Week- 7 - Batch mesh and casting

Objectives:- Perform Manual, Batch, and Casting method for given component with given quality criteria and with good mesh flow.

Sr. No	Quality Criteria	Value
1	Target/Average length	3
2	Minimum Length	1
3	Maximum Length	5
4	Aspect	3
5	Warpage	15
6	Skewness	45
7	Jacobian	0.7
8	Minimum Quad Angle	45
9	Maximum Quad Angle	135
10	Minimum Tria Angle	30
11	Maximum Tria Angle	120
10	Tria Percentage	15

Procedure:-

1. Firstly, Import the model.

2. Given model:-

3. Check the geometrical errors and fix them.

CASE 1: Use Manual approach to take Mid-surface, Use Manual meshing approach for 2D meshing.

4. Now, take mid-surface of given model using offset method.

As the thickness is 1 mm for whole component it is easy to take mid-surface.

5. Now, set the PID.

6. Before meshing, set the length parameter, then your meshing will be better.

Command:-{Mesh>>Perimeter>>length>>select all component>>put target element size}

Also use the slide command to rotate the holes for better mesh.

6. Now, set the quality criteria and mesh the component with good mesh flow.

CASE 1 Model-

CASE 2: Use Casting method to take Mid-surface and 2D Meshing.

In the Casting Method, It's very simple procedure, and it takes less time to complete the entire procedure.

For that, go to mid-surface and select casting and set the criteria.

Command:- {Topo>>Faces>>Mid-surface>>Casting}

After completing the casting method.

There are too much off element, so perform the smooth command. Then there is no off element present in the model.

But it's not captured some areas.

CASE 2 Model-

CASE 3: Use Skin method for taking Mid-surface and Batch meshing for 2D meshing.

In the Batch Meshing method, It's also required less time to complete the entire procedure.

Now, take mid-surface using skin method.

Command:-{Topo>>Faces>>Mid-surface>>Skin}

Set parameters and select offset.

Now, open the model browser and create a new part.

Then set part.

Now, go to the batch mesh manager and create a new meshing scenario.

Then open the meshing scenario and select part.

Now again go to batch mesh manager and run the model.

If the status is not completed, then there is something wrong. Repeat the process until the status is completed.

In this batch meshing method, there are some elements to fail. So we have to use smooth and reconstruct the elements where it requires.

CASE 3 Model-

Learning Outcomes:-

1. In this challenge, we learn about new meshing methods like batch meshing as well as casting method.

Conclusion:-

1. In the manual method, we mesh the component with good mesh flow, but it takes 3 hours to complete the entire model.
2. In the casting method, we mesh the component, but the meshing flow is not good enough and the entire procedure completed within seconds.
3. In the batch meshing method, we mesh the component, but the meshing flow is quite enough and the entire procedure completed within minutes.

The overall conclusion is that whenever you have to complete the model within a few minutes, so go for batch or casting method. After that, work on the failure elements and improve mesh flow. Otherwise, use the manual method for better mesh flow.