Week- 8 - Solid meshing

Report on solid mesh generation of rear view mirror component after clearing geometrical error, topological clean-up and meshing the surfaces using 2D tria elements as per given quality criteria by using ANSA software.

Aim:

To generate solid mesh using tetra elements and meshing the surfaces using 2d elements like tria and ortho tria after correcting the geometrical errors and topological clean up using ANSA Software. The whole process is to be carried out using given quality criteria and mesh parameters. Also to check 2D elements for minimum and maximum length errors, and 3D elements for Tet collapse errors.

Procedure with CAD model images:

• The given CAD model of component.

FIG. 1: FRONT VIEW GIVEN CAD MODEL.

Fig. 2: BACK VIEW OF GIVEN CAD MODEL.

• After importing .IGS file in ANSA, the observation found that many areas where geometry needs to be check for topological clean-up and geometrical errors.
• By Starting with checking single, double and triple cons. I have used topo command to clear unnecessary single cons.

FIG.3. MODEL AFTER TOPOLOGICAL CLEAN-UP.

• The achieved geometry of model after using topo command is checked for the errors in check manager by executing it for single cons, cracks, overlap faces, Needle faces, triple cons, collapsed cons, unchecked faces and sharp edges etc. as shown in fig.4 below.

Fig.4. GEOMETRY PRESENTATION WITH CHECK MANAGER EXECUTION.

• Surface (2D ELEMENT) meshing using tria and ortho tria elements for ball casing part.
• Here I stared the meshing for individual part of mirror glass assembly. First i took intermediate ball casing part for meshing the same.
• The given mesh parameter and quality criteria values are assigned as shown in fig.5 and 6 below.

FIG.5. INPUT VALUES FOR MESH PARAMETER.

FIG.6. INPUT VALUES FOR QUALITY CRITERIA – PRESENTATION PARAMETER.

• In mesh module element target length as a 1mm is given as input for perimeters and macros using length command in perimeters group.
• Spot mesh command is used which is available in mesh generation group for implementing ortho tria elements for curve surfaces and tria elements for plane surface.

FIG.7. ACHIEVED MESH FOR SURFACES USING 2D ORTHO TRIA ELEMENTS UNDER GIVEN QUALITY CRITEIA OF BALL CASING PART.

• Volume (3D Element) meshing using tetra rapid elements for ball casing part.

• After moving into the volume mesh module for starting the 3D meshing, first I had to define volume for the same part, the volume is defined by using define command which is available in volumes group.
• The ID is generated for the same part automatically after defining it manually. Also I have assigned separate name for the volume of the same part as ‘BALL_CASING_MIRROR’.
• Tetra rapid command is used for volume meshing which is available in unstructured mesh group.
• After completing volume meshing by hiding some part the sectional view has taken for observation of the 3D elements as shown in fig. 8 and 9 below.

FIG.8. ACHIEVED MESH FOR SURFACES USING 2D ORTHO TRIA ELEMENTS AND VOLUME MESH USING 3D TETRA RAPID ELEMENTS UNDER GIVEN QUALITY CRITEIA OF BALL CASING PART.

FIG.9. SECTIONAL VIEW FOR OBSERVATION OF 3D-ELEMENTS OF BALL CASING PART.

• Surface (2D ELEMENT) meshing using tria and ortho tria elements for mirror glass casing part.
• The mirror glass casing is kept visible only by hiding other parts using not command which is available in focus bar at bottom section.
• In mesh module element target length is set as 1mm for perimeters and macros using length command in perimeters group.
• Spot mesh command is used which is available in mesh generation group for implementing ortho tria elements for curve surfaces and tria elements for plane surface as shown in figs. below.

FIG.10. THE CURVED SURFACES ARE SELECTED FOR ORTHO TRIA MESHING.

• Meshed curved surfaces are meshed using ortho tria elements as shown in fig.11 below.

FIG.11. THE CURVED SURFACES ARE MESHED USING 2D ORTHO TRIA ELEMENTS.

FIG.12. THE FLAT SURFACES ARE MESHED USING 2D TRIA ELEMENTS.

• Volume (3D Element) meshing using tetra rapid elements for glass mirror casing part.

• After moving into the volume mesh module for starting the 3D meshing, first I had to define volume for the same part, the volume is defined by using define command which is available in volumes group.
• The ID is generated for the same part automatically after defining it manually. Also I have assigned separate name for the volume of the same part as ‘GLASS_CASING_PART’.
• Tetra rapid command is used for volume meshing which is available in unstructured mesh group.
• After completing volume meshing by hiding some part the sectional view has taken for observation of the 3D elements as shown in fig. 13 and 14 below.

FIG.13. ACHIEVED MESH FOR SURFACES USING 2D ORTHO TRIA ELEMENTS AND VOLUME MESH USING 3D TETRA RAPID ELEMENTS UNDER GIVEN QUALITY CRITEIA GLASS CASING PART.

FIG.14. SECTIONAL VIEW FOR OBSERVATION OF 3D-ELEMENTS OF GLASS CASING PART.

• Surface (2D ELEMENT) meshing using tria and ortho tria elements for Mirror glass part.
• The mirror glass is kept visible only by hiding other parts using not command which is available in focus bar at bottom section.
• In mesh module element target length is set as 1mm for perimeters and macros using length command in perimeters group.
• Spot mesh command is used which is available in mesh generation group for implementing ortho tria elements for curve surfaces and tria elements for plane surface as shown in figs. below.

FIG.15. SURFACES MESHED OF GLASS PART UDSING 2D ELEMENTS.

• Volume (3D Element) meshing using tetra rapid elements for mirror glass part.
• After moving into the volume mesh module for starting the 3D meshing, first I had to define volume for the same part, the volume is defined by using define command which is available in volumes group.
• The ID is generated for the same part automatically after defining it manually. Also I have assigned separate name for the volume of the same part as ‘GLASS_PART’.
• Tetra rapid command is used for volume meshing which is available in unstructured mesh group.
• After completing volume meshing by hiding some part, the sectional view has taken for observation of the 3D elements as shown in fig. 16 and 17 below.

FIG.16. ACHIEVED MESH FOR SURFACES USING 2D ORTHO TRIA, TETRA ELEMENTS AND VOLUME MESH USING 3D TETRA RAPID ELEMENTS UNDER GIVEN QUALITY CRITEIA OF MIRROR GLASS PART.

FIG.17. SECTIONAL VIEW FOR OBSERVATION OF 3D-ELEMENTS OF MIRROR GLASS PART.

• Surface (2D ELEMENT) meshing using tria and ortho tria elements for Mirror holder part.
• The mirror glass is kept visible only by hiding other parts using not command which is available in focus bar at bottom section.
• In mesh module element target length is set as 1mm for perimeters and macros using length command in perimeters group.
• Spot mesh command is used which is available in mesh generation group for implementing ortho tria elements for curve surfaces and tria elements for plane surface as shown in figs. below.

FIG.18. THE CURVED SURFACES ARE SELECTED FOR ORTHO TRIA 2D ELEMENTAL MESHING.

FIG.19. THE SURFACES ARE MESHED USING 2D ORTHO TRIA AND TRIA ELEMENTAL MESHING.

• Volume (3D Element) meshing using tetra rapid elements for mirror holder part.
• After moving into the volume mesh module for starting the 3D meshing, first I had to define volume for the same part, the volume is defined by using define command which is available in volumes group.
• The ID is generated for the same part automatically after defining it manually. Also I have assigned separate name for the volume of the same part as ‘mirror holder part’.
• Tetra rapid command is used for volume meshing which is available in unstructured mesh group.
• After completing volume meshing by hiding some part, the sectional view has taken for observation of the 3D elements as shown in fig. 16 and 17 below.

FIG.13. ACHIEVED MESH FOR SURFACES USING 2D ORTHO TRIA,TRIA ELEMENTS AND VOLUME MESH USING 3D TETRA RAPID ELEMENTS UNDER GIVEN QUALITY CRITERIA OF MIRROR HOLDER PART.

FIG.17. SECTIONAL VIEW FOR OBSERVATION OF 3D-ELEMENTS OF MIRROR HOLDER PART.

• After completing meshing of all parts of mirror frame assembly, the all parts are kept visible for getting complete meshed assembly of mirror frame component as shown in figs. below.

FIG.18. ACHIEVED MESH MODEL OF MIRROR COMPONENT ASSEMBLY.

FIG.19. FRONT VIEW OF ACHIEVED MESH MODEL OF MIRROR COMPONENT ASSEMBLY.

FIG.20. BACK VIEW OF ACHIEVED MESH MODEL OF MIRROR COMPONENT ASSEMBLY.

FIG.21. BACK VIEW OF ACHIEVED MESH MODEL OF MIRROR COMPONENT ASSEMBLY IN SOLID BOUND MODE.

LEARNING OUT COMES:

The new things here I have learned is solid meshing of mirror component assembly by taking individual parts for creating surface mesh first and then by completing volume meshing. The surface meshing has done by using commands like spot meshing with 2D elements ortho tria and tria. Also where to use ortho tria and tria elements and how to get better results from it. Specially in volume meshing I have learned how to define volume for parts and to generate 3D mesh by using tetra rapid command for generating 3D tetra elements using given quality criteria.

CONCLUSION:

The solid mesh generation of rear view mirror component assembly tetra 3D elements after clearing geometrical error, topological clean-up and meshing of surfaces using 2D elements as per given quality criteria by using ANSA software has been carried out successfully. The remarks are based on the observation of a time taken for process execution and the result outcomes.

NOTE: PFA FOR IMAGES AND .ANSA FILE.