Week 5 Challenge : Surface wrap on Automotive Assembly

Objective:

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

Target length for Wrap = 3 mm

AIM:

As we are doing surface wrap of engine, gearbox and transmission models, we have to take care of outer surfaces of 3 models. Then we will import all 3 models in on workspace of ANSA using merge option and fit them by some tools like move, translate or symmetry called surface wraping.

Steps on ANSA:

1. importing the models one by one on ANSA for topo cleanup by rectifying the errors only associated with outer surfaces that are in our scope of interest only.

ENGINE:

lets start with engine model. we can see there are so many donuts kind of structures present in this model inside and outside of the required structure those are of no use as while modelling these were created to get fine curved surfaces. There are so many rings and sphere are also present and the elements those are not even connected to the model. Few are even embedded into the modelWe can select all in one go and delete.

Easiest way to delete then is by using Not option in below tool bar to hide out the elements under PID mode.

we have to take care of critical surfaces that are very usefull to study flow simulation or control volume like the 4 pipes where few donuts are embedded badly with them. we have to tackle out the unworthy donuts and delete them if glitches are present. If the donuts are the part of pipe surfaces the we need to use intersection command. It will seperate all the possible surface in glitching zone. We can easily delete the useless faces.

At some places the disconnected faces are present. There we have to create new faces.

we will look after the single cons by doing geometry check and get resolved. By tracking triple cons we can track glitches and intersecting faces.

After doing this much we need to close all the holes present in the model. There must be no surface open that is involved in fluid flow, that connects outter volume to inner volume.

closing all the holes is important as in wrap meshing the outer surface will be selected and if the opening and it will mesh it from inside which we don’t need so we need to close all the open holes

GEARBOX:

Here we dont have much errors. we have to check and find out glitches by using triple cons mode on.

similarly like we did in engine model, closing all the holes after rectifying the geometrical errors.

TRANSMISSION:

triple and single cons are targetted and resolved and then holes are closed using new face creation command

Step 2: merging all 3 models in their respective position in one workspace of ANSA

while merging i could find that the transmitter is not at correct relative position. By using Symmetric option, the position is corrected

by importing this model using merge option, the corrected model is automatically taken up at correct position with respect to engine and gearbox.

The merged complete assembly we can see above.

step 3: surface wrap

Select constant length as we have same target length through out

Double click on first empty we will get a pop up and then click on untitled below parameters

Here we are going to put the target length

Now selecting contents so double click on 0

Select all PIDS and put it in right box those will get selected, as shown there are 115 items in octree scenario. It will take long time.

To check whether its done correctly or not. we will take a section plane to see thoroughly inside or cut both ends of this assembly. If we able to see from one end hole to another end hole then our surface wrap is done correctly.

CONCLUSION:

We learned to merge the geometry and then we created the surface wrap mesh