Chapter 5: Tetra Meshing

Chapter 5

Tetra Meshing
HyperMesh provides several methods of generating a tetrahedral mesh. The standard
method creates tetras from an enclosed volume of shell elements, plus several parameters.
This provides the user with a lot of control over the final tetra mesh. The volume tetra
mesher quickly and automatically creates a tetrahedral mesh on an enclosed volume of
surfaces or solid geometry with only a few inputs. Finally, the quick tetra mesher creates a
tetra mesh that maintains user specified quality requirements, but may sacrifice details in the
shape of the part to do so. All methods are valid in certain situations. The exercise in this
section focuses on the standard and volume tetra meshing methods.
In this chapter, you will learn about:
 Volume tetra mesher
 Standard tetra mesher
 Checking tetra element quality
 Re-meshing tetra elements

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Section 1: Standard Tetra Meshing

Standard Tet Meshing involves wrapping a volume in 2D elements and then using that
predefined mesh to “grow” Tetra elements to fill the volume. The process is as follows:
1. Generate a surface mesh of shell elements
2. Check quality and connectivity of the plate elements
3. Generate the tetrahedral mesh
4. Delete the original surface mesh
5. Edit if necessary to obtain good quality

The standard method of Tetra Meshing can be found through the Mesh > Create >
Tetramesh pull-down menu and then select the tetra mesh subpanel.
 Requirements for the shell mesh:
 Enclose one, and only one, continuous volume.
 There can be no free or T-connected edges.
 There can be no duplicates in the mesh.
 Elements should not fold over and overlap each other.
 Avoid very low minimum tria angles.
 Avoid a large difference in size between adjacent elements.
 Avoid a large difference in size between two sides of a wall thickness.
 For quad elements in the shell mesh:
 Split quads into 2 trias and create tetra elements under them
- OR –
 Keep the quad element and create pyramids under them
When using the Standard Tetramesh, the user will select the trias/quads that will define the
mesh and optionally the user can select fixed trias/quads. HyperMesh will, when creating
the tetra mesh, flip the diagonal of the 2D elements if it deems the resulting tetra mesh will
be of a higher quality with the flip. HyperMesh will not do this to elements selected in the
fixed selection.
 Standard Trias/Quads
 Adjacent tria faces on the tetrahedral mesh may have their diagonal reversed
from the shell mesh if tetras are better quality

 Fixed Trias/Quads:

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 Adjacent tria faces on the tetrahedral mesh always match the shell mesh

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Section 2: Volume Tetra Meshing

The volume tetra meshing utility, found in the Mesh>Create>Tetramesh pull-down menu and
in the volume tetra subpanel, provides a quick method for generating a tetra mesh. No
initial 2D mesh is required and the tetra mesh can be generated on solid geometry or inside
surfaces fully bounding a volume.

Two options are available to control the mesh:

 Use Proximity – Creates smaller elements next to small features to make a smooth
transition from small to large elements.
 Use Curvature – Will place more elements along curved surfaces based on user
specified settings.

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Exercise 5a: Tetrameshing

Step 1: Load the model

1. Load the model Exercise_5a.hm

Step 2: Attempt to TetraMesh the part

1. Either from the menu bar or the panel area, enter the panel to create a 3D Tetramesh.
2. Select the Volume tetra sub panel.
3. Change the enclosed volume switch to surfs.
4. Attempt to select a surface on the model. (Note: You will not be able to.)
With a properly enclosed model, the volume tetra panel will automatically select the
entire volume and allow a mesh to be created. With the model now in a topological
display mode, you will note there are many issues with the topography of the model.
Only a fully enclosed volume can be properly TetraMeshed, so we need to fix the model.

Step 3: Fix the topography.

1. Using the Geometry menu in the menu bar, use the geometry cleanup tools to ensure a
fully enclosed volume.

Hints: Equivalence and Toggle will solve most of the problems. Some issues require
filler surfaces and point replacement. Remember that topology visualization can
assist in finding problems.

Step 4: TetraMeshing
With a properly enclosed volume you can now create the TetraMesh
1. Either from the menu bar or the panel area, enter the panel to create a 3D Tetramesh.
2. Select the Volume tetra sub panel
3. Change the enclosed volume switch to surfs.
4. Select a surface on the model. HyperMesh will automatically select all of the surfaces
that enclose the volume. If this fails to happen there are still errors in the volume and
need to be corrected using the geometry cleanup tools.
5. Leave all the default values and enter 30 into the element size= field.
6. Mesh the part.

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7. The part should now look similar to this:

Masking half the part shows the Tetrahedral Element structure thorough the part.

8. Now delete the mesh.

Step 5: Using Proximity and Curvature Options

Proximity and Curvature options can provide a mesh that adheres closer to the geometry
in areas of curvature or small cross sections.
1. From the Volume tetra subpanel, select the part and select the Use proximity and Use
curvature options
2. Set the following fields to the values shown:

3. Mesh the part.

Note the areas of curvature have a

smaller mesh size to better capture the
geometric curvature.

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4. Optional: Mask half the part to view the internal structure

Step 6: Improve the mesh quality.

To improve the overall Tetrahedral Element quality we will check the tet collapse value
of the elements. Tet collapse uses a normalizing equation that checks the ratio of the
distance from each of the nodes to the area of the opposing face.
1. Find the Check Elements option from the Mesh menu in the menu bar.
2. Select the 3-d sub panel.
3. Enter 0.3 into the tet collapse< field and click the tet collapse button.
Note the number of failed elements in the dialog bar. The value should be around 39
elements.
4. Save the failed elements by selecting save failed.
5. Isolate the failed elements
Failed elements can be isolated on the screen anytime using the following procedure.
A. Go to the mask function.
B. Click the elems button.
C. Select retrieve.
D. Click the elems button again.
E. Select reverse.
F. Mask the elements.

6. Using the unmask adjacent button twice to retrieve two layers of elements
surrounding the failed elements.

7. In the tetramesh panel select the Tetra remesh subpanel.

8. Select the displayed elements and remesh them.

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9. Check the tet collapse again and note the number has dropped. Many of the remaining
elements are constrained by geometry but continued remeshing can result in further
drops in this number.
10. Delete the mesh.

Step 6: Defining Mesh Patterns

In instances where the user needs to define a specific mesh pattern for surfaces or features,
the volume tetra function can incorporate that pattern into the created tet mesh.
1. Mesh the flat ring area with an element size of 10 and type of R-Tria. Set all edges to
45 elements. The resulting mesh pattern should look similar to the one below

2. Create a new volume tetra mesh, this time selecting the match existing mesh option.
Make sure to set the tetra element size back to 30.
3. Note the Tetra Mesh has incorporated the defined mesh pattern

OPTIONAL Step 7: Improve Mesh Quality

1. Use Geometry Cleanup tools and tetra remesh functions to try to achieve the best
possible mesh. Experiment with different techniques and discover the results.

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Section 3: TetraMesh Process Manager

The Process Manager is a step-by-step tool providing a checklist of procedures to allow the
user to quickly organize and tetmesh a geometric model. Each step is provided in a
hierarchal list providing the order in which the process needs to be performed and providing
specialized tools at each step to simplify the process. These steps, while they can be done
manually, can be performed in the TetraMesh Process Manager template in a much
reduced timeframe.

Using the TetraMesh Process Manager

In this section, you will learn about using the TetraMesh Process Manager to:
 Import geometry or an HM File
 Clean up the geometry
 Organize the model (holes and features)
 Establish mesh size and pattern for the organized geometry
 Create a 2-D Mesh
 Clean up the 2-D mesh
 TetraMesh

The TetraMesh Process Manager will create a new

tab (shown to the right) that will show the step-by-step
process required to create the tet mesh. The current
step will be indicated with a white arrow while
completed steps will be shown with a green arrow .
Additionally, the panel area will change from the
standard HyperMesh panels and will provide all the
tools and functions needed to complete the current
step. The standard HyperMesh panels can be
retrieved at any time by undocking the Process
Manager panels using the icon . Selecting the icon
will redock the Process Manager panels.

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Exercise 5b: Using the Tetramesh Process Manager

Step 1: Initiate the Process Manager.

1. From the Menu Bar, select Mesh > Create > TetraMesh Process >Create New to
access the Process Manager.
2. Enter a session name or leave it as my_session.
Note: Creating a session name and saving the session allows the user to stop
the process before completion and then load it again at a later time, picking up
the process at the point it was left off.
3. Select a working folder.
4. Click Create.

Step 2: Import geometry.

At this point the TetraMesh Process tab will open in the Tab area and will automatically
assemble the TetraMesh Process Flow. The first step, Geometry Import, is highlighted
and the panel area has been configured with specific panels for aiding the Tetramesh
Process Manager template. You can access the HyperMesh panels by undocking the
Process Manager panels using the icon in the upper right corner of the panel area. This
will separate the Process Manager panels so that you can also access the HyperMesh
standard panels. To redock the Process Manager panel, simply click on in the upper right
corner of the Process Manager panel.
1. In the panel area, change the Import Type to HM Model.
2. On the toolbar, click Open File ( ) and select the file tetmesh_pm.hm from
<installation_directory>/tutorials/hm/.
3. Click Import.
The model will import and a green check will appear next to Geometry Import in the
Process Manager indicating that step is now complete.

Step 3: Clean up the geometry.

1. From the Geometry Color Mode selector ( ) pick By Topo and click
Shaded Geometry and Surface Edges ( ).
2. In the panel area, select the Edge Tools tab.
3. Click Isolate.
This will isolate the surfaces with free edges on them.

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Isolated Surfaces with free edges.

4. Select the Free Edges tab and click Equivalence.

This will fix all the free edges. If this did not correct all of the free edges, the
Tolerance value could be increased until all free edges are equivalenced.
5. Select the Edge Tools tab and click Isolate again.
A window should appear with the message, “No edges found…” This confirms all
edges have been fixed.
6. Click Display All.
7. Click ACCEPT.
The Geometry Cleanup step has been completed and should have a green
checkmark by it.

Step 4: Organize and Clean up holes.

This step will allow you to organize the surfaces that form holes in the model. The
TetraMesh Process Manager can automatically sort and organize holes into separate
component collectors based upon their diameter. This will allow you to specify mesh type,
circumference element count, and longitudinal element size for different hole groups.
1. In the panel area, click the + ( ) button.
This will add a third line to the table.
2. On the first line, enter 3.3 into the D< field.
This will organize all holes with a diameter between 0 and 3.3 units, as indicated by
the Range field, into a collector.
3. Enter 5 into the second row and 10 into the third.
This will allow HyperMesh to organize the holes into three collectors that will include
holes ranging from 0 - 3.3 units, 3.3 - 5 units and 5 - 10 units collectively.
4. Click Auto Organize.
All of the holes in the model less than 10 units will now be organized into three
component collectors, each with a different color.
5. Click the HyperMesh Model Browser tab and expand the folder for Components.
You will see three new component collectors with the name solidholes followed by
the numerical average of the diameter range of the holes organized.

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Transparent view of model showing all holes and bores organized

6. Return to the TetraMesh ProcessManager tab

7. In the Num Circumference Elems field enter 12 for each row.
8. In the Longitudinal Elem Size field enter 1 for each row.
The Num Circumference Elems field governs the number of elements that will be
meshed around the hole while the Longitudinal Elem Size field dictates the unit
size of the elements through the length of the hole.
9. Click ACCEPT.
The Organize & Cleanup Holes step is now complete should now have a green
checkmark next to it.

Step 5: Mesh holes.

1. In the panel area you will notice that each hole diameter row has a Mesh Type field
with a pull-down providing the options of R-tria regular and R-tria union jack.
Verify that all are set for R-tria regular and click Mesh All. (The R-tria union jack
mesh pattern will be discussed in a later step.)
You will notice this process provides a perfectly straight tria mesh down the length of
the hole with no twisting.

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2. Click ACCEPT.
The checkmark in the Mesh Holes step will now turn green.

Step 6: Organize and clean up features.

This step allows you to highlight and organize features that require specific mesh controls
beyond the overall mesh pattern that will be applied to the remainder of the part in a later
step. This organizational tool will place the required surfaces into their own collector or
collectors and allow you to set mesh size and pattern requirements for each.
1. In the panel area, click the + ( ) button.

2. In the Define New window that opens, type Faces and click OK.
3. Select all five of the flat faces around the circumference of the part as shown in the
following image.
4. Click proceed.

Faces that need to be picked

The panel will switch to the Organize panel with your surfaces pre-selected to move
into a new component called grp_Faces.
5. Click move, then return.
6. Click the + ( ) button again.
7. In the Define New window that opens, type TopHole and click OK.

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8. Rotate the model so you are looking at it from underneath into the center, and select
the surfaces shown in the following image.

Note: With this tool you need only select one of the two surfaces that make up a
cylinder; when you click proceed HyperMesh will automatically select the other
surfaces.
9. Click proceed.
10. In the Organize panel, click move, then return.
Your model should then look similar to the following image, with the faces in one
collector and the top hole in another. Your colors may vary slightly.

11. Click ACCEPT.

Step 7: Organize and clean up filets.

Often a better mesh can be achieved if your fillets are split down the center. The step will
allow you to automatically split your fillets based on minimum and maximum radius criteria.
1. Click Components.
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2. Select the part in an area that has not been organized into a new component so that
the large purple part is selected.
3. Click proceed.
4. Leave the Min Radius at 0 and the Max Radius at 5 and make sure the Suppress
Fillet Tangent Edges option is active.
5. Click Cleanup.
You will notice that many of the fillets now have an edge running down the center
and the original edges are suppressed.
6. Click ACCEPT.

Step 8: Mesh features.

In this step you will mesh the features that you organized in Step 6. The panel area will
show a table with your organized features in it and will give you the option of selecting a
mesh type and size for each feature.
1. For the Faces feature, click the pull-down under Mesh Type and pick trias.
2. In the field under Elem Size, enter 0.5.
3. For the TopHole feature, select R-tria union jack for the Mesh Type.
4. For Elem Size, enter 0.5.
5. Click Mesh All.

6. Note the distinctive Union Jack mesh pattern ( ) in the top hole area and the
connectivity of the mesh to the previously meshed holes.
7. Click ACCEPT.

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Step 9: Organize and clean up.

This step allows the user to organize and clean up the remaining portion of the model that
will then fall under the global meshing parameters. As the remaining surfaces are already in
the component you wish them to be in, there is no need for further organization.
1. Click ACCEPT.

Step 10: Mesh/remesh.

This step is where the remaining model will be globally meshed. Element size and type can
be set for all remaining components that remain unmeshed.
1. In the Element Size field, enter 1.
2. Set Mesh Type to trias.
3. Click Mesh.
4. Click ACCEPT.

Step 11: Clean up elements.

At this point the model should be entirely surface meshed. Proper adherence to the
previous steps ensures a surface mesh that is properly connected and controlled by the
previously entered values. This step will now allow the user to verify a proper mesh and
clean up any issues that are found.
1. In the panel area, click Components.
2. Select all of the components and click proceed.
3. Leave all of the values at their default (Min Size – 0.25, Max FeatureAngle – 60.0,
Normals Angle – 150.0) and click AutoCleanup.
The following message should appear.

This indicates that all failed elements have been fixed and there are no further errors
in the model.
4. (Optional) The Manual tab allows the user to manually check the model for free
edges and t-junctions and fix any that are found. There is also the option to display
normals. Use these options to find and fix any errors.
5. Click ACCEPT.
Note: The Tetramesh Process Manager will automatically place any elements that
fail this AutoCleanup procedure in the user mark. This will allow for easy retrieval of
problem elements and the user can employ the tools from the standard HyperMesh
panels to fix these remaining elements.

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Step 12: Tetra mesh.

This is the final step in the TetraMesh Process Manager Template and will be the point
where the model is Tetra meshed. The Process Manager will automatically open the
TetraMesh panel and pre-select all of the float and fixed elements.
1. Click elems under select trias/quads to tetra mesh.
The surface elements will be selected under the general mesh selection option. This
will define them as “floatable” elements, meaning that the diagonals of the underlying
tetra elements can be flipped from the generated shell elements if HyperMesh
determines a better element quality will result.
2. Click elems under fixed trias/quads.
The elements that represent the interior of holes and bores will be selected under
this option. The will be defined as “fixed” elements meaning HyperMesh will always
adhere to the shell mesh pattern with generating the tetra elements.
3. Click mesh.
4. Click the Model tab in the Tab area.
5. Expand the Components list if necessary.
6. Right-click the tetmesh component.
7. Select Isolate Only.
The tetra mesh will be displayed.
8. Click Mask ( ).
9. Hold the SHIFT key down and while holding the left mouse button down, drag a box
to include roughly half of the model.
10. Click mask.
Your tetra mesh should look similar to the following image.

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Step 13 (Optional): Save your work.

1. You can now save your model if you wish.

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