Meshing an Automobile Side Door Interior Plastic Component

AIM:

      To mesh the given component(side door of a passenger vehicle) & assign thickness by following the given quality criteria.

QUALITY CRITERIA:

Target Element Length = 4 Units

PROCEDURE:

GEOMETYRY CLEAN-UP & MID-SURACE EXTRACTED:

•  The side door model is imported. We need to delete the solid surfaces by selecting the whole model.
•  Geometry clean-up is done, as there is lot of fillets, which ahs been removed by using (defeature-surf fillets)
•  By using quick edit option, if two lines are much closer to neglect the minimum element quality failure, we can toggle those lines by using(quick edit - toggle edge)
•  If some lines are not connected by using toggle edge(ruled or spline option) is used to connect the edges.
•  Mid-surface is extracted seperately for each surface. If some surfaces are not extracted, by using off-set option the remaining surface is extracted.

MESHING &  ELEMENT QUALITY CHECKING:

•   By using (2d- automesh) mesh is created for each component seperately. Once meshing is done for each part, we have to check if any element fails for minimum quality length, it should be clear by meshing the respective region again.   
•   After meshing the component, by using quality index, the failed element size can be adjust by element optimize, place node, dragging the tria elements & splitting the quad elements.
•   While meshing is followed in the flat surface, there should be zero element failure according to the given quality criteria, mesh flow & feature capturing should be followed.  
•   Apart from the above given quality criteria, there shouln't be any trias in the edges & corners of the geometry. No opposite trias, back to back trias & roatational quads shouldn't occur in meshing.
•   Once all edges are meshed, we need to check for connectivity of elements by using (tools-edges)

ASSIGNING THICKNESS OF MATERIAL:

•   For assigning the thickness of the material, we need to create property of required thickness & assign the property according to the              thickness of the surfaces.

RESULTS:

•   For the given component geometry is cleaned up & mid-surfaces has been extracted.
•   Proper mesh flow is obtained, by following the given quality criteria.
•   Thickness has been assigned for the required property of the material.