Create the Connectors and Attaching Various Parts

· Choose the use profile as Hypermesh Radios. Click on Open.

· Use the geometry color mode and choose by Auto Mode.

· The component appears in wireframe mode. Change it o surface. At LHS we get the no. of component which we have to mesh. Here we have to we have to create component according to given geometry. namely

A. Geometry Cleanup

· Now we have fully equivalence mid surface. We have to clean the surface to get clean and clear meshing. It will avoid the pinholes, very small edge and surface fillets automatically. We have to set the parameters according to requirement.

· Go to defeature option and set the target fillets(max.radius and min.radius). Select the taget surface and hit on find. Hypermesh will automatically recognize the surface fillets not hot on remove. It will remove the fillets which we don’t want.

· Apart from that , Click on auto cleanup. Click on edit parameters. Se the parameters according to requirements. We have to decide it according to customer requirements and accuracy required.

Eg. Target Element Size= 5 as shown in picture.

· Now click on edit criteria. This is where we have to specify the criteria for the Quality index of meshing.

· These are the criteria on which our meshing gets checked on quality of meshing.

E.g. Min/ Max Size of element, Aspect ratio, Warpage, Min/Max Quad angle, Scewness etc

· Click on Apply and hit OK. Click on auto cleanup.

B. Meshing

· Now go to 2D mesh panel or hit F12 on keyboard. Go to 2D elements. Select the surface displayed and set element size as 6. Mesh with only Quads.

· Hit on mesh. Adjust the nodes according to requirements. Make sure the mesh flow is good. Adjust each area of meshing with care to get a quality mesh. Hit middle mouse button to exit the mesh.

· Mesh flow near cutouts and at edge will specify mesh quality. Now meshing is done. It’s time to check the quality of the mesh.

1. Quality Check 2D

· Click on F12 and select the elements. Select the element from the outer edge to remesh the surface.

· Make a square to remeshing. It will easy to remesh targeted area. This is way to get remesh all the surface again and again. Repeating this procedure you will refine mesh.

· Now again we can check for the quality criteria. These tools also help to get rid off from bad mesh.

· Apart from these entire tools smooth tool is used for very minor adjustments in the elements to complete quality criteria.

· After doing all this you will get a quality mesh which will pass all the quality criteria. In industry point of view the tolerance is given for quality criteria’s it may be in 5% to 10%.

C. Connector Tab

Go to view-> Hypermesh->Connectors-> hit mouse button.

This will launch the connector tab on left side tool bar.

D. Connectors

1. Right Rail_2 and Front Truss_1- Seam- Quad(angled+Capped+L) – Not available in V2017

Go to Connectors. Hit Seam.

1. Click on Location- Select the target Nodes.

2. Connect the required components. Select the Components or Assemblies.

3. Give the Search Tolerance according to distance between two components.

4. Select the type of connector.( Here it is Quads).

5. If you want you can create properties for different connectors. If not then click on no property.

6. Keep the quad transitions and imprints and hit create.

7. The seam with quad will be created. See the status at bottom left corner. It’s essential that the connectors should be realized. If it is realized then it will shows the green color.

8. Green Color- Realized Yellow Color- Not Realized Red Color- Failed

2. Left Rail_2 and Front Truss_1- Seam- Quad

Go to Connectors. Hit Seam.

9. Click on Location- Select the target Nodes.

10. Connect the required components. Select the Components or Assemblies.

11. Give the Search Tolerance according to distance between two components.

12. Select the type of connector. (Here it is Quads).

13. If you want you can create properties for different connectors. If not then click on no property.

14. Keep the quad transitions and imprints and hit create.

15. The seam with quad will be created. See the status at bottom left corner. It’s essential that the connectors should be realized. If it is realized then it will shows the green color.

16. Green Color- Realized Yellow Color- Not Realized Red Color- Failed

3. Right Rail_1, Front Truss_1 and Front Truss_2- Seam- Spot Weld with 3 Layers and 5mm Diameter

Go to Connectors. Hit Spot.

17. Click on Location- Select the target Nodes.

18. Connect the required components. Select the Components or Assemblies.

19. Give the Search Tolerance according to distance between two components.

20. Select the type of connector. (Here it is weld).

21. If you want you can create properties for different connectors. If not then click on no property.

22. Change the number of layers = 3 and spot dia= 5mm

23. The spot weld will be created. See the status at bottom left corner. It’s essential that the connectors should be realized. If it is realized then it will shows the green color.

24. Green Color- Realized Yellow Color- Not Realized Red Color- Failed

4. Left Rail_1, Front Truss_1 and Front Truss_2- Seam

Go to Connectors. Hit Seam.

25. Click on Location- Select the target Nodes- Use by path option.

26. Connect the required components. Select the Components or Assemblies.

27. Give the Search Tolerance according to distance between two components.

28. Select the type of connector. (Here it is Hexa Adhesive).

29. If you want you can create properties for different connectors. If not then click on no property.

30. Change the number of strips or coats if required. We can change the width of connector.

31. The seam adhesive will be created. See the status at bottom left corner. It’s essential that the connectors should be realized. If it is realized then it will shows the green color.

32. Green Color- Realized Yellow Color- Not Realized Red Color- Failed

5. Rear Truss_2 and Right rail_2 – Bolt Connector

Go to Connectors. Hit Bolt.

33. Click on Location- Select the target Nodes- Use by path option.

34. Connect the required components. Select the Components or Assemblies.

35. Give the Search Tolerance according to distance between two components.

36. Select the type of connector. (Here it is Bolt General).

37. If you want you can create properties for different connectors. If not then click on no property.

38. Adjust the Create hole if Not in geometry. Adjust the hole position.

39. The Bolt general type will be created. See the status at bottom left corner. It’s essential that the connectors should be realized. If it is realized then it will shows the green color.

40. Green Color- Realized Yellow Color- Not Realized Red Color- Failed

6. Rear Truss_2 and Left rail_2 – Bolt Connector

Go to Connectors. Hit Bolt.

41. Click on Location- Select the target Nodes- Use by path option.

42. Connect the required components. Select the Components or Assemblies.

43. Give the Search Tolerance according to distance between two components.

44. Select the type of connector. (Here it is Bolt General).

45. If you want you can create properties for different connectors. If not then click on no property.

46. Adjust the Create hole if Not in geometry. Adjust the hole position.

47. The Bolt general type will be created. See the status at bottom left corner. It’s essential that the connectors should be realized. If it is realized then it will shows the green color.

48. Green Color- Realized Yellow Color- Not Realized Red Color- Failed

7. Right rail_1 and Right rail_2 – Spot weld with rigid Elements

Go to Connectors. Hit Spot.

49. Click on Location- Select the target Nodes- Use by path option.

50. Connect the required components. Select the Components or Assemblies.

51. Give the Search Tolerance according to distance between two components.

52. Select the type of connector. (Here it is Rigid).

53. If you want you can create properties for different connectors. If not then click on no property.

54. Adjust the Create hole if Not in geometry. Adjust the hole position.

55. The spot rigid type will be created. See the status at bottom left corner. It’s essential that the connectors should be realized. If it is realized then it will shows the green color.

56. Green Color- Realized Yellow Color- Not Realized Red Color- Failed

All the connector realized not realized and failed is shown in in Connector tab, according to type of connectors.

Conclusion: