Week 9-Creation of 1D Connectors Challenge

AIM:

Mesh the given Component with a Mesh size of 5mm.Create connector and Attach the various parts of the given model.

METHODOLOGY:

Methodology to perform Meshing the given Component with a Mesh size of 5mm.

Create connector and Attach the various parts of the given model

1. IMPORT MODEL
2. DELETE SOLIDS
3. GEOMETRY CLEANUP
4. MESHING
5. CREATING CONNECTOR

PROCEDURE:

1. IMPORT MODEL:

• Import the given model into hypermesh.
• Importing model may not be possible if the file format is not supported by the hypermesh.

2.DELETING SOLIDS:

• Before generating 2D mesh for the components then the solids should be deleted.
• It can be done by using the delete tool and select solids and select all to delete all solids from the component.

3.GEOMETRY CLEANUP:

• After importing the model the main process is geometry cleanup.
• In some cases if the model is imported to hypermesh due to some graphical issues the geometry changes may occur, So geometric cleanup plays an important role.
• Remove all unnecessary lines from the model.
• Check if any surface is missing or overlapped.If any surface is missing, create a new surface over there by using a surface tool or filler surf tool.

• If two surfaces are not stretched together then use a toggle edge tool to stretch together.
• By using the toggle edge tool the feature lines can be suppressed for the better mesh generation.

4.MESHING THE COMPONENT:

• For the given housing model to perform the meshing select 2D.
• In 2D by using AUTOMESH tool mesh is generated.
• Before meshing, always assign the quality criteria.
• Select the whole surface to generate quads mesh and proceed with the meshing.
• After meshing, check the failure elements and solve the failure elements by using cleanup tools.
• After creating connectors between the components the meshflow may change.
• So after creating the connector check the mesh flow.

5.CREATING CONNECTOR :

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

• Select seam from connectors in 2D.
• From seam select Seam-Quad(angled+capped+L).
• Select the nodes where seam weld should be required and switch on the retain nodes.
• Select the components.
• Mention spacing and tolerance value.
• The spacing value is equal to the element size and tolerance is the distance between two components.
• Input weld angle, cap angle and runoff angle as required.
• Click on the create button, to create seam weld.

1. Left_Rail_2 & Front_truss_1:- Quad elements.

• Select seam from connectors in 2D.
• From seam select Quad.
• Select the nodes where quad should be required.
• Select the components.
• Mention spacing and tolerance value.
• Click on the create button, to create quads between components.

1. Front_truss_2, Front_truss_1 & Right_Rail_1:- Spot weld with 3 Layers and 5mm diameter.

• Select spot from connectors in 2D.
• Select weld tool from spot.
• Select the nodes for creating spot weld.
• Select the components.
• Input the tolerance value for realising the connector.
• Click on create, to create spot weld between components.

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

• Select seam from connectors in 2D.
• From seam select Hexa (Adhesive).
• Select the nodes where Hexa (Adhesive) should be required and switch on the retain nodes.
• Select the components.
• Mention spacing and tolerance value.
• The spacing value is equal to the element size and tolerance is the distance between two components.
• Input STRIPS, CODES and width value of adhesive to create.
• Click on the create button, to create Hexa (Adhesive).

1. Rear_truss_2 & Right_Rail_2:- Bolt Connector and Rear_truss_2 & Left_Rail_2:- Bolt Connector.

• Select bold connector.
• Select the centre node where bold is to be created.
• Select the components .
• Select numbers of layers to be weld and mention the value.
• Input tolerance value.
• Click the create button, to create bolts on components.

1. Right_Rail_1 & Right_Rail_2:- Spot-weld with Rigid Elements and Left_Rail_1 & Left_Rail_2:- Spot-weld with Spring Elements.

• Select spot from connectors in 2D.
• Select rigid tool from spot for spot weld with rigid elements.
• Select spring tool from spot for spot weld with spring elements
• Select the nodes for creating spot weld with rigid elements.
• Select the components.
• Select the remesh option instead of adjust realization in mesh dependent.
• Input the tolerance value for realising the connector.
• Click on create, to create spot weld with rigid elements between components.

SPOT WELD WITH RIGID ELEMENTS

SPOT WELD WITH SPRING ELEMENTS

LEARNING OUTCOMES:

• Meshing.
• Creating suitable connectors between the components.

RESULT:

Meshed the given Component with a Mesh size of 5mm, And created connector and Attached the various parts of the given model successfully.