Week 5 Challenge : Surface wrap on Automotive Assembly
Objective- surface wrapping of an automotive assembly.
Introduction – surface wrapping is the water type flow mesh around an assembly which contains FEM and macros.
It is the process of meshing a surface from outside, and here we are dealing with outside surface only.
Procedure- here in an automotive assemble of an vehicle contains mainly 3 major equipment
- Engine
- Transmission
- Gear box
Step-1 in the initial step we are going to deal with the engine part and going to perform some clean-up task over the model, all the unnecessary part (the part of the model that are not connected with any other part and just laying free over space) needed to be deleted.
Here one point that we need to keep in mind while working over the model that in the wrapping of the surface we are only dealing with the outside geometry of the model so all the work need to perform over outside geometry only, we do not need to worry about any inside geometry and part.
Unchecked surface is the surface whose length are les then the given target length for the model.
The outside shape of the model must be proper, while dealing with the surface wrapping.
Here we need to delete all type of ring and ball type assembly because these were used in making fillet while designing the model, so it is not doing any work here and will need to remove.
This work can be performed by two ways.
- Delete manually one by one after identifying the object.
- Second isolate PID wise all the important components of the model then delete all the unnecessary part.
Step-2 same thing we will perform with the transmission part, will delete all the unnecessary ring, part, unchecked surfaces, and ball type object.
Here also the same work can be performed by both the above mentioned ways.
Step 3 now the same clean-up work will be performed over the gear box, one thing we will keep in mind here we don not need to worry about triple cons because we only worry about the outer surface of the model.
Step 4 now before starting the final surface wrap we will bring our all three part in one GUI.
To merge the all three part in the single GUI use merge> locate the file>do not need any offset>merge with current file. Middle click.
This will automatically detect the part location and will add the new part with the old file.
Step 5- now here we need to fill all the possible hole by the use of NEW> fitted> loop> pick the cons> middle click.
Because while dealing with the surface wrap if the hole is open in the model somewhere it will create some kind of defect while wrap mesh and we will not allow this as the good work.
The single cons hole can be filled with the tool fill hole as well.
Step-6 Now the final step we will start with the wrap under classic mesh< element<wrap<constant length<double click<provide the name< target length 3mm<smooth factor0.5< compress the unnecessary PID < select the available PID (can be identified with the yellow bulb, the not used PID will be look like as off bulb) < RUN.
Now the available model over the space is wrapped as the surface mesh we can see the surface is mesh with the given target length, also the surface is hollow from inside as the surface wrap is deal with the the outside geometry only.
Result- the size of the file is so large your dash board is not allowing it to upload here even after the zip compression, so the import screenshot of the project is attached here.
Learning outcomes- the learning was different in this week challenge because the engine is very complicated and bulky structure and to deal with this type of model is kind of challenging work, identifying the unnecessary part and then deleting it accordingly.
Also to merge or assemble the different part in the single GUI and at the end surface wrap which was dealing only with the outside surface of the model was the new work in the week.
Conclusion- In the vast ANSA software the surface wrapping was the one more learning here, and the clean-up that was performed in this task was very different with the previously performed topo clean-up where we were focused to deal with kind of different work.
Also the ford engine assembly is the kind of industry project as the engine has various kind of large and small object performing different work, to identify the important and unnecessary work was the new learning in the week.