Week 5 Challenge : Surface wrap on Automotive Assembly

CHALLENGE REPORT :
AIM :

To check for the geometrical errors and delete surfaces which are unwanted for Surface wrap mesh.

THEORY :

SURFACE WRAP MESH :

Surface wrap is the process of meshing where the designer is only interested in the outside surface & the components or surfaces located inside the components will be kept as it is. The external flow simulations which are performed only on outside surfaces without affecting or affected by the inside components are using surface wrapp meshing method.

PROCEDURE :

i) Topo Cleanup of Engine:

* The imported model has many unwanted surfaces & CONS which are not associated with the assembly. These unnecessary things are required to removed from the geometry before proceedings to Meshing.

* After importing the models, 1st we wants to found all the unwanted surfaces like rings, balls, small surfaces & other elements which are might be used to create slots, profile curvature or just for reference by hiddending all other surfaces and delete it.

* And we wants to clear all the errors like triple cons, single cons.

* Delete all the next faces and clear all the triple cons in the models.

* Clear all the single cons by creating the new faces and we can also used the topo option to auto correct the cons joints to clear the single cons.

* Close all the openings.

ii) Merging :

* After clearing all the error in all three models, we wants to merge it with one other to performmesh.

* By clicking the file option, we can select the merg option and select the Transmission first and then the Gearbox.

* There will show the pop up like merg parameter and select the merg with current model and turn on the auto fit model and merge parts and MB containers.

* After merging them, the complete assembly was checked to make the close volume & at some places new surfaces were also created.

iii) Surface wrap meshing :

* To create surface wrap, the "Wrap" available in Elements toolbar has been used.

* The procedure is taken to assigned element size, type, properties to elements and to apply surface wrap to assembly.

* Using "Run" option is used to apply surface wrap.

MODEL IMAGES :

Before Geomentrical error cleanup of Engine :

Before Geomentrical error cleanup of Transmission :

Before Geomentrical error cleanup of Gearbox :

After Geomentrical error cleanup of Engine :

After Geomentrical error cleanup of Transmission :

After Geomentrical error cleanup of Gearbox :

MERGED MODEL :

SURFACE MESH MODEL :

CONCLUSION :

The combined model is surface wrapped successfully with element size of 3mm.

model file link :

https://drive.google.com/file/d/1MaF7On0LF-SKcPQ47gRLLHdeiYE9J0gc/view?usp=sharing