Week 5

Objective:

For the given component, check for the geometrical errors and mesh with the given element Quality criteria. Use tetra elements to model the component and there should not and kinks and dips on the surface of the component.

Procedure:

The given component was a rear-view mirror. It was divided into 4 PIDs (PSHELL):

1. Holder:
2. Ball
3. Mirror Handle
4. Mirror

• Topo command was used to convert all Single CONS to Double/Triple CONS.
• The unnecessary Triple CONS were converted to Double.
• Since the target size was 1mm, all distances (including fillets) were maintained over 1mm.
• Once the geometry was corrected, spot meshing process was started.
• The spot meshing was done one-by-one on all macros using Spot Mesh Command.
• For rounded profiles, ortho-tria mesh was followed.
• For flat surfaces, normal tria mesh was generated.
• If the mesh generated was not satisfactory, reconstruct command was used to regenerate mesh until the mesh obtained was satisfactory. This was carried out for both ortho-tria as well as tria elements.
• Once the whole part was meshed, a new volume was defined using Define command.
• The Define command helps to create a closed volume for tetra mesh generation.
• Quality parameters were assigned as per the values given in the question.
• After volume definition, Tetra Rapid command was used to generate Tetra mesh inside the newly defined Solid Volume with element size as 1mm.
• The solid mesh was checked for quality compliance.
• This solid mesh was transferred to a separate PID.

• A cross-sectional view of all the components can be seen below.

Learning Outcome:

This challenge has helped me understand how to perform 3D meshing (Tetra and Hex mesh). I learned the uses of many new commands under the V.Mesh tab in this challenge.

Conclusion:

The given Component and Switch Panel was meshed as per the specified quality criteria and thickness was assigned.