Week 9-Challenge

CONNECTORS

Connectors are simply a database of information defining specific requests for connections at specific locations. They are a medium to create both solver independent or solver dependent connections between geometric and FE entities. Connectors are primarily used to create spot and seam welds, but also used to create adhesives, bolts and masses.

OBJECTIVE -

1. Generate different types of connectors on the frame assembly.
2. Understanding different types of connector and how to debug them.

PROCEDURE -

• Import the model file, frame assembly.hm.
• Create a shell mesh on the components. Go to the Automesh panel and access the size and bias subpanel. Select the surfaces and click displayed from the extended menu. For elem size specify 5 and choose mesh type as quads. Click mesh to mesh the surfaces.

1. Right Rail-2 & Front truss-1: - Seam-Quad(angled+capped+L)

Go to seam tool under 2D page. For location, change the selection option to nodes. Select the nodes by path option to select the nodes faster. Click spacing and input a value of 5. In connect what selection, select the two components Right Rail-2 & Front truss-1. Put type as Seam-Quad(angled+capped+L) and then set the tolerance to 10. Then click create.

fig : SEAM CONNECTOR BETWEEN RIGHT RAIL 2 & FRONT TRUSS 1

2. Left Rail-2 & Front truss-1: - Quad elements

We can find quad connector under seam. For location select nodes (by path) at the edge of the truss. Provide spacing as 5. In type choose Quad and select the two components to create the connector. Arrange the mesh if it's distorted.

fig: LEFT RAIL 2 & FRONT TRUSS 1 CONNNECTED

3. Front truss-2, Front truss-1 & Right Rail-1: - Spot weld with 3 Layers and 5 mm Diameter

Click on spot panel and access for spot subpanel, then for location select nodes. Like before set the tolerance to 20, the type to weld, and then num layers as 3. Put the diameter 5 and click create. Toggle mesh dependency if the connector is not getting realised.

4. Front truss-2, Front truss-1 & Left Rail-1: - Hexa (Adhesive)

Go to the Area panel. Select nodes for the location. Click node list and select by path. Select the row of nodes on the component. Define width as 10 and put offset equals to 3. Select comps Left Rail 1 and Front truss 2 and front truss 1. Click create.

fig: HEXA ADHESIVE BETWEEN FRONT TRUSS 2, FRONT TRUSS 1 & LEFT RAIL 1

5. Rear truss-2 & Right Rail-2: - Bolt Connector

Click on connector tool in 1-D element page. Access the Bolt panel by clicking on connector. Verify that location is set to nodes and select the node to create hole in the component Rear Truss 2. For connect what click on comps and select Right Rail 2 and Rear Truss 2. In number of layers select two and in the tolerance field, type 10. Set type as bolt (general). Toggle the connection to link entity if there are no holes.

6. Rear truss-2 & Left Rail-2: - Bolt Connector

We will follow the same steps as above to create bolt connector between Rear Truss-2 & Left Rail-2.

fig: BOLT CONNECTORS

7. Right Rail-1 & Right Rail-2: - Spot-weld with Rigid Elements

Click the Spot panel and go to the spot subpanel. For location select nodes by path from one end of right rail 1 to another. Click comps and select the Right Rail 1 and Right Rail 2. Select type as rigid and for tolerance specify 10. Click create to generate the connector.

8. Left Rail-1 & Left Rail-2: - Spot-weld with Spring Elements

Follow the same steps as above to create spot connector. Just select type as spring and for connect what, select component Left Rail-1 & Left Rail-2.

fig: SPOT WELD WITH SPRING AND RIGID ELEMENTS

9. Rest all the component left Join them with suitable connectors

Creating welds between the geometry for the two front trusses. Access the Spot panel and go to the spot subpanel. Verify that the current component is "Con Frt Truss". Switch the location entity selector to points and select the six pre-defined weld points by selecting points by collector and selecting the component. Click comps and select the Front Truss 1 and Front Truss 2. For connect what toggle elems to geom and for tolerance = specify 5. The connector will connect any selected entities within this distance itself. For type select weld and click create.

fig: FRAME ASSEMBLY

CONCLUSION -

1. Achieved an error free connections between different components of frame assembly.
2. Performed a quality check for the connectors.

LEARNING OUTCOMES -

1. Understanding different types of connections available in hypermesh.
2. Gained knowledge about the properties of connectors.