Lecture 13

Shell Meshing
14.5 Release

Introduction to ANSYS
ICEM CFD
© 2012 ANSYS, Inc. April 1, 2013 1 Release 14.5
 Introduction to Shell Meshing
Usages of shell meshing:
– Thin sheet solid modeling (FEA) – stamped parts
– 2D cross sectional analysis (CFD)
– Input for volume meshing (FEA/CFD) – Delaunay, Advancing Front, T-grid
– Filling a surface mesh is faster than tetra octree but requires well-connected geometry
Procedure
– First need to decide mesh setup parameters
– Mesh method
– Algorithm used to create mesh
– Mesh type
• quad/tri/mix
– Mesh sizes
– Small enough to capture physics, important features
– Large enough to limit grid size (number of elements)
– Memory limitations
– Faster mesh/solver run
– Set mesh sizes on parts, surfaces, and/or curves
– Based on edge length
– Can have different types/methods set on different surfaces
© 2012 ANSYS, Inc. April 1, 2013 2 Release 14.5
 Global Mesh Setup
Mesh Setup Icons Mesh tab

Global Mesh Setup

• To change defaults globally
for size, method and type • Global Mesh Size
• For entire model – For entire model
• For Shells – Scale factor
• For Volume • Global setting by which many local settings
• For Prism are multiplied
• To set periodicity • Good for scaling overall mesh
– Global Element Seed Size
• Parameters relative to
• Maximum possible element size in model
scale factor
• Default size if don’t wish to set local sizes
– Max size
– Curvature/Proximity Based
• Global and local Refinement
– Min size limit • Automatically creates smaller element size
• Global and local to better capture geometry
• Only for Patch Independent method and
– Max deviation
tetra octree
© 2012 ANSYS, Inc. April 1, 2013 3 Release 14.5
 Global Shell Meshing Parameters

Global Shell Meshing Parameters

• From Global Mesh Setup tab
• Set surface mesh parameters globally
– Defaults for the selected mesh method
• Methods
– Autoblock
– Patch dependent
– Patch independent
– Shrinkwrap
– Delaunay
• Type
– All Tri, Quad w/one tri, Quad dominant, All quad
• Options for different mesh methods
• Global types and methods can be overridden by
– Surface Mesh Setup
• Local settings
– Compute Mesh
© 2012 ANSYS, Inc. April 1, 2013 4 Release 14.5
 Part Mesh Setup
Part Mesh Setup (pop up spread sheet)
• Set mesh parameters on all entities within part
• Max. size
– Multiplied by global Scale Factor = actual size

• Quad layers grown from curves (e.g. rings around holes),

use these 3 parameters:
– Height: First layer quad height on curves
– Height ratio: growth ratio which determines the heights of
each subsequent layer (multiplication factor)
– Num layers: Number of rings/inflation layers
• For quad layers, the minimum required to be set is height
(for 1 layer) or numlayers (height = max. size)
• If done in the Part Mesh Setup spreadsheet you must Or set on
toggle on Apply inflation parameters to curves individual
curves
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 Local Surface Mesh Setup
• Surface Mesh Setup
– Same parameters as part mesh
setup but also includes:
• Mesh type
• Mesh method
– Select surfaces first from screen,
set sizes/parameters and Apply
– Mesh method/type will override
global shell mesh settings for
selected surface(s)
– Will override Part Mesh Setup
settings if set afterward
– Display mesh sizes
• Right mouse, select in Model tree
on Surfaces > Tetra/Hexa Sizes
– One Icon appears for each
surface
– Gives you a visual estimate of
prescribed max. size and height
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 Local Curve Mesh Setup – General
Curve Mesh Setup
• General
– Same as Surface Mesh Setup
– But also can prescribe Number of nodes
• Instead of element size
– Also includes node biasing along curves
• Initial spacing from either
curve end
Side 1 Display
• Bunching laws • Right mouse
select in Model
• Expansion ratios from either Tree, Curves ->
curve end Curve
Tetra/Hexa
Side 2 • Matching of node spacing to Sizes or
adjacent curves • Curve Node
Arrow Spacing
shows • For a better description, Tetra sizes
side 1 and
side 2
refer to the Hexa chapter –
Edge Parameters
– Select curves first, middle mouse to
accept selection, then type in
parameters/sizes - Apply
Node spacing Release 14.5
© 2012 ANSYS, Inc. April 1, 2013 7
 Local Curve Mesh Setup – Dynamic and Copy
Curve Mesh Setup
• Dynamic
– Adjust mesh parameters on
screen
– Interactively toggle displayed
values near curve with left (to
increase) or right mouse (to
decrease) keys
Left mouse to
• Copy Parameters increase
– Copy parameters set on one
Right mouse
curve to others
to decrease
– e.g. parallel curves
downstream
• Curve Mesh Setup will
override Part Mesh Setup
parameters if set afterward

© 2012 ANSYS, Inc. April 1, 2013 8 Release 14.5

 Mesh Methods
Algorithm used to create mesh
• Patch Dependent
– Based on loops of curves surrounding patches
– Best for capturing surface details and creating
quad dominant mesh with good quality
• Patch Independent • Set in Global Mesh
– Robust octree algorithm Setup or locally
– Good for dirty geometry, ignoring small features, using Surface Mesh
gaps, holes Setup
• Autoblock
– Based on 2D orthogonal blocks
– Best for mapped meshing, mesh follows contours
of geometry
• Shrinkwrap
– Automatic defeaturing
– Quick Cartesian algorithm
– Allows ignoring of larger features, gaps and holes
• Delauney (beta options)
– Allows for transition in mesh size
• Coarser towards surface interior
– Tri only
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 Patch Dependent Method
• Patch defined by a closed loop of
curves
– Typically each surface defines a patch
• Loop defined by boundary curves loop 3
• Curves automatically created by Build loop 2
Diagnostic Topology - a must!
– Can remove or filter out curves to
define multi-surface patches loop 1
• Delete curves (non-permanently)
• Turn on filter points/curves when Filtered or
building topology deleted curves
(dormant)
• Mainly uses curve sizes (curve
nodes seed loop perimeter)
• Paving algorithm used to fill
interior of loop
– Interior nodes typically projected to surface
– Adjacent loops share nodes at common
edge making mesh conformal throughout
Build topology MUST be done first to build
• Default method, fastest method surface connectivity and curves
© 2012 ANSYS, Inc. April 1, 2013 10 Release 14.5
 Patch Dependent – Common Options
All method options set from Global
Mesh Setup -> Shell Meshing
Parameters section
General
• Ignore Size
– Small features, such as
sliver surfaces smaller than
defined value are ignored.
Merges loops behind the Sliver Surface,
scenes 0.6 mm wide
– Will override max. size
setting if smaller
• Respect line elements
– Line elements (bars) on
existing mesh are
Surrounding mesh done afterwards
is conformal to existing mesh respected
– Maintains conformal mesh Ignore size =1,
between newly created
Sliver surface is ignored
mesh and existing mesh on
adjacent surfaces

© 2012 ANSYS, Inc. April 1, 2013 11 Release 14.5

 Patch Dependent Mesher - Boundary option
Boundary
• Protect given line elements
Standard
– Keeps existing line elements which are
smaller than the Ignore size
– Grayed out unless Respect line elements is on
• Smooth boundaries
– Smoothes mesh boundaries after mesh Simple
generation. Ignores curve mesh settings
• Offset type
Interior
• Force mapping
– Forces mapped mesh on regular (4 sided)
surfaces to desired degree (0-1)
– Adjusts the number of nodes on opposite
sides (0.2 = change number nodes by 20%)
• Project to surfaces
– Interior nodes project to surface rather than
interpolate position
• Adapt mesh interior Would require too many
nodes increased from
– Allows transition to larger element size in the original setting based
interior of the surface (uses surface max size ) on force mapping
© 2012 ANSYS, Inc. April 1, 2013 12 setting Release 14.5
 Patch Dependent Mesher - Repair option
• Repair
– Try harder
• For loops that fail with requested paving algorithm
• Levels (1-3) make further attempts to create grid
• 0 - No further attempts, failed surface(s) marked and put into a
subset
• 1 - Simple triangulation of surface, converted to requested type
• 2 - Same as 1, but dormant curves activated
• 3 - Run octree, same as patch independent
– Improvement Level
• Levels (0-3) to improve mesh quality
• 0 - Laplace smoothing only
• 1 - STL tri mode, with conversion to quads (if requested)
• 2 – tri to quad conversion, splitting of bad quads
• 3 - allow nodes to move off boundary with smoothing

• Other options and fuller descriptions may be found in the Help

menu.

© 2012 ANSYS, Inc. April 1, 2013 13 Release 14.5

 Patch Independent
Uses robust Octree method
• Volumetric tetra elements created around geometry
• Faces projected to surfaces
• Only surface mesh is retained
• Discussed in more detail in Volume Mesh lecture
Mesh sizes defined on surfaces and curves
Can walk over small details, thin gaps, small holes Volume
around is
• Relative to mesh size first
meshed
Nodes and edges don’t have to be lined up with surface
edges
• Only lined up where curves exist

Nearest nodes
projected to surface
and only surface
Matches up with
mesh is left
previously meshed
surfaces

© 2012 ANSYS, Inc. April 1, 2013 14 Release 14.5

 Autoblock
Surface (2D) blocks are created automatically from
each surface
• Internal, blocks aren’t recognized or visible
• For further description of blocking, refer to Hexa chapter
Blocks structurally connected
• Conformal mesh between blocks and surfaces
Structured blocks result from 4-sided surfaces
• For regular or four-sided blocks, structured (mapped) mesh
follows contours of geometry

Best for recognizing rounds or fillets

Irregular (non-4 sided) or trimmed surface patches may
be unstructured
Mesh sizes set on surfaces or curves
Options
• Ignore size
• Mapped or free (unstructured as in patch dependent)
Build Topology MUST be run beforehand

© 2012 ANSYS, Inc. April 1, 2013 15 Release 14.5

 Shrinkwrap
Cartesian (rectilinear) method
• Can ignore larger features, gaps, holes
Cube faces partially projected to geometry
Quickest method for creating surface mesh
Can’t recognize sharp features
• Currently in development phase
Best for “wrapping” complicated geometry
• Quick and dirty surface meshing of complex geometries
For “solid” models
• Not recommended for thin sheet solids
Options
• No. of smooth iterations
– To improve grid quality
• Surface projection factor
– To fully project to original geometry (1.0), to not
project at all (0.0), or partially (0.0 < factor < 1.0)

© 2012 ANSYS, Inc. April 1, 2013 16 Release 14.5

 Mesh Types
Mesh Types
• Set in Global Mesh Setup > Shell Mesh Parameters or
Surface Mesh Setup (local upon selected surface Examples
entities done with
patch
– Global defaults overridden by local settings dependent
or Compute Mesh options mesher

• All Tri
• Quad w/one Tri
– Almost all quad except with one tri per
Global
surface
settings – Single tri allows transition between uneven
mesh distribution on loop edges
– Where pure quad will fail
• Quad Dominant
– Allows for several transition triangles
Local – Very useful in surface meshing complicated
surface surfaces where a pure quad mesh may have
settings poor quality
• All Quad All quad,
autoblock
These mesh types will look different with the different
mesh methods
© 2012 ANSYS, Inc. April 1, 2013 17 Release 14.5
 Compute Mesh
Once sizes, methods and types are set – ready to
compute!
Select Mesh > Compute Mesh > Surface Mesh Only
• Most of the time can just select Compute at bottom of
panel which will create shell mesh for entire model
(Input = All)
• Other options
• Overwrite Surface Preset/Default Mesh Type/Method
– To quickly override global and local settings
– Avoid going back to other Mesh Setup menus to
change parameters
• Input
– Can mesh All (default – entire model)
– Visible – only visibly displayed surfaces/geometry
– Part by Part
• Parts meshed separately
• Mesh will be non-conformal between parts
– From Screen
• Select surfaces or a loop of curves to mesh from
screen
© 2012 ANSYS, Inc. April 1, 2013 18 Release 14.5
 Demo - Stamping
• Build topology
• Curve sizing
• Patch dependent mesher
• Quad rings
• Dormant curves
• Delete elements, all attached
• Remesh one surface with different
method
– Delaunay, all tri
– Patch independent, all quad
• Check single edges
• Merge nodes tolerance

© 2012 ANSYS, Inc. April 1, 2013 19 Release 14.5

 Workshops
• Workshop 3.1 - stamping
– Build diagnostic topology
– Setting curve parameters
– Patch based surface mesher
– Dormant curves
– Ignore size
– Quad rings

• Workshop 3.2 - Wingbody

– Global element size
– Mesh setup by parts
– Different mesh method on selected surfaces
– Curve parameters – dynamic method
– Deleting elements – flood fill
– Try harder setting – patch independent
– Respect line elements
– Remesh only selected surfaces

© 2012 ANSYS, Inc. April 1, 2013 20 Release 14.5