SIMLAB GUIDE

MESH SPECIFICATION FILE

Mesh control created can be saved in an external file, called "Mesh Specification" and saved file can be imported
back into SimLab. This is very useful when meshing models of similar types when the mesh control created for one
can be reused for the others. For example, the meshing requirements for modelling most engine heads are similar.
So if a mesh control is created for one engine head model, then it is most likely that this can be reused for other
engine head as well. This option also helps standardize the meshing process.

When creating mesh controls, geometry must be selected. The selected geometry ids are stored with the mesh
control. When a mesh control is exported the specification file can have the geometry ids. It is not necessary for two
different CAD models to have the same ids for the geometry. So, a mesh specification file that refers to ids for one
CAD model will not be useful for another CAD model. So, when exporting a mesh specification file one can choose to
export with no geometry ids (Template option), with geometry ids (Body option), face colour (Face colour option) or
group name (Group option).

When importing a mesh specification file that was exported with "Template" option, it will create mesh control
objects in the "Mesh Control" tree view but with empty icons Ø in the second column of the Model Browser. The
empty icons Ø indicates that these mesh controls have not been assigned to geometry. User can double click to
open these mesh control and assign them to geometry and this will turn the mesh control object on the tree view to
become bright.

PRIORITY
When many "Mesh Controls" are assigned, it is possible that multiple "Mesh Controls" can have an influence on one
geometry. The meshing code looks at all the mesh control and determines what size it should use for a geometric
entity. For each geometry type the mesh size is determined as follows. First imposed mesh control and mesh
pattern, then Global Mesh Size (Size defined in the Surface Meshing dialog box).

FACE MESH CONTROL

Face Mesh Control is used to control the mesh on the selected local faces. A uniform mesh is generated on the face
that has the face mesh control specified. The curvature is ignored.
Use rest of the parameters from Global

Use rest of the parameters from Global option is used to modify the values of Minimum Element Size, Aspect Ratio,
Maximum Angle Per Element, Curvature Minimum Element Size and Surface Mesh grading.

Mesh Grading

The variation of the mesh in the face from the boundary to the interior is controlled by the Surface Mesh Grading.
Default Surface Mesh Grading value is 1.5. (Average Element size marches 1.5 times from fine to coarse).

EDGE MESH CONTROL

The mesh on an edge is controlled using the Edge mesh control.

Two edge mesh controls are available.

1. Uniform Seeding

2. Bias Seeding

UNIFORM SEEDING

Edge Seeds are applied either by specifying the average element size or by specifying the number of elements.

In case of edges that forms a circle (or a part of a circle), the seeds can be distributed using “Distribute seeds along
selected edges” option. This option is made available only when the “Number of Elements” option is used.
BIAS SEEDING

Bias Seeding is used to seed an edge such that a constant ratio is maintained between adjacent bar elements. Edge
Length will be in the following series: Lmin, Lmin * r, Lmin * r * r, . . . where Lmin is the minimum edge length and r is
the ratio.

Bias seeding is applied either by specifying

1. The Ratio and the number of elements, or

2. The minimum element length and maximum element length.

For Bias Seed, the user has to select an edge and the direction of seeding. When an edge is selected, the direction of
seeding is indicated by an arrow. It could be changed using Reverse option.
FILLET MESH CONTROL
Fillet Mesh Control is used to control the mesh over fillets along the length and the curve direction. The fillet faces in
a body can be identified by selecting the body on display window and Right Click | Select Features.

The user can apply the fillet mesh control either to the selected faces or bodies. To apply fillet mesh controls to
bodies, the "Radius Range" option should be turned on.

Length along fillet

Length along fillet is used to define the element length along the length of the fillet.

Maximum angle per element

The approximation of a geometry is related to the angle made by an element edge on a perfect circle. Suppose the
angle is 45 deg, then this will approximate a circle by 8 elements. If the angle is 30 deg, then this will approximate a
circle by 12 elements. This same measure is extended to an arbitrary curved surface.

Based on the angle specified, the number of rows of elements through the curvature of the fillet will be determined.
If the fillet varies in curvature, then the number of rows will change accordingly.

Curvature minimum element size

The mesh approximates the geometry by varying the mesh size as a function of the curvature. Such geometry
approximation cannot result in a mesh size smaller than Curvature Minimum Element Size.

Number of elements for uniform curvature

Number Of Elements can be specified instead of the angle to create a specified number of rows of elements through
the fillet curvature. Note that the number of rows will remain same even if the fillet varies in curvature.

Aspect Ratio Influence on Mesh

Aspect ratio

Aspect ratio determines the quality of mesh. Aspect Ratio value varies from 1(equilateral element) to infinity (flat
element).

Adjust "Length along fillet" to satisfy aspect ratio

This option would adjust the length along fillet to make sure the aspect ratio is satisfied.
Collapse elements to satisfy "Aspect ratio".

This option would collapse the elements which are failing for aspect ratio.

Assign to Fillets in Body (Radius Range)

This toggle is used to apply fillet mesh control to a body. The user must specify the fillet radius range. The Mesher
will extract the fillets within this range at the time of meshing and create the mesh. Using Right Click | Select
features, the list of faces for which the fillet mesh control will be applied can be cross-checked.

Merge tiny fillets

When this option is turned ON, fillets having only one element along its length (i.e., length along the fillet) are
considered as tiny fillets and will be merged with the adjacent fillet.

Retain Mesh Flow on the Boundary

If "Retain Mesh Flow on the Boundary" toggle is turned ON the Mesher will force the fillet faces to isomesh. This
fillet special case will be used in meshing crank bore faces in engine block and for connecting rod special cases.
Capture non-uniform curvature

Capture non-uniform curvature toggle is used to capture the concentrated local curvature by adding more layers.

CYLINDER MESH CONTROL

Cylinder Mesh Control is used to control the mesh both axially and in circular direction on the selected cylindrical
surfaces.

Element size in axial direction

This size is used to control the element size along the length of the selected cylindrical faces.

Number of elements in circular direction

The number of nodes along the circular direction of the cylindrical face can be controlled by specifying the number
of circular mesh seeds.

Assign to Cylinders in Body (Radius Range)

This option is used to apply the cylinder mesh control to a body. The cylindrical surfaces within the specified
minimum and maximum radius range in the selected body will have the cylinder mesh control applied to them. Using
Right Click | Select Features, the list of faces for which the cylinder mesh control will be applied can be cross-
checked.

WASHER MESH CONTROL

Washer Mesh Control is used to create rings around a circle. The circle must be inside one face.

This mesh control is used only on cad models.

The Width of the washer can be specified using one of the following options.

1) Ratio of washer outer to inner radius

The washer width is calculated based on the ratio of washer outer radius and inner radius (selected circular edge).

2) Washer width

Washer width is used to define the width of the washer around the circle.

3) Washer outer radius

Washer outer radius defines the outer radius of the washer. Here, the Washer width will be the difference between
the Washer Outer Radius and the Radius of the circle

Number Of layers of elements along washer width

Number of layers specifies the number of layers of element along the width of washer.

Assign to Circles in Body (Radius Range)

This option is used to apply the washer mesh control to a body. The circular edges within the specified minimum and
maximum radius range in the selected body will have the washer mesh control applied to them. Using Right Click |
Select Features, the list of edges for which the washer mesh control will be applied can be cross-checked.

When body-based washer mesh control is applied, washer faces will be created only if the washer outer edge
completely within the face and it should not intersect the boundary edges.
REMOVE LOGO MESH CONTROL
Remove Logo mesh control is used to remove the logo faces and merge with the adjacent faces. The logo faces that
needs to be removed are to be selected. It works for both CAD bodies and FE bodies.

MESH PATTERN
The way elements are arranged in a face are known as mesh pattern.
4. Aligned Mesh

All the elements in the selected faces will get aligned to a certain direction. This can be applied to any face.

MESH > 2D CREATE > MESH

Global parameters to mesh surfaces of a body with 2D elements (TRI/QUAD) and edges of a bar-body with 1D
elements (BAR) is specified using the Mesh dialog box. The 2D/1D element types supported are,

Tri3

Tri Mesh Parameters

The parameters to create Tri3 and Tri6 mesh are,

The global parameters include

Element Type

This option can be used to create a Tri3 or Tri6 surface mesh.

Mesh Size

Average element size

The Average Element Size is the average element edge length for Tri/Quad elements and is the distance between
two end nodes for Bar mesh. The element edge length will vary between (Average Element Size)*Sqrt(2) and
(Average Element Size)/Sqrt(2).

Maximum element size

This toggle allows the user to choose Maximum Element Size instead of Average Element Size. When Maximum
Element Size is specified, then the mesh will have no elements with edge length greater than this value.

Minimum element size

The Min Element Size is used to remove all the elements that have element edges less than this value.

Grade factor

The mesh size transition on a surface mesh is controlled by Grade Factor. Default Grade Factor value is 1.5. (Average
Element Size marches 1.5 times from fine to coarse).

Geometry Approximation

In case of curved surfaces/curves, the curvature is captured based on Maximum angle per element and Curvature
minimum element size along the curvature direction. By varying the Maximum angle per element and Curvature
minimum element size, the desired geometry approximation can be attained.

The default Maximum angle per element is 45 degrees. This will create 8 elements on a circular hole. A better
approximation of the surface can be obtained by using a smaller Maximum angle per element. If the Maximum angle
per element is reduced to 30 degrees, 12 elements will be created on a circular hole. For a very small hole the
Maximum angle per element will create tiny elements and might not be desired. The creation of tiny elements can
be prevented by setting the Curvature minimum element size. The geometry will be approximated using the angle as
long as the resulting element edges are greater than the Curvature minimum element size. Otherwise, the Curvature
minimum element size will be used to define the mesh size.

Aspect ratio
The quality of mesh can be controlled by setting the Aspect Ratio. The value can vary from 1 (equilateral element) to
infinity (straight line). The default Aspect Ratio is set to 10.

NOTE:
Mesher uses single core as default, to perform the meshing. When an assembly has multiple bodies, single core
meshing will mesh one body at a time. So, the total time taken is the sum of the time to mesh each body. If the
hardware supports multiple cores, user can request the Mesher to use the multiple cores when meshing. When
multiple solids are selected to mesh, the Mesher will distribute the bodies between the cores and mesh them
simultaneously. This will reduce the meshing time for assemblies with large number of bodies. Note that the amount
of physical memory in the machine will also determine the performance of meshing. User can specify the number of
cores in File | Preferences | System. Currently multi core meshing is supported for Parasolid, Step and CATIA
(imported only through File | Import | CATIA - Direct (New)) models.

Advanced Options

The less often used controls are available in Advanced Surface Mesh Options.

CAD Body

The options which are under "CAD Body" available only for CAD bodies.

1. Identify features and mesh

Identify features and mesh will mesh the fillets and cylinders as if the fillet and cylinder mesh controls are applied
with the global meshing parameters. Mesh size, curvature angle, curvature minimum size and aspect ratio will be
derived from the global meshing parameters applied either through body mesh control or in the mesh generation
form. Fillets with radius less than “Global mesh size * 15” only will be considered and rest of the fillets will be
ignored.
 2. Imprint meshing (Parasolid Assembly)

Imprint meshing option is available only when meshing of Parasolid solid bodies that are imported with "Imprint
solid bodies" option. This option allows the user to create matching faces between bodies. Gap tolerance will be
turned on when Parasolid or step sheet bodies are selected. It will be used to define gap tolerance to stitch the
selected sheet bodies.

FE Body

The options which are under "FE Body" available only for meshed bodies.

Improve skew angle

Improve skew angle option allows the user to improve the skew based on the skew parameter values set in File >
Preferences. This is supported for both CAD and FEM inputs. Refer the following link for setting the skew parameter
values. Improve skew angle

a) None: Improve skew angle option will not be considered while meshing if None is selected.

b) Auto: Auto signifies the skew angle improvement by mid-line collapse, zigzag mesh and node movement for
tessellation-based meshing and only node movement for the CAD meshing.

c) Simplify Ribs: Simplify Rib option works only for CAD inputs. Here, the skew angle will be improved by mid-
line collapse, projection, reducing the local size and node movement.

Mapped mesh

a) Auto: The Mesher will automatically determine the faces that can be iso-meshed. All regular 4-edged faces and
faces that are 4-sided will be iso-meshed.

b) Regular 4-sided faces: All regular 4-edged faces, even if the edges are not of similar size will be iso-meshed.
Though a mapped mesh is created, the quality can be poor. There is no transition when a surface tapers or enlarges.

c) None: Free mesh (the interior angles are 60-60-60 degrees and not 90-45-45) will be forced for all faces in the
body, even if it is a regular 4-edged face.

Mesh pattern

Mesh pattern defines the pattern on faces that are mapped meshed.

a) IsoMesh: IsoMesh option creates elements that are right angled, and the edges of adjacent elements are
inclined in the same direction.

b) Union jack: Union jack option creates elements that are right angled, but the edges of adjacent elements
are inclined in the opposite direction.

The iso mesh is done by default on the cylinders and 4sided faces on a FE Body.

RE-MESH
Re-mesh helps the user to re-mesh a portion of a meshed body. This comes in handy when the user wants to modify
the mesh only in few places and retain the mesh elsewhere. One more advantage is that Re-Mesh respects the local
mesh controls. This means that, new local mesh controls can also be assigned prior to Local Re-mesh.

Mesh faces (shared or non-shared faces), mesh edges and set of 2-D elements can be locally modified. In case of
assembled mesh bodies, the shared faces and shared edges can be re-meshed.

The global parameters to re-mesh selected faces with 2-D elements (TRI / QUAD) is specified using the Re-Mesh
dialog box. The 2-D element types supported are,

1. Tri3
Tri Mesh Parameters

The parameters to create Tri3 and Tri6 mesh are,

The global parameters include

Element Type

This option can be used to create a Tri3 or Tri6 mesh.

Mesh Size

Average element size

The Average element size is the average element edge length for Tri/Quad elements. The element edge length will
vary between (Average element size)*Sqrt(2) and (Average element size)/Sqrt(2).

Minimum element size

The Minimum element size is used to remove all the elements that have element edges less than this value.

Grade factor

The mesh size transition on a surface mesh is controlled by Grade factor. Default Grade factor value is 1.5. (Average
element size marches 1.5 times from fine to coarse).

Geometry Approximation

In case of curved surfaces/curves, the curvature is captured based on Maximum angle per element and Minimum
element size along the curvature direction. By varying the Maximum angle per element and Minimum element size,
the desired geometry approximation can be attained.

The default Maximum angle per element is 45 degrees. This will create 8 elements on a circular hole. A better
approximation of the surface can be obtained by using a smaller Maximum angle per element. If the Maximum angle
per element is reduced to 30 degrees, 12 elements will be created on a circular hole. For a very small hole the
Maximum angle per element will create tiny elements and might not be desired. The creation of tiny elements can
be prevented by setting the Minimum element size. The geometry will be approximated using the angle as long as
the resulting element edges are greater than the Minimum element size. Otherwise, the Minimum element size will
be used to define the mesh size.

Aspect ratio

The quality of mesh can be controlled by setting the Aspect ratio. The value can vary from 1 (equilateral element) to
infinity (straight line). The default Aspect ratio is set to 10.
Preserve boundary edges

Preserve boundary edges option instructs the Mesher to preserve the nodes along the boundary edges. Boundary
edges, here, refers to edges that are common to the faces to be re-meshed, and the faces that are not selected for
re-mesh.

When this toggle is selected the common edges will be preserved. When this toggle is not selected, in addition to the
selected faces to be re-mesh, one more layer of faces will be re-meshed. Free Edges will be re-meshed in either case,
because, it does not comes under the list of common edges between the faces to be re-meshed and the faces that
are not re-meshed

Advanced Options

The less often used controls are available in Advanced Options.

Mapped mesh

a) Auto: The Mesher will automatically determine the faces that can be iso-meshed. All regular 4-edged faces and
faces that are 4-sided will be iso-meshed.

b) Regular 4-sided faces: All regular 4-edged faces, even if the edges are not of similar size will be iso-meshed.
Though a mapped mesh is created, the quality can be poor. There is no transition when a surface tapers or enlarges.

c) None: Free mesh (the interior angles are 60-60-60 degrees and not 90-45-45) will be forced for all faces in the
body, even if it is a regular 4-edged face.

Mesh pattern

Mesh pattern defines the pattern on faces that are mapped meshed.

a) IsoMesh: IsoMesh option creates elements that are right angled, and the edges of adjacent elements are
inclined in the same direction.

b) Union jack: Union Jack option creates elements that are right angled, but the edges of adjacent elements
are inclined in the opposite direction.

The iso mesh is done by default on the cylinders and 4sided faces on a FE Body.

Re-Mesh Shared faces

Re-Mesh Shared faces option is used to re-mesh the shared faces in the assembled bodies.

After assembling the FE bodies (using Assembly | Connect | Join), it becomes necessary to re-mesh the affected
shared faces. This option comes in handy when all the shared faces in the assembled FE Bodies are to be re-meshed.
This can also be used in automation.

In addition to the shared faces, one layer of adjacent faces will also be re-meshed to clean up the bad quality
elements (along the shared edges and in the vicinity of the shared edges) as well as to grade the mesh from fine to
coarse, if the mesh size desired in the shared face is fine. The mesh in the adjacent faces will be modified only to a
certain layer of elements decided by the Mesher.

Re-Mesh Shared edges

Re-Mesh Shared edges option is used to re-mesh the shared edges in the assembled bodies.

This option is used to re-mesh all the shared edges. Here, three layers of elements in the faces adjacent to edges will
be re-meshed.

CAD local re-mesh

Re-mesh on faces is done on CAD, when CAD Local remesh option is selected in Advance Options. When CAD model
is present, selected face is searched in CAD body and meshing is done on CAD body. Then the meshed face is
stitched to the existing mesh.

Note:

1. When elements are selected for local re-mesh, only the selected elements will get re-meshed. All other elements
remain as such without any modifications.

2. When re-meshing edges, three layers of elements will be modified.