Week 9 - Creating connection for Rear door

Report on creating connection for rear door FE model by using ANSA software (week 9 challenge).

Aim:

The main aim is to learn how generate the necessary connections for rear door FE model like RBE2 (for Bolt and spot weld connection), CONMi (for door handle) and RBE3-CBUSH-RBE3 (for glass) (without doing changes in given FE model as per given instruction).

Procedure with FE model images:

• The following figures shows below outside view and inner view of rear door FE model.

Fig. 1: OUT SIDE VIEW OF REAR DOOR FE MODEL.

FIG.2: IN-SIDE VIEW OF REAR DOOR FE MODEL.

• RBE2 CONNECTION: The NAS deck module is used for connection purpose. In this RBE2 option is available in elements group for connection purpose.
• After selecting RBE2 option it will ask you to select slave nodes as shown in fig.3 below.
• Then after entering next button it will ask for master node to select, if it is created then select the same for further procedure or else it will automatically generate the same as shown in fig. 4 below.

FIG.3. RBE2 MANY NODE CARD PRESENTATION.

FIG.4. RBE2 MANY NODE CARD FOR MASTER NODE SELECTION.

• Entering the next button it will show the entity creation card, in that the details of element id, grid no., and no. of nodes etc. information is there as shown in fig.5 below.
• After entering finish button it will generate RBE2 connection in a spider type view as shown in fig.5 below.

FIG.5. RBE2 MANY NODE CARD FOR ENTITY CREATION.

• By using similar procedure I have generated multiple RBE2 connections as shown in figs. below.

FIG.6. RBE2 FOR BOLT CONNECTION.

FIG.5. RBE2 FOR CONNECTION WITH RBE2 MANY NODES CARD.

FIG.6. CLUSTERED RBE2 BOLT CONNECTION.

• RBE2 BOLT WITH STEM REPRESENTATION CONNECTION: In this type of connection the bolt stem is visible in the form of single yellow line and other are in spider structure as shown in fig. below.
• For this type of connection first I had to create COG point at bolt centre. For that I have used ‘ON COG’ option in point group which is available in topo module.

FIG.7. POINT ON COG FOR BOLT CONNECTION.

• After getting COG point at bolt location, it has to be converted into bolt type connection using convert option which is available in assembly menu as shown in fig.8 below.

FIG.8. COG POINT TO BOLT TYPE CONNECTION CONVERSION.

• After pressing ok by selecting bolt type it will convert into bolt symbol as shown in fig.9 below.

FIG.9. COG POINT TO BOLT TYPE CONNECTION CONVERSION.

• For further process connection manger is to be use for completing connection which is available in the same menu as shown in fig. below.

FIG.10. CONNECTION SELECTION ASSISTANT FOR BOLT CONNECTION.

• By selecting and pressing middle click connection manager window will pop-up as shown in fig below.

FIG.11. CONNECTION MANAGER FOR BOLT CONNECTION.

• In connection manager, input is given as a bolt in FE rep. setting and there after selecting P1, P2 and P3 as part of surfaces over bolt is attaching.
• For selecting parts, press right click over P1 and press f1 for selecting individual parts.

FIG.12. INPUTS IN CONNECTION MANAGER FOR BOLT CONNECTION.

• As shown in fig below individual part is selected by repeating same procedure.

FIG.13. INPUTS IN CONNECTION MANAGER FOR BOLT CONNECTION.

• Then input is given in zones section as In/Out X as shown below.

FIG.14. INPUTS IN CONNECTION MANAGER FOR BOLT CONNECTION.

• After pressing apply and realize the bolt representation will show in spider and yellow line as shown in fig. below.

FIG.15. BOLT CONNECTION REPRESENTATION AS SPIDER STRUCTURE AND YELLOW LINE VIEW.

• Similar procedure is followed for other bolt connections.
• RBE2 WITH HINGE (PIN) CONNECTION FOR DOOR AND BODY CONNECTING LINK:
• Here first RBE2 connections are made in connecting link hole portion as shown in fig below.

FIG.16. RBE2 MANY NODE CONNECTION.

FIG.17. RBE2 MANY NODE CONNECTION.

• The hinge connection is made using RBE2 two node selection mode as shown in fig below.

FIG.17. RBE2 TWO NODE CONNECTION FOR HINGE PORTION.

• After selecting two nodes for hinge the RBE2 card will show for confirmation and name assignment as shown in fig below.

FIG.18. RBE2 TWO NODE CONNECTION FOR HINGE PORTION.

• In this card I had freed rotational movement along Z-axis by removing 6^th degree of freedom as shown in fig. below.

FIG.19. RBE2 CARD FOR HINGE PORTION.

FIG.20. RBE2 WITH HINGE (PIN) CONNECTION FOR DOOR AND BODY CONNECTING LINK.

• Similarly two bolt connecting holes are made rigid using RBE2 many nodes option as previously done before as shown below.

FIG.21. RBE2 WITH HINGE (PIN) CONNECTION FOR DOOR AND BODY CONNECTING LINK.

• SPOT WELD FOR CONNECTION:
• In spot weld connection two, three or max four different surfaces are joint.
• The initial procedure is to create centre point at location where spot welding is to be done. The similar procedure is used for creation of centre point as shown in fig. below.

FIG.22. CENTRE POINT CREATION FOR SPOT WELD CONNECTION.

• In connection type selected as a spot weld point for further RBE3-HEXA connection.

FIG.23. CONNECTION TYPE FOR SPOT WELD CONNECTION.

FIG.24. SPOT WELD CONNECTION POINT.

• Connection selection assistant for spot weld point selection.

FIG.25. CONNECTION SELECTION ASSISTANCE.

• After selecting spot weld point connection manager will pop up for input information like FE Rep Type, search distance, P1, P2, P3 etc. as shown in fig. below.

FIG.26. CONNECTION MANAGER FOR INPUT INFORMATION.

• After giving input information and realizing the same it will replicate RBE3 HEXA connection as shown in fig. below. (Similar procedure is done before for RBE2 bolt connection.)

FIG.26. CONNECTION MANAGER WITH RBE3 HEXA SPOT WELD CONNECTION.

FIG.27. RBE3 HEXA SPOT WELD CONNECTION.

• Similarly other spot weld connections are done using the same procedure for many areas.

• RBE2 WITH CON MASS CONNECTION FOR HANDLE :
• The rigid connections are made using RBE2 many nodes procedure which is previously done as shown in figs. Below.

FIG.27. MANY NODES RBE2 CONNECTIONS.

FIG.28. MANY NODES RBE2 CONNECTIONS.

• After doing many nodes connections the con mass has to be added to replicate handle.
• Using RBE2 many node connection the two master nodes of RBE2 connection are connected as shown in fig. below.

FIG.29. MANY NODES RBE2 CONNECTION.

• For applying con mass, CONMi option is used which is available in ELEMENTs group as shown in fig below. After selecting CONMi2 as centre point and confirming it by middle click the CONMi2 card will pop up on display.
• There I had edited name as handle and entered mass value as 100g in terms of ton unit i.e. 1e-4 as shown in fig. below.

FIG.30. CONMi for mass replication.

• After entering ok the mass will replicate in dark pink colour as shown in fig. below.

FIG.31. CONMi FOR MASS REPLICATION OF HANDLE.

• RBE3 CBUSH CONNECTION FOR DOOR GLASS :
• First step is to create curve on perimeter of the glass.
• Feat2curve option is used which is available in perimeters group in mesh module.

FIG.32. CURVE CREATION ON THE PERIMETER OF A GLASS.

• Hence the curve is created as shown in fig below.

FIG.33. CREATED CURVE AT GLASS PERIMETER LOCATION.

• Also at bottom another horizontal curve is generated by using transform copy operation as shown in fig. below.

FIG.34. HORIZONTAL CURVE AT BOTTOM FOR RBE3-CBUSH CONNECTION.

• This curve is converted into spot line connection type using convert option.

FIG.35. CONNECTION TYPE FOR RBE3-CBUSH CONNECTION.

• Then spot line is selected for further RBE3 CBUSH connection by middle click and in connection manager parts are selected and other input like FE Rep as RBE3-CBUSH-RBE3, search dist as 50 are given for further procedure.
• After confirming for apply and realize the RBE3-CBUSH connection are visible at bottom perimeter of glass.

FIG.36. CONNECTION MANAGER WITH CBUSH REPRESENTATION AT GLASS BOTTOM.

• Similarly at other perimeter of glass RBE3 CBUSH connections are made as shown in fig below.

FIG.37. CONNECTION MANAGER WITH RBE3 CBUSH REPRESENTATION AT GLASS PERIMETER.

LEARNING OUT COMES:

• In this rear door connection creation process the different type of connections are made using multiple commands. Here I have learned how to create rigid bolt (RBE2), spot weld (RBE3-HEXA-RBE3), and RBE3 CBUSH connection between door glass and frame, and Con mass connection for handle. Also how to apply hinge connection for connecting door and car body.

CONCLUSION:

The conclusion are made on the basis of connection types, purpose of each connection for their visual Representation and for identifying the connections for further work. Hence the connection is one of the important part in learning of pre-processing of ANSA software.