Challenge

Week 9-Creation of 1D Connectors Challenge

Aim: To mesh the given geometry and create 1D connectors at desired location using Hypermesh.

As per below mentioned Element Quality-

Target Element Size-5 Units

Procedure:

Setting up model

All the components are seperated and meshed.
If required, the component can be cleaned for topological errors and defeatured using manual or auto clean upmethod.

2D Surface Meshing & Mesh Refinement:

To generate a mesh over each component we will go to 2D then Automesh then selecting the surface as displayed and setting up target element length to 5 and specifing the mesh type and order then meshing the component.
However to achive a perfect mesh without quality errors the component is sectioned into different surfaces using surface trim option and meshed separately.

Assigning property card:

A Single property and material card is added for every component.
Assuming every component has the identical thickness and material, a single card is added to each.
To Create material card we will right click on model tab then create material name it as steel.
Then the necessary material values like poissions ratio, youngs modulus etc are specified.
The thickness of the component is also specified in the property card itself.

1D Connections:

1. Seam-Quad (Angled +Capped+L)

For: Right_Rail_2 & Front_Truss_1

To create a seam weld we will go to 3D then connectors then seam.
Then we will be selecting the nodes (by path) on one of the component.
Put tolerance specify the search distance (10MM)
Select the two components and keepthe imprint check on.
Weld type is set as Seam-Quad (Angled+Capped+L)
The Weld angle can be altered but an angle of 60 or45 is widely prefered based on alignment of the two components.
The spacing is set as 5mm, spacing defines the distance between the two adjecent weld elements.

2.Seam-Quad elements

For:Left_Rail_2 & Front_truss_1

To create a seam weld we will again go to 3D then connectors then seam.
Then selecting the nodes by path on one of the components
we will put tolerance of 10mm.
Then selecting the two components and keep the imprint check on.
Weld type is set as quad and the spacing that is distance between the two adjecent weld elements is kept as 5 mm.

3. Spot weld with 3 Layers and 5mm Diameter

Front_truss_2,Front_Truss_1 & Right_Rail_1

To Create a spot weld we will go to 2D then connectors then spot then going to type as weld.
Select all the required nodes where the location of the spot weld has to be placed and also keeping the tolerance as 10 and spacing as 5mm.
Then select all the 3 components.
specify the diameter as 5mm and number of layer as 3.

4.Hexa (Adhesive)

For: Front_truss_2,Front_truss_1 & Left_Rail_1

To create this we will go to option 3D then connectors then seam.
Select the nodes (by path) on one of the component.
And keeping the tolerance as 10mm then selecting the two components and keeping the imprint check on. then set weld type as hexa(adhesive) under the weld type category.
The strips and coats of the weld can be altered.In this perticular 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 we will go for 3D then we will go to connector then selecting bolt.
We will select two single nodes on the surface at thecertain distance in one 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 one thing to noted is that it will modify and alter the neighbouring mesh.

6. For: Rear_truss_2& Left_Rail_2

7. Spot-Weld with Rigid Elements

For:Right_Rail_1 & Right_Rail_2

It is similar operation to spot weld creation, this spot weld is created using rigids instead of weld.
To create a spot weld we will go to connectors then spot then selecting type as rigids.
Selecting the required nodes where the location of the spot weld has to be placed.
Then selecting both the component.
Specify the diameter and number of layer.

8. Spot Weld with Spring Elements

For: Left_Rail_1 & Left_Rail_2

It is also similar operation as of the previous one, this spot weld created using spring instead of weld.
To create we will go to connector then spot then selecting the type as spring.
Now will select all the required nodes.
And also selecting both components on which this operation needs to be carried out.

9. For other Components

In case of shell component with the hole, a hex (adhesive) connection is made.
To create this we will selecting the connector then seam then selecting the nodes on one component and specifying the tolerance as 50mm then selecting the two components.
checking the weld type as hexa (adhesive) under weld type category.

Conclusion:

Here we understand how to provide different types of connectors on the components.

Ship work like this
in your own course.