Q: What is considered as Thin-walled part? parameters for 'thin-ness'?
A: A decent rule of thumb is that the ratio of the shortest non-thickness dimension to the thickness is >= 10. Just remember that shell element theory is making some assumptions about the stress through the thickness of the part.
Q: Where do you find Thin Wall parts - in Sheet Metal or Injection Moulding or Casting or Milling?
A: Typically sheet-metal parts, but injection molded could also see the application. If by milling you mean machined part, then typically no.
Q: For which domain Midsurface is used most- consumer plastic , automotive ?
A: I'm not 100% sure what you mean by this, but if I understand you correctly, then automotive (lots of sheet-metal).
Q: Which software has best Midsurface - Benchmarking?
A: Shell element theory is pretty well defined, so I don't know if you can say there is a "best" when looking at solvers. Some solvers can do non-linear effects with shell element (Nastran for example) while others can't (Mechanica for example).
Q: Typical problems in creating midsurface and in the results ?
A: Usually creating the mid-surface is pretty straight forward; most CAD programs of pre-processors have the ability to auto-generate them. Again, the accuracy of the results depends on the geometry, connection, and results that you're after.
Did I just answer a bunch of homework questions?!
