Week 9-Creation of 1D Connectors Challenge

AIM:- Creation of 1D Connectors

OBJECTIVE:-

For this challenge, you will have to mesh the given geometry. Provided below are the quality parameters that you have to follow.

Target Element size - 5 Units

Create connector and Attach the various parts of the given model 

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 weld with 2 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 with Spring Elements

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

OBJECTIVE 1:-

For this challenge, you will have to mesh the given geometry. Provided below are the quality parameters that you have to follow.

Target Element size - 5 Units

Aspect ratio: = 3.33

Skewnees = 0% failed

Warpage:= 0% failed

Minimum length 2units

0% failed

Maximum length 8 units

Objective:-2

Create connector and Attach the various parts of the given model 

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 weld with 2 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 with Spring Elements

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

Setting up model

• Import the .hm model and the connector points in the model tree are hidden while meshing

Each individual component is separated and meshed seperately.

If required, the components can be cleaned for topological errors and defeatured using manual or autocleanup method.

To clean geometrical errors: Geom - autocleanup - set parameters - clean

2D surface Meshing & Mesh refinement

To generate a shell mesh over each component:

2D - automesh - surfs (displayed) - target length =5 - specify elem type and order  - mesh

However to achieve a perfect mesh without quality errors the comp is sectioned into different surfaces using surf trim option and meshed separately.

Seam-Quad(angled+capped+L)

Right_Rail_2 & Front_truss

To create a seam weld: Connectors - seam

Select the nodes (by path) on one of the component

Tolerance = Specify the search distance (10mm)

Select the two components and keep the imprint check on

weld type is set as seam-quad (angled+capped+L)

The weld angle can be altered but an angle of 60 or 45 is widely preferred based on the alignment of the two components.

The spacing is set a 5mm. Spacing defines the distance between the two adjacent weld elements

 Seam- Quad elements

For: Left_Rail_2 & Front_truss_1

To create a seam weld: Connectors - seam

Select the nodes (by path) on one of the components

tolerance = Specify the search distance (10mm)

Select the two components and keep the imprint check on

weld type is set as quad and the spacing (distance between the two adjacent weld elements) is kept as 5mm

3.Spot weld with 3 Layers and 5 mm Diameter

Front_truss_2, Front_truss_1 & Right_Rail_1

To create a spot weld: 2D - connectors - spot - type=weld

Select all the required nodes where the location of the spot weld has to be placed.

Then select all the 3 components

Specify a diameter of 5mm and number of layers as 3.

NOTE: Since the layer is set as 3, a minimum of three components have to be selected and in case only two components are present then the layer has to be set as 2.

4. Hexa (Adhesive)

For: Front_truss_2, Front_truss_1 & Left_Rail_1

To create a seam weld: Connectors - seam

Select the nodes (by path) on one of the component

tolerance = Specify the search distance (10mm)

Select the two components and keep the imprint check on

weld type is set as hexa (adhesive) under the weld type category.

The strips and coats of the weld can be altered. In this case, the strip is set as 2 and a single coating is specified

5. Bolt Connector

For: Rear_truss_2 & Right_Rail_2 

To create a bolt connector: Connectors - bolt

Specify the location of the bolt by selecting two single nodes at a certain distance in one of the component since two bolt connectors are being realised.

Select the two components which has to be fixed by the bolt.

Select the option to create a hole to define the bolt as a physical element (Note that this will modify and alter the neighbouring mesh )

Specify the search length (about 10mm)

For: Rear_truss_2 & Left_Rail_2

. Spot-weld with Rigid Elements

For: Right_Rail_1 & Right_Rail_2

As similar to previous spot weld creation, this spot weld is created using rigids instead of weld

To create a spot weld: 2D - connectors - spot - type=rigids

Select all the required nodes where the location of the spot weld has to be placed. (by path)

Then select all the 2 components

Specify the diameter and number of layers as 2 (since only two components are present)

Spot-weld with Spring Elements

 For: Left_Rail_1 & Left_Rail_2

Similarly as done for the previous case, here the spot element type is set as spring instead of rigid or weld

CONCLUSION:

Hence every components have been meshed and required connections have be defined and sucessfully realized.

Finally the entire connections and meshed components are shown below.