Week 9-Creation of 1D Connectors Challenge

AIM

 To mesh the given geometry and create 1D connectors at desired locations using Hypermesh.
        The following connections 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 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

PROCEDURE:

• Import the .hm model .

• Each individual component is separated and meshed separately.

• If required, the components can be cleaned for topological errors and defeatured using the manual cleanup method.

2D surface Meshing & Mesh refinement

• To generate a shell mesh over each component:
• 2D - auto mesh - surfs (displayed) - target length=5 - specify elem type and order - mesh

. However, to achieve a perfect mesh without quality errors the comp is sectioned into different surfaces using the surf trim option and meshed separately

• Since volume tetras aren't being generated, the surfaces can mesh with quads majority.

.Check for the quality criteria for the mesh.

. Similarly, symmetrical components can also be trimmed about the midpoint and meshed and reflected about the central axis
. Finally, all components have been meshed using 2D elems (trias and quads)

 

1D Connections

1. Seam-Quad(angled-capped+L)

For: Right Rail_2 & Front_truss_1• To create a seam weld: Connectors - seam
• Select the nodes (by path) on one of the components
• tolerance = Specify the search distance (10mm)
• Select the two components and keep the imprint check on
• weld type is set as seam-quad (angled+capped+L)
The welded angle can be altered but an angle of 60 or 45 is widely 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. Seam-Quad elements

For: Left Rail_2 & Front truss 1
• To create a seam weld: Connectors - seam
• Select the nodes (by path) on one of the components
• tolerance = Specify the search distance (10mm)
• Select the two components and keep the remesh check on
• weld type is set as a quad and the spacing (distance between the two adjacent weld elements) is kept as 5mm

3. Spot weld with 3 Layers and 5 mm Diameter

Front truss 2. Front_truss 1 & Right Rail 1
• 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 a number of layers as 3.
• NOTE: Since the layer is set as 3, a minimum of three components have to be selected and in case only two components are present then the layer has to be set as 2.4. Hexa (Adhesive)

For: Front truss 2, Front truss 1 & Left_Rail 1

• To create a seam weld: Connectors - seam
• Select the nodes (by path) on one of the components
• tolerance - Specify the search distance (20mm)
• Select the two components 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 be altered. In this 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: Connectors - bolt
Specify the location of the bolt by selecting two single nodes at a certain distance in one of the components since two-bolt connectors are being realized
. Select the two components which have to be fixed by the bolt.
• Select the option to create a hole to define the bolt as a physical element (Note that this will modify and alter the neighboring mesh)
Specify the search length (about 10mm)
. The realized bolt connection is shown below.

6. For: Rear_truss_2 & Left_Rail_2

• To create a bolt connector: Connectors - bolt
• Specify the location of the bolt by selecting two single nodes at a certain distance in one of the components since two-bolt connectors are being realized

• Select the two components which have to be fixed by the bolt.
• Select the option to create a hole to define the bolt as a physical element (Note that this will modifyand alter the neighboring mesh)
• Specify the search length (about 10mm)
. The realized bolt connection is shown below.

7. Spot-weld with Rigid Elements

For: Right_Rail_1& Right_Rail_2
• As similar to previous spot weld creation, this spot weld is created using rigid instead of weld
• To create a spot weld: 2D - connectors - spot - type=rigids
. Select all the required nodes where the location of the spot weld has to be placed (by path)
• Then select all the 2 components
Specify the diameter and number of layers as 2 (since only two components are present)

8. Spot-weld with Spring Elements

For: Left_Rail 1 & Left Rail 2
Similarly as done for the previous case, here the spot element type is set as spring instead of rigid or
weld.

9.
After all the given connections check the remaining important that are still lef with no connections.
Connect them with the suitable connections

 

CONCLUSION:

. Hence every component has meshed and required connections have to be defined and successfullyrealized.

• Finally, the entire connections and meshed components are shown below

Learning Outcomes
• Connecting the two components as per the requirement
• knowing about different connections and where it is used between the components