1. WS4.3-1 ANSYS, Inc. Proprietary © 2009 ANSYS, Inc. All rights reserved. July 2009 Inventory #002664 Chapter 4 Volume Meshing – Workshop 3 Femur BF Cartesian Meshing ICEM CFD Introductory Course

2. Volume Meshing – Workshop 3 WS4.3-2 ANSYS, Inc. Proprietary © 2009 ANSYS, Inc. All rights reserved. July 2009 Inventory #002664 Training Manual Set Working Directory Set working directory – File > Change Working Dir… – Choose Femur – OK

3. Volume Meshing – Workshop 3 WS4.3-3 ANSYS, Inc. Proprietary © 2009 ANSYS, Inc. All rights reserved. July 2009 Inventory #002664 Training Manual Import Geometry File -> Workbench Readers Select the file LeftFemur.agdb (Design Modeler Geometry) Push the “Open” button Before importing the Geometry, the user is presented with options Keep Workbench defaults Import Geometry Create Subset from Named Selection Named Selections can be setup in DM, Simulation or CAD packages such as UG, Pro/E or SolidWorks We are not setting any Named Selection Prefixes Accept the Defaults and apply

4. Volume Meshing – Workshop 3 WS4.3-4 ANSYS, Inc. Proprietary © 2009 ANSYS, Inc. All rights reserved. July 2009 Inventory #002664 Training Manual Create Parts from Subsets Each Body comes in as a Part The named Selections appear as Geometry Subsets – These can be used to control display or selection – These can be turned into Parts Make sure all the Subsets are active Right Click on “Subsets” and choose “Create Part” The new parts can be displayed

5. Volume Meshing – Workshop 3 WS4.3-5 ANSYS, Inc. Proprietary © 2009 ANSYS, Inc. All rights reserved. July 2009 Inventory #002664 Training Manual Global Mesh Setup Mesh > Global Mesh Setup > Global Mesh Size Set Max element = 64 Hit Apply Mesh > Global Mesh Setup > Volume Meshing Parameter Set the Mesh Type to “Cartesian” Set the Mesh Method to “Body-Fitted” Keep the defaults as shown Refinement Type is set to “Uniform” Project Inflated Faces is Checked Apply

6. Volume Meshing – Workshop 3 WS4.3-6 ANSYS, Inc. Proprietary © 2009 ANSYS, Inc. All rights reserved. July 2009 Inventory #002664 Training Manual Part Mesh Setup Mesh -> Part Mesh Setup – This brings up the Part Mesh Setup dialog Left Click on the max size header – This brings up the MAX SIZE dialog – Set max size to “5” – Accept Left Click in the BONESHAFT max size field – Change the “5” to a “15” Left Click on the Prism Header Apply Dismiss The prism control is used to control which surfaces are inflated in BFCart

7. Volume Meshing – Workshop 3 WS4.3-7 ANSYS, Inc. Proprietary © 2009 ANSYS, Inc. All rights reserved. July 2009 Inventory #002664 Training Manual Initialize hexa blocking Blocking -> Create Block – This step is optional, BFCart could create its own cartesian mesh – This enables us to control the biasing with ICEM CFD Hexa’s advanced edge parameter and splitting functionality Initialize Blocks – Type should be set to 3D Bounding Box We just want a rectangular box to represent cartesian space – Click the “select geometry” icon – Click on the “all” icon in the Select geometry toolbox Or use the “a” hotkey Click the middle mouse button to end

8. Volume Meshing – Workshop 3 WS4.3-8 ANSYS, Inc. Proprietary © 2009 ANSYS, Inc. All rights reserved. July 2009 Inventory #002664 Training Manual Split Block The Two primary ways to create Cartesian Stations are splitting and Edge Params Blocking -> Split Block – Click on the “Select edges” icon – as prompted, hold-left click on one of the long edges With the left button still down, drag the split to create a box around the ball joint release the left mouse button and click the middle mouse button to accept the split – This DEZ will auto-iterate (repeat) When prompted again repeat the above process to create a box around the knee joint Middle mouse button Twice to accept the split and then end the command

9. Volume Meshing – Workshop 3 WS4.3-9 ANSYS, Inc. Proprietary © 2009 ANSYS, Inc. All rights reserved. July 2009 Inventory #002664 Training Manual Pre-Mesh Params Expand the Blocking Branch of the Model Tree Right Click on Edges – Left Click on Bunching – This will display Edge Bunching (Station Distribution) Blocking -> Pre-Mesh Params – The blocking is a separate entity from the geometry – This next step will transfer the Part Mesh Params to the blocking Update Sizes – Update All – Apply

10. Volume Meshing – Workshop 3 WS4.3-10 ANSYS, Inc. Proprietary © 2009 ANSYS, Inc. All rights reserved. July 2009 Inventory #002664 Training Manual Pre-Mesh Params Pre-Mesh Params -> Edge Params Click the “Select edges” icon and Left Click on one of the longest edges (along the shaft) – Depending on your exact split locations, this should show approximately 26 Nodes – Change the Spacing 1 and Spacing 2 to “5” This will match the spacing at the ends – Change the Ratio 1 and Ratio 2 to “1.2” – Turn on Copy Parameters – Set Copy Method to “To All Parallel Edges” – Apply

11. Volume Meshing – Workshop 3 WS4.3-11 ANSYS, Inc. Proprietary © 2009 ANSYS, Inc. All rights reserved. July 2009 Inventory #002664 Training Manual Write Cartesian Grid File -> Save project As Save as Femur.prj File -> Blocking -> Write Cartesian Grid – This converts the splits and Biasing to Cartesian Stations – The file (FEMUR.crt) is saved in the Project dir You don’t need to view the Cartesian mesh; but if you did, it would look like this High aspect ratio w/Biasing

12. Volume Meshing – Workshop 3 WS4.3-12 ANSYS, Inc. Proprietary © 2009 ANSYS, Inc. All rights reserved. July 2009 Inventory #002664 Training Manual Compute Mesh Select Mesh > Compute Mesh > Volume Mesh Set the Mesh Type to “Cartesian” Set the Mesh Method to “Body-Fitted” Stair step is also an option The Volume Part will be automatically created Turn on the option to Use Split from Grid File This is why we made the cartesian file Click on the File Browse icon and Select the FEMUR.crt file we just created Note: one was also included in the tutorial files Set Inflate Parts to “Defined’ This will use the Part Mesh Params to control the inflation Compute If you are prompted to save the tetin file, accept it BFCart is a batch process that runs off the last saved file

13. Volume Meshing – Workshop 3 WS4.3-13 ANSYS, Inc. Proprietary © 2009 ANSYS, Inc. All rights reserved. July 2009 Inventory #002664 Training Manual Mesh The mesh should take about 30 seconds to generate. Biasing toward high aspect ratio hexas in the middle Note: this mesh is pure Hexa. There is a global option for creating pyramids which is useful if the model has sharp features inducing poor quality.

14. Volume Meshing – Workshop 3 WS4.3-14 ANSYS, Inc. Proprietary © 2009 ANSYS, Inc. All rights reserved. July 2009 Inventory #002664 Training Manual Cutplane View Adjust the Method to “Middle Y Plane” In the Model Tree, turn on the Mesh -> Volume Adjust the Fraction Value to cut thru different parallel slices. – Try out some other Methods When you find a cross section you want to “keep” – Click Create mesh subset – You can view these later thru the Mesh subsets in the model tree. In the model tree, Right Click on Mesh Select Cut Plane -> Manage Cut Plane