Meshing on a Bottle cap by using ANSA
OBJECTIVE:
The main objective of this Challange is the given shell element has to been meshing for Structural Analysis using ANSA (Automatic Net generation of Structural Analysis) Software for solving the problem by given eligibility criteria to improve the goodness of the product before into the manufacturing unit.
Methodology:
To make the Mid-Surface of the Given Bottle cap by following the steps to avoid the Errors.
- Check for Geometrical errors. ( If present, Fix them)
- Mid-Surface Extraction.
- Assigning PID, MID & Thickness.
- Assign the Quality Criteria.
- Mesh Creation.
- Converting shell to solid.
Given Data:
The Given model is Bottle cap & the quality criteria are,
S.NO Quality criteria Value
1 Target/Average length 1
2 Minimum length 0.5
3 Maximum length 3
4 Aspect Ratio 3
5 Warping 15
6 Skewness 45
7 Jacobian 0.7
8 Minimum Quad Angle 45
9 Maximum Quad angle 135
10 Minimum Tria angle 30
11 Maximum Tria angle 120
12 Tria Percentage 15
PROCEDURE:
- Open the latest version of ANSA software in your system.
- Import the given sheet metal cad geometry file (.step) in the ANSA, it will automatically changed their file extension into ANSA readable file(.ansa).
- Identify the topo errors present in cad geometry by the way, check > geometry present in the top.
- The topological errors are notified as single con, triple cons , cracks, overlapping faces and many more.
- Understand the reason of the error and perform the actions to resolve it.
- Material identities(MID) and part identities(PID) should be set before doing the meshing operations.
- Extract the middle surface of the geometry, they are several ways to achieve it like manual mid-surfacing(faces>offset) and automated one(faces>mid.surface).
- Change the module (topo – mesh) and perform the 2D mesh with your favourite mesh operations like free mesh, best mesh, spot mesh etc.,
- Check the mesh quality with the given quality criteria and resolve if any error occurs.
Importing :
Open the latest version of ANSA in your Pc/Laptop. Import the cad geometry files through file > open or ctrl + O.
Geometry check :
Topological errors has to be checked for the given Hood Assembly component through the following steps – Tools > checks > geometry
After checks the geometry, If there is any error is present then the check bar will shown the error with its origin and reason like single con, triple cons, needle face etc.,
After checks the geometry,
If there is any error is present then the check bar will shown the error with its type, message code, entity, ID and reason like cracks, triple cons, collapsed cons, needle face etc., and also its shown if the error has been by auto fix itself that’s a great advantage for us.
If the error has been able to clear with the use of auto fix then,
We have to done with ~ ctrl+A to select the whole errors then right click the mouse and fix it. After the problem has been resolved then the check manager will shown the execution is 100% like below.,
Mid - Surface :
Mid – Surface extraction is the method to simplify the meshing operation. If we didn’t use the mid surface then the simple geometry of meshing process can take very long time to achieve the proper result.
NOTE:- Please untick the option[Delete Original Faces]
Mid-surface extraction is creating a shell in the middle of the outer and inner surface of a solid model or geometry. It converts the solid geometry into a thin shell, which reduces the time taken for meshing by reducing the areas to mesh.
In the above image, the red indicates the bottom surface and the green indicates the top surface and the blue indicates the thickness of the geometry. The ANSA automatically takes the offset value by calculating the blue surfaces.
Assign the offset value of the shell, before assigning check the thickness value of the sheet metal ~
Set PID & MID :
Setting PID (property ID) and MID (material ID), which is most important thing that we don’t forget to perform ~ Topo > Module buttons > Faces > Set PID
First we select the surface and property bar will open like this
We can devolpe the mid surface every part and assign the property ID to all. Double click the property of the part.’ T’ which indicated the values of the thickness and ‘MID’ which indicates the material ID(shift +?) to get the material details be sure er need to get the tick in the box.
Material has to been assigned properly.
Meshing :
After transforming the solid part into the shell to be created, assign the target element length as 1 mm and the type is mixed element.
Assign the Meshing quality criteria(f11) that were given in the challenge.
Keep the mesh flow smoothly as much as follows;
- Avoid trias on the construction lines.
- Avoid opposite tria element.
- Avoid quad element.
- Convert quad element into two trais.
Resolve the offs and the unmeshed areas and finish the challenge with neat mesh flow.
After all the following criteria the meshing of the bottle cap is shown as below.,
After done all the process,
Release the element from the geometry and tick the box in draw the shell as solid from the presentation parameter.
And the final output of the meshing of the Bottlecap is done as per the quality criteria.
Learning outcome :
A lot of things learned during this challenge such as,
- Making the mid surface even better and faster when compared before.
- Understanding the error even better and solving the issue with a clear mind.
- Fasten the meshing.
- Understanding the split option even better.
Conclusion :
Finally, the meshing of the bottlecap takes so much time for me to finish but which keeps me engaging while doing the mid surface and meshing. This has been done completely as per the quality criteria and the design norms.
During meshing, faced a lot of challenging operations that create construction lines that are have been in a critical area with the required quality criteria and also the shape of the model has a good view without changing its original shape.
Final Mesh Bottlecap Assembly :
https://drive.google.com/file/d/1F87sOXehlVJTWreQsfs1KGGzeodK68Ys/view?usp=sharing