Tutorial

BATCH MESH
SHELL MESHING
Table of Contents
1. Introduction....................................................................................................................................2 1.1 Prerequisites............................................................................................................................2 1.2 Problem description..................................................................................................................2 1.3 Data files..................................................................................................................................2 2. Read and prepare the geometry.....................................................................................................3 2.1 Read and merge the parts........................................................................................................3 2.2 Check eometry......................................................................................................................! 3. "he #atch $esh $anager...............................................................................................................% 3.1 Create the meshing scenario...................................................................................................% 3.2 &et the meshing parameters....................................................................................................' 3.3 Define quality criteria..............................................................................................................1! 3.! (eep important features.........................................................................................................1) 3.) Run #atch $esh and *ie+ statistics.......................................................................................1, !. $esh impro*ement........................................................................................................................1!.1 Check mesh quality and correct *iolations.............................................................................1!.2 Check and correct Penetrations.............................................................................................22 ). Conclusion....................................................................................................................................23

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Shell Meshing using the Batch Mesh Manager 1. Introduction

"he scope of this tutorial is to guide the user through the basic functionality of the #atch $esh $anager in order to automatically mesh a model specifying the necessary meshing parameters and quality criteria. "he tutorial mainly focuses in understanding +hy and ho+ the meshing parameters must be set. according to the si/e and shape of features in the model. to get the best possible result. "he steps described in this tutorial are0 1 $erge the 23&2 databases containing the geometry 1 Check geometry 1 Create the meshing scenario 1 &et the parameters and quality criteria 1 Run the batch mesh 1 4ie+ statistics 1 $anual mesh impro*ement and final checks ! 3ote that the results that you +ill produce by the #atch $esh may ha*e some small *ariations compared +ith those presented in the pictures of this tutorial.

1.1 Prerequisites It is highly recommended to ha*e read the 5Introduction 6 getting started7 document as +ell as to ha*e performed the 5basic 23&27 tutorial or to ha*e basic meshing background. 2lso. 8ser9s uide paragraphs 12.1 and 12.2 gi*e a brief o*er*ie+ of the #atch $esh "ool. "he after_batch_mesh_practices.pdf document e:plains ho+ the mesh can be impro*ed after running the #atch $esh. 1.2 Problem description "he model. a half frontal rail structure. consists of fi*e parts sa*ed in separate databases +hich need to be merged in one. "hen the geometry must be checked before being meshed by the #atch $esh "ool using a global element length of ,mm. "he meshing parameters must be set in a +ay that the resulted mesh +ill only need minor manual impro*ements in order to fulfill all the defined quality criteria.

1.3 Data files "he files required for this tutorial are CrossLower.ansa. CrossUpper.ansa. Reinf.ansa. SideMemberInner.ansa and SideMemberOuter.ansa. "he result file is batch_mesh_result.ansa. Also the mesh parameters and quality criteria can be found in 8mm.ansa_mpar and 8mm.ansa_qual respecti*ely.

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Shell Meshing using the Batch Mesh Manager 2. Read and prepare the geometry
2.1 Read and merge the parts &tart 23&2 and create a ne+ empty database from ;ile<3e+ =Ctrl>3?. "hen. select ;ile<$erge to open the File Manager.

3a*igate and select all the files from Parts_To_Merge directory. Click on @PA3.

In Merge Parameters +indo+ lea*e the default settings and press @(.

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@pen the Part Manager =Ctrl>R? and s+itch to 5Icon 4ie+7. Bou can see the fi*e merged Parts and an empty one named 5untitled7 +hich has to be deleted.

"o do so. right click on it and select 5delete7. Confirm and close the Part Manager.

2.2 Chec !eometry It is highly recommended before meshing the model to correct any geometrical problems +hich may e:ist. ;irstly. you must change the C@3& resolution to equal the target element length of ,mm. "o do so. acti*ate the Cindo+s<@ptions =Ctrl>I?. 8nder the &ettings. in Resolution. change the C@3& Resolution to ,. Press 2PPDB. confirm and close the +indo+. Ea*ing all parts *isible. acti*ate from the D.8"ID group the CEAC(< A@$A"RB. &elect all checks e:cept the 8nmeshed $acros and &ingle #ounds and confirm.

"he check sho+s in green that there aren9t any geometrical errors present.

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Shell Meshing using the Batch Mesh Manager

Bou must also check that single =red C@3&? bounds are present only at the edges of each part and +here holes are present. Deacti*ate from the 4isibility group the &E2D@C. D@8#DA and E@" P3" flag buttons.

"o *isually check the Parts one by one. open the Part Manager and right click on each one and select 5sho+ only7. Bou can confirm no+ that there no boundary problems. Chen finished. acti*ate &E2D@C. D@8#DA and E@" P3" flag buttons.

;inally you can check for intersections by acti*ating from the D.8"ID group the CEAC(<PA3A"R2"I@3<I3"AR&AC"I@3& Click @( on the dialog to start the check. "here are no intersection errors.

! It is *ery important to ha*e a model free of geometry errors before meshing it to get the best possible results. eometry or intersection errors depend on the C@3& resolution. 2l+ays check in resolution same as the target element length or finer. 3o+ you can proceed to the meshing process.

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Shell Meshing using the Batch Mesh Manager 3. "he #atch $esh $anager
3.1 Create the meshing scenario @pen the Batch Mesh Manager by clicking to its shortcut icon or by CI3D@C&<#2"CE $A&E =Ctrl > #? Create the meshing scenario by 3e+<$eshing &cenario. "he default session is automatically created. 2s all the parts are going to be meshed using the same parameters. no additional sessions need to be added.

"he ne:t step is to load the fi*e parts into the meshing scenario. Double click on 5F7 in the Items column. "he Contents +indo+ opens. 2G

2s you are only going to use the default session all parts +ill be added there. &elect all parts from the 5Pending Items7 list by clicking on the 5select 2ll7 button and mo*e them in the 5$eshing &cenario7 list by pressing the green arro+. Confirm and close the +indo+ by pressing on @(. 2ll parts are automatically loaded no+ into the default session.

Note: In case that more sessions and filters were created, the parts would automatically be distributed to sessions according to these filters. ee !".#.$ of %N % &ser's (uide.

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Shell Meshing using the Batch Mesh Manager

3.2 %et the meshing parameters "he main and most important setting in the meshing parameters is the target element length. In addition. there are settings concerning the treatment of *arious features like holes. flanges and fillets. In order to correctly set up these. it is obligatory to kno+ the *iolating limits of each quality criterion for the mesh that +ill be generated. especially the minimum and ma:imum element length. It is already mentioned that the target element length is ,mm. "he quality criteria to be used are the follo+ing0 2spect Ratio &ke+ness Carping $in Dength $a: Dength $in 2ngle Huads $a: 2ngle Huads $in 2ngle "rias $a: 2ngle "rias 32&"R23 P2"R23 IDA2& IDA2& IDA2& IDA2& IDA2& 3 !) 12.) )mm 1)mm %F 12F 3F 12F

For more information on )uality criteria definition see %N % &ser's (uide !*.+.! "o edit the $esh Parameters. +hich are currently named 58ntitled7. double click on their name under the $esh Parameters column. 2lternati*ely. you can right click on it and select 5Adit < $eshing Parameters7. 2G

"he Mesh Parameters Cindo+ opens +ith all options set to default *alues. @n top. in the 3ame field optionally type 5,mm7. Bou can see that the parameters are di*ided in tabs; the &hell $esh. Defeaturing. ;illets. ;langes. Eoles. "ubes and ;i: Huality tabs.

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Shell Meshing using the Batch Mesh Manager

In &hell $esh tab. by default. the type of mesh is configured as eneral. $i:ed +ith 1st order elements. "he target element length is automatically set to ,mm taken from the C@3& resolution. Distortion distance and Distortion angle are set by default to 2FI and FJ respecti*ely. 3one of the options under 5Remo*e triangle from07 is acti*e. $ake sure that all these settings are set as sho+n in the picture on the left. 2lso. in the Defeaturing tab lea*e all default settings making sure that the Defeaturing le*el is set to 5fine7 and the 5Koin perimeters +ith distance L7 is set to t+o thirds of minimum element length. In this case =min length )mm?. perimeters +ith distance less than M3.3 mm +ill be Noined by the #atch $esh. &+itch to ;illets treatment and acti*ate the fillet and chamfer treatment by clicking on their flag buttons.

In the fillet treatment you can specify +hich fillets +ill be sharpened or split as +ell as ho+ many ro+s of elements +ill be created. #efore setting. you +ill take some measurement on the model to get some information about the present flanges and chamfers. $iddle click on the +indo+ title to minimi/e it.

Note: For recommended settings and optimum results refer to %N % &ser's (uide O1F.%.,

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Shell Meshing using the Batch Mesh Manager

2cti*ate the $easure "ool by selecting $A2&8RA from the A@$A"RB group of functions. In order to measure the +idth of fillets. acti*ate the selection of C@3&. 3ote also that you can toggle bet+een the selection entities using the keyboard key 517.

Note: ,ou are able to use the M-% &.- tool without lea/ing the Batch Mesh Manager. &elect t+o C@3& that describe a fillet along its length.

In the Results field. Change the result to Distance to sho+ the distance bet+een the t+o C@3&. Confirm the measurement by middle click. Proceed to measure other fillets by selecting pairs of C@3& and pressing the middle mouse button to temporarily store the measurement for each pair.

0ptionally you can isolate all the fillets of the model before measuring by acti/ating the I 01%2-3.%4I& from the Focus group of functions and entering a /alue of "* on the dialog box.

2fter taking the measurements you +ill notice that the fillets present in the model start from a +idth of about 1.!mm up to 1).)mm.

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2dditionally to the classic fillets. there are some features in our model ha*ing the shape of a half tube. "hese ha*e a length of about 2'mm.

Concerning the chamfers. the only present in the model are located around the tube on Part named Cross8pper.

$easure the +idth of the chamfer.

In addition. measure the angle by acti*ating the nodes selection in measurement tool and selecting successi*ely the three Eot Points as sho+n in the picture. "he +idth of the chamfer is about 2.')mm. "he feature angle bet+een the chamfer and the face is about !) =1,F113)).

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@pen the #atch $esh $anager. the mesh parameters and s+itch to ;illets tab. In the ;illet treatment. fill the first line so that ;illets ha*ing a Radius up to 1.) and Cidth up to 3mm to be treated by &harpen. "his +ill sharpen the ;illet e:actly as the D2CE function +ould do. Click on the green cross to add more lines. &et for ;illets +ith a +idth from 3 to 1Fmm to ha*e one ro+ of elements and for fillets from 1F to 2Fmm to ha*e t+o ro+s of elements. ;inally. set ! ro+s for fillets 2F to !Fmm.

;or chamfers set the treatment so that any chamfers ha*ing a feature angle from !F to )FJ and a +idth up to 1Fmm to be sharpened. Chen setting the number of ro+s according to the +idth ranges. take in account the minimum element length and also the ma:imum distance from perimeter used +hen fi:ing the quality of the generated mesh. "his +ill be set later at about 2.)mm. &o. if one ro+ of elements +ill be generated on a fillet of 3mm. the elements +ill be resi/ed at least at )mm and they +ill not *iolate the minimum length criterion. "he ne:t treatment in meshing parameters is the flanges treatment. &+itch to ;langes tab and click on the flag button to acti*ate it. If not already set. acti*ate the option to recogni/e the flanges by shape of faces.

If you do similar measurements as for the fillets you see that the +idth of the flanges present in the model *aries from about 1' to 1,mm.

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&et to create one ro+ of elements on flanges up to +idth of 1Fmm and t+o ro+s of elements on flanges from 1F to 1-mm. 3o+ s+itch to the Eoles treatment tab. Anable the general holes treatment by clicking on its flag button.

Eere. for *arious diameters ranges. the nodal distribution on the diameters and the creation of /ones around them can be set.

8se $A2&8RA to get a re*ie+ of the holes present in the model. "here are holes +ith diameter from about % to )Fmm.

"he small holes ha*e to be filled because *ery small elements +ould be created around them. "o do so. in the holes treatment list. set 'mm in the Diameter range field and select the option 5;ill7 in the "arget Diameter field. Press the green cross to one more line. "hen. for holes ha*ing a diameter up to 12mm set to ha*e four nodes by selecting under the 3ode 3umber field the 5e:pression7 option and setting 3P!

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Create t+o more lines. ;or diameters up to 2! and 3%mm set the perimeter of the hole to ha*e an element length of ).) and %mm respecti*ely using the DFP e:pression 2lso set the creation of a /one for each one by using in the Qone field the e:pression CP).) and CP% respecti*ely.

&+itch to ;i: Huality tab. 2cti*ate all flag buttons e:cept the 5&plit remaining *iolating quads7. &et the 5$a:imum distance from surface7 to )I of the target length =F.!mm? and the 5$a:imum distance from perimeter to )FI of minimum length =2.)mm?. Refer to 12.!.' of 23&2 8ser9s information. uide for more

"he meshing parameters.optionally. can be sa*ed in a separate file =*.ansa_mpar? and loaded in other batch mess sessions in the same or other 23&2 databases. Click on the &a*e icon.

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3.3 Define quality criteria "o open the 5uality Criteria +indo+ double click on 58ntitled7.

2G

2s it +as seen in the ;i: Huality part of the meshing parameters. by default. the #atch $esh is set to automatically fi: the quality of the produced elements in order to satisfy the corresponding threshold *alues defined in the Huality Criteria. "o ha*e a satisfactory result. at least the minimum element has to be set. Eere the criteria +hich +ere presented before. +ill be used. Crite 5,mm7 in the name field. "hen acti*ate the quality criteria using their flag buttons and set their limits in the ;ailed column. "ake care +hich calculated method is selected for each criterion. 2s in meshing parameters. you can sa*e the criteria under a separate file =*.ansa_qual?. Press @( to close the +indo+. A*en if the the $eshing scenario is no+ ready to run. e:it the Batch Mesh Manager by pressing A&C.

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Shell Meshing using the Batch Mesh Manager

3.& 'eep important features Bou ha*e already configured in the meshing parameters the defeaturing and feature treatment options according to our needs. "hough. as a side effect. there may be in the model. some areas +here you need to keep the geometry +ith higher accuracy. ;or this model. such an area can be seen in the first picture. "hese features are important for e:ample in a frontal crash analysis. In this case. if you run the batch mesh as it is right no+. due to defeaturing. some Perimeters +ill be Noined =see orange perimeters in second picture? and the resulted mesh +ill not completely match the initial geometry.

Refer to paragraph O12.!.3. of 23&2 8ser9s mesh algorithm.

uide for more information on defeaturing by the batch

Bou can indirectly instruct the #atch $esh not to Noin these Perimeters by including their respecti*e C@3& in a &A".

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Shell Meshing using the Batch Mesh Manager

If not already open. sho+ the Database #ro+ser by pressing the ;12 key. Right click on empty space and create a ne+ &A".

In the +indo+ that opens. e:pand the (-0M-2., group by clicking on its arro+ and select C@3&.

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Qoom in the area and select the C@3& as sho+n in the picture. Chile selecting in 5In &A"7 column the number of selected C@3& is sho+n in red. 3ote that all selected C@3& are %F. Confirm by middle click. gi*e a name to the set and close its card.

"he contents of the &A" can be re*ie+ed anytime by acti*ating the 5Eighlight7 flag and selecting the &A" from the -2 list. "hese C@3& +hich belong to a set are respected by the #atch $esh and they +ill not be Noined during mesh generation.

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3.( Run #atch $esh and )ie* statistics @pen the #atch $esh $anager. $ake sure the scenario and the session are checked and press R83. #atch $eshing starts. It +ill take a couple of minutes to complete. Check the progress in the &tatus column.

Chen finished the &tatus of the session is 5Arror7. Double click on it to see the report +indo+.

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Eere you can see analytically +hy the status of the session is 5Arror7. In this case four of the parts are *iolating the quality criteria.

;or more details select all the parts and click on statistics.

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23&2 creates a report +hich can be sa*ed as a te:t or html document. It gi*es information for each part separately as +ell as for the +hole session. "o sa*e. select the type of document and press the sa*e icon.

Press A&C t+ice to return to #atch $esh $anager.

&. $esh impro)ement

&.1 Chec mesh quality and correct )iolations Right click on Default &ession and select 5Copy to lobal &ettings < $eshing Parameters and Huality Criteria7. "his +ill copy the quality criteria to the ;11 +indo+. 2lso the meshing parameters +ill be copied to the meshing options so that can be used later by the mesh impro*ement functions. Close the Batch Mesh Manager and s+itch to $esh menu. Press ;11 to open the 5uality Criteria 6 Presentation Parameters +indo+. Check that the quality settings are no+ set in this +indo+. Click on Presentation Parameters tab.

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;or being able to *ie+ all details independently from the *ie+ing distance slide the 5Detail on Demand Affect7 bar to the left end. Press @( to to close the +indo+.

2t this point optically e:amine the generated mesh and see ho+ each area and feature +as treated.

$eshed model

;illet &harpening

Chamfer &harpening

Qone around hole

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Shell Meshing using the Batch Mesh Manager

2s it +as sho+n in the #atch $esh Report. some elements are *iolating the quality criteria. "hese need to be located and corrected manually.

2cti*ate the EIDDA3 flag button from the *isibility group. 2ll the failed elements are no+ dra+n in color according to the criterion they *iolate. 2lso on the screen the number of *iolating elements is reported.

"o quickly correct some of the *iolating elements use the ;IG H82DI"B algorithm located in the &EADD $A&E group of functions. 2utomatically. only the areas around the *iolations are selected. Confirm the selection by middle click. 2 pre*ie+ is sho+n. 2ccept the changes by clicking on @(.

"o isolate the $acroareas containing *iolating elements press AG"RA$A. located in the ;ocus group of functions.

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"he ne:t steps +ould be to fi: all the remaining *iolating elements. "he techniques for doing so are not going to be presented in this tutorial as all cases of *iolating elements you may encounter are presented in after_batch_mesh_practices.pdf document. Bou can also refer to 23&2 8ser9s uide O1F.'

&.2 Chec and correct Penetrations Due to the fact that the minimum element length does not allo+ some elements to lie e:actly on the geometry. it is possible to ha*e intersections or penetrations bet+een t+o parts specially in areas +here there are flanges.

$ake all *isible and use CEAC(< PA3A"R2"I@3&<PR@PAR"B "EIC(3A&& Dea*e the factor to one and press A3"AR to start the check. Intersections and penetrations are found. &elect them and press &ho+ @nly to see them.

;or information and guidelines on ho+ to fi: intersection and penetration problems refer to 23&2 8ser9s uide O1F.,.3

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Shell Meshing using the Batch Mesh Manager (. Conclusion

"his tutorial presented shortly the most commonly used shell meshing scenario using the #atch $esh manager. It +as sho+n ho+ the model should be prepared before meshing and ho+ to set the meshing parameters and the quality criteria. "he case +here different mesh density is needed for different model areas by the addition of more meshing session it +as not presented as for each one. the same techniques can be used. @ther features like setting ranges in the quality criteria can al+ays be studied using 23&29s 8ser uide chapter 12. ;inally. some techniques for the mesh impro*ement and the checks to be performed after meshing +ere referred. ;or more information use after_batch_mesh_practices.pdf document and 23&29s 8ser uide O1F.%. O1F.' and O1F.,.

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