Week 9-Challenge

Link for frame- https://1drv.ms/u/s!AlDYq9nTGAGCg32nz_n2JzI9XwZt?e=tfd8aC

Objective : To provide specified connections representation for the given Frame assembly to attach parts after meshing.

Procedure :

Connectors are used to connect the different FE entities. After the meshing we need to connect the components with various connectors like seam weld, spot weld, bolt, adhesives are also used. Without connectors the proper results in analysis may not be obtained. This is a special modelling technique for the joints and it can transfer the force and moment to the in appropriate way in appropriate loading.

CONNECTIONS DATA :

1. Right_Rail_2 & Front_truss_1:- Seam-Quad (angled+capped+L)
2. Left_Rail_2 & Front_truss_1:- Quad elements
3. Front_truss_2, Front_truss_1 & Right_Rail_1:- Spot weldwith 3 Layers and 5 mm Diameter
4. Front_truss_2, Front_truss_1 & Left_Rail_1:- Hexa (Adhesive)
5. Rear_truss_2 & Right_Rail_2:- Bolt Connector
6. Rear_truss_2 & Left_Rail_2:- Bolt Connector
7. Right_Rail_1 & Right_Rail_2:- Spot-weld with Rigid Elements
8. Left_Rail_1 & Left_Rail_2:- Spot-weld withSpring Elements
9. Rest all the component left Join them with suitable connectors.

MESHING

• Import the hmfile to hyper mesh.
• 2D > Auto meshthe entire component for target element size 5mm.
• Eliminate trias using Quality Index > Drag tria elementcommand
• 2D >Smooth the reworked mesh until final displacement iteration equals 0.0000.
• Set Steelas material with appropriate values.
• Set properties for each component.

CONNECTIONS

• At first the RIGHT RAIL and FRONT TRUSS 1 need to join using SEAM QUAD(angled+capped+L).For this we need to go to 2d>CONNECTORS>Choose SEAM>select the type as SEAM QUAD(angled+capped+L)> select the nodes on the Right rail 2 and choose both the components >hit create. Then if the selected nodes are green then the connector is realized and if it is seems in red then it is not realized. And if it is yellow then it means the connector is need to be realized.
• Then next is to connect the Left_Rail_2 & Front_truss_1using Quad elements. For that go to 2D>connectors> SEAM> choose the nodes in any one of the above two components >Choose both the components>choose type as quad>choose imprint>hit create .That will realize the connector. And we use imprint to have proper connectivity between the elements.
• For connecting Front_truss_2, Front_truss_1 & Right_Rail_1 using Spot weld with 3 Layers and 5 mm Diameter We need to go to 2D>connectors>SPOT>choose type as weld>then choose the nodes in the location at which we need to have connector>then select the components>change num layers to total 3 >set a tolerance of 10>enter the diameter as 5mm >create.
• Connect Front_truss_2, Front_truss_1 & Left_Rail_1 using Hexa (Adhesive) For hexa adhesive connector go to 2D>connector> Seam >choose the nodes in a component at which we need to connect with Hexa adhesive>choose the components>set the tolerance as 10 >Choose the type as HEXA ADHESIVE>type in number of strips and coats >hit create.
• To connect Rear_truss_2 & Right_Rail_2 using Bolt Connector for that Go to 2D>connectors>Choose bolt general > choose two nodes at which we need to create the the bolt>Choose the components>Choose the type as bolt(general)>set tolerance as 10>choose create hole if none> and hit create.
• To connect Rear_truss_2 & Right_Rail_2 using Bolt Connector For that Go to 2D>connectors>Choose bolt(general)>choose two nodes at which we need to create the the bolt>Choose the components>Choose the type as bolt(general)>set tolerance as 10>choose create hole if none> and hit create.
• To connect Right_Rail_1 & Right_Rail_2 using Spot-weld with Rigid Elements To connect with spot weld, Go to 2D>connectors> select the nodes at which we need to create the spot weld> Choose the components>set the tolerance as 10>Set the type as RIGID> hit create.
• To connect Left_Rail_1 & Left_Rail_2 using Spot-weld with Spring Elements To connect with spot weld, Go to 2D>connectors> select the nodes at which we need to create the spot weld> Choose the components>set the tolerance as 10>Set the type as spring> hit create.
• Rest of the components are connected using the spot weld. Since the sheet metal component is having thicknessless than 2 mm we can use the spot weld to connect the components.
• When the thickness is so less we cannot use arc welding since that can burn of the parent material itself

Conclusion:

From this challenge the process of connecting 2D components using 2D connectors in hyper mesh is learned. Proper modelling of the connectors is essential for obtaining accurate results in analysis of these components. Otherwise the failure areas will not be properly display in simulation and that can cause ambiguity. So connectors are essential.