:

The following images represent the mid-surface generated for multiple curved teeth:

• The mid-surface of the adjacent surface of a curved tooth is generated by using offset.
• The mid-surface is then extended to it's bottom base.
• The mid-surface is then choosen as an entity to Transform > Copy > Rotate 25 times with an angle of 13.854 degrees.
• mid-surface for multiple teeth is achived.

Step 1: Step 2:

Step 3: Step 4:

• PID and Thickness is achieved for all the features by measuring the thickness of the parent geometry.

The following images represent the thickness values and PID of each feature of the bottle cap:

3. Meshing:

• The Best mesh method is used to generate an automated mesh for the entire component initially.
• Commands such as Re-construct and Smooth are used to achieve a good mesh flow.
• Split, Swap, Split Quad, Move are used to eliminate tria-elements and off-elements in-order to match the quality criteria:

• The mesh flow has a few distorted elements which cannot be eliminated due to the presence of triple-cons on the surface.

ERRORS FACED:

The following images show distorted elements which do not fulfil the quality criteria:

CONCLUSION:

Successfully achieved a proper mesh flow with a minimal of 2.06% of tria elements and 0.19% of off-elements for a plastic components by assigned the designated thickness to all features.

The following image represent the meshed component and midsurface as solid with the assigned thickness values: