Week 5 Challenge : Surface wrap on Automotive Assembly

For the given models, check for the geometrical errors and delete surfaces that are unwanted for Surface wrap as shown in the videos. After clearing geometry, Merge all 3 models and perform surface wrap.

The target length for Wrap = 3 mm

Write a detailed report on the steps followed to finish this challenge.

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STEP 1 - IMPORT THE MODELS AND PERFORM A CLEANUP (Remove unnecessary components)

Part 1 - Engine

Step 1 - Import the Engine Model (Given)

Step 2 - Geomeytry Clean Up

                                                     Image 1 - Initial Engine

                                                       Image 2 - Final Engine

Part 2 - GearBox

Step 1 - Import the Gear Box (Given)

Step 2 - Geomeytry Clean Up

                                             GearBox Initial

                                                             GearBox Topo

                                                  Final GearBox

                                                   Final GearBox

Part 3 - Transmission

Step 1 - Import the Transmission Box (Given)

Step 2 - Geomeytry Clean Up

                                   Initial Transmission

                                        Final Transmission

STEP 2 - MERGE ALL 3 MODELS (ENGINE, GEARBOX AND TRANSMISSION BOX)

Merge

File ---> Merge ---> Engine ---> Transmission ---> Gearbox

                                                              Engine with Transmission

                       Engine With Transmission and GearBox

                                                            File Merge Analytics

STEP 3 - MERGE ALL 3 MODELS (ENGINE, GEARBOX AND TRANSMISSION BOX)

Surface Wrap

Before Doing surface wrap  Compress the PID 

Utilities ----> Compress

Now Surface Wrap

Step 1

Mesh ----> 

Step 2

Elements ---->Wrap ---->Constant Length ---->

Step 3

Double Click Empty --->Target Length = 3mm

Step 4  ---> Modify Contents

Step 5 - Run

Result - Final Surface Wrapped for  Engine

Conclusion

Surface wrap meshing is a technique used in computer-aided design (CAD) and finite element analysis (FEA) to generate a mesh around a complex or irregular geometry. This process involves creating a mesh that conforms closely to the shape of the given surface, capturing its details and ensuring accurate representation in numerical simulations or analyses. Here are some reasons why surface wrap meshing is helpful:

Accurate Representation:

Surface wrap meshing allows for a more accurate representation of complex geometries. It captures intricate details and contours of the surface, which is crucial for simulations requiring high-fidelity results.

Conformity to Geometry:

In many engineering applications, such as structural analysis or fluid dynamics simulations, the accuracy of the results depends on how well the mesh conforms to the actual geometry. Surface wrap meshing ensures that the mesh closely follows the shape of the surface, providing a better representation of the physical structure.

Boundary Layer Resolution: 

Surface wrap meshing is particularly useful in capturing boundary layer effects. In fluid dynamics simulations, for example, the mesh near the surface needs to be refined to accurately capture boundary layer phenomena. Surface wrap meshing helps in generating a mesh with varying element sizes to achieve this resolution.

Ease of Use:

Generating a mesh directly on a complex surface can be more convenient than creating a volume mesh, especially when dealing with irregular or intricate shapes. It simplifies the mesh generation process and can save time and effort compared to alternative methods.

Compatibility with CAD Models:

Surface wrap meshing is often employed in CAD software to generate meshes directly from the surface geometry. This ensures compatibility with the original design and allows for seamless integration between the CAD model and the mesh used for analysis.

Reduced Computational Cost:

By focusing the mesh only on the surfaces of interest, surface wrap meshing can reduce the overall computational cost compared to generating a volumetric mesh for the entire domain. This can be particularly beneficial in large-scale simulations.