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  1. Home/
  2. jeya soorya/
  3. CROSS CAR BEAM ASSEMBLY USING ANSA V20.1.4

CROSS CAR BEAM ASSEMBLY USING ANSA V20.1.4

OBJECTIVE: The main aim of this project is, To mesh the cross-car beam parts as per the quality criteria shown below. To provide necessary connections. To assign thickness. QUALITY CRITERIA: S.No  Quality Criteria  Value  1 Target/Average length   5 2 Minimum Length  3 3 Maximum Length â€¦

  • ANSA
  • jeya soorya

    updated on 20 Feb 2021

OBJECTIVE:

The main aim of this project is,

  • To mesh the cross-car beam parts as per the quality criteria shown below.
  • To provide necessary connections.
  • To assign thickness.

QUALITY CRITERIA:

S.No 

Quality Criteria 

Value 

1

Target/Average length  

5

2

Minimum Length 

3

3

Maximum Length 

7

4

Aspect 

3

5

Warpage

15

6

Skewness

45

7

Jacobian 

0.7

8

Minimum Quad Angle 

45

9

Maximum Quad Angle 

135

10

Minimum  Tria Angle 

30

11

Maximum Tria Angle 

120

10

Tria Percentage 

15

PROCEDURE:

GEOMETRY CLEAN UP AND MIDSURFACE EXTRACTION:

  • Imported the given .iges file in the ANSA work page.
  • In order to view the model geometry clearly, the perimeter length of 1mm is applied to the model using the mesh module --> perimeter--> length option.
  • Checked for orientation i.e. the upper part of the model should be in gray color meaning positive and the lower part in yellow color meaning negative.
  • The issues with orientation are cleared using the topo module-->faces-->topo.
  • The model is then subjected to a geometry checkup to check any free edges between the models, duplicate surface, irrelevant CONS using the option tools--> checks-->geometry.
  • The geometrical errors are fixed by using the Auto option and some are cleared manually.
  • Since the thickness of the parts remains constant, extracted the mid surface using the topo module-->faces--> mid surface--> skin, while keeping the parent geometry not getting deleted.
  • Geometry check-up is done and a property ID is created with their respective thickness.
  • By default, ANSA creates a steel material ID, which is defined so that the material is assigned to the model.
  • The surfaces are split accordingly to attain good mesh flow and to avoid element failures using mesh module--> macros-->cut option.
  •  
  •                                                                           1.Mid-surface

MESH GENERATION:

  • The Quality criteria are applied to the model using utilities--> Quality criteria as shown below,
  •                                                             2.Quality Criteria
  • Mesh parameters are applied as shown below, using utilities--> mesh parameter.
  •                                                       3.Mesh Parameter
  • The perimeter elemental length is applied to the model using the mesh module --> perimeter--> length option.
  • The split surfaces are meshed one by one using mesh module--> mesh generation--> Best option.
  • During meshing the opposite trias, back to back trias, tias present at the edges, rotational quads can be removed using shell mesh--> reconstruct option.
  • Trias present at edges, fillet areas, pattern formation, opposite trias can be avoided using split, swap, reconstruct, edge2 perimeter, Num +/- options.
  • The elements which fail for quality can be viewed by using the Draw mode toolbar --> hidden option and corrections are done for the elements which fail for quality.
  •                                                                             4.Meshed Model

THICKNESS ASSIGNMENT:

  • The thickness assigned to the model can be viewed using utilities--> quality criteria--> presentation parameters --> draw shell as solid.
  •                                                                          5.Thickened Model

CONNECTION:

  • In order to connect the model with appropriate connections, here the bolt connections and seam weld connections are used.

Bolt connection:

  • The bolts can be represented as rigids, it can be modeled with RBE2 elements.
  • Here, the automatic blot representation method is used.
  • To create that, a 3D point has to be created on the hole COG as shown below using Topo>points>on COG.
  •                                      6.3d Point
  • Then the 3D point has to be converted as blot representation using convert>3D point>bolts in assembly toolbar as shown below,
  •                                7.Bolt Representation
  • Then the connection manager in the assembly toolbar is used and required inputs are provided for the bolt representation as shown below,
  •                                                   8.Control Manager for Bolt Creation
  •                                                         9.Bolt connections

Manual Bolt connection:

  • Bolt connections are provided to the holes, where the parts are to be connected with bolts.
  • That can be identified when the part holes are located next to each other.
  • It is recommended that the bolt representation to the holes can be captured using a washer split of one layer.
  • Generally, bolts can be represented as cluster RBE2 as well as two-node RBE2 connecting the master nodes of spider RBE2s.
  • Generally, these bolt representations are done manually using Nastran deck>elements>RBE2.
  •                                                                  10.Manual Bolt Representations

Seam connection:

  • Seam weld is used to connect the parts in continuous seam line.
  • It provides more structural rigidity to the system.
  • To generate seam weld, the seam data has to be obtained and then curve is created along the length to represent the seam length.
  • Then the curve has to converted into seam line using the assembly toolbar convert>curves> seam line.
  • Then the seam line can be realized using connection manager from assembly toolbar and inputs are provided as shown below,
  •                                              11.Control Manager for Seam Weld Connection-y-joint 
  •                                          12. Control Manager for Seam Weld Connection-Overlap joint
  • The seam weld representation as follows,
  • Basically, if the parts are parallel to each other, then the FE rep type has to chosen as overlap shell.
  •      13.Seam Weld Representation for Parallel Parts
  • If the parts are perpendicular to each other, then the FE rep type has to chosen as Y-joint shell.
  •   14.Seam Weld Representation for Perpendicular Parts

 

  • Finally, save the file.

RESULT:

Hence,

  • The cross-car beam model is meshed as per the quality criteria given.
  • The appropriate connections are provided to the model.
  • The thicknesses are assigned to the model.

LINK TO VIEW THE MODEL:

CROSS CAR BEAM ASSEMBLY

 

 

 

 

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