Week 9-Creation of 1D Connectors Challenge

To create various types of 1-D connectors using hyperworks for given component

Aim :- To mesh the component withing given quality parameters and connect all the parts with following connector

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 3 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

Software used :- Hyperworks 2020 – student version

Methodology :-

1. Import given CAD model to hyperworks.
2. Check and rectify geometric errors.
3. Meshing as per given quality criteria.
4. Establishing connections as mentioned in given problem statement.
5. Realizing and debugging connections.

Procedure :-

1. Import given CAD model to hyperworks :- Import given model into hyperworks, given model is in .hm format so we can directly open the model.

2. Check and rectify geometric errors :- After importing model gets geometric errors like surface missing, surface duplication, etc. so we have to cleanup geometric errors. These errors are cleaned by manually or automatically by Geometric > autoclean > select target element leangth up > select model > autocleanup option option.

Here, no any errors are found so we can move further.

3. Meshing as per given quality criteria :- Here, I used automesh for meshing. Before meshing need to assigned the quality parameters by Toolbar > Preference > Criteria file settings > Assign the given values as shown in image below.

Mesh the surface part by part by using 2D > Automesh > select surface > select mesh size 5 mm > mesh option as shown in image below. After meshing need to check elements which are violating thresholds, for that go to 2D > Quality index option it will highlight the elements which are not as per assigned quality criteria. For eliminating these elements need to use 2D > Quality index > Cleaning tool option in that we can use smooth, element optimization, node optimization, place node, drag tria element, combine tria element, etc options.

4. Establishing connections as mentioned in given problem statement.

1. Right_Rail_2 & Front_truss_1:- Seam-Quad( angled + capped + L ) :- Visible only FE model of right rail 2 and front truss 1 and establish angled + capped + L connection by following steps –

• Open Connectors panel in 2D menu.
• Select components to be connected.
• Select Seam-Quad( angled + capped + L ) option.
• Select nodes path
• Select components to be connected
• Define proper tolerance and click on create option the connection is established

2. 2. Left_Rail_2 & Front_truss_1:- Quad elements :- Hide all components except Left_Rail_2 & Front_truss_1 and deploy Quad elements connection by following steps –

• Select seam weld option in connector panel
• Select nodes by path for connectors to be deployed
• Select component
• Select weld type as quad element
• Define tolerance as 20 and click on create option and connection is established

3. Front_truss_2, Front_truss_1 & Right_Rail_1:- Spot weld with 3 Layers and 5 mm Diameter :- Hide all components except Front_truss_2, Front_truss_1 & Right_Rail_1 and deploy Spot weld with 3 Layers and 5 mm connection by following steps –

• Select spot weld option in connector type
• Select nodes by path
• Select components to be connected
• Select spot weld type as weld
• Define tolerance as 10
• Define diameter as 5mm and layers as 3 and click on create it will established connection

4. Front_truss_2, Front_truss_1 & Left_Rail_1:- Hexa (Adhesive) :- Hide all components except Front_truss_2, Front_truss_1 & Left_Rail_1 and deploy Hexa (Adhesive) connection by following steps –

• Select seam weld option in connector type
• Select nodes by path
• Select components to be connected
• Select type as Hexa (Adhesive)
• Click on create tab it will generate adhesive connection.

5. Rear_truss_2 & Right_Rail_2:- Bolt Connector :- Hide all components except Rear_truss_2 & Right_Rail_2and deploy bolt connection by following steps –

• Select bolt option in connector type
• Select nodes by path
• Select components to be connected
• Select type as Bolt (general)
• Select create hole, if none option
• Click on create tab it will generate Bolt connection.

6. Rear_truss_2 & Left_Rail_2:- Bolt Connector :- Hide all components except Rear_truss_2 & Left_Rail_2 and deploy bolt connection by following steps –

• Select bolt option in connector type
• Select nodes by path
• Select components to be connected
• Select type as Bolt (general)
• Select create hole, if none option
• Click on create tab it will generate Bolt connection.

7. Right_Rail_1 & Right_Rail_2:- Spot-weld with Rigid Elements :- Hide all components except Right_Rail_1 & Right_Rail_2 and deploy Spot-weld with Rigid Elements connection by following steps –

• Select spot weld option in connector type
• Select nodes by path
• Select components to be connected
• Select type as rigid element
• Select number layers as 2 or auto and select tolerance as 10
• Click on create tab it will generate Spot-weld with Rigid Elements connection.

8. Left_Rail_1 & Left_Rail_2:- Spot-weld with Spring Elements:- Hide all components except . Left_Rail_1 & Left_Rail_2and deploy Spot-weld with Spring Elements connection by following steps –

• Select spot weld option in connector type
• Select nodes by path
• Select components to be connected
• Select type as Spring Elements
• Select number layers as 2 or auto and select tolerance as 10
• Click on create tab it will generate Spot-weld with Spring Elements connection.

9. Rest all the component left Join them with suitable connectors :- For the rest of components connection I had given spot weld connections and for holes RBE2 spider connection, as shown in image below

Final View of model :-

Conclusion :- Thus, the given CAD model is completely meshed and established proper connection in it and model is ready for further post-processing and solving.