Week 9-Creation of 1D Connectors Challenge

2D Meshing of Frame and 1D Connector

AIM:

To generate a 2D mesh for the given model after clearing the geometrical errors present in the model followed by meshing with the given Quality Criteria and finally providing specified connections.

PROCEDURE:

Geometry Import:

First, the Hood model has been imported to the Hypermesh software using the IMPORT MODEL option from the IMPORT tab. Figure 1 shows the model imported into hypermesh software.

Fig. 1 The model imported into Hypermesh Software

Geometry Clean-up:

The model has been cleared for geometrical errors using the AUTO CLEAN UP option from the GEOMETRY menu with the default parameters and criteria. The below figure provides a visual aid for the cleared geometry.

Fig. 2 Auto clean-up performed.

The blue dotted/toggled lines in the model show the geometry clean-up carried out where the unnecessary lines were suppressed to make the model easy to meshing. Since the given model is symmetrical, one-half of the model was deleted so that after meshing is completed it can be mirrored.

Meshing:

After auto clean-up, meshing has been carried out on the model with the following mesh parameters shown in figure 3.

Fig. 3 Mesh Parameters.

The mesh was carried out using the AUTOMESH option from the 2D menu bar. Figure 4 shows the mesh created on the surface.

Fig. 4 Surface Meshed.

Quality Checks:

After mid-surface meshed, quality checks have to be performed and the mesh should be free from quality errors. Figure 5 shows the Quality Criteria set for the given model.

Fig. 5 Quality Criteria Check.

The quality check was performed and quality errors were cleared. The mesh model free from quality error is shown the figure 6.

Fig. 6 Quality Checks performed on the mesh.

Fig. 7 Quality cleared on the mesh.

After clearing all the quality issues, elements norma; were checked using the NORMAL option from the TOOL menu.

Fig. 8 Final Meshed Model with CAD Geometry.

CONNECTIONS:

Seam-Quad (angled+capped+L):

The seam L angled weld connection was provided using the SEAM - SEAM-QUAD (ANGLED+CAPPED+L) type by selecting the node list and the two components needed to be seam welded from the CONNECTORS tab under the 1D menu. This type of connection is given for the specified components. A Separate Component Card was created for assigning the seam weld elements.

Fig. 9 Seam Welded (angled+capped+L) components.

Fig. 10 Seam L angled weld option.

Seam-Quad Elements:

The seam quad weld connection was provided using the SEAM - QUAD type by selecting the node list and the two components needed to be seam welded from the CONNECTORS tab under the 1D menu. This type of connection is given for the specified components. A Separate Component Card was created for assigning the seam weld elements.

Fig. 11 Seam Quad Welded components.

Fig. 12 Seam Quad weld option.

Spot Weld with 5mm diameter:

The spot weld connection was provided using the SPOT – RIGID/SPRING type by selecting the node list and the two components needed to be spot welded from the CONNECTORS tab under the 1D menu. This type of connection is given for the specified components. A Separate Component Card was created for assigning the spot weld elements.

Fig. 13 Spot Welded components.

Fig. 14 Spot weld option.

Hexa (adhesive):

The Hexa adhesive connection was provided using the SEAM – HEXA (ADHESIVE) type by selecting the node list and the two components needed to be connected from the CONNECTORS tab under the 1D menu. This type of connection is given for the specified components. A Separate Component Card was created for assigning the adhesive elements.

Fig. 15 Spot Welded components.

Fig. 16 Seam adhesive option.

Bolt Connector:

The bolt connection was provided using the BOLT – BOLT(GENERAL) type by selecting the node list and the two components needed to be connected with the option of CREATING HOLES IF NON from the CONNECTORS tab under the 1D menu. This type of connection is given for the specified components. A Separate Component Card was created for assigning the bolt elements.

Fig. 17 Bolted components.

Fig. 18 Bolt connector option.

Spot Weld with Rigid Elements:

The spot weld connection was provided using the USING ELEMENTS/NODES – RIGID type by selecting the elements and node list of the two components that needed to be spot welded from the SPOTWELD tab under the 1D menu. This type of connection is given for the specified components. A Separate Component Card was created for assigning the spot weld elements.

Fig. 19 Spot Welded components.

Fig. 20 Spot weld option.

Spot Weld with Rigid Elements:

The spot weld connection was provided using the USING ELEMENTS/NODES – SPRING type by selecting the elements and node list of the two components that needed to be spot welded from the SPOTWELD tab under the 1D menu. This type of connection is given for the specified components. A Separate Component Card was created for assigning the spot weld elements.

Fig. 21 Spot Welded components.

Fig. 22 Spot weld option.

Other Connections:

Spot weld – CWELD:

The spot weld connection was provided using the USING ELEMENTS/NODES – CWELD type by selecting the elements and node list of the two components that needed to be spot welded from the SPOTWELD tab under the 1D menu. This type of connection is given for the specified components. A Separate Component Card was created for assigning the spot weld elements.

Fig. 23 Spot Welded components.

Fig. 24 Spot weld option.

Seam-Hexa(RBE2-RBE3) Elements:

The seam Hexa weld connection was provided using the SEAM – HEXA(RBE2-RBE3) type by selecting the node list and the two components needed to be seam welded from the CONNECTORS tab under the 1D menu. This type of connection is given for the specified components. A Separate Component Card was created for assigning the seam weld elements.

Fig. 25 Seam – Hexa (rbe2-rbe3) connection for Front Truss 1&2 and Reinforcement Plate.

Fig. 26 Seam – Hexa (rbe2-rbe3) connection option.

Fig. 27 Final Model with mesh and connections.

RESULTS:

The given model has been cleared for geometrical errors and meshed for the specified mesh criteria. Then the model has been removed for all the quality issues for the given quality criteria. Finally, the model is passed for all the given quality parameters, and connections were provided as per the given data.