PowerWRAP Examples
When PowerFLOW is your CAE software you can include as much detail in the CAD model as you like. In fact, you want to include every detail you can in your CAE mesh models, because you never know which one may make a difference.
The Original CAD Model.
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How to handle detailed data
The problem is production CAD data is complex. Every manufacturing detail must be included, from the casting and strengthening ribs to the nuts, bolts and washers. The best CAE mesh would include all of the these details, but who has the time to track each one down and create a complete manifold mesh over each one? And to compound the problem even the best of CAD is never perfect; cracks, gaps and overlaps are the norm and there will always be a few missing pieces that make a properly closed casing into a hollow shell.
Some of the many small pieces typically found in the real production CAD you have to use every day.
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Speeding the preparation time
So what’s the solution? PowerWRAP brings together the mathematical and computing technologies to reduce a six week process to half a day. The input to PowerWRAP is a simple, unconnected, automatically generated mesh created on each CAD surface. These can be the basic visualization meshes from your CAD system or, if you prefer, PowerWRAP has options to import your CAD model directly.
Once the model is inside PowerWRAP, key features that help define potential problems in the original model are identified (opening to interior regions that are not wanted in the final mesh). These key features are used to cap off these access points. A grouping (like that shown in picture below) for example, is created in a few minutes.
Large openings in the CAD model are quickly identified and closed by PowerWRAP.
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Complete part, ready for simulation
The entire collection of parts are now wrapped with a process that converges a single manifold mesh onto the outer surface of each independent body; covering over small gaps, holes and overlapping or poorly defined geometry automatically. The global mesh density is set as a parameter and local regions of the model can be set to have increased mesh resolution. The final wrapped mesh usually requires some post processing to clean up the mesh quality and the result is ready for PowerFLOW.
The final wrapped mesh with PID’s set automatically during wrapping to match the original partitioning.
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Other Examples
The PowerWRAP process is so effective in terms of time efficiency and quality simulation results that Exa recommends that every simulation include the complete vehicle geometry including wrapped models of the engine, all underhood detail, drivetrain and chassis components.
Complex engine wrapped by PowerWRAP. Before wrapping on left - wrapped on right (fan blades removed - usually left unwrapped).
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