Mid-Surface Junction Assembly for Hole-Free B-Rep Simulation Meshes
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Solution Overview
Problem
Existing CAD software solutions for generating mid-surfaces from thin solid portions of B-rep models often result in incomplete or inaccurate junctions, leading to holes and inefficiencies in structural simulations, particularly in the automotive industry.
Innovation Solution
A method for computing junction wires between mid-surfaces based on border wires, determining multi-junction points, and connecting mid-surfaces to these wires, ensuring seamless integration and accurate meshing without manual post-processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If existing CAD software solutions are used to generate mid-surfaces from thin solid portions, then the process can be automated, but the junctions become incomplete or inaccurate creating holes in the mesh
Solution Approach 1:
The patent applies preliminary action by pre-computing junction wires before generating the final mid-surface mesh. The junction wires are calculated in advance based on the border wires of mid-surfaces, and multi-junction points are determined beforehand. This preliminary computation of connection geometry ensures that when the mid-surfaces are assembled, the junctions are already properly defined, eliminating holes and improving accuracy without requiring manual post-processing.
2Manufacturing precision
If manual post-processing is used to fix junction holes, then the accuracy can be improved, but the productivity decreases
Solution Approach 1:
The patent implements self-service by enabling the system to automatically resolve its own junction issues without human intervention. The algorithm autonomously computes junction wires, determines multi-junction points, and assembles mid-surfaces into a complete mesh. This self-resolving capability eliminates the need for manual post-processing to fix junction holes, thereby maintaining high accuracy while preserving productivity through full automation.
3Reliability
If 3D meshing is used for thin solid portions, then the structural simulation can be performed, but the memory footprint and computing resources increase
Solution Approach 1:
The patent applies the extraction principle by separating thin solid portions from thick solid portions and applying different meshing strategies to each. Thin portions are represented by 2D mid-surfaces with 2D mesh elements, while thick portions use 3D mesh elements. This extraction of thin portions into a simplified 2D representation reduces the number of elements and memory requirements while maintaining sufficient accuracy for structural simulation, as thin portions contribute less to the overall structural behavior.
Data Source
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AI summary
It is disclosed a method of B-rep processing for performing structural simulation of a mechanical part. The method comprises providing mid-surfaces of a B-rep representation of the part. Each mid-surface represents a thin portion. The method comprises computing junction wires corresponding to a respective junction of respective mid-surfaces, based on border wires of the respective mid-surfaces. The method comprises determining one or more groups. Each group consists in extremities of junction wires to connect. The determination of the one or more groups is by identifying connected border wires corresponding to the junction wires. The method comprises, for each determined group of extremities, determining a multi-junction point. The multi-junction point is a connection point of the extremities. The method comprises connecting the junction wires using the determined multi-junction points. The method comprises connecting the mid-surfaces to the connected junction wires.