Week 7 - Creating connection for Rear door

Objective: Create and Apply different PIDs for different components and Perform suitable connections.

Given model: Rear automotive door, with more than 20+ components. As shown below,

Front View:

Rear View:

Procedure:

• Open the given ANSA file, And Assign PID for each component (Topo>faces> set PID)
• Examine the FE model to see the possible connection
• There are 4 types of connection required, those are
  1. Seam Weld
  2. Bolt
  3. Window damper (Window liner)
  4. Revit joint.

Seam Weld :

• Most of the Automotive parts parmantely joined with the help of seam welding method.
• Again there are two sub category of weld, Overlap and T- Weld.
• In overlap weld, both the plates are parallel to each other, where in T-weld, plates are perpendicular.
  • Overlap seam weld:
    • Create curved using FEA, ie (Mesh>perimeter>feat2Curve)
    • Select the curve and convert it into seam line (Assembly tab>Convert>Curve>seam line)
    • Once the curve converted into seam line, the curve turn into bight pink curve.
    • Open connection Manager and select the seam line.
    • Select P1 as base plate, second plate as P2.
    • Select the FE rep Type as "Overlap-shell"
    • Enter the Search distance, Element Step, weld width, Root shell (Primary, offset or Double) and set weld PID of the weld.
    • Do, apply and realize.
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  • T-Seam Weld:
    • Similar to overlap weld
    • Select the FE rep Type as "Y-Joint shell"
    • Enter the Search distance, Element Step, weld width, Root shell (Primary, offset or Double), Height(Optional) and set weld PID of the weld.
    • Do, apply and realize.

Bolt:

Bolt join can be don't either manually or automatically

• Manually:
  • To perform manually, select RBE2 element (Nastran>Elements>RBE2)
  • Select many Nodes, if only the perifery nodes are only required then select the individual nodes.
  • then proceed next, and apply degree of freedom if required, and set PID for the for bolt joint.
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• Automatica:
  • Create 3D point at the centre of the hole.
  • convert the 3D Point as a bolt (Assembly tab>Convert>3D point>Bolt)
  • Open connection Manager and select the Bolt point.
  • Select different plate in different section of P1, P2 etc. Max(4 Plate)
  • Select the FE rep Type as "RBE2"
  • Enter the Search distance and Do, apply and realize.
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Window damper (Window liner)

• In order to provide the window liner create the curve though FE (Mesh>perimeter>feat2Curve)
• Select the curve and convert it into seam line (Assembly tab>Convert>Curve>Spotline)
• Once the curve converted into seam line, the curve turn into bight pink curve.
• Open connection Manager and select the spotline line.
• Select P1 and P2, and space (S).
• Select the FE rep Type as "RBE3-CBUSH-RBE3"
• Enter the Search distance and set CBUSH PID.
• Do, apply and realize.

• Perfrom the same step on all the 4 side, and the small fixed glass.
• Once done, Re-orent the CBUSH co-ordinate with the golbel co-ordinate system, by performing modify option.

Revit joint/Spot Weld

It is very similar to bolt connection

• Create 3D point at the centre of the element or edge centre.
• convert the 3D Point as a bolt (Assembly tab>Convert>3D point>Revit/Spotweld Point)
• Open connection Manager and select the point.
• Select different plate in different section of P1, P2 etc. Max(4 Plate)
• Select the FE rep Type as "RBE3-HEXA-RBE3" for Spot weld and "RBE2" for Revit
• Enter the Search distance and Do, apply and realize.
• Spot Weld
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• Revit Joint

Result:

• All the component are assigned with different PID
• Assembly of the component are done based on suitable connections

Learning outcome:

• creating connection automatic and manually
• RBE2,RBE3, window linear, seam weld, revit and spot weld were learned during the project.

Concultion:

• Differernt PID are assigned to different componet and suitable connections are use to connect the components.