Week 5 Challenge : Surface wrap on Automotive Assembly

OBJECTIVE: PERFORM SURFACE WARP AFTER MERGING ALL 3 GEOMETRY

Perform geometrical cleanup after performing geometry check for multiple checks & rectify them to ensure a close surface for performing a CFD meshing using appropriate element size. The nature of the element shape should be TRIA element.

GEOMETRY

Below is the CAD model required for preprocessing. We have to remove all missing faces, single & unwanted triple cons. Gaps within the tolerances limit are acceptable but there should not be any significant geometrical error.

ENGINE MODEL

The figure below shows the wireframe model of the engine. We can see multiple single & triple cons. There are unwanted rings also. These must be cleaned up before proceeding for mesh.

The figure below shows the ENT mode where we can see the entire geometry along with rings.

Now after removing the cleaned part we can see all extra & unnecessary features in the below figure.

GEARBOX MODEL

The figure below shows the gearbox model in wireframe mode. We can see some single cons on lower right side in tapered cross section.

Let's have a look at the PID mode of the gearbox model

There are some single cons & glitching due to overlap surface which we can observe after isolating them as shown below

TRANSMISSION MODEL

The figure below shows the transmission model in wireframe mode. There are some single & triple cons. We have to check for triple cons that they are really required or not. Based on the situation we can work on triple cons.

We can also see the above image in PID mode as shown below

After performing all the above geometrical cleanup we can proceed with surface warping. The figure shown below shows the merged surface.

Above we have done surface warping successfully. Now we can proceed with meshing as shown below. There is a single volume from end a to end b.

Final meshed surface looks like as shown below