Improving the Mesh Quality for SAE BAJA Roll Cage

PRASHANT JHA

Hey everyone,

I meshed my roll cage using element size 5, checked the element quality after setting the criteria file to Opti struct solver, did smoothing & all stuffs, manually did the improvisation of mesh quality, but still some elements are failing. So, is there any way to improve the mesh quality even more and if it is so, then how?

Also, which parameters needs to be taken care off in quality index panel. I have ignored only taper & chordal deviation & tria parameters( min/max angle & % of trias) as i am only using quads and do not want to use trias?

Please help me out.

The major problematic areas are the regions where tubes are welded. I even tried to remesh those regions but failed to achieve the best mesh at the end.

Any help would be of great help to me

Q.Nguyen-Dai

Split your surfaces to better control the mesh.

Begin with fine mesh:

And you got:

 

Have a look at my modified model in attachment.

 

Q.Nguyen-Dai

In pratice, you can not do a "good" mesh with a good value for every criteria.

Take some criteria as important for you, like jacobian, aspect ratio,...

Another point: split your geometry and do fine mesh within critical area.

PRASHANT JHA

So, if at all at the end, i don't get zero elements violating the thresholds, then how to run the analysis using Opti struct solver as it gives error message 'Problem while element quality check' even if some elements are are violating the threshold. 

Q.Nguyen-Dai

You mesh, as show in your picture, is NOT so good. You have to improve alot to get a good mesh.

Here's my 10-minute-mesh to give you some idea.

 

 

 

PRASHANT JHA

Can you please help me by posting a video that how have you achieved this much fin mesh starting from the geometry cleanup?

It would be of great help to me. Please, Please help me. 

Q.Nguyen-Dai

I have no time to make a video, sorry. But if you have any question, I could give you some ideas.

Can you share your HM model?

PRASHANT JHA

Hi, I have attached mine surface model, it is unmeshed one, can you please help me in showing how to mesh the joint where five tubes are welded?

It would be of great help to me.

Q.Nguyen-Dai

Split your surfaces to better control the mesh.

Begin with fine mesh:

And you got:

 

Have a look at my modified model in attachment.

 

PRASHANT JHA

Thanks for your guidance.