MESHING

INTRODUCTION

Before the material to be used for a part is finalized and the part is sent for production, analysis

should be done on the design to reduce the risk of remodeling at a later stage. This analysis is

done using softwares like MoldFlow Plastics Insight (MPI). Analyzing a design structure

involves complex calculations. It is difficult to model molten plastic flow through intricate

shapes of the design geometry. Further, the partial differential equations which govern heat

transfer and fluid flow are not in accord with analytical solutions. To overcome these issues, a

model is partitioned into several smaller sub-domains that are joined together at the nodes. The

sub-domains are called elements or cells and are usually triangles or quadrilaterals in 2D and

hexahedrons or tetrahedrons in 3D. The collection of these elements or cells is called mesh or

grid. Analysis is done on one element and the results are extrapolated to the entire surface.

TYPES OF MESHING
There are three different types of mesh used in MPI:

Midplane

Dual Domain

3D
MIDPLANE MESHING

In this type of meshing, the thickness of the part is calculated and a surface plane is

allocated and passed through the center of the thickness. This surface is then divided into small

triangular elements that are joined along their edges and corners (nodes). The thickness of the

part at each node is noted. This measurement is then incorporated by the analysis and the

thickness of the part is partitioned into thin layers called laminae. This presents a defined part

volume on which computations can be performed.

To use this type of meshing, it must be ensured that the CAD package used can directly generate

a Midplane model.

DUAL DOMAIN MESHING

In this type of meshing, the surface of the model is covered with small triangular

elements and hence, it represents a solid CAD model. The triangular elements are joined along

their corners and edges, called nodes. The model can be imagined to look like a hollow body

covered with a surface shell. During the analysis of the part, the volume of the model is

characterized by usually 10 or more layers through the thickness of the part. It is essential that

there are matching elements on the opposite faces of the part to build these layers. The alignment

of the layers through the thickness is ensured by these matched elements. The layers facilitate an

accurate representation of the thin cross sectioned parts, where there is a rapidly changing

characteristic profile such as temperature and flow front velocity.

3D MESHING

In this type of meshing, the volume of the model is made up of four-node, tetrahedral elements

(tetra) that are joined along the edges. Tetra gives an accurate three dimensional representation

of the model and thus, this type of meshing works well for parts that are thick or solid. Further,

this mesh is more advantageous as it does not make the assumptions that are made in Midplane

and Dual Domain meshes. Taking all these factors into consideration, 3D meshes take more

computation time to complete and as such are more appropriate for thick, complicated parts

while Midplane and Dual Domain meshes are more suited for thin-walled, hollow, shell-like

parts.

Of the three types of meshes discussed above, Dual Domain mesh is most commonly used as:

Most part geometry is shell-like in appearance which is most appropriate for this type of

meshing.

Mid-plane meshes need more clean-up compared to Dual Domain meshes. This makes

them, more complicated and time consuming. In case an analysis is required that be

performed only on a Midplane mesh, Dual Domain mesh id first generated in an external

CAD package and then imported as a Midplane mesh.

A 3D mesh requires a good Dual Domain mesh as its starting point. After importing, it is

then converted into a 3D mesh.

ERRORS IN MESHING

In CAD programs, several simple surfaces are combined together to form the final design and

thus, represent a complex model. When importing such complex models into MPI or while

meshing, the interface between these separate surfaces can be misinterpreted. This is the reason

for many errors, especially in the areas of fine detail. Though minute details like surface texture,

fillets and small radii are important to the finished product; their inclusion usually leads to

unnecessary complexity during mesh generation.

In MPI, if errors are found during meshing, the Mesh Repair Wizard is run to check for and

repair most of the common defects.

SNAPSHOTS OF DENTAL BRACKET AFTER MESHING

Isometric view
Front view

Top view