Week 9-Challenge

AIM:

To create connectors on respective areas of a mid surface model inorder to connect or rigidize the model.

PROCEDURE:

• Import the .STEP file from the file source folder. Use the option Import from geometry  
                                         
• In this model, 2D mesh need to performed with the given element size.
• Ensure that on meshing look for the hole areas to avoid trias from free edge.
• After the meshing is complete, remesh the surface to get a proper mesh flow.
• In this model certain connections need to be created on some areas of the model to achieve rigid connections.
• Connectors are geometric entities which are primarly used to represent the CAD geometric connection in terms of FEA.
• The model is divided into sub surfaces, inorder to have rigid connection. Below image shows a clear idea of the model

          

• In Right_Rail_2 & Front_truss_1 perfrom Seam-Quad(angled+capped+L) connection.

Steps to perform Seam-Quad(angled+capped+L) connection are:

1. Select 1D/2D-> Connectors->Seam option
2. Now select the location, where the weld has to be created by clicking the Node list
3. Tick the checkbox of retain nodes option to retain the position of the nodes , while creating and realizing a connector
4. Specify the spacing value and select the comps option under connect what, inorder to create the weld between those two components
5. Specify the tolerance value based on the distance between the two components
6. Select the type as Seam-Quad(angled+capped+L) 
7. Click on the create button to create the seam weld. 
8. After completion of the seam weld , the components will connected shown as below

    In Seam weld connections there are main 3 terms need to note about
                      Weld Angle: The angle between the normal projection of nodes and slant length of the weld elements
                                         

                     CAP angle: Angle between the normal of the first slant weld element (A) and its adjacent side elements (B) 
                                   

                     Run off angle : Angle between the first slant weld element and its adjacent wel elements

                                    

 In Left_Rail_2 & Front_truss_1 perform Quad connection

Steps to perform Quad connection are:

• Select 1D/2D-> Connectors->Seam option
• Now select the location, where the weld has to be created by clicking the Node list

• Specify the spacing value and select the comps option under connect what, inorder to create the weld between those two components
• Specify the tolerance value based on the distance between the two components
• Select the type as Quad connection 
• After completion of the seam weld , the components will connected shown as :

In Front_truss_2, Front_truss_1 & Right_Rail_1 perform Spot weld with 3 Layers and 5 mm Diameter

Steps to perform Spot weld connection are:

1. Select 1D/2D-> Connectors->Spot option
2. Now select the location, where the weld has to be created by clicking the Node list
3. Tick the checkbox of retain nodes option to retain the position of the nodes , while creating and realizing a connector

1. Specify the spacing value and select the comps option under connect what, inorder to create the weld between those two components
2. Specify the number of layers and diameter
3. Specify the tolerance value based on the distance between the three components
4. Select the type as weld
5.  After completion of the spot weld, the components will connected shown as :

In Front_truss_2, Front_truss_1 & Left_Rail_1 perform Hexa (Adhesive) 

Steps to perform Hexa (Adhesive) connection are:

1. Select 1D/2D-> Connectors->Seam option
2. Now select the location, where the weld has to be created by clicking the Node list
3. Tick the checkbox of retain nodes option to retain the position of the nodes , while creating and realizing a connector
4. Specify the spacing value and select the comps option under connect what, inorder to create the weld between those two components
5. Specify the tolerance value based on the distance between the three components
6. Select the type as Hexa (Adhesive)
7. Perfrom Hexa adhesive connection as follows:

In Rear_truss_2 - Right_Rail_2 and  Rear_truss_2 - Left_Rail_2 perform Bolt Connector

Steps to perform Bolt Connector connection are:

1. In order to create a Bolt connection, first change the optistruct to Radios mode. Then only Bolt connection will get deployed on the surface
2. Here 2 surface is not having holes, so hole need to be created
3. Click 1D/2D-> Connectors->Bolt option
4. Under location select the node which we create to establish the Bolt connnection
5. Slect the comps in order to create Bolt connection
6. select the number of layers to be welded under the "num layers" option
7. Specify the tolerance value based on the distance between the two components
8. Select the type as Bolt general
9. Specify if hole is not available, change the option to "create a hole, if none".
10. Perfrom Bolt Connector connection as follows:

            

In Right_Rail_1 & Right_Rail_2  perform Spot-weld with Rigid Elements
Steps to perform Spot-weld with Rigid Elements are:

1. Select 1D/2D-> Connectors->Spot option
2. Now select the location, where the weld has to be created by clicking the Node list
3. Tick the checkbox of retain nodes option to retain the position of the nodes , while creating and realizing a connector
4. Specify the spacing value and select the comps option under connect what, inorder to create the weld between those two components
5. Specify the tolerance value based on the distance between the three components
6. Select the type as "Rigid"
7. Perfrom Rigid connection as follows:
      

 In Left_Rail_1 & Left_Rail_2 perform Spot-weld with Spring Elements:

Steps to perform Spot-weld with  Spring Elements are:

1. Select 1D/2D-> Connectors->Spot option
2. Now select the location, where the weld has to be created by clicking the Node list
3. Tick the checkbox of retain nodes option to retain the position of the nodes , while creating and realizing a connector
4. Specify the spacing value and select the comps option under connect what, inorder to create the weld between those two components
5. Specify the tolerance value based on the distance between the three components
6. Select the type as "Spring"
7. Perfrom Spring connection as follows :

         

In other areas Spot weld and Seam weld connections are generated:

CONCLUSION:

The given model of frame assembly which is made of different parts have been connected together using various 1D connections and made it rigidised.