Mesh the Turbocharger Model using the ANSA

Aim

Perform the meshing the turbocharger model using the ANSA.

  1. Cleaning the turbocharger part and Assign the PID'S
  2. Do the surface and volume mesh of the turbocharger.

Turbocharger

A turbocharger, colloquially known as a turbo, is a turbine-driven forced induction device that increases an internal combustion engine's efficiency and power output by forcing extra compressed air into the combustion chamber.

Types of turbocharger

  1. Single Turbo
  2. Sequential turbo
  3. Twin-Scroll
  4. VGT
  5. Variable twin Scroll
  6. Electric Turbo

1. Received CAD File Image

Above showing wireframe pic we see the three Colors

  1. Red showing the Single surface (Free Boundary)
  2. Yellow showing the two surface attached to each other
  3. Blue showing the more than two surface attached to each other

Form the observation of CAD file we get geometrical errors

  1. Missing Surface
  2. Extra Matched Surface
  3. Single and Triple coon

Because CFD Meshing the always required the Double coons as possible.

A. Cleaning the geometry

Impeller Casing surface generation process

Create a hot point > Parametric > Specific the distance (Range 0-1) > 0.5 > Middle Mouse Button > Created Hot Point

Create a Face > Select Surface 1.EXISTING SURF 2.PLANER 3.FITTED 4. COONS> Select Coons option > Select the Hot Point and edges > Middle Mouse Button > Observe the face > ok

Remove the Extra Extrude > CONS > Project > Select the Cons > Middle Mouse Button >Select Face > Middle Mouse Button

TOPO > Select Cons > Select Upper face > Select Bottom Face > Delete face > Select Face >Yes

Intersect > First Face > middle Mouse > Second Face > middle Mouse > Delete unnecessary face and keep remain

Cons > Project > Select Edge > middle Mouse > Select face > middle Mouse  

Creating the Single Volume

  1. Face topo Drop and Drag middle Mouse create a triple point
  2. use not with entity and delete the unnecessary faces

The above figure shows the error-free surface of the given model after resolving the errors.

Mesh Length

  1. Blade Section 1 = 1mm
  2. Blade Section 2 = 2mm
  3. Compressor Casing = 5mm
  4. Impleller = 2mm
  5. Inlet Casing Cover = 5mm
  6. Shaft Rotor =  1mm
  7. Turbo Casing = 5mm

Element Type: - Tria

Surface Mesh

Perimeter > length > 1.Perimeter 2.Macros > Macros >Select all By Drag and Drop > length (1-20) > Define the Length > middle Mouse

free mesh > Select Option > middle Mouse

Mesh Generated

Volume Mesh

Before the starting volumetric meshing, the topology is closed completely create the volume, then it is checked the pre-volume definition

Bounding the volume > creating the complete bound area > by creating a face 

Creating the PID's

Face > Set PID's > Face/Shell> Select the Hatch >middle Mouse> Shell Property Help > New  > Naming the PID >Shell Property > Apply > Select Face PID > middle Mouse

  • Created PID Surface
  1. Turbo-casing Inlet
  2. Turo-casing Outlet
  3. Compressor Inlet
  4. Compressor Outlet

Module - V Mesh > create volume mesh element > Define > Select the volume from the list and delete the surface

unmeshed(4) > Click and Show only > Unstructured Mesh > Tetra CFD > Drag and Drop Select the Volume > Middle Mouse

From the above figure, we can see that the impression are remains of inner parts because their fluid has been not flowing. 

Conclusion

We obtain the clean surface and create volumetrically Mesh


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