Tutorial

BASIC ANSA
GEOMETRY CLEANUP
AND SHELL MESHING
Table of Contents
1. Introduction...................................................................................................................................2
1.2. Prerequisites.........................................................................................................................2
1.3. Problem description...............................................................................................................2
1.4. Data files...............................................................................................................................2
2. Read the CAD file.........................................................................................................................3
3. Perform Cleanup...........................................................................................................................8
4. Defeaturing..................................................................................................................................37
5. Shell meshing..............................................................................................................................50
6. Conclusion..................................................................................................................................63

BETA CAE Systems S.A.

 BASIC ANSA – Geometry Cleanup and Shell Meshing

1. Introduction
This tutorial presents in detail all the steps taken to read a CAD file of a part, perform cleanup, as
well as some geometry simplification, in order to create a good quality shell mesh.

The steps described in this tutorial include:

• Read the IGES file with different tolerance settings and assess the results.
• Cleanup geometry, close gaps, modify or create new Faces etc.
• Optionally, repeat the previous step with the help of Automatic Cleanup functionality.
• De-featuring, removing details such as small holes and fillets.
• Mesh the parts with an element length of 10 mm
• Improve the mesh by manually optimizing the shape of the Macro Areas

1.2. Prerequisites
Reading the 4 pages of section Introduction and Getting Started document is recommended in
order to obtain a familiarization with the ANSA interface and terminology.
1.3. Problem description
The geometry of the part is shown here
in its final state. Note that the part
consists of more than one Property IDs
(PIDs), as shown in different colors.

1.4. Data files

The files of this tutorial are: one IGES file named basic.igs contains the geometry and the result
can be found for reference in the file basic_result.ansa .

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2. Read the CAD file

Start ANSA. By default you are in the TOPO
menu.

Before reading any CAD data into ANSA you

can specify some settings concerning the
application of Topology (the connectivity of
neighboring Faces), and the Resolution (the
appearance of geometrical entities on the
screen). These settings should correspond to
the dimensions, level of detail and tolerances of
the CAD file to be input.
Activate the WINDOWS>SETTINGS function. In the Settings
->Translators input topology section all flags are by default
active. The Perform ANSA Topology flag ensures that the
Topology is performed during CAD file opening. As a result
when the IGES file is read later, the topology process will be
applied.

For educational purposes de-activate the Clean Geometry flag button and press OK. In this way
the automatic geometry cleanup step will not be performed and the cleanup will be examined and
performed manually.
Note that the automatic topology is performed
according to the tolerance settings that are specified in
WINDOWS->Settings->Tolerances. Make sure to
specify appropriate tolerance values before reading a
CAD file, to avoid collapsed Faces (large tolerances),
or gaps (very small tolerances). For demonstration,
activate the function and select extra fine tolerance
settings (Nodes 0.003125, Curves 0.0125) and press
OK.
Also note that the appearance of geometrical details
depends on the Resolution settings under WINDOWS-
>Settings-> Resolution. Activate the function, press OK
in the Warning window, and the Resolution Definition
window appears. Keep the default value of 20 for
Perimeter Length in the CONS Resolution menu.
(Note that this value also corresponds to the initial
discretization length, or element length). For 3D Curves
specify a smaller resolution (2) to view small
geometrical features in more detail. Press OK to close
the window. (You may also cross-check that the default
distance distortion is of 20% in the
PERIMETERs>DISTOR function, in the MESH menu).

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Now read in the IGES data from FILE>OPEN.

The File Manager window appears. Navigate
and select the IGES file basic.igs.
Ensure to switch the filter type to IGES or All
Supported Files to be able to view the iges file!

The CAD file is read and topology is applied.

You should see the part as shown. Change the
view of the part to better understand the
geometry.
Press: Ctrl

Ctrl + left mouse button to rotate the part

Ctrl + middle mouse button to translate

the part

Ctrl + left and middle mouse button to

zoom in and out.

You can also zoom in and out with the F7 and F8 keys.
F7 F8

F9 If at any time the view is lost, press F9 to fit all to the screen.

Notice that as by default the mode is ENT (Entity)

display mode, you can see the red, yellow and cyan
CONS (Curves ON Surfaces).

The coloring has to do with the connectivity of the

Faces.
Red: a SINGLE free edge CONS
Yellow: a DOUBLE CONS shared by two neighboring
connected Faces
Cyan : a TRIPLE CONS shared by three or more
connected Faces.

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To make things clearer, you can activate and

deactivate the visibility of each of the three types of
CONS separately using the SINGLE, DOUBLE and
TRIPLE flag buttons.

De-activating here the DOUBLE flag shows only the

free red and triple cyan CONS. Apart from the free
edges of the sheet metal there are other opening
(gaps, untrimmed Faces etc.) that must be corrected.

Note that the current specified Tolerances are Extra Fine and the topology process has left many
gaps, as the CAD description is not very accurate. What if the specified Tolerances were larger?
Activate the WINDOWS->Settings
->Tolerances function.
Select middle tolerance settings (Nodes 0.05,
Curves 0.2) and press OK.

Activate the FILE>OPEN function to read again

the same CAD file with the middle Tolerance
values.
A Confirmation window opens, in case you want
to save the current database.
Press Discard.

The File Manager opens next. Select again the basic.igs file and press OK. Be careful to select
the IGES and NOT the ANSA file! Switch the filter type to IGES in the File Manager.
The CAD file is read and Topology is applied,
this time with middle tolerance values.

The red free edges are now less, because the

topology process resulted in the connection of
more Faces automatically.

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Activate back the visibility of

DOUBLE CONS to view the whole
part.

Activate the SHADOW view mode flag.

You can now view the Faces in gray and

yellow (as you are always in ENT view mode).
Gray color represents the positive side of the
Faces while Yellow the negative.

The orientation is currently random. There is

not a uniform Face orientation.

Press the FACEs> ORIENT. function. There

are the options to apply the Orientation:
1. on Visible Entities or
2. on Selected Entities
The orientation of all the visible Faces
becomes uniform. The Yellow side of the
Faces indicates the negative side, while the
gray color marks the positive one.

In order to flip the now uniform

ORIENT orientation, you can use the
FACEs>ORIENT. Function
once again.

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Switch to PID color view mode.

You can now view the Faces colored
according to their Property ID. (Note
that the assigned colors to different PIDs are
random when opening a CAD file, so you may
see different colors).

Switch back to ENT color view mode

to proceed with the cleanup process.

Save the file from FILE>SAVE AS to your local directory under the name basic.ansa. The File
Manager opens in order to specify the path and the ANSA database filename. Remember when
you save or output in ANSA you must always type the appropriate extension for each file type.
You will now proceed with Geometry cleanup.
(If at any time you want to pause your work you can exit ANSA from FILE>QUIT, and then start
ANSA again and read the ANSA database basic.ansa from FILE>OPEN to resume work).

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3. Perform Cleanup
De-activate SHADOW mode and the
visibility flag button for DOUBLE
CONS.

You will now isolate a region of your part to

work on.

Activate the OR function of the Focus

Toolbar functions. Select with left mouse
button box selection the area shown.

The OR function leaves visible only the selected

Faces.
(If you accidentally select wrong Faces, press
the ALL function of the same Group to bring all
the entities back to visible).

Activate the LOCK [LOCK ON] flag button in the

Focus Toolbar to lock the currently visible
entities.

To view the complete Faces that you have left

visible, activate again the DOUBLE CONS
visibility flag.

Activate also the CROSH (cross hatch) visibility

flag. This allows the visualization of two green
dashed lines along the center isoparametrics of
the Faces. Apart from visualization purposes,
the crosshatches are also used for selecting
Faces.

Activate SHADOW mode again.

Note the problem in this area.

There seems to be a Face that is untrimmed

and extends well out of the boundaries of the
other Faces.

Activate the NOT function, of the Focus

group, and select with the left mouse
button this Face from its crosshatch.

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The selected Face is removed from the visible.

This leaves a better view of the other Faces.

You must somehow trim the big Face so that it

matches exactly to the boundaries of the other
Faces.

Press the ALL function of the Focus

group.

Only the locked entities (all the entities that

were visible at the time that you activated the
LOCK flag) appear.
Notice that because we have specified a
Resolution length of 20, some Faces appear
coarser than their actual geometrical
description.

Activate the FINE

function from the
AUXILIARIES
Group functions in TOPO Menu and left click on
the crosshatch of the big Face twice.
Each time you press the left mouse button the
Resolution length of the selected Face is
halved. This makes the Face appear with more
detail. The curvature of the Face is now clearly
visible. (Note that if you use the FINE function
with the right mouse button you double the
Resolution length of selected entities, making
them appear coarser).

! Note: do not left click more than a couple of

times as the resolution length will become very
small and this will delay the SHADOW
operation.

Rotating the part you can see that this Face

covers well the gap of the remaining Faces. It is
only a matter of trimming it correctly.
PROJECT Activate the
PROJECT>NORMAL function
NORMAL from the TOPO>CONS
functions group.
Select with the left mouse button the four red
CONS of the Faces behind (if you cannot pick
them, turn the view of the part around, or de-
activate SHADOW mode).De-select with right
mouse button if required.
Confirm with middle mouse button.

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Next select the Face to project and cut the

selected CONS onto.

You can pick the Face from its crosshatch or

one of its red CONS. De-select with right mouse
button if required.

Confirm with middle mouse button.

The selected red CONS are projected on the

Face and cut it.

Press the ESC key to exit the

Esc PROJECT function.

Remember you can press the ESC key to abort

any function if you are unsure.

Activate the FACEs>DELETE

DELETE function.
Select the excess Face to be
deleted from its boundary. The Faces Delete
List window appears.

Press DELETE to delete the Face.

(! Note that to retrieve a Face, which was
deleted unintentionally, activate the
FACEs>UNDELETE function, select it among
the previewed deleted Faces. Press middle
button. Use FACEs>TOPO function to re-
establish connectivity).
The Face is now properly trimmed, but not
topologically connected with the neighboring
Faces (note the red CONS).
Activate the FACEs>TOPO function.
Select with left mouse button box selection the
CONS shown. Confirm with middle button.

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Topology is applied by ANSA according to the

specified tolerances.
All CONS appear yellow, indicating proper
double connectivity.

De-activate the LOCK function

Press ALL to bring all the Faces back to

visible.

Moving to the next problematic region on

the left.

Here we have the opposite problem. A Face

that is not large enough, and a resulting gap.

Activate the function

INFO SURFs>INFO.
Select this Face from its
crosshatch.

Its Surface (its underlying CAD description) is

also not big enough to cover the gap.

Notice that the visibility of

the Surface can be
controlled from the
Options window

Activate the FACEs>DELETE

DELETE function.

Select the Face with the left mouse button from

its crosshatch.

! Note that when selecting a Face from its

crosshatch, this is deleted without any warning.
In contrast, when selecting it from its boundary
CONS, the Delete Face preview window
appears for confirmation.

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Notice two magenta cross Hot

DELETE Points that were left over after
the deletion of the Face.

Activate the HOT POINTs> DELETE function.

Select with the left mouse button these two Hot
Points.

The Hot Points are deleted. (Although not

necessary, you can always delete such Hot
Points. This leaves uniform longer CONS that
are easier to select for Face creation, and also
results in better quality mesh later).

Now you will create a new Face to cover this

opening.

COONS Activate the SURFs>COONS

function. (COONS stands for the
1 4
name of the mathematician).
Select sequentially the four red CONS that form
the boundaries of the Face to be created.

Confirm with middle mouse button.

A preview of the Surface to be created is given

as a cyan net.

Press OK in the Coons window that appears if

you are satisfied with the result.

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Upon accepting the Surface the new Face is

also created, and is also topologically
connected with the neighboring Faces.

Note that if you have selected the CONS in a

anti-clockwise order, the orientation would be
positive (gray) outwards, according to the right
hand rule.

If you have not, use the function

FACEs>ORIENT to assign the preferred
orientation.

De-activate SHADOW, CROSH and DOUBLE

flags.

Note how the problematic regions drop in

number.

Activate back SHADOW, CROSH and DOUBLE

flags.

Move to the small triangular gap at the front.

Activate the SURFs>INFO

INFO function.

Select the Face from its crosshatch.

The previewed underlying Surface appears to

cover the gap.

In this case you will create a new Face using

the already existing Surface.

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Activate the FACEs>NEW function.

In the New Face Options window that appears
select the Existing Surf option.
2
3

Select with the left mouse button the three red

CONS and confirm with middle mouse button.

Next select with the left mouse button the

crosshatch of the Face whose Surface you will
use for the new Face.

The new Face is created. If you enquire its

Surface with SURFs>INFO you will see that it
uses the same one as the larger neighboring
Face.

Rotate the part to the other side.

You can see that in this area there are two

untrimmed and intersecting Faces.

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De-activate SHADOW, CROSH and DOUBLE

flag buttons.

Activate the NOT function from the

Focus group.

Select with left mouse button the two red CONS

as shown.

Their Faces become not visible.

Next press the INVERT function of the

Focus group.

The visible-not visible status of all entities is

inverted, making only the two selected Faces
now visible.

Activate DOUBLE and CROSH flags two view

better the two intersecting Faces.

Activate also the CURVEs visibility flag. To find

the intersection of these two Faces you will use
3D Curves. These are auxiliary curves that are
not connected to the Faces and are used for
CAD constructions in ANSA. 3D Curves appear
in magenta color and their visibility is controlled
by the CURVEs visibility flag.

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Activate the CURVEs>SURF

SURF INT
INT function.

Ignore the Extend Values window that appears.

Select with the left mouse button the first Face

from its crosshatch.
Next select the second Face from its
crosshatch.

ANSA calculates the intersection of the two

Faces and creates a 3D Curve. (The CURVEs
flag must be active to be able to see the Curve).

Activate the SHADOW flag button to view better

the intersection area.

Here you could project this 3D Curve on the two

Faces in order to cut them.

However a plain intersection would not suffice to

fix this area. In this location a fillet exists in the
neighboring Faces.

You will recreate the boundaries of this fillet and

then project and cut the two Faces.

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Activate the CURVEs>TRANSF.

TRANSF. function. This function creates a
new Curve by transforming an
existing one to fit new start and end point
positions.

Select with the left mouse button the 3D Curve.

Confirm with middle mouse button.

Note the arrow that appears next. This arrow

indicates the start of the segment.

2 Select two point positions as target start and

end for the new transformed 3D Curve to be
created.
1
! Note that the start and end positions should
correspond to the direction arrow.

Select the Hot Points as shown.

A new 3D Curve is created, from a

transformation of the selected one. Notice how
this Curve follows the shape of the initial one.

(if you accidentally picked wrong Hot Points,

delete the unwanted new Curve, using
CURVEs>DELETE).

While still in the CURVEs>TRANSF. function,

select again the initial 3D Curve.

Confirm with middle mouse button.

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According to the direction of the arrow, select

the two target start and end Hot Points as
shown, on the other Face.
2

Another similar 3D Curve is created.

PROJECT Activate the CONS>

NORMAL PROJECT [NORMAL]
function.

Select the 3D Curve shown.

Confirm with middle mouse button.

Next select the Face to project onto.

You can select the Face from its crosshatch or

boundary CONS.

Confirm with middle mouse button.

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The 3D Curve is projected and cuts the Face. A

yellow CONS appears along the cut.

While still in the CONS>PROJECT function

select the other 3D Curve.

Confirm with middle mouse button.

Select the Face to project onto and cut.

Confirm with middle mouse button.

Having completed the work with the 3D Curves,

de-activate their visibility flag button.

Now you will delete the excess Faces using the

DELETE function from the Utilities Toolbar.

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Activate the DELETE function.

Select the two Faces with the left mouse
button. Confirm with middle mouse button.

A Warning window appears.

Press OK to proceed with the deletion of the

selected Faces.

(The advantage of the DELETE function of the

Utilities Toollbar in comparison with the
FACEs>DELETE, is the fact that you can select
more than one Face, without being prompted
each time for confirmation).

Press the ALL function in the Focus

group to bring all the Faces to visible.

Here you will create a curved face to close the

fillet area.

Activate the SURFs>COONS

COONS
function.

Activate the Loop flag button in the Feature

Selection window that appears.
1

Select with the left mouse button one red

CONS.

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As the Loop flag is active, after selecting the

first CONS, ANSA automatically identifies and
selects the whole closed string of CONS of the
2
same loop.

(Use right mouse button to de-select CONS if

required).

Confirm with middle mouse button.

The Surface to be created is previewed as a

cyan net.
main
body

Press OK in the window that appears. Note that

flange in this case, in order to create this Face you
have selected CONS that belong to Faces of
different Property ID. (Remember that the flange
has a different PID than the main body).

As a result ANSA prompts you to select a PID

for the new Face that you have created.
The Properties window appears.

You can double-click on one of the available

PIDs in the list. As here you may not know
which is the correct PID to select, you can left
click on another Face (crosshatch or CONS)
from the screen. ANSA will mark the Property of
this Face on the list so that you can middle-click
in order to confirm it.

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The Face is created. You can switch to PID

display mode to check the different PIDs in
color. (You can always change the PID of
selected Faces using the FACEs>SET PID
function, by selecting them and pressing middle
mouse button. The Property list window will
appear; you select a Property and double-click
or press OK).

Moving on to the next problematic area.

Activate the OR function of the Focus

group.

Select with box selection as shown.

(If you select wrongly, press ALL to bring all the

Faces back to visible and re-select. You may
also use the NOT and AND functions of the
Focus group).

You should leave visible only the round

protrusion and the large Face shown here.

It appears that the round protrusion is not

connected to the Face. See the red CONS all
around.

Rotate to the other side to see that the large

Face has no corresponding opening for the
protrusion.

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Back to the front side, notice that again due to a

relatively large Resolution length the protrusion
appears quite coarse and it is hard to
distinguish its proper shape.

Activate the FINE function from the

AUXILIARIES Group functions in TOPO Menu.
Left click a couple of times on the crosshatches
of the Faces in order to reduce the Resolution
length.

Note that if the resolution length is dropped too

much, you may loose the shadow of the Face.
To fix this, you can use the right mouse button
to do the opposite, i.e. increase the Resolution
length and make entities appear coarser.

Now the geometry appears much clearer.

Activate the CONS>

PROJECT PROJECT [NORMAL]
NORMAL function.

Select the four red CONS around the protrusion.

Note that if you activate the flag in the Feature

Selection window that appears, you only need
to select one CONS and ANSA selects the
whole string provided the angle between two
CONS is smaller than the specified limit
Confirm with middle mouse button.

Next select the large Face to project the CONS

onto.

Confirm with middle mouse button.

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The CONS are projected and cut the Face.

Rotate the part to the rear side to view the

yellow CONS along the cut that was made.

Note that although the cut was made, still the

protrusion is not connected.

Activate the FACEs>TOPO

TOPO
function.
Select with box selection the CONS as shown.

Confirm with middle mouse button.

ANSA perform topology connection.

Now the boundary appears in cyan indicating

that three Faces are connected at each CONS.

Now you can delete the interior excess of the

large Face.

Activate the FACEs>DELETE function.

Select the crosshatch of the inner Face.

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Note that as you selected from the crosshatch

the Face was deleted without confirmation.

(Again in case of accidental deletion of a Face,

use the FACEs>UNDELETE function. ANSA
previews all previously deleted Faces in white.
Select one with left mouse button to retrieve it).

Press ALL from the Focus group and

rotate the part to view from outside as
shown.

Activate the FACEs>DELETE

DELETE
function and select with the left
mouse button the crosshatch of the small round
Face shown.

The Face is deleted without confirmation and

the hole is opened.

Activate the
ORIENT
FACEs>ORIENT>[Visible]
function to make the orientation of all the Faces
uniform.

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Moving to the next area shown here.

De-activate SHADOW, CROSH and DOUBLE

flag buttons, to view the remaining gaps more
easily.

Activate the OR function from the

Focus group and select with box
selection the area shown.

Activate back the CROSH and DOUBLE flags to

view the four Faces that remain visible.

Here we have a gap that was not closed by the

topology operation during CAD input.

Point the cursor near the opening and

F7 zoom in real close using the F7 key.
(The F8 can be used to zoom out).

Note that as you zoom in closer and closer, two

white horizontal lines appear at the bottom left
corner of the display.
These lines represent graphically the tolerance
values that you have specified in
SETTINGS>TOLERANCES. These are the
tolerances that are used by ANSA for the
automatic topology operation.
Notice that the gap here is larger that the
tolerances.
As a result ANSA did not connect the Faces at
curves match dist this location. You will have to connect (paste)
nodes match dist these CONS manually.

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Activate the CONS>PASTE

PASTE
1 function. Select with the left
mouse button the CONS as shown.
2 Confirm with middle mouse button.
As you are exceeding the tolerances a Warning
window appears. Press OK to confirm.

Upon confirmation the first CONS is moved and

pasted to the second one.

Perform the same operation for

PASTE
the two CONS at the bottom.

(What will happen to this small red CONS??)

1
Select the two CONS.
2

Confirm with middle mouse button.

Again the first CONS is pasted on the second

one.
As a result a white dot appears.
This is a topological problem, as a white dot in
the TOPO menu represents a collapsed CONS,
that is a CONS that has its start and end
coincident.

To fix such a problem you must

RELEASE
first release all topological
conditions at that location.
Activate the HOT POINTs> RELEASE function
and select with box selection the area shown.

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All topological conditions are released. The

HOT POINTs>RELEASE function can always
be used to correct improperly pasted CONS.

As a result all CONS now appear in red, and

five distinct Hot Points are visible.
To be able to pair these CONS in pairs you
must ensure that they are properly segmented.

Activate the HOT POINTs>

DELETE
DELETE function and select with
the left mouse button the Hot point shown.

The Hot Point is deleted leaving one uniform

CONS at that edge of the Faces.

Now the CONS can be pasted correctly is pairs.

Activate the CONS>PASTE

PASTE
function and select the CONS as
shown.

2
1

Confirm with middle mouse button.

Perform the same on the

PASTE
opposite side. (Note that if you
have not exited the function you can proceed
with the selection of CONS without pressing the
PASTE button).
2
Here, although you cannot distinguish them,
1 there are two red CONS which are
superimposed.

Confirm with middle mouse button.

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Now you have a gap that can be closed.

Still in the PASTE function select the CONS as

shown.
1
2

Confirm with middle mouse button.

And the two CONS here.

Confirm with middle mouse button.

2 1

The problem is fixed.

Topology is correct with yellow CONS and a

single Hot Point at the center.

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Press ALL from the Focus menu to

bring all Faces back to visible.

Press F9 to fit all to screen.

F9

De-activate CROSH and

DOUBLE visibility flags.

Some problematic red CONS that remain are at

the top of the image.

Activate the DOUBLE visibility flag and zoom in

close to that area.

Some CONS are not connected.

Activate the CONS>PASTE

PASTE
function and select them with the
left mouse button.
Remember when you PASTE CONS, the first
CONS moves and is pasted on the second one.

1
2

Confirm with middle mouse button.

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Select also the two remaining CONS.

2 1

Confirm with middle mouse button.

The geometry here is now clean.

Press F9 to zoom all.

De-activate the DOUBLE and

SINGLE bounds flag button.
Only the cyan CONS remain
visible.

Cyan CONS show connectivity of more than two

Faces. Cyan CONS are usually present at T-
junctions. If there are no T-junctions present,
then usually cyan CONS imply the existence of
multiply defined Faces.

Zoom in to the area on the right.

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Activate back the DOUBLE and SINGLE

bounds.
Activate SHADOW and CROSH button.

The resolution is a bit coarse to clearly identify

the problem.

FINE Activate the FINE function and

left click once on the crosshatch
of both Faces.

The resolution is better.

This is an area of overlapping Faces.

INFO To inquire, activate the

FACEs>INFO [INFO]
INFO function and click on one red
CONS.

ANSA highlights the whole Face.

You can do the same for the other red CONS to

see the overlap.

Activate the CONS> PROJECT [NORMAL]

function.

PROJECT
NORMAL

Select with left mouse button the CONS shown.

Confirm with middle mouse button.

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Next select the Face to be trimmed, from its

crosshatch.

Confirm with middle mouse button.

The Face is trimmed.

Activate the FACEs>DELETE

DELETE function and select the excess
Face.

Press DELETE in the Delete Face window that

appears.

A gap remains.

Activate the FACEs>TOPO

TOPO function, select with box selection
the area and confirm with middle
mouse button.

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DELETE
Activate the HOT POINTs>DELETE function
and use box selection to delete all remaining
unnecessary Hot Points.

Finally zoom in to the area where cyan CONS

are present.
De-activate CROSH visibility so as not to
accidentally select a Face from its crosshatch.

To identify and correct the problem you will use

the FACEs>DELETE function and its preview
capabilities.

Activate the FACEs>DELETE

DELETE function.
Select the Face from one cyan CONS.

The Delete Face preview window appears,

indicating that 3 Faces are connected at that
CONS. The first one (1 of 3) is highlighted.
(! Note the order of preview may be different in
your case).

Press the KEEP button

(or K in the keyboard) to
keep this Face and
proceed to the next one.

The second Face (2 of 3) is then previewed.

Again press the KEEP button (or K in the
keyboard) to keep the Face.

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Finally, the third Face is previewed.

This Face must be deleted, as it is redundant.

Press the DELETE button (or D in the

keyboard)

The Face is deleted.

Only yellow CONS remain.

The geometry is clean.

One last check by de-activating CROSH and

DOUBLE, leaves red CONS only at expected
locations, i.e. free edges and openings.

Activate SHADOW and DOUBLE flag buttons.

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Save the file from FILE>SAVE.

At this stage, you could optionally start again
from the beginning, reopening the IGES file, but
this time prior to doing so, activate the Clean
Geometry flag in WINDOWS->Settings->CAD
Input Topology. Your Tolerances should be kept
in Middle again.
Several of the problems you previously fixed
manually, can be solved automatically.

In addition, you can use the HOT PNTs>RM.OVERL function. This function
RM. OVERL. automatically trims overlapping Faces, and will fix one of the two cyan CONS
problem areas. An identical example of that case is the third picture on p.33.

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4. Defeaturing
Some small openings exist at the bottom flange
of the part. You will remove these, as they are
too small to be included in the mesh.

FILL HOLE Activate the CONS>FILL HOL

function.
The Fill Hole Parameters window opens.

Select with the left mouse button the opening

shown.

The selected opening (red CONS perimeter) is

highlighted.
Alternatively you can enter a value of 20 and
press the Select button.

All the openings with an effective diameter

smaller than the input value are selected
automatically.

Press OK.

All the selected openings are filled.

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Move to the top of the part.

Here there is a small non-uniform flange.

Activate the MEASURE function from

the Utilities Toolbar.

The Measure window opens, where by default

the Nodes selection mode is active.

Select with the left mouse button the two Hot

points shown.

As long as a selection has been made, the

possible available results are listed in the
Measure window.

The distance as shown on the screen and

reported in the Text Window is less than 3mm.

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You will replace this flange all around with a

constant height flange of 10mm.

FLANGE
WIDTH

Activate the FACEs>FLANGE [WIDTH] function.

Select all the red CONS shown (in the direction

of flange extension only) with the left mouse
button.
Confirm with middle mouse button.

The Flange Distance window appears.

Type a value of 10 and activate the Delete Old
Flange flag.

Press OK.
The Faces of the old flange are deleted and
new Faces of the specified height are created.

Note some remaining red CONS.

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Activate the FACEs>TOPO

TOPO function.

Select with box selection the CONS as shown.

Confirm with middle mouse button.

Topology is applied.

The CONS are now yellow.

Activate the HOT POINTs>

DELETE DELETE function.

Select with box selection the area shown.

The unnecessary Hot Points are deleted.

ORIENT Finally press the FACEs>

ORIENT. function to assign a
uniform orientation to all visible Faces.

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Press again the ORIENT. button to flip the

current orientation if necessary.

The next step will focus on fillet sharpening.

Zoom in closer to the base of the top round

flange.

Although not very clear due to the coarse

Resolution, this base is a round fillet.

(You can check this using the SURFs>INFO

function to view the underlying Surface
description).
DACH Activate the FACEs>DACH
DACH [DACH] function. The Dach
Selection window opens.

Type in the
values shown
and press
Select.

ANSA identifies
and selects all
the fillets with
radius of curvature less than 3 and width less
than 5. Check that no other Faces have been
selected. De-select them with right mouse
button if necessary.
Press middle mouse button to confirm and
proceed.
A preview of the new Surfaces to be created, to
replace the fillets with sharp corners is provided.

The Dach Parameters window appears.

Select the DELETE FILLET option.

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Keep the Join Macros flag active.

While in preview mode, rotate the part to view

better the Surfaces to be created.

Zoom out to ensure that ANSA has created nice

Surfaces.

Press OK in the Dach Parameters window.

The Faces of the fillet are deleted and new

Faces forming sharp corners are created.

Note that as you have used the Join Macros

option, some Double CONS are colored in light
brown color instead of yellow. This means that if
you switch to MESH menu, you will not see
them as they are joined. This allows a better
mesh, as it avoids narrow Macro Areas.

Zoom out.

You will apply DACH function to the fillet around

the large flange all round the part. This time you
will manually select the Faces.

Zoom in to this area.

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Activate the FACEs>DACH

DACH [DACH] and pick with the left
DACH mouse button the CONS
shown.

Ignore the Dach Selection window and select

with left mouse button the CONS shown.

ANSA should highlight the string of Faces

shown. Use right mouse button to de-select any
Faces that should not be included.

Confirm with middle mouse button the selected

Faces.

Again you get a preview of the Surfaces to be

created, and the Dach Parameters window
appears. The DELETE FILLET flag is now
active from the last time.

Press F9 to zoom all and ensure that all

Surfaces are well described.

Press OK in the Dach Parameters window.

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The Faces of the fillet are deleted and replaces

with new Faces that form sharp corners.

Zoom to the top flange.

Notice that its corners appear sharp (due to the

relatively coarse resolution), but in fact they are
not.

Use the FINE function in the

FINE Geometry Group and click with
the left mouse button on the red
CONS to examine its actual form.

For shell meshing purposes, it would be better if

these corners were sharp and the corner node,
well defined. In the next steps you will modify
these round corners to sharp ones.

Use the HOT PNTs>INSERT function and place

four Hot Points, one on each side of the two
round corners, as shown here.

This is done so as to define the arc area of the

round corner.

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Activate the FACEs>FLANGE

FLANGE [CORNER].
CORNER

The Radius Definition

window appears.
Keep the MANUAL flag
button option.

Pick with the left mouse button the CONS

between the manually inserted Hot Points.

ANSA makes the corner sharp and inserts a Hot

Point automatically, and deleted the inserted
Hot Points.

Left click on the opposite corner, to do the same

there also.

The flange now has sharp and well-defined

corners.

(You may have to use the FACEs>ORIENT

function to re-establish uniform face orientation).

This will help in the creation of a good quality

mesh.

Press F9 to zoom all.

F9

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Switch to PID display mode.

You can now view the Faces colored according

to their Property ID. (Note that the colors may
appear different in your case, but this is not
important here).

Zoom in close to this area.

As you can see the DACH function that split the

fillet in two has left a discontinuity in Property.

(You may have to use the FINE function to

improve the Resolution locally and better
understand the geometry).

You will correct this in order to avoid quality

problems in the shell meshing later.

First de-activate SHADOW mode, to facilitate

viewing.

Activate the FACEs>CUT

CUT function.

Select with the left mouse button the two Hot

Points shown.

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A cut is made between these two positions and

a new CONS appears (note that you can always
undo an unwanted CUT by selecting the new
CONS with right mouse button, while in the CUT
function).

SET PID Now Activate the FACEs>SET

PID function.
Select with the left mouse button the small
triangular Face from its crosshatch.
Confirm with middle mouse button.
The Properties window appears, so that you can
select the PID you want to assign to the
selected Face.

To make it easier, pick with the left mouse

button a Face from the screen to get its PID.
ANSA marks it in the list. Press OK to confirm.

The PID is assigned to the Face.

Activate again the SHADOW display mode.

The area is now better shared by the two

properties.

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The same PID difference problem occurs on the

other side as well.

Treat it in a similar manner.

Switch to ENT display mode.

The cleanup process should now be

complete.

You will make some final checks.

De-activate SHADOW, CROSH and DOUBLE

visibility flags.

You should only see three closed paths of red

CONS corresponding to the outer perimeter and
two openings of the part.

If not correct the problems.

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Bring back SHADOW and DOUBLE flags.

Note in case that there are Faces that fail the

SHADOW operation, the so called Unchecked
Face, then these Faces are reported on the
Screen

Using the Context Menu of

the unchecked faces, these
can be isolated on the screen in order to be
corrected
Such Faces usually are thin
needle shaped Faces or Faces
that have bad Surface
description.

If in your case no Unchecked Faces are

reported on the screen, then no such problems
exist in your model.

Press ALL from the Focus group to

make all the Faces visible.

The geometry defeaturing is completed. Save the file from FILE>SAVE.

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5. Shell meshing
Switch to MESH menu.

In MESH menu the Faces are now Macro

Areas and the CONS are Perimeter Segments.
The Hot Points are here displayed as white
dots. Along the Perimeter Segments you can
see magenta Perimeter nodes. These are
places initially according to the CONS
Resolution settings. In this case the nodes are
placed every 20mm, apart from some regions
where you have used the FINE function to
change the Resolution locally.
You will assign a uniform distance between
Perimeter Nodes, or Element
LENGTH Length.
Activate the
PERIMETERs>LENGTH function.
Select all the Macro Areas with left mouse
button. Confirm with middle mouse button.
The Input window opens.

Type in a value of 10 in the Length field, leave

the other fields empty (default values will be
used) and press Enter.
The new element length is applied to all the
Perimeter Segments of the selected Macro
Areas.

(Note that although we started with a CONS

Resolution length (and correspondingly Element
Length) of 20mm, we will mesh the part with an
element length of 10, so as to keep more
details).

FREE Activate the MESH GEN.> FREE

function.

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In the Options window enable the reconstruct

option to be run right after the meshing
algorithms in order to get high quality mesh. For
element type select mixed.

All the Macro Areas are meshed with the FREE

algorithm.
The number of the visible elements is given in a
text legend on the left (Note, the values may
vary slightly).
You will use some functions to improve the
quality of the generated mesh.

Zoom in to the front of the part. Notice how the

elements are squeezed in the small triangular
shaped Macros Area.

Activate the MACROs>JOIN

JOIN [Erasing Mesh] function. Select
with the left mouse button the
two Perimeter Segments shown.

The Perimeters are removed and the two

Macros are joined to form a larger one. The
mesh is of course erased.
Note that if you join a Perimeter by mistake, you
can retrieve it using the MACROs>RELEASE
function, just picking it from the preview).

Notice that some Hot Points are left over.

DELETE Activate the HOT POINTs>

DELETE function and select
them with the left mouse button.

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The Hot Points are removed and the Perimeter

Segments are connected into longer, more
uniform Segments. The mesh of the neighboring
Macro is also erased.

Activate the
RE-MESH MESH GEN.>RE-MESH>
Visible [Visible] function.

The erased Macros Areas are remeshed with

the same meshing algorithm, in this case the
FREE.

Still you can see the middle Macro Areas are

quite narrow and do not leave space for a good
quality mesh.

You will split these in half.

Switch to TOPO to perform a vertical

cut along the middle.

DACH
Activate the FACEs> DACH
Divide Face [Divide Face) function.

Ignore the Dach Selection window that appears

and select with the left mouse button the red
CONS at the bottom. ANSA selects and
highlights the whole string of Faces along that
path.

Confirm with middle mouse button.

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The Divide Parameter window opens.

Ensure the Join Macros flag is active and press

OK.

ANSA splits the selected Faces in two.

Switch to MESH menu.

The mesh has been locally erased, as the

Macros have been modified.

Notice that the split Faces were joined with their

neighboring ones, as the Join Macros flag was
active. This will leave better space for the shell
mesh.

Use the RE-MESH [Visible]

RE-MESH function to remesh all the
Visible affected Macros.

The mesh now appears better in this area.

As you can see every action that results in the

modification of a Macro, leads to the erasure of
its mesh. Then you have to use the function
SHELL MESH>RE-MESH to remesh it.

Note that you can activate the Delete hot

points flag as the Remesh Macros in the
Options window that appears.

This option will allow the automatic deletion of

any remaining Hot Points after JOIN operations
and the automatic remesh of the Macros.

Move to the top round flange area.

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Notice here a Perimeter Segment that is too

short to have even one Perimeter Node. This
leads some triangular elements that could
otherwise be avoided.
NUMBER Activate the PERIMETERs>
NUMBER function.
Select with the left mouse button the small
Perimeter Segment. The Number Input window
opens, where the current nodal number is
reported.

Type in the value 1 and press Enter.

In the Options window enable the Remesh
Macros option so that macros are remeshed
after each modification is made to the mesh and
cause the erase of it. Make sure that this option
is from now on enabled on all those functions
that support it.

One nodal number is assigned to this Segment,

which is now colored red, to indicate the nodal
number has been specified explicitly and not via
the element Length.

JOIN Notice how this inclined

Perimeter distorts the mesh.
Activate the MACROs>JOIN function and join it.

The mesh is better.

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Move to the other side of the top flange.

A similar problem exists here also.

NUMBER Activate the PERIMETERs>

NUMBER function and apply a
nodal number of one.

The mesh is improved here as well.

Moving now to the round flange itself.

Suppose you want to have two rows of

elements along the flange.

Apply again the NUMBER function as above

and assign a nodal number of 1 to the vertical
Segment, as shown.

Type in a value of 1 and press Enter.

ANSA assigns automatically the specific nodal

number to all of the Perimeter Segments that
are parallel to the selected Segment in a
continuous path of Macro Areas.

However the automatic remeshing does not give

the desired result. In this case the FREE
algorithm did not produce two rows of elements
everywhere.

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Activate the
MAP MESH GEN.>MAP [Re-
Re-Generate Generate] function. The Re-
Generate option means
erase and mesh from new with the current
algorithm and settings).

Select with the left mouse button the Macros of

the flange, and confirm with middle

ANSA erases the mesh and meshes with the

MAP algorithm to produce the desired result.

(Actually you will see in the more advanced

tutorial that mesh treatment of flanges, holes,
fillets etc. can be prescribed in ANSA in
advance and applied automatically).

Move on to the top flange of the part.

Notice how the elements are misaligned.
Making a Cut along the symmetry plane of the
part would improve the mesh.
2
PROJ.CUT Activate the
MACROs>PROJ.CUT function.
Select the bottom Hot Point and the opposite
1 top Perimeter.

A new Hot Point is created at the projection

location and a CUT between the two is made.

ANSA remeshes automatically.

While still in the PROJ.CUT function select the

top Perimeter, as shown, in order to continue
from the last position with the cut operation
further upwards.

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ANSA projects, cuts and remeshes.

The last Hot Point remains highlighted for

further cut operations, but in this case press
ESC to exit the function.

NUMBER Finally use the PERIMETERs>

NUMBER function to place one
node in the two short vertical Perimeters.

Press Enter.
ANSA applies the new nodal number and
remeshes.

While still in the NUMBER function select the

upper vertical Perimeter with the right mouse
button to assign the same nodal number to
other Perimeters.

ANSA assigns there also a number of one.

Still you can improve the mesh of the fillet

region, by meshing it with a different algorithm.

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MAP Activate the function

Re-Generate MESH GEN.>
MAP [Re-Generate].

Select the Macro Area with the left mouse

button. You can de-select with right mouse
button if required.

Confirm with middle mouse button.

ANSA erases the current mesh and meshes

from new with the algorithm MAP.

The resulting mesh better represents the curved

fillet.

Move on to the area shown.

See how this tilted Perimeter Segment

interrupts the orientation of the mesh.
1
CUT Activate the MACROs>CUT
function.

Select the Hot Point and then the Perimeter

Node as shown.
2

A cut is made and a new Segment is created.

The affected Macros are remeshed.

JOIN Now activate the MACROs>JOIN

function and select the tilted
perimeter Segment.

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The Segment is removed as the two Macro

Areas are joined into one.

The resulting mesh is better, but still contains

some triangles, that could be removed.

Activate the
RECONS SHELL MESH>RECONS
Select [Select] function.

Switch to Macro Area selection mode.

Then select with left mouse button this Macro

and confirm with middle mouse button.

ANSA Reconstructs the mesh, removing the

unwanted triangles, and gives a preview of the
result.

Press OK in the Results Preview window that

appears next.
The mesh is now OK.

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Move to the area of the round protrusion.

Notice how many small elements are confined

in narrow Macro Areas.

JOIN Use the MACROs>JOIN function

to join the Segments, and create
larger Macros.

DELETE Then activate the HOT POINTs>

DELETE and select with box
selection the area shown.

NUMBER Optionally you can use the

PERIMETERs>NUMBER
function and assign numbers (1 and 7 nodes) to
the two remaining Segments shown.

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Moving to the last area, near the top end of the

big flange.

Join these two small Segments.

NUMBER Assign a nodal number of 1 to

this Segment.

The mesh is improved.

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Press F9 to zoom all.

F9

JOIN Join these two Segments that

interrupt the mesh of the flange.

The mesh is complete. Note that the number of

elements displayed in the legend may differ
depending on the actions that were taken during
Macro manipulation.

(You can output the shell mesh in any of the

available output formats, through
FILE>OUTPUT).

You can de-activate the

visibility flag buttons for
PERIMs and HOT PNTs
(under the Perimeters Points flag) in order to
view the mesh better.

Notice that in case the Perimeter flag is

deactivated the Perimeters Points get also not
visible.

The tutorial is completed.

Save the file from FILE>SAVE.
Quit ANSA from FILE>QUIT.

! Having quit ANSA, you may, or may not, want to delete the ANSA.defaults file that you have
created from the main menu: Windows > Settings > 'Save settings to ANSA.defaults' icon. This file
is located in your home directory. You can otherwise specify a different directory by selecting the
'Save settings as...' icon. Changes that may have occurred in the Graphics User Interface may be
saved in the ANSA.xml file, by selecting the corresponding icon from: Windows > Settings... > GUI
Settings group icon option.
Deleting the corresponding files will ensure that the next time you start ANSA, it will appear with its
inherent default settings.

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6. Conclusion
In this tutorial you have followed all the basic steps to cleanup the geometry of a part, remove some
small details and mesh it with shell elements. Not all capabilities were demonstrated. Refer also to
ANSA v14.x User’s Guide and to the On-Line Help for the functionality of ANSA and detailed
description of functions and procedures.

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