Learning Forum

[22503862]

Hello, I'm trying to mesh an FSAE car and am using wrapping since I'm doing a self-contained journal file. The journal takes a STEP file as an input and goes through to the solution. I've been struggling to get it to mesh now for around 2 weeks and I'm at my wits' end. The most frustrating thing of all is that I used the same settings for a half-car symmetry simulation (over 100, in fact) and they all meshed fine, but now the complete vehicle refuses to mesh. I am using a wrappnig factor of 0.7. I have 2 main errors, as described below with corresponding pictures:

1) Bad surface mesh whereby some parts grow elements inside of them, or elements do not obey edges properly. I have no idea how to fix this. My geometry import tolerance is at 5e-4 which makes everything really slow and this should be more than enough. The geometry faceting looks excellent. The wing in the first image below is on the left side of the car. There is an identical wing on the right side of the car that meshed perfectly - I don't understand how this discrepancy is possible. In the second image below, the endplate and wing element were one zone due to the cad setup. I have since separated them and this sort of resolves the issue, but between the wing and the chassis there are still elements that grow in the corner.

 

2) If the surface mesh does generate and is okay, then the volume mesh fails. Some elements on the surface mesh face just won't turn into polys and I get this disgusting set of triangles and no prisms. 

I tried altering the sizings and it didn't help. I don't understand what I'm doing wrong, this seems like the software just being full of bugs. I'm on 2023 r1 and have tried 2024 r1 but it produces the same bad results.

[Federico]

Hello, 

The FTM wrapper may require some fine tuning to ensure proper resolution of the model. You said you are using a wrapper ratio of 0.7. I would suggest trying a lower ration, while preserving the target mesh size to see if your geometry gets resolved better.