Challenge

Week 9-Creation of 1D Connectors Challenge

AIM :

To Mesh the given geometry and create 1D connectors at desired locations using Hypermesh.
The following connection have to be realized in each respective component.
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.

IMPOARTANCE :

Connectors are geometric entities primarily used used to create Spot and Seam welds, but also used to create adhesives,bolts and masses.They are mainly used to define which parts of a model have to be fastended to each other and how connections have to be performed.The connectors can take into account the mechanical and structural condition of the model.

PROCEDURE :

First , we need to import the given model and the connector points in the model tree are hidden while meshing.

Each indiviual components is separted and meshed separetly.
If required , the component can be cleaned for topological errors and defeatures using manual or autocleanup method.
To cleanup geometrical errors : GEOM > AUTOCLEANUP > SET PARAMETER > CLEAN.

2D Surfae Meshing :

To generate a shell mesh over each component.2D > AUTOMESH > SURF (DISPLAYED) > TARGET = 5 > MESH.
However to acheive a perfect mesh without quality errors the comp is sectioned into different surfaces using surf trim option and meshed separetly.
The surface can be meshed with quads majority.

Similarly, symmetrical components can also be trimmed about the mid point and meshed and reflected about the central axis.

Assigning Property Card:

A single property and material card is added for every component.
Assuming every comp has the identical thickness and material , a single card is added to each.
Then the necessary material values like poission ratio, young's modulus etc.. are specified.
Similarly a new property card is created with the PSHELL card image and the above mat card is assigned to it.
The thickness of the comp are also specified in each property card.
Each card is assigned the perperty card which is linked to the material card.

1D Connections :

1. Right_Rail_2 & Front_truss_1:- Seam-Quad(angled+capped+L)

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 component and keep the imprint check on
Weld type is set as SEAM - QUAD ( angled + capped + L ).
The weld angle can be altered but an anle of 60 to 45 is widly 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.

2. Left_Rail_2 & Front_truss_1:- Quad elements

To create Seam weld : Connectors > Seam
Select the nodes (by path) on one of the components.
Tolerance = specify the search distance (10mm) . Select the two componets 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. Front_truss_2, Front_truss_1 & Right_Rail_1:- Spot weld with 2 Layers and 5 mm Diameter

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 layer as 2.

4. Front_truss_2, Front_truss_1 & Left_Rail_1:- Hexa (Adhesive)

To create a Seam weld : 2D > Connectors > Seam.
Select the nodes (by path) on one of the component.
Tolerance = Specify the search distance (10mm).select the two component 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 altered. In this case, the strip is set as 2 and a single coating is specified.

5. Rear_truss_2 & Right_Rail_2:- Bolt Connector

To create Bolt connectors : 2D > 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 is will modify and alter the neighbouring mesh ).
Specify the search distance as 10mm
The realized bolt connection is shown below.

6. Rear_truss_2 & Left_Rail_2:- Bolt Connector

To create Bolt connectors : 2D > 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 is will modify and alter the neighbouring mesh ).
Specify the search distance as 10mm
The realized bolt connection is shown below.

7. Right_Rail_1 & Right_Rail_2:- Spot-weld with Rigid Elements

As specified to previous spot weld creation , this spot weld is created using rigids instead of weld.
To create Spot weld : 2D > Connectors > Spot > Type = Rigids
Select all the required nodes (By path) where the location of the spot weld has to be placed.
Then select all the 2 components.specify the diameter and number of layer as 2

8. Left_Rail_1 & Left_Rail_2:- Spot-weld with Spring Elements

Similarly as done for the previous case, here the spot element type is set as spring instead of rigid or weld.
To create Spot weld : 2D > Connectors > Spot > Type = Spring
Select all the required nodes (By path) where the location of the spot weld has to be placed.
Then select all the 2 components.specify the diameter and number of layer as 2

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

In case of the shell element component with the hole. a adhesive connections is made.
Adhesives are RBE3 elements that distribute the load applied to its master node.
To create adhesives using area connector method.
2D > Connectors > Area > Type = Adhesive > Select elems and components > specify coat layer > Specify search tolerance > Create.

Similarly , a Seam weld is created on other components.
A Seam weld with a ( Vertical + angled )type is created as shown below.
2D > Connectors > Seam > Type = Quad ( Vertical +angled )
Then specify the weld angle as 45 degree and select the required elems and components .
The realized connection is shown below.

CONCLUSION:

Hence every components have been meshed and required connections have be defined and successfully realized.
Finally the entire connections and meshed components are shown below.

FINAL OUTCOME IMAGE :

Ship work like this
in your own course.