Post Graduate Program in Automation & Pre-Processing for FEA & CFD Analysis

Week 01 & 02 - Introduction to ANSA GUI and Tools

• In this module, you will be introduced to the CAE domain along with an introduction to FEA basics. You will learn the Graphical User Interface(GUI) of the ANSA tool.
• You will get to know about different solvers and types of analysis carried out using them.
• You will be introduced to basic tools that will help you with geometric cleanups and other deck setups in ANSA.

The topics covered in this module are 

• Introduction to FEA
• ANSA GUI
• Geometric Tools and Topology Cleanup
• Types of CAE Process Tools for Structural CAE
• Types of Elements
• Different Tools used in TOPO Deck

Week 03 - Manual Mid-surfacing, 2D Meshing and Quality Criteria

• In this module, you will study the basics of 2D meshing.
• You will also learn how to extract mid-surface, deploy 2D mesh on the mid-surface, reconstruct already meshed areas, along with various techniques for achieving the mesh flow.
• You will also learn how to eliminate the tria concentration present in the geometry and capture the important features in the geometry.
• You will be working on a sheet metal component in this module.
• You will also be taught how to achieve mesh quality for the component by assigning the quality criteria parameters.
• You will study the following topics in this module.
  • Manual mid surfacing for sheet metal components
  • 2D meshing on sheet metal components
  • Quality checkup and taking measures to achieve quality 
  • Introduction to different tools used in mesh deck
  • Revising the basic commands
  • Basic commands used in TOPO and MESH deck
  • Practice model provided 

Week 04 - Manual Mid-surfacing - Plastic Trims and Cast Parts

• In this module, you will be learning about extracting the mid-surface and working on a plastic part.
• Plastic parts are of variable thickness therefore, extracting the mid-surface and assigning the thickness is more tricky when compared to the sheet metal component.
• You will study the following topics in this module 
  • Manual mid-surfacing for plastic trim components & cast parts
  • 2D meshing, quality checkup 
  • Different tools used in mesh deck

Week 05 - Solid Meshing(Tetra & Hexa)

• In this module, you will learn the different tools and techniques to generate the Tetra mesh for a given geometry.
• You will also learn the different methods involved in generating a Hexa mesh.
• You will also understand the quality checks for Tetra elements and how to rectify failed tetra elements.
• You will study the following topics in this module.
• Establishing solid (Tetra) meshing on 2 different components
  • Solid (Tetra) meshing 
  • 3D meshing quality criteria
  • Volume mesh deck
• Introduction to solid (Hexa) meshing
  • Solid (Hexa) meshing
  • Volume mesh deck

Week 06 - Connections (Seat and Door)

• In this module, you will be introduced to connections in ANSA.
• This enables the user to generate FE models for durability, NVH, and crash analysis.
• Connections are now efficiently designed with the help of the tool.
• You will also generate connections for the automotive seat & front door.
• These are the topics that you will learn in this module, different types of connectors such as:
  • Two Nodes RBE2
  • Cluster RBE2
  • RBE2-CBUSH-RBE2
  • RBE2-HEXA-RBE2
  • Nut and Bolt representation
  • Seam weld data representation
  • Different operations such as:
    • Converting and realizing operations
    • Connection manager operations
    • Assigning mass to a node

Week 07 - Introduction to Batch Meshing/Casting

• In this module, you will learn about batch meshing, casting methods, and their applications in industries.
• The batch meshing/casting method will help you to model the component efficiently and quicker than if you tried to model them manually.
• But these tools do not guarantee the best results always, and there will be areas where you need to manually check the results.
• You will study the following topics in this module.
  • Introduction to casting & batch meshing operations
  • Auto mid-surfacing and meshing by using casting and skin methods

     

Week 08 - Introduction to Morphing Basics

• In this module, you will learn about a few morphing techniques in ANSA.
• ANSA allows a full-fledged morphing menu that is completely integrated with ANSA's interface.
• The functions of the morphing menu can be used to efficiently re-shape both FE and/or geometry-based models.
• You will study the following topics in this module.
  • Direct morphing
  • Box morphing 
  • Hatches
  • Morphing in FE model
  • Morphing in CAD geometry

Week 01-Basics of FEA

• In this module, you will study the fundamentals of Finite Element Analysis (FEA). FEA is a generic technique used to solve boundary value problems.
• FEA finds a lot of applications in structural analysis.
• In this module, we will discuss the math behind FEA, along with the following topics 
  • 5Ws of Finite Element Analysis
  • Types of engineering problem-solving methods
  • CAE process types
  • Model setup

Week 02-Introduction to HyperMesh GUI

• In this module, you will study the meshing software, HyperMesh.
• HyperMesh is a highly capable simulation software, and in this module, you will learn about the various tools and features that HyperMesh has to offer.
• In this module, you will learn about the following topics
  • Introduction to the Geometric Tool and the Tools Menu
  • Basic geometric tools
  • Geometry cleanups (includes auto cleanup)
  • Midsurface creation

Week 03-Key Geometric Tools

• While dealing with complex 3D components, it is important to remove small features and holes that are inevitable when designing a CAD model.
• You will be introduced to the batch mesher macro that will be instrumental in accomplishing this.
• In this module, you will study the following topics
  • Geometry cleanup criteria files
  • MNode's creation & node editing
  • Point edit
  • Edge edit

Week 04-1D Meshing

• 1D Meshing is a great way to speed up the simulation time without compromising on accuracy.
• There are different types of 1D elements, each featuring its own shape function, and characteristics. 
• In this module, you will learn the following
  • 5Masses, Bar, Rod, Rigid, RBE3, Springs, Gaps
  • Connectors, HYPER BEAM, Linemesh, Linear 1D
  • Edit, Element, Split, Replace, and Detach
  • Order change, configuration edit, and element type

Week 05-Geometry Cleanup and Midsurface

• In this module, you will learn to perform surface clean-up on a given geometry and to extract the mid-surface using an in-built tool, auto-mid-surface.
• You will also learn how to clean up the surface manually because relying only on the auto-mid-surface option may give rise to a distorted surface while dealing with complex geometry.
• Here is a list of topics that you will learn about in this module.
  • Surface clean up
  • Midsurface generation
  • Handling distorted surfaces

Week 06-2D Meshing Introduction and Examples

• In this module, you will learn the basics of 2D meshing, how to mesh a surface, how to re-mesh a meshed surface using elements, and how to attain mesh flow in the geometry.
• You will also learn how to handle the tria elements in the model.
  • Introduction to 2D meshing
  • 2D basic tools
  • Mesh flow
  • Handling tria element

Week 07-Quality Criteria

• In this module, you learn what a quality check is and understand the different quality checks that HyperMesh offers.
• You will also learn how to fix areas that failed the quality check.
• Here, is a list of key concepts that you will learn in this module,
  • 1D element quality check
  • 2D element quality check
  • Understanding the quality parameters for 2D meshing

Week 08-Advance 2D Meshing

• In this module, you will learn how to do manual mid-surfacing when the auto-mid surfacing option fails. You will also learn how to handle geometry if it is symmetrical, normal check-in the model and its significance, and free edges along with their significance.
• The following topics are covered in this
  • Manual mid-surface
  • Handling symmetric geometry
  • Free-edge checks
  • Normals check 

Week 09-3D Meshing

• In this module, you will learn the different tools and techniques to generate a hexamesh for a given geometry.
• You will also learn a variety of techniques to generate tetra meshes. You will also understand the quality checks for tetra elements and how to rectify areas that have failed these checks.
• The following topics are covered in this module.
  • Hexa meshing
  • Tetra meshing
  • Different methods of tetra mesh generation
  • 3D element quality check

Week 10-Connectors

• Sometimes, meshes are made with both 2D and 3D meshes that are interspersed.
• Connectors help the computer understand that the interface is between two different kinds of meshes.
• Connectors are time-saving features that are a must in large models.
• In addition to this, connectors offer a way to let the computer know that two components have been seam welded.
  • Seam weld
  • Spot weld
  • Bolt connection
  • Spring element
  • Adhesive modelling-HEXA

Week 11-Batch Meshing

• In this module, you will understand the uses of batch meshing and its applications in industries. You learn about the parameter file and criteria file, how they can be optimized for the requirements.
  • Here is a list of key concepts that you will learn in this module.
  • Understand quality parameter and criteria files
    Optimizing these files according to the requirement.

Week 12-Morphing Techniques and Macro Generation

• In this module, you will learn about morphing, which can be done using constraints, volumes, and geometry.
• Also, you will be working with the manipulation of TCL commands, running a TCL command using the inbuilt run options.
  • Morph constraints
  • Morph volumes
  • Map to geometry
  • Basic macro generation using TCL commands

Week 01 - Fundamentals

• Strength of materials
  • Stress, Pressure, Strain
  • Lateral Strain - Why does it happen
  • Poisson’s Ratio - Practical Application
  • Shear
  • Modulus of Rigidity
  • Moment of Inertia
  • Kinetic Energy, Rotational Kinetic Energy
  • Continuity equation
  • Shear Force and Bending Moment
  • Beams and Truss - Theory and Problems
  • Materials and it is Mechanical Properties
  • Stress and Strain Curves
  • Theory of Failures
  • Vibration
• Finite Element Analysis
  • FEA - Significance and Scope
  • Applications in Various Industries - Examples
  • Types of Analysis
  • Implicit and Explicit - An Overview
  • Degree of Freedom
  • Governing Equations
  • Shape Functions
  • Gaussian Quadrature
  • Boundary Conditions
  • FEA Crash Course - Tool-Based Questions

Week 02 - ANSA Part 1

• Introduction and GUI in ANSA
  • Tool knowledge in ANSA
  • Basics of FEA
  • What is Meshing?
  • Significance of Meshing
  • Elemental Errors
  • Types of Elements in Meshing
  • How to choose and When to choose elements
• Midsurfacing and Methods of Meshing
  • Types of Midsurfacing Techniques
  • Rearrangement of Construction lines
  • Different meshing strategies
  • Manual and Auto Meshing in sheet metal component
• Mesh Quality improvement
  • Various different quality criteria and working with them in ANSA
• Tool Practice

Week 03 - ANSA Part 2

• Mesh Evaluation
  • Things to remember for obtaining a good mesh
  • Important checks to perform
• Time Management in ANSA
  • Various strategies for Time management while working on the component
  • Tips and Tricks on How to approach a general Tool test
• Tool Practice

Week 04 - HyperMesh Part 1

• Introduction
  • HyperMesh - Introduction
• Meshing in HM
  • Meshing Fundamental
  • Mid Surface extraction methods
  • Meshing methods for mesh flow
  • Quality criteria - Checks and fixes
  • Tool Test approach
• Mesh Improvisation
  • Various different quality criteria and working with them in HyperMesh
• Evaluating FE
  • Things to remember for obtaining a good mesh
  • Important checks to perform
• Tool Practice

Week 05 - HyperMesh Part 2

• Time Management
  • Various strategies for Time management while working on the component
  • Tips and Tricks on How to approach a general Tool test
• Tool Practice

Week 1 - Introduction to MATLAB

MATLAB has a series of commands and functions that instruct the program to perform a task. Just like any other programming language, it has a syntax that defines the rules of the symbols and characters used to write a code. It is important for learners to understand the MATLAB syntax, basic commands, and functions to write effective programs. 

This week will cover

• MATLAB syntax and commands 
• Methods and ways to use commands in different scenarios
• Manipulation of calculations and comparisons
• Use of arrays.
• Functions (plotting, creating animations, creating figures, and more)

Week 2 - Forward Kinematics Simulator

Forward kinematics is the process of determining the position of a robot’s end-effector by using kinematic equations with known values of angular velocities and joint parameters. It is important for learners to understand how MATLAB can be used to determine the unknown values in the kinematic equations, as well as simulate the movement of the manipulator.  

This week will cover

• Manipulator motion using ImageMagick
• Simulation of a 2R robotic arm manipulator
• Creating a movie clip with the spatial motions of a robotic arm
• ‘For’ loop in programming
• Working of the “hold on” command
• Arrays and linspace commands

Week 3 - Air Standard Cycle Simulator

The air standard cycle considers air as the working fluid which goes through heat addition and heat rejection. This is a thermodynamic closed loop cycle in which heat energy is converted into mechanical power. By using MATLAB, the pressure and volume diagram of air standard cycles can be plotted and simulated. It is important to understand how to solve for the kinematic equations involved in the air standard cycle, and how to plot the diagram using MATLAB. 

This week will cover

• Solving piston kinematics equation to calculate volume trace
• PV diagrams for different operating conditions.
• Thermodynamic relationships
• Pressure-volume variations
• Order of the program
• Plots & legends used in the graphs
• Piston kinematics

Week 4 - Vibrations and Dynamics

Vibrations and dynamics are at the core of physical systems. Most mechanical engineering systems are dynamic in nature. These systems can be represented by equations of motion that form a set of ordinary differential equations (ODEs). It is important for learners to understand how to solve these ODEs, and their application in a real-world context.

This week will cover

• Backward difference formula (BDF) and forward difference formula (FDF) methods to solve ODEs
• Real use of differential equations
• How differential equations relate to real-world applications
• Solving differential equations
• ODE solvers, syntax of ODEs, and various supplementary commands

Week 5 - Curve Fitting and Regression

Curve fitting is used to understand the relationship between different variables by constructing a curve that fits best through a series of data points. Regression analysis identifies the strength of the relationship between two or more variables. This lets engineers understand the relationship between system input and output, as well as predict how the system will behave in the future. Curve fitting and regression can both be done using MATLAB. It is important to understand curve fitting and regression analysis when working with physical systems in MATLAB. 

This week will cover

• Polynomials and their best fits
• PolyFit and PolyVal commands
• Calculating errors
• Sum of squares regression (SSR)
• Sum of squares error (SSE)
• Sum of squares total (SST)

Week 6 - Genetic Algorithm

The genetic algorithm is based on Charles Darwin’s theory of natural selection in which each step identifies the ‘best’ set of parents to reproduce children. Overtime, the continuous process of doing this yields an optimal population. In the same way, the genetic algorithm can be applied to optimization problems and performed using MATLAB. It is important for learners to understand the genetic algorithm, and how it can be used as an optimization technique.  

This week will cover 

• Optimization techniques 
• Working of the genetic algorithm
• Genetic algorithm syntax and finding the global maxima
• Stalagmite functions and how it works
• Population size, number of generations, fitness value, and termination of further generations

Week 01-Introduction to Python

• This module provides an introduction to Python using different mathematical operations and performing operations such as,
  • Array manipulations
  • Plotting and understanding the relationship between 2 variables
  • Looping using one or more looping conditions

Week 02-Plotting and Visualization

• In this module, you will write programs that plot the p-v line of an air standard cycle and also create animations for a robotic arm with 2 degrees of freedom and simulate the motion of a pendulum.
  • In this module, you will learn the following,
    • Understanding the relationship between 2 variables using plots
    • Saving plots and creating animations using ImageMagick
    • Using tables

Week 03-Solving Dynamic Equations

• In this module, you will learn to solve ordinary differential equations using the SciPy module. This is of particular interest since differential equations govern the equations of motion for various mechanical systems and this method can be used to numerically solve initial value problems.
  • Using odeint to solve initial value differential equations
  • Create a pendulum using the available coordinates
  • Plotting and saving images
  • Creating an animation using ImageMagick

Week 04-Curve Fitting and Regression

• In this module, you will learn how to perform curve fitting using Python.
• Curve fitting finds widespread use in predicting the relationship between different variables for which an existing relationship doesn’t exist.
• Furthermore, curve fitting can also be used as a predictive tool in machine learning and AI to predict what will happen in the future using the trend of the plot.
• Students will learn about, 
  • Curve fitting using the SciPy module
  • Learning how to check how well the data has been fitted

Week 05-Understanding Iterative Solvers

• This module covers iterative solvers, which find widespread use in the solution of polynomial equations, and other aspects like understanding how to obtain the solution in the most optimised manner possible.
• This module also explains,
  • How to use an iterative solver
  • How to use while loops?

Week 06-Data Analysis

• The final module of the coursework deals with data manipulation, which is used in many industries like CAE and CFD to post-process the results from the simulation.
• This is particularly useful if the same simulation is run multiple times for different configurations, and this code can be used to obtain the data automatically.
• At the end of this module, you will be able to,
  • Take data from a file and manipulate the data to create meaningful plots.
  • Make the necessary calculations.
  • Automate the post-processing procedure.

Week 01-Introduction to ANSA GUI and Tools

• In this module, you will be introduced to the ANSA Software. You will learn the Graphical User Interface(GUI) of the ANSA tool.
• You will get to know about different solvers and the types of analysis carried out using them.
• You will be introduced to the basic tools that will help you with geometric cleanups and other deck setups in ANSA.
• The topics covered in this module are,
  • Introduction to ANSA
  • ANSA GUI
  • Geometric tools and topology cleanup
  • Different tools used in the TOPO deck

Week 02-2D (Surface) Meshing to Pressure valve

• In this module, you will be introduced to the pressure valve model. You will learn to perform surface meshing on a pressure valve model.
• The topics covered in this module are,
  • PID creation and PID assignment
  • Different selection techniques and visibility tools
  • Basic Topology cleanup
  • Basic tools used in surface meshing

Week 03-3D (Volume) Meshing to Turbocharger

• In this module, you will be introduced to the turbocharger model.
• You will get to know, how to perform volumetric meshing to a turbocharger model.
• The topics covered in this module are,
  • Geometry cleanup to define volumes
  • Various geometry checks
  • Surface meshing as per quality criteria
  • Volumetric meshing as per requirements

Week04- CFD meshing to BMW M6 Model inside Wind tunnel

• In this module, you will be introduced to the BMW M6 model.
• You will learn how to perform CFD meshing on a BMW M6 model.
• The topics covered in this module are,
  • Advanced topology cleanup to define volumes
  • Variable surface meshing part by part
  • Solving quality failed elements as per quality criteria
  • Symmetry operation for surface and mesh elements
  • Wind tunnel creation
  • CFD meshing for wind tunnel

Week 05-Surface Wrap to an Automotive Assembly

• In this module, you will be introduced to three different automotive models: engine, transmission, and gearbox.
• You will learn how to perform surface wrap on an automotive assembly for CFD analysis of the outer flow.
• The topics covered in this module are,
  • Geometry cleanups for the surface wrap.
  • Merging of different models into one GUI.
  • Surface wrapping for an assembly.

Week 1 - Get to know your tools

• In this module, you will learn HyperMesh GUI, what is TCL compiler and hands-on practice of the TCL commands in Notepad++
  • HyperMesh GUI overview
  • TCL compilers
  • Notepad ++
  • “Hello World” TCL code

Week 2 - Let’s learn a new language

• In this module, you will learn TCL commands like loops, arrays and how TCL is linked with HyperMesh 
  • Looping structures
  • Array manipulation
  • TCL wiki
  • HyperMesh and TCL linkage

 Week 3 - Dissecting HyperMesh using TCL commands

• In this module, you will learn several commands and how they can be used in HyperMesh to perform operations
  •  “ * ” and “hm_” commands

Week 4 - Let’s build the GUIs with TK

• In this module, you will learn how to build a GUI using TK for the TCL command used in HyperMesh 
  • Introduction to TK
  • Creating TK popup box
  • Creating TK buttons
  • Creating TK input boxes

Week 5 - Problem of normal

• In this module, you will be able to understand the problem of normals in pre-processing and how it will affect the results in a simulation. You will also learn how to automate to align the normal in a few quick mouse clicks.
  • Element normals and their significance
  • Fixing normals: code vs. standard

Week 6 - Let’s take care of “zero”

• In this module, you will learn how to handle a null case when you write a code in HyperMesh to automate a process 
  • Handling null cases
  • Delete displayed
  • Delete empty
  • Isolate displayed

Week 7 - Let’s meet the CAE nightmare – Free edges

• In this module, you can understand the concept of free edges and how it will affect the simulation, and also you will be able to write a code to automate the fix for the Free edge issue that occurs during meshing.
  • Free edge and their significance
  • Detecting free edges using available tools

Week 8 - Collectors

In this module, you will learn the significance of a collector, property card, and material card along with a manual method to assign them. Once you understand that you will also be writing code to automate the process.

• Different collectors and prop and material assignment
• Renaming- as per thickness

Week 9 - Auto reflect

• In this module, you learn the importance of Reflect command for the symmetrical models along with the manual renaming of the components and their material and property cards. Once you understand that this method is time consuming and tiring, you will also learn how this can be automated with a few lines of codes. 
  • Explain the physics
  • Explain procedure
  • CAD manipulation using TCL

Week 10 - The importance of order

• In this module, you will understand the significance of numbering  in a model for nodes, elements, components, sets, etc., and learn how to automate them with learn the code and its logic
  • Creating ordered sets
  • “Remembering” the selection order
  • Midline generation

Week 11 - Element Quality Check

• In this module, you will understand the importance of mesh quality. You will also understand the importance of automating this process
  • Quality criteria check
  • How to highlight these elements
  • Popup and report generation

Week 12 - Miscellaneous

• In this module, you will learn how to code to automate the part list and how to read and understand the Userpage.mac
  • Auto part list
  • Userpage.mac understanding
  • Automatic deck setup